(F6177) 156, Avenue de Metz - 93230 Romainville - France Tél. (33) (0)1 49 15 36 00 - Télex 235566F COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST AIRCRAFT BATTERY P/N 4078-2/40678-2 Date of issue : Dec 18/2000 24-31-15 Title page - page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Title page - page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 RECORD OF REVISIONS REVISION No. original 1 ISSUE DATE INSERTED DATE BY June 1987 June 1987 May 25/2000 May 25/2000 REVISION No. ISSUE DATE INSERTED DATE BY SAFT SAFT 24-31-15 ROR Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 ROR Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 RECORD OF TEMPORARY REVISIONS TEMPORARY REV. No. PAGE NUMBER ISSUE DATE BY DATE REMOVED 24-31-15 BY RTR Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 RTR Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SERVICE BULLETIN LIST NUMBER BRIEF DESCRIPTION TYPE AFFECTED 24-31-15 SBL Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 SBL Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 LIST OF APPROVED REPAIRERS TRADE NAME SAFT ADDRESS 156, Avenue de Metz 93230 ROMAINVILLE Telex - 235566 F Phone: (33) (0)1 49 15 36 00 Fax: (33) (0)1 49 42 91 15 24-31-15 LOAR Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 LOAR Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 LIST OF EFFECTIVE PAGES CONTENT PAGE TITLE PAGE 1 2 DATE OF LATEST REVISION Dec 18/2000 Blank RECORD OF REVISIONS 1 2 Dec 18/2000 Blank RECORD OF TEMPORARY REVISIONS 1 2 Dec 18/2000 Blank SERVICE BULLETIN LIST 1 2 Dec 18/2000 Blank LIST OF APPROVED REPAIRERS 1 2 LIST OF EFFECTIVE PAGES CONTENT PAGE Dec 18/2000 Blank TESTING AND FAUL- 1001 TISOLATION 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 DATE OF LATEST REVISION Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 1 2 Dec 18/2000 Dec 18/2000 SCHEMATIC AND WIRING DIAGRAMS 2001 2002 Dec 18/2000 Blank TABLE OF CONTENTS 1 2 Dec 18/2000 Dec 18/2000 DISASSEMBLY TABLE OF ILLUSTRATIONS 1 2 Dec 18/2000 Dec 18/2000 3001 3002 3003 3004 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank CLEANING INTRODUCTION 1 2 3 4 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 4001 4002 4003 4004 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank CHECK DESCRIPTION AND OPERATION 1 2 3 4 5 6 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank 5001 5002 5003 5004 5005 5006 5007 5008 5009 5010 5011 5012 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 24-31-15 LEP Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 LIST OF EFFECTIVE PAGES CONTENT PAGE REPAIR 6001 6002 DATE OF LATEST REVISION Dec 18/2000 Dec 18/2000 ASSEMBLY 7001 7002 7003 7004 7005 7006 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank FITS AND CLEARANCE 8001 8002 Dec 18/2000 Blank SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001 9002 9003 9004 9005 9006 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank ILLUSTRATED PARTS LIST 10001 10002 Dec 18/2000 Blank INTRODUCTION 10003 10004 10005 10006 10007 10008 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 VENDOR CODE INDEX 10009 10010 Dec 18/2000 Blank ALPHA NUMERICAL INDEX 10011 10012 Dec 18/2000 Blank CONTENT PAGE DATE OF LATEST REVISION 10001-0 Dec 18/2000 10001-1 Dec 18/2000 DETAILED PARTS LIST STORAGE (INCLU15001 DING TRANSPORTA- 15002 TION) 15003 15004 15005 15006 24-31-15 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Dec 18/2000 Blank LEP Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TABLE OF CONTENTS INTRODUCTION 1 2 3 4 5 6 7 PAGE 1 1 2 2 2 3 3 4 - General - How to Use the Manual - Measurements - 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 1008 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 - Equipment required - 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 24-31-15 TOC Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 10001-0 SPECIAL PROCEDURES NOT APPLICABLE REMOVAL NOT APPLICABLE INSTALLATION NOT APPLICABLE SERVICING NOT APPLICABLE STORAGE (INCLUDING TRANSPORTATION) 1 - Storage 2 - Storage procedure 3 - Servicing after storage 4 - Transportation 15001 15001 15001 15005 15005 REWORK (service bulletin instructions) 16001 24-31-15 TOC Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TABLE OF ILLUSTRATIONS Figure 1 - 4078-2/40678-2 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 1008 Figure 2001 - Schematic sensor 2001 Figure 5001 - Periodical check 5003 Figure 5002 - Level adjustment with a syringe and calibrated nozzle 5004 Figure 5003 - Regular check 5007 Figure 5004 - General overhaul 5011 Figure 7001 - Liner spacer kit installation 7003 24-31-15 TOI Page 1 Dec 18/2000 NENT MAINTENANCE MANUAL 4078-2/40678-2 Figure 7002 - Cell installation PAGE 7005 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 - 4078-2/40678-2 BATTERY 10001-0 Figure 15001 - Short term storage 15003 24-31-15 TOI Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 INTRODUCTION 1. General A. This manual is written to the ATA Specification 100 and in AECMA Simplified English. IS units of measure are used in this manual, with imperial units in parentheses. B. This manual describes maintenance on components in a workshop. It does not describe maintenance on components when they are installed in aircraft. C. Only approved persons with the necessary skills can do maintenance tasks described in this manual. D. Maintenance Task Oriented Support System (MTOSS) task and subtask identification is used in this manual. 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. 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. The instructions in this manual must be used for all components maintenance. Read all the applicable WARNINGS and CAUTIONS before you do the work on the component. 24-31-15 INTRO Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 C1 A 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 24-31-15 INTRO Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 5. Abbreviations The abbreviations given below are used in this manual: 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 describes the warnings used in this manual. Warnings call attention to use of materials, steps procedures, or limits, which must be followed precisely to avoid injury to persons. Cautions call attention to steps procedures which must be followed to avoid damage to equipment. Notes call attention to procedures which make the job easier. 24-31-15 INTRO Page 3 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 7. Disposal Ni-Cd batteries contain : - nickel, - cadmium, - potassium hydroxide. They must therefore be discarded or used again, in agreement with local legislation. For more information, contact your local SAFT supplier. 24-31-15 INTRO Page 4 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 DESCRIPTION AND OPERATION 1. Description A. General The alkaline battery has 20 vented nickel-cadmium VHP430KH-3 cells with welded polyamide cases. The battery is connected to the aircraft systems. It can be used: (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 The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PART LIST. B. Characteristics (1) Technical data Nominal voltage 24 V Rated capacity C1Ah 43 Ah (see Note below) Battery terminals Connector according to ISO 5064/II MS 3509 Electrolyte Solution of KOH Consumable volume of electrolyte 25 cm3 (3 in3) per cell Maximum dimensions of the battery - Length - Width - Height 254 mm (10 in) 248 mm (9.8 in) 262 mm (10.32 in) Battery maximum weight 38.6 kg (85.1 lbs) Note: 43 Ah at 1 h rate noted as 43 C1Ah or 43 C1Ah. Current value equivalence : 43 A = 1 C1A and 4.3 A = 0.1 C1A for this 43 C1Ah 24-31-15 Page 1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 battery. (2) Operational characteristics - Operating temperature : - 40 to + 71 °C (- 40 to + 160 °F) (3) Electrical characteristics List of all values used to service the battery: Item Value Use for 1 C1 A 43 A Charge/Discharge 0.5 C1A 21.5 A Charge 0.1 C1A 4.3 A Charge C. Detailed description The battery has 20 VHP430KH-3 (130) cells housed in a stainless steel box. The box (320) is lined with thin sheets of insulation and wedges (200). The cells are kept upright by means of a molded silicone elastomer part (040) fastened to the cover which presses against the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (080 thru 120). The connector (240) connects the battery to the aircraft. The cover (020), which can be removed, is attached to the box (320) by four latches. 24-31-15 Page 2 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 4078-2/40678-2 Battery Figure 1//TASK 24-31-15-991-001 24-31-15 Page 3 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Identification plate Figure 2/TASK 24-31-15-991-002 Amendment plate Figure 3/TASK 24-31-15-991-003 24-31-15 Page 4 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Overall dimensions Figure 4/TASK 24-31-15-991-004 24-31-15 Page 5 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 6 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 24-31-15-700-801 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%. 24-31-15 Page 1001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (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 that give 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. 