24-31-07 - Documentation / Downloads

To: Holders of 539CH-1 (Saft 024147-000) and 5319CH1 (Saft 025920-000) batteries
Subject: CMM Revision No. 4 Dated Jul 28/10
HIGHLIGHTS
The entire CMM was revised to include battery 5319CH1 with the following Part Numbers:
Saft Type
5319CH1
Saft P/N
025920-000
ELDEC P/N BA35-02
Boeing P/N S282T003-4
Pages which have content in addition to the header revision to include new battery 5319CH1
are outlined below together with the highlights of the revision.
Discard any previous revision of the CMM and use the current revision dated Jul 28/10.
NOTE: The CMM can be downloaded from the internet at www.saftbatteries.com
Chapter/Section and
Page Number
Title page
Page T-1
Title page
Page T-1
Title page
Page T-1
Record of Revisions
ROR Page 1
Record of Temporary
Revisions
RTR Page 1
List of Effective Pages
LEP Page 1
Introduction
Intro Page 1
Testing and Fault Isolation
Page 1001
Testing and Fault Isolation
Page 1006
Testing and Fault Isolation
Page 1007
Testing and Fault Isolation
Page 1010
Description of Change
Add Saft cage code, telephone phone and
fax numbers to the header
Add part description and Saft website
Effectivity
All Models
Add new battery part numbers
All Models
Add Revision 4
All Models
Correct 24-3 Rev 1 record
All Models
Revise all pages
All Models
Change IS to International Standard
All Models
Correct grammar
All Models
Add note defining C1A
All Models
Change part number
All Models
Correct paragraph letter
All Models
All Models
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Highlights Page 1 of 2
Jul 28/10
Chapter/Section and
Page Number
Testing and Fault Isolation
Page 1011
Disassembly
Page 3002
Cleaning
Page 4001
Cleaning
Page 4002
Check
Page 5001
Assembly
Page 7001
Assembly
Page 7004
Assembly
Page 7005
Fits and Clearances
Page 8001
Special Tools, Fixtures
and Equipment
Page 9001
Illustrated Parts List
Page 10001
Illustrated Parts List
Page 10001
Illustrated Parts List
Page 10003
Illustrated Parts List
Page 10007
Description of Change
Correct paragraph letters
Effectivity
All Models
Correct torque
All Models
Change part number
All Models
Correct grammar
All Models
Correct grammar and torque
All Models
Correct torque
All Models
Correct torque
All Models
Correct torque and revise Technical Note
revision and date
Correct torque
All Models
Change maintenance kit part number,
Change Figure 9001; Add notes 1 and 2
All Models
Add battery 5319CH1
All Models
Revise battery nomenclature for battery
024147-000, 539CH-1 and add ELDEC P/N
BA35-01 and ELDEC cage code
Change Figure 1, Sheet 1, Battery Exploded
View to include Index part 10A
Add battery 5319CH1 and Case, Marked to
parts list
All Models
All Models
All Models
All Models
24-31-07
Highlights Page 2 of 2
Jul 28/10
Cage Code 09052
711 INDUSTRIAL BOULEVARD
VALDOSTA, GEORGIA 31601
Phone: 1 (229) 247-2331
Fax: 1 (229) 247-8486
Nickel Cadmium Aircraft Battery
SAFT Type No. 539CH-1
SAFT Part No. 024147-000
ELDEC Part No. BA35-01
BOEING Part No. S282T003-1
SAFT Type No. 5319CH1
SAFT Part No. 025920-000
ELDEC Part No. BA35-02
BOEING Part No. S282T003-4
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
Website: www.saftbatteries.com
24-31-07
Page T-1/T-2 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
RECORD OF REVISIONS
REV
NO.
1
2
3
4
ISSUE
DATE
07/13/01
02/28/05
05/01/06
07/28/10
INSERT
DATE
07/13/01
02/28/05
05/01/06
07/28/10
BY
REV
NO.
