24-33-96 component maintenance manual with illustrated

(F6177)
12, Rue Sadi Carnot - 93170 Bagnolet - France
Tél. (33) (0)1 49 93 19 18 - Fax (33) (0)1 49 93 19 56
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
P/N 151CH1
P/N 151CH2
Date of initial issue: sep 15/1998
Revision n° 1
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151CH1
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SERVICE BULLETIN LIST
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LIST OF APPROVED REPAIRERS
TRADE NAME
SAFT
ADDRESS
12, Rue Sadi Carnot
93170 BAGNOLET
Telex - 235566 F
Phone: (33) (0)1 49 93 19 18
Fax: (33) (0)1 49 93 19 50
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LIST OF EFFECTIVE PAGES
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PAGE
TITLE PAGE
1
2
DATE OF
LATEST
REVISION
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RECORD OF REVISIONS
1
2
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RECORD OF TEMPORARY REVISIONS
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SERVICE BULLETIN
LIST
1
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LIST OF APPROVED
REPAIRERS
1
2
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LIST OF EFFECTIVE
PAGES
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TABLE OF CONTENTS
1
2
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TABLE OF ILLUSTRATIONS
1
2
Feb 15/2001
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INTRODUCTION
1
2
3
4
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DESCRIPTION AND
OPERATION
1
2
3
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5
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TESTING AND FAUL- 1001
TISOLATION
1002
1003
1004
1005
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CONTENT
PAGE
1006
1007
1008
1009
1010
1011
1012
1013
1014
DATE OF
LATEST
REVISION
Feb 15/2001
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SCHEMATIC AND
WIRING DIAGRAMS
2001
2002
Feb 15/2001
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DISASSEMBLY
3001
3002
3003
3004
Feb 15/2001
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CLEANING
4001
4002
4003
4004
Feb 15/2001
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CHECK
5001
5002
5003
5004
5005
5006
5007
5008
5009
5010
5011
5012
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REPAIR
6001
6002
Feb 15/2001
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ASSEMBLY
7001
7002
Feb 15/2001
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COMPONENT MAINTENANCE MANUAL
151CH1/ 151CH2
LIST OF EFFECTIVE PAGES
CONTENT
PAGE
7003
7004
7005
7006
7007
7008
7009
7010
DATE OF
LATEST
REVISION
Feb 15/2001
Feb 15/2001
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FITS AND CLEARANCE
8001
8002
Feb 15/2001
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SPECIAL TOOLS,
FIXTURES AND
EQUIPMENT
9001
9002
9003
9004
9005
9006
Feb 15/2001
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Feb 15/2001
Blank
ILLUSTRATED
PARTS LIST
10001 Feb 15/2001
10002
Blank
INTRODUCTION
10003
10004
10005
10006
10007
10008
VENDOR CODE
INDEX
10009 Feb 15/2001
10010
Blank
ALPHA NUMERICAL
INDEX
10011 Feb 15/2001
10012 Feb 15/2001
10013 Feb 15/2001
DETAILED
PARTS LIST
10014
10015
10016
10017
10018
CONTENT
PAGE
DATE OF
LATEST
REVISION
STORAGE (INCLU15001 Feb 15/2001
DING TRANSPORTA- 15002 Feb 15/2001
TION)
15003 Feb 15/2001
15004 Feb 15/2001
15005 Feb 15/2001
15006
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
TABLE OF CONTENTS
PAGE
INTRODUCTION
1
2
3
4
5
6
7
1
1
1
2
2
3
3
4
- General
- How to Use this Manual
- Measure
- Units of Measure
- Abbreviations
- Definition
- Disposal
DESCRIPTION AND OPERATION
1 - Description
1
1
TESTING AND FAULT ISOLATION
1 - General
2 - Testing
3 - Charge
4 - Discharge
5 - Fault isolation
1001
1001
1001
1007
1010
1010
SCHEMATIC AND WIRING DIAGRAMS
1 - General
2 - Schematic sensor
2001
2001
2001
DISASSEMBLY
1
2
3
4
5
- General
- Safety
- Risks
- Safety measure
- Disassembly
3001
3001
3001
3001
3002
3002
- General
- Necessary equipment
- Materials
- Cleaning procedure
- Lubrication
4001
4001
4001
4001
4001
4003
CLEANING
1
2
3
4
5
CHECK
5001
5001
5001
1 - General
2 - Maintenance steps in workshop
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
PAGE
6001
6001
6001
6001
REPAIR
1 - General
2 - Equipment
3 - Repairs
ASSEMBLY
7001
7001
7001
1 - General
2 - Assembly procedure
FITS AND CLEARANCES
1 - Torque table
8001
8001
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 - General
2 - Special tools, fixtures and equipment
3 - Consumables
9001
9001
9001
9005
ILLUSTRATED PARTS LIST
1 - Introduction 2 - Vendor code index 3 - ALPHA Numerical index 4 - Detailed parts list -
10001
10003
10009
10011
10014
STORAGE (WITH TRANSPORTATION)
- Storage
- Storage procedure
- Servicing after storage
- Transportation
15001
15001
15001
15005
15005
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
TABLE OF ILLUSTRATIONS
Figure
1
- 151CH2 Battery
PAGE
3
Figure
2
- Identification plate
4
Figure
3
- Amendment plate
4
Figure
4
- Overall dimensions
5
Figure 1001 - Preliminary Functional Tests
1003
Figure 1002 - Insulation Check
1004
Figure 1003 - Insulation Parameters
1005
Figure 1004 - Cell connections battery 151CH1
1007
Figure 1005 - Cell connections battery 151CH2
1008
Figure 2001 - Schematic sensor Battery 151CH1
2001
Figure 2002 - Schematic sensor Battery 151CH2
2002
Figure 5001 - Periodical check
5003
Figure 5002 - Level adjustment with a syringe and calibrated nozzle
5004
Figure 5003 - Regular check
5007
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Figure 5004 - General overhaul
PAGE
5011
Figure 7001 - Battery 151CH1 liner spacer kit installation
7003
Figure 7002 - Battery 151CH2 liner spacer kit installation
7004
Figure 7003 - Battery 151CH1 cells assembly
7005
Figure 7004 - Battery 151CH1 assembly
7007
Figure 7005 - Battery 151CH2 cells assembly
7008
Figure 9001 - Polyamide key for vent valve (T01)
9002
Figure 9002 - Syringe with nozzle (T02)
9002
Figure 9003 - Equalizing resistor (T03)
9003
Figure 9004 - Cell extraction tool (T04)
9004
Figure
1
- 151CH1 BATTERY
10014
Figure
2
- 151CH2 BATTERY
10016
Figure 15001- Short term storage
15003
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and in AECMA Simplified English. This manual
uses IS units of measure, with imperial units in parentheses.
B. This manual gives the procedures of maintenance on components in a workshop. It does not give
the procedures of maintenance on components when they are installed in aircraft.
C. Only approved persons with the necessary skills can do maintenance tasks given in this manual.
D. This manual uses Maintenance Task Oriented Support System (MTOSS) task and subtask
identification. Maintenance tasks and other data have special MTOSS numbers for the use of
Electronic Data Processing (EDP). MTOSS numbers can be ignored by the user of the manual.
E. This manual contains:
- Technical data for components.
- Maintenance and repair procedures for components.
- An Illustrated Parts List (IPL) with data for parts of components. Parts are identified in all sections of the manual by the IPL figure and item number.
F. We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY
procedures by doing them.
NOTE: This manual gives the description and the maintenance procedures of two batteries
(P/N 151CH1 and P/N 151CH2). The description of operations is written for both batteries. If a special operation or description is necessary, the P/N of the applicable
battery is written in the title of the paragragrph or figure.
2. How to Use this Manual
A. Make sure the manual contains information applicable to your component. Look for the part
number on the Title Page.
B. If you need to identify a part or find a part number, refer to the IPL, which has an Introduction
chapter showing the procedure.
C. You must use the instructions in this manual for all components maintenance. Read all the
applicable WARNINGS and CAUTIONS before you do the work on the component.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
3. Measure
Measure given in this manual are taken from original manufacturing drawings.
Quantities are given in I.S. Units followed by U.S. Units in parentheses.
4. Units of Measure
A. I.S. Units
A
Ah
C1A
C1Ah
g
min
N
N.m
VDC
°C
%
Ω
Ampere
Ampere hours
Rated current
Rated capacity for an hour
Gram
Minute
Newton
Newton meter
Volt direct current
Degree Celsius
Per cent
Ohm
B. U.S. Units
ft
in
lb
lbf.in
°F
Foot
Inch
Pound
Pound force inch
Degree Fahrenheit
C. Multiplying Prefixes
µ
m
da
k
M
Micro
Milli
Deca
Kilo
Mega
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
5. Abbreviations
This manual uses the abbreviations given below.
ATA
DIA
FIG.