24-31-15 Page 1002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-720-001 C. Preliminary Functional Tests (Ref. Fig. 1001) 1 Discharge at 1 V/cell Tighten the nuts (060) 1 Ω cell shorting 12 h charge at 1 C1A (43 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 45 ml added in all cells electrolyte in the box Yes box or cells damaged No Yes Yes see para. 5.B (2) Yes see para. 5.B (3) voltage of 1 cell < 1.5 V No Yes see para. 5.B (4) capacity check < 100% C1Ah Yes see para. 5.B (5) Yes see para. 5.C (4) see para. 5.C (2) see para. 5.C (3) more than 45 ml added in 1 cell No No battery voltage = 0 V see para. 5.B (1) No Topping up at the end of charge No metallic parts corroded Yes Yes see para. 5.A (1) 1 or more cell has a voltage > 0.1 V than the others No No 1 or more cell = 0 V Yes see para. 5.B (7) No 1 or more cell < 0 V Yes see para. 5.B (5) No No insulation between cell and box < 250 kΩ No Yes a link or a nut is too hot see para. 5.A (3) No do a General Overhaull to detect battery fault or external cause Preliminary Functional Tests Figure 1001/TASK 24-31-15-991-005 24-31-15 Page 1003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-720-002 D. Testing procedure (1) Insulation check - Put the megohmeter as the figure below shows: MΩ Insulation Check Figure 1002/TASK 24-31-15-991-006 - ≥ 250 kΩ under 250 VDC = Min value. - > 10 MΩ under 250 VDC = value after cleaning and drying. 24-31-15 Page 1004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 250 K Ω problem 2 MΩ Necessary to clean 10 M Ω Can wait until next maintenance In b atte ry m ainte na nce sho p Cleaning necessary OK Always necessary after cleaning and drying Cleaning necessary A ccepta ble Check the cause (overcharge…) Insulation Parameters Figure 1003/TASK 24-31-15-991-007 (2) Polarization test Charge the battery at 4.3 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 volts, charge the battery. 24-31-15 Page 1005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (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 Vent valve (180) 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 vented filler cap 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 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 (180) (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 4.3 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 1.5 V. - Adjust the electrolyte level during the last 30 minutes of charge. - Discharge at 43 A down to 1 V/cell. - After this test, discard the defective cells: - Cells with a voltage of less than 1.5 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 volts). 24-31-15 Page 1006 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TASK A24-31-15-800-801 3. Charge SUBTASK 24-31-15-820-001 A. Flight charge The decrease of water from the electrolyte is in direct proportion to the overcharge current. SUBTASK 24-31-15-820-002 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 > 1.5 V) AND ELECTROLYTE ADJUSTMENTS BY THE MEAN OF A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT: 4.3 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. Cell connections Figure 1004/TASK 24-31-15-991-008 24-31-15 Page 1007 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (1) Constant-current charge (Battery fully discharged) (a) To charge a fully discharged battery, do one of these procedures CONSTANT-CURRENT CHARGE Main charge Final charge 4.3 A (0.1 C1A) until 30 V as battery voltage mini 10 h Periods: maxi 12 h 4.3 A (0.1 C1A) for a 4 h period 21.5 A (0.5 C1A) until 31 V as battery voltage mini 2 h Periods: maxi 2 h 30 minutes 4.3 A (0.1 C1A) for a 4 h period 43 A (1 C1A) until 31.4 V as battery voltage mini 1 h Periods: maxi 1 h 15 minutes 4.3 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 43 A (1 C1A) down to 20 V. Refer to paragraph DISCHARGE. Charge : refer to B (1) (a) above constant current charge. 24-31-15 Page 1008 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TASK 24-31-15-800-802 4. Discharge Rated capacity (C1Ah) 43 Ah : minimum value obtained for a fully charged battery, when discharged at 43 A, down to 20 V. Other rates (C1A) Depending on temperature and time: up to 25 C1A. TASK 24-31-15-700-802 5. Fault isolation SUBTASK 24-31-15-760-001 A. Battery electrical faults PROBLEM PROBABLE CAUSE CORRECTION (1) Zero battery open-circuit volt- (a) Defective electrical connector Examine electrical contacts, age (no contact made) links and tightness of nuts (refer to CHECK chapter). (b) Link loose or broken Make sure the nuts are tight (refer to CHECK chapter). (2) Zero volts with the battery set (a) Battery fully discharged to "discharge" (3) Low insulation 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). 24-31-15 Page 1009 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-770-001 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 CHECK chapter). very different from the other cells the average : leaks from the 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 1.5 V at 4.3 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 60 min at 1 C1A). (a) Usual wear after long opera- Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND tion. 