ISSUE
DATE
INSERT
DATE
BY
Saft
Saft
Saft
Saft
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ROR Page 1/ROR Page 2 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
RECORD OF TEMPORARY REVISIONS
PAGE
TEMPORARY
REV NO
NUMBER
24-3 Rev 1
1007/1008
ISSUE DATE
Nov 02/05
BY
SAFT
DATE
May 01/06
BY
SAFT
24-31-07
RTR Page 1/RTR Page 2 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
REVISION NUMBER
DATE BULLETIN
INCORPORATED INTO
MANUAL
PRODUCT IMPROVEMENTS
Product Improvements have been incorporated using service bulletins entered in the
service bulletin list. Service bulletin highlights are as follows:
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SBL Page 1/SBL Page 2 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
SUBJECT
PAGE
DATE
Title Page
T-1
T-2
Jul 28/10
Blank
Cleaning
4001
4002
Jul 28/10
Jul 28/10
Record of Revisions
RR-1
RR-2
Jul 28/10
Blank
Check
Record of Temporary
Revisions
RTR-1
RTR-2
Jul 28/10
Blank
5001
5002
5003
5004
Jul 28/10
Jul 28/10
Jul 28/10
Blank
Service Bulletin List
SBL-1
SBL-2
Jul 28/10
Blank
Repair
6001
6002
Jul 28/10
Blank
List of Effective Pages
LEP-1
LEP-2
Jul 28/10
Blank
Assembly
Table of Contents
TC-1
TC-2
Jul 283/10
Blank
7001
7002
7003
7004
7005
7006
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Feb 13/10
Blank
Introduction
INTRO-1
INTRO-2
1
2
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Fits and Clearances
8001
8002
Jul 28/10
Blank
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
Jul 28/10
Jul 28/10
Jul 2810
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Blank
Special Tools,
Fixtures, and
Equipment
9001
9002
Jul 28/10
Blank
Illustrated Parts List
10001
10002
10003
10004
10005
10006
10007
10008
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Jul 28/10
Blank
3001
3002
Jul 28/10
Jul 28/10
Description and
Operation
Testing and Fault
Isolation
Disassembly
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LEP Page 1/LEP Page 2 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
TABLE OF CONTENTS
PARAGRAPH TITLE
PAGE
Description and Operation
1
Testing and Fault Isolation
1001
Automatic Test Requirements (ATLAS)
N/A
Disassembly
3001
Cleaning
4001
Check
5001
Repair
6001
Assembly (Including Storage)
7001
Fits and Clearances
8001
Special Tools, Fixtures, and Equipment
9001
Illustrated Parts List
10001
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TOC Page 1/TOC Page 2 Blank
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
INTRODUCTION
1.
General
A.
This manual is written to the ATA Specification 100 and in AECMA Simplified English.
International Standard 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 personnel with the necessary skill can do maintenance tasks
described in this manual.
D.
This manual contains:
a. Technical data for components
b. Maintenance and repair procedures for components
c. An Illustrated Parts List (IPL) with data for parts of components. Parts are
identified in all sections of the manual by IPL figure and item number.
E.
We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and
ASSEMBLY procedures by doing them.
The manual is divided into separate sections:
1.
2.
3
3.
4.
5.
6.
Title Page
Record of Revisions
Record of Temporary Revisions
List of Effective Pages
Table of Contents
Introduction
Procedures and IPL Sections
The disassembly, repair, and assembly sections generally contain only specific instructions
to be used on the equipment covered herein. Most standard aerospace practices are not
described herein.
24-31-07
Intro Page 1
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
An explanation of the use of the Illustrated Parts List (IPL) is provided in the Introduction to
that section.
Every effort has been taken to provide complete and accurate component maintenance
instructions. However, if a situation should arise that is not adequately covered by this
manual, please contact SAFT America Inc. for specific information. SAFT America Inc. can
be contacted at the following address:
Saft America, Inc.
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Telephone: (229) 247-2331
FAX:
(229) 247-8486
Saft
12 Avenue Sadi Carnot
93170 Bagnolet
France
Telephone: 33 1 49 93 19 18
FAX: 33 1 49 93 19 58
Verification:
Testing / Fault Isolation
Disassembly
Assembly
6/30/97
6/30/97
6/30/97
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Intro Page 2
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
DESCRIPTION AND OPERATION
1.
Description
The Nickel Cadmium Battery provides power either to the standby system or to start
the auxiliary power unit. It is a nickel-cadmium type with sintered and plastic bonded
electrode plate construction, and uses a potassium hydroxide electrolyte. The battery
consists of a case and cover, 20 cell assemblies and a temperature sensor harness
assembly. The sensor assembly includes a thermostat mounted on a plate against
the face of the end cell of the center row of cells. A charge control thermistor is
located between cells 6 and 9 in the center row of cells.
2.
Operation
The battery is charged on the aircraft by an on-board charger. The charge control
thermistor provides a signal to the charger to compensate the charge according to the
battery temperature. The thermostat will cut off the charger if the battery temperature
exceeds a safe operating limit.