IPL
MAX.
MFR
MIN.
NO.
OD
P/N
PARA.
REF.
S/A
TBD
AIR TRANSPORT ASSOCIATION OF AMERICA
DIAMETER
FIGURE
ILLUSTRATED PARTS LIST
MAXIMUM
MANUFACTURER
MINIMUM
NUMBER
OUTSIDE DIAMETER
PART NUMBER
PARAGRAPH
REFER TO
SUBASSEMBLY
TO BE DEFINED
6. Definition
This paragraph gives the warnings of this manual.
Warnings call attention to use of materials, steps procedures, or limits, which must be followed precisely to prevent injury to persons.
Cautions call attention to steps procedures which must be followed to prevent damage to equipment.
Notes call attention to procedures which make the job easier.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
7. Disposal
Ni-Cd batteries contain :
- nickel,
- cadmium,
- potassium hydroxide.
You must therefore discard or use them again, in agreement with local legislation. For more information, contact your local SAFT supplier.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline batteries 151CH1 and 151CH2 have each one 20 semi-open nickel-cadmium
CVH 150KH cells with welded polyamide cases.
The battery is connected to the aircraft systems.You can use it:
(1) To start the engine or the APU in reference to the aircraft system.
(2) On the ground, before electrical power is supplied to the aircraft systems.
(3) In flight, if a malfunction or a failure occurs in the power supply system.
NOTE: The 28 VDC electrical system charges the battery in the aircraft.
In this chapter, the figure and item numbers correspond to those of the ILLUSTRATED PART
LIST.
B. Characteristics
(1) Technical data
Nominal voltage
24 V
Rated capacity C1Ah
15 Ah (see Note below)
Battery terminals
Two M8 terminal
Consumable volume of electrolyte
15 cm3 (0.92 in3)
Maximum dimensions of the batteries :
- Length
- Width
- Height
307 mm (12.09 in)
147 mm (5.78 in)
210 mm (8.27 in)
151 CH1 Battery maximum weight
15 kg (33 lbs)
151 CH2 Battery maximum weight
15.2 kg (33.5 lbs)
NOTE:
15 Ah at 1 h rate noted as 15 C1Ah or 15 C1Ah.
Current value equivalence : 15 A = 1 C1A and 1.5 A = 0.1 C1A for these
15 C1Ah batteries.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
(2) One complete temperature sensor set with:
(a) For battery P/N 151CH1
- 1 thermostat closing at 71°C + 2.8°C (160°F + 5°F) on temperature rise with a 2.2 kΩ
resistor in parallel,
- 1 thermal sensor 300 kΩ at 25°C (77°F).
(b) For battery P/N 151CH2
- 1 thermostat closing at 71°C + 2.8°C (160°F + 5°F) on temperature rise with a 2.2 kΩ
resistor in paralell,
- 1 thermostat opening at 8°C + 2.8°C (46.4°F + 5°F) when temperature is 8°C + 2.8°C
(46.4°F + 5°F) with a heater (maximum voltage 230 V AC - 50 Hz)
- 1 thermal sensor 300 kΩ at 25°C (77°F).
(3) Serviceable characteristics
(a) Operate temperature:
- 40 to + 71 °C (- 40 to + 160 °F)
(4) Electrical characteristics
The list below gives the servicing values of the batteries:
Item
Value
Use for
1 C1A
15 A
Charge/Discharge
0.5 C1A
7.5 A
Charge
0.1 C1A
1.5 A
Charge
C. Detailed description
Each battery has 20 CVH 150KH cells (01-140) and (02-140), housed in a stainless steel box.
The box (01-290) and (02-290) is lined with thin sheets of insulation and wedges (01-200) and
(02-200). The cells are kept upright by means of a molded silicone elastomer part (01-070) and
(02-070) attached to the cover which presses against the top of the cells. Rigid, nickel-plated
copper links (01-110 thru 01-130) and (02-110 thru 02-130) connect cells.
Two terminals (01-210) and (02-210), installed at the end of cells, and two nuts (01-020 and 030)
and (02-020 and 030) connect the battery to the aircraft.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
The cover (01-010) and (02-010), that you can remove, is attached to the box (01-290)
and (02-290) by four washers (01-050) and (02-050) and four screws (01-040) and (02040).
Cover
Negative nut
Screw
Filling instruction plate
Positive nut
SAFT label plate
Sensor
heater
Range plate
Sensor
thermostat
Box
151CH2 Battery
Figure 1/TASK 24-33-96-991-001
Identification plate
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Identification plate
Figure 2/TASK 24-33-96-991-002
Amendment plate
Figure 3/TASK 24-33-96-991-003
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Overall dimensions
Figure 4/TASK 24-33-96-991-004
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
TESTING AND FAULT ISOLATION
1. General
This chapter gives the tests and inspections necessary to find the condition of the unit removed for
unscheduled maintenance. The TESTING AND FAULT ISOLATION TABLE gives the test procedure.
Each test refers to a specific procedure that gives all parameters you must apply, and those you must
inspect.
The figure and item numbers in this chapter correspond to those of the ILLUSTRATED PARTS LIST.
TASK 24-33-96-700-801
2. Testing
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
- charge/discharge bench (constant current 0 - 60 A).
- power supply: 0 - 45 V, range 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V - 50 V, accuracy 1%.
- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
(4) Check conditions
- Ambient temperature: 23 + 5 °C.
- Pressure: 85 to 106 kPa.
- Relative humidity: < 85 %.
B. Precautions
You must always do regular maintenance. It is then necessary to obey the precautions below to
make sure of the correct operation of the battery:
- Do not install the battery in an aircraft which is too hot.
- Carefully obey the instructions given by the aircraft procedure to make sure of a good flow of air.
- Make sure of the capacity of the battery regularly.
- Charge the battery in a battery shop.
- You must do the maintenance (Refer to CHECK chapter), in particular to make sure of:
- Level of electrolyte. Specially when ambient temperature is high, time between maintenance must decrease.
- Tightness of the connection nuts.
- Correct charging.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
SUBTASK 24-33-96-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (01-090)
and (02-090)
1 Ω cell shorting 12 h
charge at 1 C1A (15 A)
Yes
see para. 5.B (6)
note the voltage of each
cell during the charge
salt or electrolyte
traces
No
Yes
see para. 5.C (1)
more than
10 ml added in all
cells
electrolyte in
the box
Yes
box or cells
damaged
No
Yes
Yes
1 or more cell = 0 V
see para. 5.A (1)
see para. 5.B (7)
No
1 or more cell < 0 V
Yes
see para. 5.B (5)
No
insulation
between cell and box
< 250 kΩ
No
Yes
see para. 5.B (2)
Yes
see para. 5.B (3)
voltage of 1 cell
< 1.55 V
No
Yes
see para. 5.B (4)
capacity check
< 100% C1Ah
Yes
see para. 5.B (5)
Yes
see para. 5.C (4)
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Feb 15/2001
see para. 5.C (3)
more than
10 ml added
in 1 cell
No
Yes
Yes
see para. 5.C (2)
No
battery
voltage = 0 V
see para. 5.B (1)
No
Topping up at the end
of charge
No
metallic parts
corroded
Yes
see para. 5.A (3)
No
1 or more
cell has a voltage > 0.1 V
than the others
No
No
a link or a
nut is too hot
No
do a General Overhaul
to detect battery fault or
external cause
Preliminary Functional Tests
Figure 1001/TASK 24-33-96-991-005
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
SUBTASK 24-33-96-720-002
D. Testing procedure
(1) Insulation check
- Put the megohmeter as the figure below shows:
Insulation Check
Figure 1002/TASK 24-33-96-991-006
- ≥ 250 kΩ under 250 VDC = Min value.
- > 10 MΩ under 250 VDC = value after cleaning and drying.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
250 KΩ
problem
2 MΩ
Necessary to clean
10 MΩ
Can wait until next
maintenance
In battery maintenance shop
Cleaning necessary
OK
Always necessary after
cleaning and drying
Cleaning necessary
Acceptable
Check the cause
(overcharge…)
Insulation Parameters
Figure 1003/TASK 24-33-96-991-007
(2) Polarization test
Charge the battery at 1.5 A for 1.5 hours.
Keep the battery in "open-circuit" condition for 1 hour.
Measure the open-circuit voltage of each cell.
If open circuit voltage of any cell is 0 V (or negative), do a second test (refer to
paragraph 4). Then repair.
If each cell has an open-circuit voltage that is more than 0 volt, charge the battery.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
(3) Vent valve test
Before you put the vent valve back on the cells, make sure that they operate correctly.
Do these steps:
1. Install the complete vent valve (01-190) and (02-190) with its O-ring on the end of a
metal tube which has an applicable end-piece.