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). 24-31-15 Page 1010 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-750-001 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 temExamine the cause of excessive perature or too much current. 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). 24-31-15 Page 1011 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PROBLEM (3) Corrosion on the links. PROBABLE CAUSE CORRECTION Make sure the battery test bench and the storage areas have no materials which can release acid fumes. (a) Operation in acid air (b) Mechanical damage to nickel Replace the damaged links (refer to DISASSEMBLY, plating 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 24-31-15-750-002 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. 24-31-15 Page 1012 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SCHEMATIC AND WIRING DIAGRAMS 1. General This chapter gives all electrical schematics of battery sensor. 2. Schematic sensor Schematic sensor Figure 2001/TASK 24-31-15-991-009 24-31-15 Page 2001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 2002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 level of disassembly. WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT ISOLATION CHAPTER). The figures and items numbers used in this chapter correspond to those of the ILLUSTATED PARTS LIST. 2. Safety The Safety rules are different from one country to another. Only local rules are applicable. 3. Risks There are three types of risks. A. Physical - Handling: lift with your legs and not your back. - Wear protective shoes. B. Electrical - Don’t wear rings, watches, chains, belt buckles. - Use insulated tools. C. Chemical - Electrolyte is very corrosive and may cause severe damage to the skin: wear gloves - Contact with eyes is very dangerous, wear protective goggles. 24-31-15 Page 3001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 neutralize the solution 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 at least 15 minutes and call a doctor. - Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the solution with water or, if possible, with milk. Call a doctor immediately. Do not try to make somebody unconscious drink . Contact with nickel can cause chronic eczema. Inhalation of cadmium oxide can cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest. Persons having inhaled cadmium oxide fumes must get fresh air or take oxygen or must have artificial respiration. - Potash can cause eczema. TASK 24-31-15-000-801 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 24-31-15-020-001 B. Disassembly procedure WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT ISOLATION CHAPTER). (1) Remove the cover (020) (2) Removal of a cell NOTE: In order to avoid a short-circuit, remove a link (080) between two cells. 24-31-15 Page 3002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (a) Remove the nuts (050) and the spring washers (060) that attach the links from the cell. (b) Remove all links (080 thru 120). (c) Fully engage the end of the special threaded tool (T03) onto one of the cell terminals. Then pull up to remove the cell. NOTE: The vent valve must stay tight when the cell is removed. (3) Removal of a vent valve (safety cap) (a) Unscrew the vent valve (180) with the special tool (T01). (b) Remove the vent valve with its O-ring. (4) Disassembly of the battery (a) Remove 1. The cover (020). 2. The cells (130). 3. The liner spacers kit (190). 4. The connector (220). (b) Remove the sensor (240) 24-31-15 Page 3003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 3004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 CLEANING 1. General The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS LIST. 2. Equipment required - 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 24-31-15-100-801 4. Cleaning procedure WARNING: THE ELECTROLYTE IS DANGEROUS. BE CAREFUL WHEN HANDLING ELECTROLYTE AND AVOID 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 AT LEAST 15 MINUTES AND, IN ALL CASES, GET IMMEDIATE MEDICAL ATTENTION. SUBTASK 24-31-15-160-001 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. 24-31-15 Page 4001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-160-002 B. Full cleaning Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components. (1) Cells Make sure that the vent valve (180) (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 and handle 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: THE CLEANING OF THE VENT VALVE (180) MUST BE DONE WHEN THE CELLS ARE ASSEMBLED IN THE BOX. (a) Remove the vent valve (180) (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. 