Battery
Cover
Battery
Receptacle
Battery
Case
Temperature Sensor
Assembly Connector
Nickel Cadmium Battery
Figure 1
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1
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
Voltage:
Nominal
Open Circuit Voltage, fully charged
24.0 Volts
26.0 Volts
Weight
Dimensions (Maximum):
Height
Length (including side brackets)
Width (including handles)
Cell Assembly Terminal
Number of Cell Assemblies
Cell Model
Rated Capacity
End of Life Capacity
43.54 kg (96 pounds) maximum
289.56 mm (11.4 inches)
330.20 mm (13.0 inches)
279.40 mm (11.0 inches)
M10 X 1.25, externally threaded
20
Saft-Type CVH-531-KA
53 Ampere-hours at 1-hour rate
48 Ampere-hours at 1-hour rate (53 amps)
Venting Pressure
Cell Assembly Case Material
Battery Case Material
Electrolyte
0.14 to 0.7 bar (2 to 10 psi)
Polyamide
Stainless Steel
Potassium Hydroxide
Leading Particulars
Figure 2
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2
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
TESTING AND FAULT ISOLATION
1.
General
This section contains battery functional tests and fault isolation information. Test
procedures are written in step-by-step formats that follow the process flow outlined in
Figure 1002. Fault isolation information is presented in chart form (refer to Figure
1006).
NOTE: The ( ) part identification numbers herein are IPL Figure 10001 numbers.
2.
Required Test Equipment (Ref. Fig. 1001)
NOTE: Test equipment having equivalent specifications can be used.
NOMENCLATURE
APPLICATION
DC Power Supply, regulated,
40V dc, 53A recommended
Testing / Fault Isolation
DC Load Bank 0-60 A
Testing / Fault Isolation
DC Voltmeter, (precision ±0.5%),
0V - 2V / 0V - 5V and 0V - 50V
scales required
Testing / Fault Isolation
Volt-Ohmmeter
Testing / Fault Isolation
Thermometer, Immersion
Testing / Fault Isolation
Megohmmeter 250Vdc
Testing / Fault Isolation
Required Test Equipment
Figure 1001
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1001
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
RECEIVED
Insulation Check
[CHECK 1(B)]
FAIL
A
NO
Cell Voltage
> 1.55V
[TESTING
3F(1)(c)]
PASS
YES
Light Cleaning
[CLEANING 2]
FAIL
Special Testing
[TESTING 3.F.6]
<100%
Capacity Check
[TESTING
3(F)5]
Check Cell Nut
Torque
[CHECK 1(C)]
PASS
Total Voltage
at Main
Connector
<21V
Polarization Test
[TESTING 3(F)7]
>100%
DISASSEMBLY
Charge
[TESTING 3F(1)]
ASSEMBLY
Adjust Electrolyte
[TESTING 3F(2)]
FAIL
>21V
PASS
Initial and
Residual
[DISCHARGE
3F(3) and (4)]
Harness
Assy
Clean Vent
Check
Valves
[TESTING 3(C)
and 3(D)]
B
Insulation Check
[CHECK 1(B)]
Clean and Test
Vent Valves
[TESTING 3(E)]
Check Cell Nut
PassTorque
[CHECK 1(C)]
Charge
[TESTING 3F(1)]
Return To
Service
B
Adjust Electrolyte
[TESTING 3F(2)]
A
3.
Process Flow for Battery Maintenance Procedures
Figure 1002
Testing
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1002
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
A.
Test Conditions
Conduct all tests with the battery temperature at 25°C (77°F) for optimum results
(unless otherwise noted in this manual).
B.
Test Equipment
Refer to Figure 1001 for test equipment recommendations.
C.
Over Temperature Thermostat
The over temperature thermostat (200, IPL Fig 10001) is part of connector
harness assembly (190). It should be tested annually. It is attached to the
thermostat mounting plate (60). Disassembly is required in order to test the
thermostat (refer to Disassembly). Check the function of the unit as follows:
(1)
Connect an ohmmeter to auxiliary connector (240, IPL Fig 10001) pins 8
and 9 of the connector harness assembly (190). Make sure the ohmmeter
shows an open (≥ 1MΩ) at room temperature 21°C ± 2.8°C (70°F ± 5).
(2)
Suspend the thermostat mounting plate (60, IPL Fig 10001) with thermostat
(200) in a beaker of water. Position the thermostat a minimum of 50.8mm
(2 inches) from the bottom and 25.4mm (1 inch) from the top of the water
surface.