2. Connect this tube to a supply of compressed air through an adjustable reducing valve.
3. Adjust the pressure to 0.5 bar (7.25 psi) and put the complete vent valve into a container of water. Air bubbles come out when the valve opens. If there are no bubbles,
increase the pressure until you see bubbles. Then decrease the pressure slowly to
0.1 bar (1.45 psi) and monitor the pressure at which the bubbles stop.
4. Reject all complete vent valves that have an opening pressure of more than
0.7 bar (10 psi) or less than 0.14 bar (2 psi).
5. Install the vent valve (01-190) and (02-190) (Refer to ASSEMBLY chapter).
(4) Second test before repair
The first test charge can be unsatisfactory if the electrolyte level is too low in some cells
(because the level is not adjusted until the end of this charge). If you find faults, adjust
the electrolyte level and do the test below:
NOTE: If you charge the battery more than necessary, you decrease the life of
the cells. Thus, do this special test only if a battery malfunction occurred
in the aircraft, or faults are found during shop maintenance.
- Charge the battery (Refer to one of the procedures given in chapter TESTING AND
FAULT ISOLATION). At the end of the total charge time, continue to charge at 1.5 A
for 5 more hours. Regularly record the voltage of the cells. The temperature of cells that
have damaged separators quite and continuously increases. The voltage of these cells
continuously decreases to less than 1.55 V.
- Adjust the electrolyte level during the last 30 minutes of charge.
- Discharge at 15 A down to 1 V/cell.
- After this test, discard the defective cells:
- Cells with a voltage of less than 1.55 V at the end of the charge.
- Cells with a voltage that decreases to less than 1 V before one hour of discharge
(during the last test discharge).
- Short-circuited cells (zero volt).
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
TASK A24-33-96-800-801
3. Charge
SUBTASK 24-33-96-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-33-96-820-002
B. Ground charge
Do all battery maintenance or overhaul steps in a workshop.
NOTE: In addition to the constant-current procedure of charging, you can use other procedures that fully charge the battery. BUT, IN EACH CASE, YOU MUST DO CELL
VOLTAGE CHECKS (U > 1.55 V) AND ELECTROLYTE ADJUSTMENTS BY THE
MEAN OF A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT: 1.5 A AT
0.1 C1A. If special instructions are not given in the charger operating manual, you
must first contact SAFT.
WARNING: REMOVE THE COVER TO CHARGE THE BATTERY ON THE GROUND. THIS IS
TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX.
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Cell connections battery 151CH1
Figure 1004/TASK 24-33-96-991-008
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151CH1/151CH2
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Cell connections battery 151CH2
Figure 1005/TASK 24-33-96-991-009
(1) Constant-current charge (Battery fully discharged)
(a) To charge a fully discharged battery, do one of these procedures:
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151CH1/151CH2
CONSTANT-CURRENT CHARGE
Main charge
Final charge
1.5 A (0.1 C1A) until 30 V as battery voltage
mini 10 h
Periods:
maxi 12 h
1.5 A (0.1 C1A) for a 4 h period
7.5 A (0.5 C1A) until 31 V as battery voltage
mini 2 h
Periods:
maxi 2 h 30 minutes
1.5 A (0.1 C1A) for a 4 h period
15 A (1 C1A) until 31.4 V as battery voltage
mini 1 h
Periods:
maxi 1 h 15 minutes
1.5 A (0.1 C1A) for a 4 h period
NOTE: If the battery voltage does not increase sufficiently during the maximum charge time: Refer to the chapter TESTING AND FAULT ISOLATION.
NOTE: If you charge the battery more than in the table above, you decrease the life of
the cells.
(b) Battery not fully discharged and discharge condition not known.
Discharge at 15 A (1 C1A) down to 20 V. Refer to paragraph DISCHARGE.
Charge : refer to B (1) (a) above constant current charge.
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151CH1/151CH2
TASK 24-33-96-800-802
4. Discharge
Rated capacity
(C1Ah)
15 Ah : minimum value obtained for a fully charged battery, when discharged at 15 A, down to 20 V.
Other rates
(C1A)
Depending on temperature and time: up to 25 C1A.
TASK 24-33-96-700-802
5. Fault isolation
SUBTASK 24-33-96-760-001
A. Battery electrical faults
PROBLEM
PROBABLE CAUSE
CORRECTION
(1) Zero battery open-circuit volt- (a) Defective electrical connector Examine electrical contacts,
links and tightness of nuts (refer
age
(no contact made)
to CHECK chapter).
(2) Zero volt with the battery set
to "discharge"
(3) Low insulation
(b) Link loose or broken
Make sure the nuts are tight
(refer to CHECK chapter).
(a) Battery fully discharged
Charge the battery again.
Do an insulation check (refer to
CHECK chapter).
(b) Battery circuit open or contacts defective
Examine the contacts and links.
Make sure the terminal nuts are
tight (refer to CHECK chapter).
(c) Cell fully dry
Refer to applicable subsequent
steps.
(a) Leakage of electrolyte
Disassemble and clean the battery (refer to DISASSEMBLY
AND CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
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151CH1/151CH2
SUBTASK 24-33-96-770-001
B. Cell faults
PROBLEM
PROBABLE CAUSE
(1) Too much water decrease for (a) Charge much more than the
all battery cells.
limit or too much charge at high
temperature.
CORRECTION
Examine the cause of excessive
charge.
If necessary, adjust to normal
operating temperature (refer to
DESCRIPTION AND OPERATION chapter).
(2) Water decrease in cell(s) is
(a) More than 30% or more than Do a leak of the cells (refer to
very different from the other cells the average : leaks from the
CHECK chapter).
in the battery.
cell(s).
(b) 30% (or less) of the
average: cell(s) with damaged
separator(s).
(3) A cell has an unsually high
(a) Dry cell.
voltage at the start of the charge.
Do the second test (refer to
CHECK chapter). If necessary,
replace the cell(s).
When the defect occurs, add
5 cm3 (5 ml) of distilled water to
the cell. Do not adjust more
accurately until the end of the
charge.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can
cause the temperature increases very much.
(4) A cell has an unsually low
voltage at the end of the charge
(Less than 1.55 V at 1.5 A at
+ 20 °C (+ 68 °F)
(a) The cell was operate
d at temperatures and charge
rates outside the limits, and the
separator is damaged.
Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND
STORAGE chapters).
(5) Low capacity cell (The cell
shows a reversed voltage or a
correct polarity voltage of less
than 1 V after a discharge of
1 hour at 1 C1A).
(a) Usual wear after long opera- Replace the cell (refer to DISAStion.
SEMBLY, ASSEMBLY AND
STORAGE chapters).
(6) Cell with a swollen case.
(a) Cell operated with low elec- Replace the cell (refer to DISAStrolyte level ; deterioration of
SEMBLY chapter).
separators and damaged plates.
(7) Cell with zero voltage when
the battery circuit is open.
(a) Short-circuited cell.
(b) Unusual operation, operation Do the applicable procedure
at high temperature or operation (refer to CHECK chapter).
with low electrolyte.
Replace the cell (refer to DISASSEMBLY chapter).
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151CH1/151CH2
SUBTASK 24-33-96-750-001
C. Physical faults
PROBLEM
(1) Leakage of electrolyte
PROBABLE CAUSE
CORRECTION
(a) Incorrect adjustment of level. Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters). Do
an electrolyte level check (refer
to CHECK chapter).
(b) Cell polarity incorrect during
high-rate discharge (for examExamine the cause of excessive
ple, during the engine start).
charge.
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
(c) Too much charge at high temperature or too much current.
Examine the cause of excessive
charge. If necessary, adjust to
normal operating temperature
(refer to DESCRIPTION AND
OPERATION chapter).
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
(2) Electrolyte found in the battery box.
(a) Damaged cell case
Do a leak test of the cells (refer
to CHECK chapter).
Replace the cell if necessary and
refer to applicable subsequent
steps.
(b) Leakage of electrolyte
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING chapters).
Do an electrolyte level check
(refer to CHECK chapter).
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151CH1/151CH2
PROBLEM
(3) Corrosion on the links.
PROBABLE CAUSE
(a) Operation in acid air
CORRECTION
Make sure the battery test bench
and the storage areas have no
materials which can release acid
fumes.
(b) Mechanical damage to nickel Replace the damaged links
plating
(refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
chapters).
(4) The links are too hot.
(a) Loose terminals nuts
Make sure the nuts are torqued
(refer to CHECK chapter).
SUBTASK 24-33-96-750-002
D. Vent valve faults
PROBLEM
PROBABLE CAUSE
CORRECTION
Valve open pressure > 0.7 bar or Clogged valve.
the valve stays open.
Change the valve.
Valve stays open for a pressure
< 0.14 bar or not closed.
Change the valve.
Pierced valve.
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SCHEMATIC AND WIRING DIAGRAMS
1. General
This chapter gives all electrical schematics of battery sensor.