24-31-15 Page 4002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TASK 24-31-15-600-801 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. 24-31-15 Page 4003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 4004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 levels, and capacity test. - General overhaul: disassembly, full cleaning, assembly and regular check. TASK 24-31-15-200-801 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 %. 24-31-15 Page 5001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (5) Referenced information REFERENCE 24-31-15-720-002 DESIGNATION Insulation check Polarisation test Vent valve test Supplementary test SUBTASK 24-31-15-210-001 B. Periodical check If the electrolyte consumption exceded the approved used between 2 regular check, apply this periodical check: - Follow the differents steps indicated 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 43 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 vented filler cap 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. 24-31-15 Page 5002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 no General overhaul figure 5004 Insulation check > 2 MΩ yes Recharge no FAULT ISOLATION Supplementary test OK? Add 5 h overcharge U > 1.5 V Adjust electrolyte Cell voltage before end of charge U > 1.5 V Adjustment of electrolyte level before end of charge (volume < 25 cm3) removal < 30 % yes yes Vent cleaning no G e n e ra l o ve rh a u l fig u re 5 0 0 4 w ith re p la ce m e n t o f fa u lty co m p o n e n ts. If more than 5* original * If 3 or more cells changed ducells, then change all ring the same check, change all cells. cells. Nut tightness Battery accepted after periodical check Periodical check Figure 5001/TASK 24-31-15-991-010 24-31-15 Page 5003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 vented filler cap and the electrolyte (Refer to figure 5002). To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vented filler cap and pull the plunger up. 20 mm (0.79 in) Level adjustment with a syringe and calibrated nozzle Figure 5002/TASK 24-31-15-991-011 24-31-15 Page 5004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 vented filler cap. (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 4.3 A is not less than 1.5 V. (b) Approximately the same quantity of distilled water is added to each cell. This quantity must be less than 25 cm3 (3 in3). NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell (3 in3/cell), 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 4.3 A charge is less than 1.5 V (refer to the chapter TESTING AND FAULT ISOLATION). (3) Clean the vent valve (180) (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). 24-31-15 Page 5005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (5) Do an insulation check. The insulation resistance mesured between the block of cells and the metal box must be at least 2 MΩ under 250 VDC if the battery has not gone through a general overhaul. If not else refer to CHECK chapter. SUBTASK 24-31-15-210-002 C. Regular check (Ref Fig. 5003) At least every 2000 operating hours and AFTER A MAXIMUM OF ONE YEAR, do this battery test: - Follow the differents steps indicated in Fig 5003. - 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 (refer to TESTING AND FAULT ISOLATION para. 2.D.2). - Discharge the batterie (refer to para. (4)) - Do an insulation test (refer to TESTING AND FAULT ISOLATION para. 2.D.1) - Adjust the electrolyte level (refer to para. (8)). - Do a capacity check (refer to para. (9)) NOTE : According to aicraft operation, the ratio between operating hours (aircraft "power on") and flying hours is generally is the 1.2 to 2 range. (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 43 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 43 A. At 1 hour of discharge, measure voltage of each cells. This voltage must be over 1 V. Continu to dischage the battery down to 20 V. Write the time necessary for the second discharge. (10) Clean the vented filler caps (180) (Refer to CLEANING chapter) when you adjust the electrolyte levels. 