(3)
Insert a thermometer, or other suitable temperature-measuring device, in
the water with the bulb adjacent to the thermostat.
(4)
Slowly raise the water temperature to 66°C (150°F) while observing the
ohmmeter. Make sure contacts remain open (≥ 1MΩ) at temperatures
below 66°C (150°F).
(5)
Continue raising the water temperature and allow to stabilize at 71°C ±
2.8°C (160°F ± 5°F). Make sure the thermostat closes (≤ 1MΩ) at a
stabilized temperature of 71°C ± 2.8°C (160°F ± 5°F).
(6)
Slowly add cool water to the beaker to reduce water temperature to 65°C ±
2.8°C (149°F± 5°F). Make sure the thermostat opens (≥ 1MΩ) within 6.1°C
(11°F) of the closing temperature.
(7) If the thermostat fails to meet any of the above criteria, replace the complete
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1003
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
temperature sensor harness assembly (190, IPL Fig 1).
(8) Allow the harness to cool to room temperature 21°C ± 2.8°C (70°F ± 5°F).
Test the two resistors in the harness assembly: Using an ohmmeter, check
the resistance between the positive lug (230) and pin 1 of the connector.
Ohmmeter reading should be 29.8KΩ (±10%). Then check the resistance
between the negative lug (220) and pin 3 of the connector. Ohmmeter reading
should be 32.4KΩ (±10%).
D.
Charge Control Thermistor Test
The charge control thermistor is part of the connector harness assembly (190, IPL
Fig. 1). It is permanently mounted on a sensor plate (210). Disassembly is
required to test the unit (refer to Disassembly). Check the function of the unit as
follows:
E.
(1)
Connect an ohmmeter to auxiliary connector pins 11 and 12 of the
connector harness assembly (190, IPL Fig 1). Make sure the ohmmeter
reads 2360Ω to 3050Ω at room temperature 21°C ± 2.8°C (70°F ± 5°F).
(2)
Immerse the thermistor plate in a beaker containing a mixture of ice and
water.
(3)
Insert a thermometer, or other suitable temperature-measuring device, in
the container, in contact with the plate.
(4)
Make sure the ohmmeter indicates 7355 ±74Ω when the plate temperature
is 0°C ±1.7°C (32°F ± 3°F).
(5)
After the low temperature test, slowly raise the temperature to 71°C
(160°F).
(6)
Make sure the ohmmeter indicates 382 ±74Ω when the plate temperature is
71°C (160°F).
(7)
If the thermistor fails any of the above testing criteria, replace the complete
connector harness assembly (190).
Vent Valve Pressure Test
Note: This test can be omitted if the vent valves are replaced annually.
Check the operation of the vent valve assemblies as follows:
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1004
Jul 28/10
(1)
F.
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
Prepare a fixture from PVC pipe and fittings with an end adapter configured
on the inside to match the vent valve lugs. The adapter can be made from
PVC pipe and fittings per Saft drawing (024398-000).
(2)
Affix the vent valve with its O-ring (350, 360, IPL Fig 1) into the adapter end
of the pressure test fixture.
(3)
Attach the fixture to a compressed air line through an adjustable pressure
reducing valve limited to 1.4 bar (20 psi).
(4)
Immerse the valve and end of fixture in water, and slowly raise the
pressure. Make sure the valve opens between 0.14 to 0.7 bar (2 psi and 10
psi).
(5)
Reuse only those vent valves found to open in the 0.14 to 0.7 bar (2 psi and
10 psi) range. Re-soak vent valves that do not open at 0.7 bar (10 psi) until
they do open (refer to Cleaning). Discard vent relief valves which are not
gas tight at low pressure.
Battery Capacity Test, Charging Voltage Tests and Electrolyte Level Adjustment.
NOTE: The success of these tests depends very much upon keeping the battery
cool. High temperature, during a discharge procedure and particularly
during a charge procedure, will result not only in poor equalization but in
a shortened life for the battery. The battery temperature at the start of a
charge procedure must be at room temperature 22.8°C (73°F). A 2-3
hour rest is required following a discharge procedure. The rest period
between the end of charge and the start of discharge procedures must be
between 1 hour and 24 hours to ensure a valid capacity test.
(1)
Charge
CAUTION: ATTEMPTING TO CHARGE BATTERIES WITH LOW
ELECTROLYTE LEVELS IN ANY CELL MAY CAUSE DAMAGE
TO THAT CELL.
(a)
Prior to charging the battery, remove the cover and loosen (do not
remove) all vent valves. Ensure that the shorting spring has been
removed.