2. Schematic sensor
Schematic sensor Battery 151CH1
Figure 2001/TASK 24-33-96-991-009
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151CH1/151CH2
Schematic sensor Battery 151CH2
Figure 2002/TASK 24-33-96-991-010
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151CH1/151CH2
DISASSEMBLY
1. General
NOTE: Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the
component or the possible cause of its malfunction. This will give the necessary
standard of disassembly.
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT
ISOLATION CHAPTER).
The figures and items numbers in this chapter correspond to those of the ILLUSTRATED PARTS
LIST.
2. Safety
Different countries have diferent safety rules. Obey the local rules.
3. Risks
There are three types of risks.
A. Physical
- Handling:The battery is heavy. When you lift it, bend your legs, not your back.
- Put on protective shoes.
B. Electrical
- Don’t keep on you rings, watches, chains, belt buckles.
- Use insulated tools.
C. Chemical
- Electrolyte can cause corrosion and dangerous damage to the skin: put on gloves.
- Contact with eyes is very dangerous, put on protective goggles.
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4. Safety measure
- The electrolyte compound is caustic and can cause severe burns. If it comes in contact with the skin,
flush the touched part with water and make the solution neutral with acetic solution, vinegar or lemon
juice, or with boric acid solution at 10% concentration.
- If the electrolyte touches the eyes, flush them with water for minimum 15 minutes and call a doctor.
- Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit.
Mix the solution with water or, if possible, with milk. Call a doctor immediately. Do not try to make
someone unconscious drink . Touching nickel can cause chronic eczema. Breathing cadmium oxide
can cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest. Persons
having breathed cadmium oxide fumes must get fresh air or have oxygen, or must have artificial
respiration.
- Potash can cause eczema.
TASK 24-33-96-000-801
5. Disassembly
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
SUBTASK 24-33-96-020-001
B. Disassembly procedure
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT
ISOLATION CHAPTER).
(1) Removal of the cover:
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151CH1/151CH2
(a) Remove the nuts (01-020, 01-030) and (02-020,02-030), and the spring washers
(01-100) and (02-100).
(b) Remove the screws (01-040) and (02-040) and washer (01-050) and (02-050).
(c) Then remove the cover (01-060) and (02-060).
(2) Removal of a cell
NOTE: To prevent a short-circuit, remove a link (01-110, 02-110) between two cells.
(a) Remove the nuts (01-090) and (02-090) and the spring washers (01-100) and (02-100)
that attach the links to the cell.
(b) Cut cable grip (01-280) and (02-280).
(c) Remove all links (01-110 thru 01-130) and (02-110 thru 02-130).
(d) Remove from battery 151CH1 the temperature sensor (01-220).
(e) Remove from battery 151CH2 the sensor thermostat (02-220)
(f) Fully engage the end of the special threaded tool (T04) onto one of the cell terminals.
Then pull up to remove the cell.
(g) Remove the sensor heater (02-230).
NOTE: The complete vent valve must stay tight when you remove the cell.
(3) Removal of a complete vent valve (safety cap)
(a) Loosen the complete vent valve (01-190) and (02-190) with the special tool (T01).
(b) Remove the complete vent valve with its O-ring.
(4) Disassembly of the battery
(a) Remove
1. The cover (01-060) and (02-060).
2. The cells (01-140) and (02-140).
3. The liner spacers kit (01-200) and (02-200).
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CLEANING
1. General
The figure and item numbers in this chapter correspond to those of the ILLUSTRATED PARTS LIST.
2. Necessary equipment
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye washing.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled water.[MO1]
- Neutral soap.[MO2]
- Non-fluffy swab.
- Non-wire brush.
TASK 24-33-96-100-801
4. Cleaning procedure
WARNING: THE ELECTROLYTE IS DANGEROUS. BE CAREFUL WHEN MOVING
ELECTROLYTE AND PREVENT SPLASHING. IT IS A STRONG CAUSTIC AGENT
AND CAN CAUSE SEVERE BURNS. ALWAYS WEAR FACE AND EYE PROTECTION
(PREFERABLY A TRANSPARENT FACE MASK, RUBBER GLOVES AND LONG
SLEEVED CLOTHING). IN CASE OF CONTACT WITH SKIN, FLUSH IMMEDIATELY
WITH MUCH WATER. IN CASE OF CONTACT WITH EYES, FLUSH WITH WATER 15
MINUTES MINIMUM AND, IN EACH CASE, GET IMMEDIATE MEDICAL ATTENTION.
SUBTASK 24-33-96-160-001
A. Light cleaning
Remove the cover.
If a clean, filtered supply of compressed air is available, do this procedure to clean the cells easily
and quickly: blow with much force across the tops of the cells to remove all dust and light traces
of mineral salts from the box. To prevent short circuits, use a rubber tube or an insulating nozzle.
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151CH1/151CH2
SUBTASK 24-33-96-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
(1) Cells
Make sure that the complete vent valve (01-190) and (02-190) (safety cap) is tight.
Do not soak the cells in water.
To easily remove all the electrolyte and mineral salts from the terminals, the cover and the
sides of the cell cases: clean in warm water with a soft brush.
Rub the cell with a cloth and let dry.
(2) Box
Clean with lightly soapy water, rub with a cloth and let dry.
(3) Nuts, spring washers and links
Clean in warm water with a brush and let dry.
(4) Liner spacer kit and sensor
Clean in warm water and let dry.
(5)
Vent valve
CAUTION: YOU MUST CLEAN THE VENT VALVE (01-190) WHEN THE CELLS ARE ASSEMBLED IN THE BOX.
(a) Remove the complete vent valve (01-190) and (02-190) (Refer to "DISASSEMBLY
chapter).
(b) Put swab on the cell holes to keep out unwanted material.
(c) Soak the vent valve for some time (during the night, for example) in a container of distilled water. Do that to remove all salts from the vent hole.
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS.
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151CH1/151CH2
TASK 24-33-96-600-801
5. Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.
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CHECK
1. General
You must do the checks which are necessary to use the SAFT batteries in flight and on the ground.
These maintenance steps must be done in a battery shop between 23 °C ± 5 °C ( 73 ± 9 °F):
- Periodical check: adjustment of electrolyte levels.
- Regular check: electrical treatment, adjustment of electrolyte level, and capacity test.
- General overhaul: disassembly, full cleaning, assembly and regular check.
TASK 24-33-96-200-801
2. Maintenance steps in workshop
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
- Power supply 0 - 45 V, 0 - 60 A.
- Discharge bench, constant current 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V and 50 V, accuracy 1%.
- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
(4) Check conditions
- Ambient temperature: 23 + 5 °C.
- Pressure: 85 to 106 kPa.
- Relative humidity: < 85 %.
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(5) Referenced information
REFERENCE
24-33-96-720-002
DESIGNATION
Insulation check
Polarisation test
Vent valve test
Supplementary test
SUBTASK 24-33-96-210-001
B. Periodical check
Regularly (with sufficient period between checks so that approved quantities are not surpassed):
- Obey the differents steps shown in Fig 5001.
- Clean the battery (See "CLEANING" chapter).
- Measure the voltage Ubat (in open circuit) at the terminal of the battery. If Ubat < 21 V do a polarization test.
- Adjust the electrolyte level.
(1) Charging the battery and adjusting the electrolyte level:
(a) Remove the cover.
(b) Discharge the remaining capacity at 15 A down to a voltage of 20 V at the battery
terminals.
(c) When the battery temperature is + 20 °C to + 25 °C (+ 68°F to + 77 °F) (usual temperature range), charge the battery (refer to one of the procedures given in the chapter TESTING AND FAULT ISOLATION for a fully discharged battery).
(d) During the last 1/2 hour of the charge (while the charge current continues to flow), adjust
the level of electrolyte in the cells. Then measure the voltage of each cell. Write down
the quantity of water that is added to each cell. The electrolyte level changes with the
battery charge. The level changes as if the plates absorbed a part of the electrolyte during the discharge and released it during the charge. Therefore the level checks are only
satisfactory if they are done almost at the end of the charge (but during the charge).
Leakage can occur during operation if you do not obey these instructions when you add
liquid. The level is correct when the distance between the seat of the complete vent valve
and the electrolyte is 20 mm (0.79 in) (distance measured in the condition given above)
(Fig. 5002).
(e) If necessary, add distilled or demineralized water to adjust the level to this value.
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151CH1/151CH2
PERIODICAL CHECK 2.B
Light cleaning
Cleaning
dust only?
yes
yes
U > 21 V
no cell with reversed
polarity
Nut tigthness
no
no
POLARIZATION TEST
Residual discharge
1 V/cell
Salt or electrolyte traces
1 Ω cell shorting
overnight
no
General overhaul
figure 5004
Insulation check
> 2 MΩ
yes
Recharge
no
FAULT ISOLATION
Supplementary test
OK?