24-31-15 Page 5006 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 > 1.5 V Adjust electrolyte no Cell voltage before end of charge U > 1.5 V Adjustment of electrolyte level before end of charge (volume < 60 cm3) removal < 30 % FAULT ISOLATION no no G e n e ra l o ve rh a u l fig u re 5 0 0 4 w ith re p la ce m e n t o f fa u lty co m p o n e n ts . If more than 5* original cells, then change all cells. Supplementary test OK? Completed charge Add 5 h overcharge no U > 1.5 V Adjust electrolyte level. Discharge > 60 min yes Capacity check 1 V/cell ≥ 60 min yes Vent cleaning yes * If 3 or more cells changed during the same check, change all cells. Nut tigthness Recharge Battery accepted after regular check Regular check Figure 5003/TASK 24-31-15-991-012 24-31-15 Page 5007 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 4.3 A is not less than 1.5 V. - The variation of water consumption in individual cell does not exceed ±30% of the average consumption for all cells.The maximum limit is 25 cm3 (3 in3). NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell (3 in3/cell), do the electrolyte level check more frequently. - 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 the correct one or one cell has a voltage of 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 4.3 A is less than 1.5 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. This means that there is a defect: - Leakage usually causes heavy decrease. - A damaged separator causes low decrease. 24-31-15 Page 5008 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-210-003 D. General overhaul (minimum 1 per year) This overhaul includes electrical tests. It also includes disassembly and cleaning procedures to do systematically for all battery components. Do these steps: - Follow the differents steps indicated in Fig 5004 - 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. Verify 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. 24-31-15 Page 5009 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 (e) Connector Make sure that the connector is in good condition (inner and outer surfaces). Replace it if contacts are burned. SUBTASK 24-31-15-280-001 E. Insulation resistance Refer to the chapter TESTING AND FAULT ISOLATION . SUBTASK 24-31-15-280-002 F. Checking of temperature sensor Refer to SCHEMATIC DIAGRAM chapter. Do this test in a climatic chamber with the sensor disassembled from the battery. CHECK OF BETWEEN VALUE Thermostat T C-D closes at 71 °C ± 2.8 °C (160 °F ± 5 °F) when temperature increase Thermistor C A-B R = 300 kΩ ± 3 kΩ at 25 °C (77 °F) Mesure the insulation resistance between each connector point and every metal housing. The value must be superior to 30 MΩ at 250 Vdc. 24-31-15 Page 5010 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 G E N E R A L O V E R H A U L 2.D S cheduled yes U > 21 V no cell with reversed polarity O n fault no P O LA R IZ A TIO N TE S T N ut tightness Residual discharge 1 Ω cell shorting overnight D isassem bly Thorough cleaning C om ponent inspection S ensor check Faulty component replacement C harge A ssem bly no Insulation check > 10 MΩ yes no F A U LT IS O LA TIO N no Other test OK? Add 5 h overcharge U > 1.5 V Adjust electrolyte Cell voltage before end of charge U > 1.5 V yes Adjustment of electrolyte level before end of charge yes FA U LT IS O LA TIO N G en e ra l overh au l w ith rep la ce m e nt o f fa u lty co m p o ne n ts . If more than 5* original cells then change all cells. * If 3 or more cells changed during the same check, change all cells. no Capacity check 1 V/cell ≥ 60 min yes Other test OK? V ent cleaning Completed charge Add 5 h overN ut tightness charge U > 1.5 V R echarge no Adjust electrolyte yes level. Discharge Battery accepted af> 60 min. ter general overhaul General overhaul Figure 5004/TASK 24-31-15-991-013 24-31-15 Page 5011 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 NOTE: If more than 5 original cells have been changed or more than 3 cells are faulty in the same maintenance, then change all cells. 24-31-15 Page 5012 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 REPAIR 1. General As indicated in the CHECK chapter, defective parts for which no repair instructions are given shall be rejected and replaced by new parts. The figure and item numbers used 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: - Changing a gasket cover (040). 24-31-15 Page 6001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 REPAIR N°1 TASK 24-31-15-900-801 1. Changing a cover gasket A. General The gasket cover (040) can be changed only one time. B. Detailed procedure - Remove the gasket cover (040). - 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 (030). Press firmly. 24-31-15 Page 6002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 ASSEMBLY 1. General Parts assembly shall be done on a clean workbench in a clean, dry room. They 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. The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED PARTS LIST. To do check points, refer to CHECK chapter. TASK 24-31-15-400-801 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. 