Add 5 h overcharge
U > 1.55 V
Adjust electrolyte
Cell voltage before
end of charge
U > 1.55 V
Adjustment of electrolyte level before
end of charge
(volume < 60 cm3)
removal < 30 %
yes
yes
Vent cleaning
no
General overhaul
figure 5004
with replacement of
faulty components.
If more than 5* original
cells, then change all
* If 3 or more cells changed during
cells.
the same check, change all cells
Nut tightness
Battery accepted after
periodical check
Periodical check
Figure 5001/TASK 24-33-96-991-010
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151CH1/151CH2
WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte
levels in nickel-cadnium cells. A very small quantity of acid is sufficient to
cause permanent damage.
The easiest tool to use to adjust the level is a plastic syringe tube (equivalent to that used for
medical injections, with a plastic nozzle on the conical end).
The length of the nozzle which goes into the cell must be 20 mm (0.79 in); this is the distance
necessary between the seat of the complete vent valve and the electrolyte (Refer to figure
5002).
To adjust the level, keep the shoulder of the syringe nozzle against the seat of the complete
vent valve and pull the plunger up.
20 mm (0.79 in)
Level adjustment with a syringe and calibrated nozzle
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Figure 5002/TASK 24-33-96-991-011
If the level is not sufficient, the syringe tube stays empty when you pull the plunger.
If there is too much liquid, this liquid is removed by the syringe until the level aligns with the
end of the nozzle.
If this check shows that the level is not sufficient in some cells, add distilled water to these
cells. (The syringe is small; it can thus be necessary to do this step more than one time for
each cell).
The level is correct when only a small quantity of liquid goes into the syringe when you pull
the plunger. To do this check (after water is added to the cell), keep the shoulder of the syringe nozzle against the seat of the complete vent valve.
(2) Results of the above procedure
The battery operates correctly if:
(a) The voltage of each cell measured during the last hour of charge at 1.5 A is not less than
1.55 V.
(b) Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 15 cm3 (0.92 in3).
If the quantity of water added to all the cells is more than 15 cm3 (0.92 in3), make sure
that the voltage adjustment in relation to the temperature during the charge is correct.
Also do the electrolyte level check more frequently.
Do a full overhaul of the battery (refer to paragraph 3 "General overhaul"):
- If the quantity of water necessary for one or more cell(s) is much higher or smaller than for
the other cells.
- If the voltage of each cell measured at the end of a 1.5 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
(3) Clean the complete vent valve (01-190) and (02-190) (Refer to "CLEANING" chapter) when
you adjust the electrolyte levels.
(4) Make sure that all the nuts that attach the links are torqued (refer to the chapter FITS AND
CLEARANCES).
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(5) Do an insulation check. The insulation resistance measured between the block of cells and
the metal box must be minimum 2 MΩ under 250 VDC if the battery has not gone through a
general overhaul. If not else refer to CHECK chapter.
SUBTASK 24-33-96-210-002
C. Regular check (Ref Fig. 5003)
AFTER A MAXIMUM OF ONE YEAR, do this battery test (follow the different steps shown
fig 5003):
(1) Remove the cover.
(2) Clean the battery.
(3) Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then do the
polarization test.
(4) Discharge the remaining capacity at 15 A down to a voltage of 20 V at the battery terminals.
Measure the time from the start of discharge to the time when the voltage reaches 20 V.
(5) Do an insulation test.
(6) Connect a resistor approximately 1 Ω 3 W (T03) across each cell and continue to discharge.
Resistors with crocodile clips attached to their leads can easily be attached to the cell terminals. Keep the resistors in position for 12 hours.
(7) Remove all resistors, charge the battery (refer to the chapter TESTING AND FAULT ISOLATION for a fully discharged battery).
(8) Adjust the electrolyte level in the cells.Then measure the voltage of each cell during the last
hour of charge. Also, write down the quantity of distilled water added to each cell.
(9) Immediately after the charge and the level adjustment, discharge the battery again at 15 A
down to 20 V; measure the terminal voltage of each cell. Write the time necessary for the second discharge.
(10) Clean the complete vent valves (01-190) and (02-190) (Refer to CLEANING chapter) when
you adjust the electrolyte levels.
(11) Make sure that all nuts that attach the links are torqued (refer to FITS AND CLEARANCES
chapter).
(12) Charge the battery (refer to the chapter TESTING AND FAULT ISOLATION).
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Light cleaning
REGULAR CHECK 2.C
yes
Cleaning
U > 21 V
no cell with reversed
polarity
Nut tigthness
dust only?
yes
POLARIZATION TEST
Residual discharge
1 V/cell
no
1 Ω cell shorting
overnight
Salt or electrolyte traces
General overhaul
figure 5004
no
no
Insulation check
> 2 MΩ
yes
Recharge
FAULT ISOLATION
Supplementary test
OK?
yes
Add 5 h overcharge
U > 1.55 V
Adjust electrolyte
no
Cell voltage before
end of charge
U > 1.55 V
Adjustment of electrolyte level before
end of charge
(volume < 60 cm3)
removal < 30 %
FAULT ISOLATION
no
yes
Capacity check
yes
no
General overhaul
figure 5004
with replacement of
faulty components .
If more than 5* original
cells, then change all
cells.
Supplementary test
OK?
Completed charge
Add 5 h overcharge
no
U > 1.55 V
Adjust electrolyte
level.
Discharge > 1 hour.
Vent cleaning
yes
Nut tigthness
Recharge
Battery accepted after
regular check
* If 3 or more cells changed during
the same check, change all cells
Regular check
Figure 5003/TASK 24-33-96-991-012
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COMPONENT MAINTENANCE MANUAL
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Results of the above tests:
The battery operates correctly if:
- The time necessary for the first discharge is more than 30 minutes.
- The time necessary for the second discharge is not less than 1 hour.
- The voltage of each cell measured during the last hour of the charge at 4 A is not less than
1.55 V.
- The variation of water consumption in individual cell is not more than ±30% of the average consumption for all cells.The maximum limit is 15 cm3 (0.92 in3).
- If the first discharge time is less than 30 minutes but the second discharge time is correct: the
battery is in good condition but was not fully charged when removed from the aircraft.
This condition can be caused by:
- An incorrect charge in the aircraft.
- And /or a discharge caused by an unusual operation of the battery after landing.
Do a full overhaul of the battery if:
- The second discharge time is less than the correct one or one cell has a voltage less than 1 V
(or incorrect polarity before 1 hour of discharge).
- The voltage of each cell measured during the last hour of charge at 4 A is less than 1.55 V.
- The quantity of water necessary for one or more cell(s) is much higher or smaller than for the
other cells.
NOTE: The decrease of water in a SAFT nickel-cadmium cell is in proportion to the overcharge. Thus, the decrease should be the same for all 20 cells in the battery.
If the quantity of water necessary for one or more cell(s) (in the same battery) is much higher (or
smaller) than the other cells, that means that there is a defect:
- Heavy decrease is usually caused by leakage.
- Low decrease is caused by a damaged separator.
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151CH1/151CH2
SUBTASK 24-33-96-210-003
D. General overhaul
(minimum every year or in accordance with the aircraft manufacturer’s instructions )
Follow the different steps shown in Fig. 5004.
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures to
do systematically for all battery components.
Do these steps:
- Disassemble the battery.
- Clean the battery.
- Do a battery inspection.
- Assemble the battery.
- Do an insulation test.
(1) Disassemble the battery (Refer to "DISASSEMBLY" chapter).
(2) Clean the battery (Refer to "CLEANING" chapter).
(3) Do a battery inspection.
(a) Cells
1. Make sure that the lower terminal nuts are tight (refer to "FITS AND CLEARANCES"
chapter).
2. Make sure that cell boxes show no leakage.
(b) Box
Make the sides of the box straight and remove dents.
(c) Nuts, links and spring washers
Discard the components that show signs of corrosion or damage.
(d) Packing parts
Discard all defective components
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
SUBTASK 24-33-96-280-001
E. Insulation resistance
Refer to the chapter TESTING AND FAULT ISOLATION .
SUBTASK 24-33-96-280-002
F. Checking of temperature sensor
Refer to SCHEMATIC DIAGRAM chapter.
Do this test in a climatic chamber with the sensor disassembled from the battery.
(1) For Battery P/N 151CH1.
CHECK OF
BETWEEN
VALUE
Thermostat T
A-B
- 2.2 kΩ ± 5 % at 25 °C (77 °F)
- closes at 71 °C ± 2.8 °C (160 °F ± 5 °F)
when temperature increases
Thermistor C
C-D
R = 300 kΩ ± 3 kΩ at 25 °C (77 °F)
Shunt
E-F
0Ω
(2) For Battery P/N 151CH2.
CHECK OF
BETWEEN
VALUE
Thermostat T
A-B
- 2.2 kΩ ± 5 % at 25 °C (77 °F)
- closes at 71 °C ± 2.8 °C (160 °F ± 5 °F)
when temperature increase
Thermistor C
C-D
R = 300 kΩ ± 3 kΩ at 25 °C (77 °F)
Heater
E-F
- 201 Ω ± 20 Ω at 5 °C (41 °F) or less
- opens at 8 °C ± 2.8 °C (46.4 °F ± 5 °F)
when temperature increases
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151CH1/151CH2
GENERAL OVERHAUL 2.D
Scheduled
yes
U > 21 V
no cell with reversed polarity
On fault
no
POLARIZATION TEST
Nut tightness
Residual discharge
1 Ω cell shorting
overnight
Disassembly
Thorough cleaning
Component inspection
Sensor check
Faulty component
replacement
Charge
Assembly
no
Insulation check
> 10 MΩ
yes
no
FAULT ISOLATION
Other test OK?
Add 5 h overno
charge U > 1.55 V
Adjust electrolyte
General overhaul
with replacement of faulty
components .
If more than 5* original cells
then change all cells.
Cell voltage before end of charge
U > 1.55 V
yes
Adjustment of
electrolyte level
before end of
charge
yes
FAULT ISOLATION
no
Capacity check yes
Other test OK?
Vent cleaning
Completed charge
Add 5 h overNut tightness
charge U > 1.55 V
Recharge
no Adjust electrolyte yes
level. Discharge
Battery accepted af> 1 hour.
ter general overhaul
* If 3 or more cells changed during
the same check, change all cells
General overhaul
Figure 5004/TASK 24-33-96-991-013
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NOTE: If more than 5 original cells have been replaced or more than 3 cells are defective in
the same maintenance, then replace all cells.
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151CH1/151CH2
REPAIR
1. General
As shown in the CHECK chapter, you must reject and replace by new parts the defective parts for
which no repair instructions are given.
The figure and item numbers in this chapter correspond with those of the ILLUSTRATED PARTS
LIST.
2. Equipment
A. Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
B. Standard tools
Standard mechanic’s tools.
C. Materials
Neoprene glue [M03]
3. Repairs
The only authorized repair applicable to the unit is:
- Replacing a cover gasket (01-080) and (02-080).
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151CH1/151CH2
REPAIR N°1
TASK 24-33-96-900-801
1. Replacing a cover gasket
A. General
The cover gasket (01-080) and (02-080) can be replaced only one time.
B. Detailed procedure
- Remove the cover gasket (01-080) and (02-080).
- Clean the joint location.
- Apply paste to the flat side of the gasket.
- Let stay dry for 2 hours in a dry place.
- Put gasket on the bottom of the cover (01-070) and (02-070). Press firmly.
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151CH1/151CH2
ASSEMBLY
1. General
You must do the assembly of parts on a clean workbench in a clean, dry room. The parts will be protected from hit damage.
For tightening parts refer to the torque table in the chapter FITS AND CLEARANCES .
Check that the storage protection layer is removed from the new part before assembly.
WARNING: The figure and item numbers in this chapter correspond with those of the
ILLUSTRATED PARTS LIST.
To do check points, refer to CHECK chapter.
TASK 24-33-96-400-801
2. Assembly procedure
A. Equipment
(1) Special tools
When special tools are used in this chapter they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
(2) Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
SUBTASK 24-33-96-420-001
B. Installation of the liner spacer kit of battery 151CH1 (01-200)
(1) Place the D insulator in the bottom of the box (01-290).
(2) Install the spacer A against the left and right panels.
(3) Install the spacer B (one or two as most as required) against front and back panels.
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151CH1/151CH2
(4) Install the spacer C (one or two at most as required) against B.
(5) Place and hold the spacer E in the middle of the box (01-310).
A
Insulator
0.5x268x175
2
B
Insulator
0.5x155x123
4
C
Spacer
1x155x123
2
D
Insulator
0.5x275x123
1
E
Spacer
1x268x152
3
C. Installation of the liner spacer kit of battery 151CH2 (02-200)
(1) Place the D insulator in the bottom of the box (01-290).
(2) Install the spacer A against the left and right panels.
(3) Install the spacer B (one or two at most as required) against front and back panels.
(4) Install the spacer C (one or two at most as required) against B.
A
Insulator
0.5x268x175
2
B
Insulator
0.5x155x123
4
C
Spacer
1x155x123
2
D
Insulator
0.5x275x123
1
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
B (1 maxi)
B
A
C (1 maxi)
E
E
A
C (1 maxi)
200
B
E
B (1 maxi)
D
Battery 151CH1 liner spacer kit installation
Figure 7001/TASK 24-33-96-991-014
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Battery 151CH2 liner spacer kit installation
Figure 7002/TASK 24-33-96-991-015
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
SUBTASK 24-33-96-420-002
D. Installation of the vent valve (01-190) and (02-190)
(1) Make sure the vent valves (01-190) and (02-190) are in good condition. Replace the vent
valves if they are worn.
(2) Install the vent valve (01-190) and (02-190) with the special tool (T01). Hold the special tool
by its upper ribbed part.
SUBTASK 24-33-96-420-003
E. Installation of a cell of battery 151CH1 (Ref. Fig. 7003 and 7004)
(1) Put five cells (01-140) onto the two corners.
(2) Put four cells (01-140) onto the two corners
(3) Put two cells (01-140) in the middle of each compartment.
Battery 151CH1 cells assembly
Figure 7003/TASK 24-33-96-991-016
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
(4) Move the last cell into position (if it is difficult to put in the last cell, remove one or two
spacers).
(5) Put the temperature sensor (01-220) in place.
(6) Install the links (01-110 thru 01-130).
(7) Install the spring washers (01-100).
(8) Install the nuts (01-090) and torque them.
(9) Install the battery terminal (01-210).and torque them.
(10) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush).
(11) Install the sensor (01-220) on the link (01-130) and install the nut (01-270). Torque them.
(12) Install the screw (01-240), the spring washer (01-250) and the nut (01-260). Torque them.
(13) Install the cable grip (01-280), while respecting cable.
(14) Install the cover (01-060).
(15) Insert the spring washers (01-050) and the screws (01-040) into their respective holes.
Torque them.
(16) Put the spring washer (01-100) and the positive nut battery (01-020).
(17) Put the spring washer (01-100) and the negative nut battery (01-030).
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Battery 151CH1 assembly
Figure 7004/TASK 24-33-96-991-017
SUBTASK 24-33-96-420-004
F. Installation of a cell of battery 151CH2 (Ref. Fig. 7005 and 7006)
(1) Put five cells (02-140) onto the two corners.
(2) Put four cells (02-140) onto the two corners
(3) Put two cells (02-140) in the middle of each compartment.
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Battery 151CH2 cells assembly
Figure 7005/TASK 24-33-96-991-018
(4) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spacers).
(5) Put the heater wiring in place.
(6) Install the links (02-110 thru 02-130).
(7) Install the spring washers (02-100).
(8) Install the nuts (02-090) and torque them.
(9) Install the battery terminal (02-210) and torque them.
(10) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush).
(11) Install the sensor thermostat (02-220) on the link (02-130) and install the screw (02-240) ,
the spring washer (02-250) and the nut (02-260). Torque them.
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151CH1/151CH2
(12) Install the sensor heater (02-230) on the link (02-130) and install the nut (02-270). Torque
them.
(13) Install the cable grip (02-280), while respecting cable.
(14) Install the cover (02-060).
(15) Insert the screw (02-040) and spring washers (02-050) into their respective holes. Torque
them.
(16) Put the spring washer (02-100) and the positive nut battery (02-020).
(17) Put the spring washer (02-100) and the negative nut battery (02-030).
SUBTASK 24-33-96-970-001
G. Inform
(1) Identification plate (01-310) and (02-310) if the box (01-290) and (02-290) has been replaced.
(2) Amendment plate. (01-350) and (02-350)
(3) Log book.
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24-33-96
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151CH1/151CH2
FITS AND CLEARANCES
TASK 24-33-96-400-802
1. Torque table
SUBTASK 24-33-96-420-001
A. Torque table
List of all applicable torque values necessary to assemble and do servicing of the battery:
NOTE: The values hereafter are "lube torque" values. The threads should be lightly
greased before installation and applying torque.
IPL
FIG ITEM
N°
NAME
TORQUE VALUE
01-270
N.m
lbf.in
Nut
2.8 + 0.1
24.8 + 0.8
02-260
Nut
2.8 + 0.1
24.8 + 0.8
02-270
Nut
2 + 0.2
17.8 + 1.7
01-260
Nut
2 + 0.2
17.8 + 1.7
02-040
Nut
2.8 + 0.1
24.8 + 0.8
01-040
Nut
2.8 + 0.1
24.8 + 0.8
01-090
Nut
8 +2
70.9 + 17.8
02-090
Nut
8 +2
70.9 + 17.8
01-210
Nut
8 +2
70.9 + 17.8
02-210
Nut
8 +2
70.9 + 17.8
01-150
Nut
5 + 0.5
44.3 + 4.4
02-150
Nut
5 + 0.5
44.3 + 4.4
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151CH1/151CH2
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General
This chapter is divided into two parts:
- The first part provides the list of SPECIAL TOOLS, AND FIXTURES AND EQUIPMENT necessary
to perform the steps listed in the order chapters.