24-31-15 Page 7001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-420-001 B. Installation of the liner spacer kit (190) (Ref. Fig. 7001) (1) Put in position the A insulator. (2) Put in position F,G, and I insulators (3) Put in position B, C, D, and E spacers. (4) Install the cells.. A Insulator 0.3x236x58 3 B spacer 2x238x75 5 C spacer 1x238x75 6 D spacer 1x220x75 1 E spacer, slotted 1x245x238 4 F Insulator, slotted 0.5x245x238 3 G Insulator 0.5x245x235 2 H spacer 1x235x210 2 I Insulator 0.5x235x210 2 24-31-15 Page 7002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Liner spacer kit installation Figure 7001/TASK 24-31-15-991-014 24-31-15 Page 7003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-31-15-420-002 C. Installation of the vent valve (180) (1) Make sure the vent valves (180) are in good condition. Replace the vent valves (180) if they are worn. (2) Install the vent valve (180) with the special tool (T01). Hold the special tool by its upper ribbed part. SUBTASK 24-31-15-420-003 D. Installation of a cell (Ref. Fig. 7002) (1) Put five cells (130) in the side compartments. (2) Put four cells (130) in the middle of each compartment. (3) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spacers). (4) Carefully position the cell (130) and push onto terminals with a piece of soft wood. (5) Install the links (080 thru 120). (6) Install the spring washers (060). (7) Install the nuts (050) and torque them. (8) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush). (9) Install the cover (020) and attach it. SUBTASK 24-31-15-970-001 E. Inform (1) Identification plate (310) if the box (290) has been changed (2) Amendment plate. (340) (3) Log book. 24-31-15 Page 7004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Cell installation Figure 7002/TASK 24-31-15-991-015 24-31-15 Page 7005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 7006 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 FITS AND CLEARANCES TASK 24-31-15-400-802 1. Torque table SUBTASK 24-31-15-420-001 A. Torque table List of all applicable torque values needed to assemble and do servicing of the battery: NOTE: The values here are "lube torque" values. The threads should be lightly greased before to installation and applying torque. TORQUE VALUE IPL FIG ITEM N° NAME daN.m lbf.in 050 Nut 12 to 14 103 to 112 140 Nut 4.5 to 5.5 39 to 47 24-31-15 Page 8001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 8002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 needed 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 CODE QTY PART NUMBER DESCRIPTION USE T01 1 015528 Polyamide key for polyamide vented filler cap 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 013169 Cell extraction tool DISASSEMBLY 24-31-15 Page 9001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Polyamide key for vent valve (T01) Figure 9001/TASK 24-31-15-991-016 Syringe with nozzle (T02) Figure 9002/TASK 24-31-15-991-017 24-31-15 Page 9002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Equalizing resistor (T03) Figure 9003/TASK 24-31-15-991-018 24-31-15 Page 9003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 Cell extraction tool (T04) Figure 9004/TASK 24-31-15-991-019 24-31-15 Page 9004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 3. Consumables NOTE: Equivalent alternatives can be used for list 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 OTAN: 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. 24-31-15 Page 9005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 9006 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 ILLUSTRATED PARTS LIST 24-31-15 TP Page 10001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 TP Page 10002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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 following sections : - 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. 24-31-15 Page 10003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 3. Numerical Index (NI) In this index, part numbers are classified in the following 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. 24-31-15 Page 10004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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. 24-31-15 Page 10005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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). 24-31-15 Page 10006 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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. 24-31-15 Page 10007 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 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. 