- The second part provides the listing of Consumable Materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for TOOLS, FIXTURES AND EQUIPMENT,
- Mxx for Consumable Materials.
2. Special tools, fixtures and equipment
PART
NUMBER
DESCRIPTION
USE
CODE
QTY
T01
1
015528
Polyamide key for polyamide
complete vent valve
DISASSEMBLY - CLEANING CHECK - ASSEMBLY
T02
1
016544
Syringe assembly (with nozzle)
TESTING AND FAULT ISOLATION - CHECK
T03
1
164829
Equalizing resistors
(1 Ω / 3 W)
TESTING - CHECK
T04
1
014735
Cell extraction tool
DISASSEMBLY
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Polyamide key for vent valve (T01)
Figure 9001/TASK 24-33-96-991-016
Syringe with nozzle (T02)
Figure 9002/TASK 24-33-96-991-017
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Equalizing resistor (T03)
Figure 9003/TASK 24-33-96-991-018
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Cell extraction tool (T04)
Figure 9004/TASK 24-33-96-991-019
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
3. Consumables
NOTE: You can use equivalent alternatives for listed items.
CODE
DESIGNATION
PARTNUMBER
AND
SPECIFICATION
MANUFACTU
RER
OR SUPPLIER
(NAME,
ADDRESS,
CODE)
M01
Distilled or deionized
water
clear, colourless, oderless
while boiling, resistivity
> 30 kΩ/cm
5 < pH < 7
Absence of organic and
reducing substances.
Reducing agent content
(expressed in weight of
oxygen) < 30 mg/l (test
with permanganate).
Total of ions
SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
Local vendor
M02
Soap
Local vendor
M03
Neoprene glue
Local vendor
Mineral vaseline
NATO: S 743
F: AIR 3565
US: VLP 236
UK: DEF 2333
M04
A
I
R
L
I
N
E
S
T
E
S
T
C
O
D
E
X
D
I
S
A
S
S
E
M
B
L
Y
C
H
E
C
K
C
L
E
A
N
I
N
G
R
E
P
A
I
R
A
S
S
E
M
B
L
Y
S
T
O
R
A
G
E
X
X
X
X
X
CAUTION: Use only distilled or deionized water.
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ILLUSTRATED PARTS LIST
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151CH1/151CH2
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COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
INTRODUCTION
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts
of the unit in disassembly sequence.
It includes the sections that follow:
- Introduction (INTRO),
- Numerical Index (NI),
- Detailed Parts List (DPL).
B. How to Use the illustrated Parts List
(1) To find the illustration for a part if the part number is known, refer to the Numerical Index and
look for the part number and the corresponding figure and item number. Refer to the Detailed
Parts List and look for the first figure and item number found in the Numerical Index for that
part. If this figure shows the part in a section or system of the equipment other than the one
necessary, refer to the other figure numbers listed in the Numerical Index.
(2) To determine the part number of a given part, refer to the illustration showing the assembly
including this part. Note the item number of the illustrated part and refer to the Detailed Parts
List which indicates its part number and identification.
2. Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and electronic
components of the items listed in alphanumeric order for the letters, numerical order for the figures.
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151CH1/151CH2
3. Numerical Index (NI)
In this index, part numbers are classified in this order:
Classification is made from left to right, each character (letter, number, hyphen) being considered
separately.
The first left row ordering is:
- hyphen
- alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
- numbers from 0 to 9.
The part number column contains all part numbers included in the Detailed Parts List. Part numbers
that have been deleted or superseded within the Detailed Part List are listed in the Numerical Index
and identified as deleted or superseded.
4. Detailed Parts List (DPL)
A. Figure and Item Number
Each assembly, sub-assembly and part holding a part number and included in the parts list is given a time number.
The figure number linked to the item number is shown on the first line at the top of each page.
Assemblies, sub-assemblies and numbered parts included in the list but not illustrated are identified by a hyphen (-) preceding the item number.
An index letter shown before the item number refers to the figure showing the modified portion of
the applicable part.
B. Manufacturer's Part Number
A manufacturer's part number is given to each assembly and detail part, whether illustrated or not.
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151CH1/151CH2
C. Parts List
The parts list is represented with indenting showing the relationship of parts and assemblies to
their next higher assemblies as follows :
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
The attaching parts are shown directly after the assembly of the part thereof. They are listed under
the same indent number as the item they are attached to, and are identified by the words "Attaching Parts" and are followed by three asterisks.
The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme righthand side of the first line of the parts list column.
D. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in relation to the next higher assembly (ies) or sub-assembly (ies).
When the effectivity is fully applicable, the usage code column remains blank.
The usage code for assemblies and detailed parts refers to the figure/item number of the next
higher assembly (ies) or sub-assembly (ies).
Example : Effectivity 1A, 1B, 1C is written 1ABC.
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151CH1/151CH2
E. Units per Assembly
The units per assembly column showns the quantity of units required for one next higher assembly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR (as required).
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151CH1/151CH2
5. Abbreviation used
ALT FROM PN XXX
AMDT
AR
DELETED
DET
DPL
EDI
IPL
LH
MFR
MODIFIED FROM
NHA
NP
OLD PN
OPT PN
OPT SEE TABLE
ORDER OVRLGTH MPN
OVERSIZE
PN
POST SB
PRE SB
R
RF
RH
SEE CMM
SEE FIG FOR DET
SEE FIG FOR NHA
SEL FROM
SUPSD BY
SUPSDS
UNDERSIZE
VL
Part that is functionally and physically interchangeable with original part
after reworking.
Amendment
As required
Deleted part
Detail
Detailed Parts List
Equipment Designator Index
Illustrated Parts List
Left hand
Manufacturer or Optional Manufacturer in the IPL
Part obtained by modifying another part
Next higher assembly
Not procurable
Old part number. This item has never been installed.
Optional part number that is fully interchangeable with the part in the
part number column.
See optional table
Part number over fifteen characters
Part with size exceeding its nominal dimension.
Part number.
After modification brought up by a Service Bulletin.
Before modification brought up by a Service Bulletin.
Modified
For reference.
Right hand.
See component Maintenance Manual.
See figure for details.
See figure for next higher assembly.
Selected from. Part which is to be selected as necessary from collection of parts.
Superseded by XXX.
Supersedes XXX.
Part with size smaller than its nominal dimension.
Vendors List.
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6. Updating
A. General
When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the
date of issue changes).
B. Added items
The basic sequence of the items given from 10 to 10 makes it possible to add new items between
the old ones in the appropriate order of the breakdown. With the addition of more than nine new
items, a new number is to be added at the end of the IPL.
C. Deleted items
Should a part number definitively deleted, the information given in the parts list zone is deleted.
The old part number always remains in the numerical index.
D. New Figure Number Added
Whenever new illustrations are necessary the alternative figures are inserted. They refer to the
same parts list.
The alternative figure is given with the basic figure number and letter. This letter precedes the item
number in the parts list.
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VENDOR CODE INDEX
VENDOR CODE
NAME-ADDRESS
F6177
SAFT
12, Rue Sadi Carnot
93170 BAGNOLET
Telex - 235566 F
Phone: (33) (0)1 49 93 19 18
Fax: (33) (0)1 49 93 19 50
V09052
SAFT AMERICA INC.
711 Industrial Boulevard
Valdosta, GA 31601
USA
Phone: (1) 912 245 2331
Fax: (1) 912 245 2827
24-33-96
Page 10009
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
PAGE INTENTIONALLY LEFT BLANK
24-33-96
Page 10010
BLANK
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
ALPHA NUMERICAL INDEX
FIG
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
031282
1
340
1
031282
2
340
1
034031
1
370
1
034031
2
370
1
062007
1
160
2
062007
2
160
2
100078
1
190
2
100078
2
190
2
100111
1
110
40
100111
2
110
40
100593
1
220
1
100593
2
220
1
100693
1
180
1
100693
2
180
1
100694
1
170
1
100694
2
170
1
101229
1
130
9
101229
2
130
9
101279
1
120
8
101279
2
120
8
102013
1
280
1
102013
2
250
1
102077
1
270
1
102077
2
240
1
105405
1
260
1
PART NUMBER
AIRLINE STOCK
NUMBER
24-33-96
Page 10011
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
FIG
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
031282
1
340
1
105405
2
270
3
116056
1
300
1
116056
2
300
1
116711
1
50
4
116711
1
290
1
116711
2
50
4
116711
2
260
1
117026
1
320
1
117026
2
320
1
164584
1
20
1
164584
2
20
1
164585
1
30
1
164585
2
30
1
280068
1
-360
1
280068
2
-360
1
411108
1
330
1
411108
2
330
1
411810
1
100
38
411810
2
100
38
411996
1
200
2
411996
2
200
2
413607
1
360
2
413607
2
360
2
413609
1
350
2
413609
2
350
2
414400
1
150
20
414400
2
150
20
PART NUMBER
AIRLINE STOCK
NUMBER
24-33-96
Page 10012
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
FIG
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
031282
1
340
1
414417
1
310
1
414417
2
310
1
414418
1
70
1
414418
2
70
1
414419
1
80
1
414419
2
80
1
414425
1
240
1
414426
1
60
1
414426
2
60
1
414427
1
-10
1
414427
2
-10
1
414429
1
-1
PM
414475
1
230
1
414475
2
230
1
414480
1
140
2
414480
2
140
2
414482
1
90
2
414482
2
90
2
414519
1
40
4
414519
2
40
4
451215
2
210
1
415218
1
210
1
415236
2
280
1
415237
2
-1
PM
PART NUMBER
AIRLINE STOCK
NUMBER
- Item not illustrated.
24-33-96
Page 10013
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
DETAILED PARTS LIST
030
100
110
120
040
050
020
100
100
130
070
060
080
240
270
220
090
230
130
250
100
A
260
190
150
210
160
170
100
140
200
100
180
A
280
320
340
350
300
310
290
330
010 (with cover) 060
151CH1 BATTERY
Figure 1/TASK 24-33-96-991-020
24-33-96
Page 10014
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
FIGURE
AND
ITEM
PART
NUMBER
AIRLINE
STOCK
NUMBER
NOMENCLATURE
1234567
EFF.
CODE
UNITS
PER
ASSY
01
-001
-010
020
030
040
050
060
070
080
090
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
-360
151CH1
414427
164584
164585
414519
116711
414426
414418
414419
411810
100111
101279
101229
414480
414400
413445
100695
100696
100479
415215
414475
414482
414425
102013
116711
102077
105405
116056
414417
117026
411108
031282
413609
413607
034031
280068
Battery, 20 CVH 150KH
. Box and cover complete
. . Nut, positive battery terminal
. . Nut, negative battery terminal
. . Screw, H M 4-8
. . Washer, spring
. Cover complete
. . Cover, assembly
. . Gasket, cover
. Nut M8X1.25
. Washer, spring
. Link, intercell, E24
. Link, intercell, E27
. Link, intercell, E24 sensor
. Cell, CVH150KH, assembly
. . Nut, M8X1.25
. . Washer, positive polarity
. . Washer, negative polarity
. . Washer, flat
. . Vent valve, complete
. Liner-spacer kit
. Terminal, battery
. Temperature sensor, complete
. . Temperature sensor, assembly
. . Screw, CL M 4-10
. . Washer, spring
. . Nut, HM4
. . Nut, 6/32"
. Cable grip
. Box, assembly
. Film, protector
. Plate, identification
. Plate, filling instruction
. Plate, SAFT label
. Plate, range label
. Plate, amendment
. Plate, recycling
PM
1
1
1
4
4
1
1
1
38
40
8
9
2
20
2
1
1
2
1
1
2
1
NP
1
1
1
1
1
1
1
1
1
2
2
1
1
- Item not illustrated.
24-33-96
Page 10015
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
110
030
100
130
040
050
020
100
320
060
120
070
080
230
270
090
240
250
220
100
260
190
150
140
160
280
170
100
180
A
B
210
100
350
200
A
B
280
360
290(010 with cover 060)
320
330
340
300
151CH2 BATTERY
Figure 2/TASK 24-33-96-991-020
24-33-96
Page 10016
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
FIGURE
AND
ITEM
02
-001
-010
020
030
040
050
060
070
080
090
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
PART
NUMBER
151CH2
414427
164584
164585
414519
116711
414426
414418
414419
411810
100111
101279
101229
414480
414400
062007
100694
100693
100078
415215
414543
414482
414425
102013
116711
102077
105405
116056
414417
117026
411108
031282
413609
413607
034031
280068
AIRLINE
STOCK
NUMBER
NOMENCLATURE
1234567
Battery 151CH2, CVH150KH
. Box and cover complete
. . Nut, positive battery terminal
. . Nut, negative battery terminal
. . Screw, CL M 4-8
. . Washer, spring
. Cover complete
. . Cover, assembly
. . Gasket, cover
. Nut M8X1.25
. Washer, spring
. Link, intercell, E24
. Link, intercell, E27
. Link, intercell, E24, sensor
. Cell, CVH150KH, assembly
. . Nut M10X1.25
. . Washer, positive polarity
. . Washer, negative polarity
. . Washer, flat
. . Vent valve, complete
. Liner-spacer kit
. Terminal, battery
. Temperature sensor, complete
. Temperature sensor, assembly
. . Screw, CLS M 4-10
. . Washer, spring
. . Nut, HM4
. . Nut, 6/32"
. Cable grip
. Box assembly
. Film, protector
. Plate, identification
. Plate, filling instruction
. Plate, SAFT label
. Plate, range label
. Plate, amendment
. Plate, recycling
EFF.
CODE
UNITS
PER
ASSY
PM
1
1
1
4
4
1
1
1
38
40
8
9
2
20
2
1
1
2
1
1
2
1
NP
1
1
1
3
1
1
1
1
1
2
2
1
1
- Item not illustrated.
24-33-96
Page 10017
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
PAGE INTENTIONALLY LEFT BLANK
24-33-96
Page 10018
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
STORAGE (WITH TRANSPORTATION)
TASK 24-33-96-600-802
1. Storage
A. Preparation of the battery before storage
- Adjust the electrolyte level (Refer to "CHECK"), then discharge at a constant current of 15 A
down to 20 V.
- Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the
connector contacts and all the components that can be damaged by atmospheric corrosion.
- Put the battery in its usual vertical position.
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommanded temperature range is + 20 °C ± 15 °C (68 °F ± 27 °F). However, occasional
excursions into the range of - 60 °C to + 60 °C (- 76 °F to + 140 °F) is permitted.
D. Packing
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommend to put the batteries in a welded plastic container. In this type of container, with the recommanded temperature range, you can keep the batteries for 10 years.
TASK 24-33-96-600-803
2. Storage procedure
A. General
When the battery arrives in the battery shop for servicing:
- Visual inspection: if dust or salt do a General Overhaul compliant with procedure (refer to
CHECK chapter).
- Then light cleaning (refer to CLEANING chapter), then service as scheduled (periodical check,
regular check or general check) (refer to CHECK chapter).
24-33-96
Page 15001
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
SUBTASK 24-33-96-610-001
B. Short term storage (Ref. Fig. 15001)
(1) Operations
- Put the charged battery (serviced compliant with CMM procedure) in a cool room or discharge to 1 V/cell (refer TESTING AND FAULT ISOLATION chapter).
- Light greasing of cells terminals.
- Put in a storage room.
24-33-96
Page 15002
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
Short term storage
Figure 15001/TASK 24-33-96-991-021
24-33-96
Page 15003
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
SUBTASK 24-33-96-610-002
C. Long term storage
(1) Operations
- Discharge to 1 V/cell.
- Light greasing of cells terminals.
- Place in a storage room.
(2) Conditions
The battery should be stored filled and discharged.
The storage life is 10 years, if using the following conditions :
- Sealed packaging.
- Temperature: + 20 °C ± 15 °C (68 °F ± 27 °F).
- Humidity: < 70 %.
- Normal vertical position.
- Isolated from detrimental agents: ie. dirt, dust, clampness, vibration, corrosive atmosphere.
NOTE: Lead batteries must be stored in a different room.
CAUTION: Saft Ni-Cd batteries may be stored in temperatures ranging from - 60 °C (- 67 °F)
to + 60 °C (+ 140 °F) for short periods of time without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years
of storage under the above conditions.
No maintenance operation needs to be performed during the storage period.
The maximum battery life, with storage, for which Saft acknowledges responsabilty is 12 years. The use of the battery after this period is only under the
responsability of the operator.
24-33-96
Page 15004
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
TASK 24-33-96-600-804
3. Servicing after storage
Storage time
Servicing procedure
Less than 3 months
Charge the battery (Do one of the procedures given in "TESTING
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year
Do the Periodical check (refer to "CHECK" chapter).
More 1 year
Do the Regular check (refer to "CHECK" chapter).
TASK 24-33-96-500-801
4. Transportation
You must discharge the battery before packing.
You must then pack the battery vertically in its original container. If the original container is not
available, you must obey the international and/or local packaging regulations applicable to the
mode of transport and destination.
24-33-96
Page 15005
Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1/151CH2
PAGE INTENTIONALLY LEFT BLANK
24-33-96
Page 15006
BLANK