24-31-15 Page 10008 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 VENDOR CODE INDEX VENDOR CODE NAME-ADDRESS F6177 SAFT 156, Avenue de Metz 93230 ROMAINVILLE Telex - 235566 F Phone: (33) (01) 49 15 36 00 Fax: (33) (01) 49-42-91 15 V09052 SAFT AMERICA INC. 711 Industrial Boulevard Valdosta, GA 31601 USA Phone: (1) 912 245 2331 Fax: (1) 912 245 2827 24-31-15 Page 10009 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 10010 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 ALPHA NUMERICAL INDEX PART NUMBER AIRLINE STOCK NUMBER 4078-2/40678-2 412802 412803 412792 412800 412488 062007 100094 012374 015539 015266 411691 114767 165949 062007 100694 100693 100094 100078 415218 412806 100431 100430 163038 102392 100713 166925 412804 105405 161061 116056 412801 412791 117026 411108 166309 413609 413611 166314 280068 FIG NUMBER INDEX NUMBER -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 -310 320 330 340 350 360 370 380 390 TOTAL REQUIRED PM 1 1 1 1 2 42 42 11 2 1 3 4 20 2 1 1 2 2 1 1 4 4 2 1 1 1 1 3 1 5 1 1 1 1 2 2 2 1 1 - Item not illustrated. 24-31-15 Page 10011 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 10012 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 DETAILED PARTS LIST 4078-2/40678-2 BATTERY Figure 1/TASK 24-31-15-991-020 24-31-15 Page 10001-0 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 FIGURE AND ITEM PART NUMBER AIRLINE STOCK NUMBER NOMENCLATURE 1234567 EFF. CODE UNITS PER ASSY 01 -001A -001B 010A 010B 020B 030A 030B 040A 040B 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 300A 300B 310 320 330 340 350 360 370 4078-2 40678-2 410220 412743 412488 410219 114300 166234 102295 113605 062007 100094 012374 015539 015266 411691 114767 165797 062007 100694 100693 100078 415218 411424 100431 100430 102392 100713 166925 410218 115763 114724 115764 105405 410035 412744 117026 411108 166309 413609 166314 413611 280068 Battery 4078-2, VHP430KH-3 Battery 40678-2, VHP430KH-3 . Box and cover complete . Box and cover complete . handle . Cover complete . Cover complete . . Cover, assembly . . Cover, assembly . . Gasket, cover . Nut M10X1.25 . Washer, spring . Link, intercell, E34 . Link, intercell, E37 . Link, intercell, E49 . Link, curved . Link, V . Cell, VHP430KH-3, assembly . . Nut M10X1.25 . . Washer, positive polarity . . Washer, negative polarity . . Washer, flat . . Vent valve . Liner-spacer kit . Screw M4X10 . Washer, lock . Connector complete . O-ring 56.75 . Protector . Sensor, complete . . Nut, . .Washer 18.5/32 . . O-ring 20.35 . . Nut 6/32" . Box assembly . Box assembly . Film, protector . Plate, identification . Plate, filling instruction . Plate, SAFT label . Plate, amendment . Plate, range . Plate, recycling PM PM 1 1 2 1 1 1 1 1 42 42 14 2 1 3 1 20 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 - Item not illustrated. 24-31-15 Page 10001-1 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 STORAGE (INCLUDING TRANSPORTATION) TASK 24-38-52-600-802 1. Storage A. Preparation of the battery before storage - Adjust the electrolyte levels (Refer to "CHECK"), then discharge at a constant current of 40 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 recommendto put the batteries in a welded plastic container. In this type of container, with the recommanded temperature range, the batteries can be kept for 10 years. TASK 24-38-52-600-803 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 according 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). 24-31-15 Page 15001 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-38-52-610-001 B. Short term storage (Ref. Fig. 15001) (1) Operations - Place the charged battery (serviced according to CMM procedure) in a cool room or discharge to 1 V/cell (refer TESTING AND FAULT ISOLATION chapter). - Light greasing of cells terminals. - Place in a storage room. 24-31-15 Page 15002 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 100 AVAILABLE CAPACITY (%C1Ah) 90 80 CHARGE RETENTION Aircraft Ni-Cd battery 70 Temp. (5°C) Temp. (15°C) Temp. (25°C) Temp. (35°C) 60 0 10 Disch. (0%C1Ah) Disch. (0%C1Ah) Disch. (0%C1Ah) Disch. (0%C1Ah) 20 30 40 50 60 70 80 90 REST TIME (days) Short term storage Figure 15001/TASK 24-31-15-991-021 24-31-15 Page 15003 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 SUBTASK 24-38-52-610-002 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 : Le. 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. 24-31-15 Page 15004 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 TASK 24-38-52-600-804 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 24-38-52-500-801 4. Transportation The battery must be discharged before packing. The battery should then be packed vertically in its original container. If the original container is not available, the international and/or local packaging regulations applicable to the mode of transport and destination must be followed. 24-31-15 Page 15005 Dec 18/2000 COMPONENT MAINTENANCE MANUAL 4078-2/40678-2 PAGE INTENTIONALLY LEFT BLANK 24-31-15 Page 15006 Dec 18/2000