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1005
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
(b)
Charge the battery using one of the procedures that follow:
NOTE: Check individual cell voltages at the beginning of the charge.
If any cell indicates an immediate voltage rise above 1.55
volts, add about 10 cc's of distilled or demineralized water
through the vent valve opening of that cell.
NOTE: C1A designates the rated one–hour capacity.
Constant Current Main Charge
Method 1: 0.1 C1A until battery
reaches 1.50 V/Cell
Overcharge
Overcharge at 0.1C1A for 4 hours
after main charge.
Time:
Minimum: 10 hours
Maximum: 12 hours
OR
Method 2: 0.5C1A until battery
reaches 1.55 V/Cell
Total charge not to exceed 16
hours
OR
Overcharge at 0.1C1A for 4 hours
after main charge.
Time:
Minimum: 2 hours
Maximum: 2 hours 30 minutes
OR
Method 3: 1C1A until battery
reaches 1.57 V/Cell
Total charge not to exceed
6 hours 30 minutes
OR
Overcharge at 0.1C1A for 4 hours
after main charge.
Time:
Minimum: 1 hour
Total charge not to exceed
Maximum: 1 hour 15 minutes
5 hours 15 minutes
Figure 1003
(c)
(2)
During the last 15 minutes of charge at 5.3A (0.1C1A), measure each
cell's voltage. Mark for replacement any cell(s) with an end of charge
voltage of less than 1.55V dc. Then, adjust the electrolyte level
according to procedure F(2) while charging battery at 5.3A. (See G.
Cell Replacement to replace cells).
Electrolyte Level Adjustment
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES
ARE LOOSENED OR REMOVED; CONTACT OF
ELECTROLYTE WITH SKIN CAN CAUSE SEVERE BURNS.
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1006
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
CAUTION: BATTERY MUST BE FULLY CHARGED BEFORE
ADJUSTING ELECTROLYTE LEVEL.
To perform the following procedure, a syringe assembly (P/N 020916-001)
is required. It is included in the battery maintenance kit (P/N 416161) (refer
to SPECIAL TOOLS)).
(a)
Before adjusting the electrolyte level, remove the vent valves (350,
IPL Fig 1) with the special, plastic vent valve wrench (P/N 093365000) from the maintenance kit. Immerse the valves and their O-rings
in distilled or de-ionized water, and let them soak to dissolve any
salts. Cover the cells with a clean damp cloth to prevent entry of
foreign matter.
(b)
Check the liquid level in the cell by inserting the syringe (P/N 020916001) into the cell opening until the shoulder of the nozzle rests on the
valve seat (See Figure 1004). Withdraw the plunger and check for
any liquid in the syringe. If the liquid level is too low, the syringe will
remain empty, indicating that the end of the syringe nozzle did not
reach the liquid in the cell. Any excess liquid in the cell will be drawn
into the syringe until the electrolyte is level with the end of the nozzle.
This is the correct level for the electrolyte.
(c)
If the electrolyte is low, use the following procedure to fill the cell to
the correct level:
NOTE: Use only distilled or demineralized water. The quantity (in
cc's) of distilled water required to fill the cell to the correct
level will serve as an approximate guide to the amount
required for the remaining cells. The water in each cell,
however, must be adjusted individually to the correct level. If
the quantity of water added per cell exceeds 88 cc's check
the charging system. If the charger is functioning properly,
shorten the period between servicing.
1
Draw a measured amount of the distilled water, such as 5 cc's
into the syringe and inject it into the cell.
2
With the syringe nozzle resting on the valve seat, slowly
withdraw the plunger in the syringe.
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1007
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
3
If the syringe remains empty, repeat steps 1 and 2, counting the
number of 5 cc injections required to achieve the correct level.
4
At the point in step 2 when some excess liquid is drawn into the
syringe, the correct level for that cell has been reached. Expel
the excess liquid into a separate container for later disposal.
5
Record the amount of water added/removed from each cell in
the battery logbook or battery test sheet.
Position of Syringe in Cell Vent Seat
Figure 1004
(3)
Initial Discharge
The purpose of this procedure is to discharge the battery to a known state
of charge.
(a)
Discharge the battery at one of the current rates shown in Figure
1005 until the battery reaches 20.0V dc.
NOTE: It is important that the discharge current be continually
maintained at the selected value, and that the time of discharge be
measured accurately.
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1008
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
(b)
Monitor individual cell voltages periodically during the discharge, and
record the time at which the first cell reaches 1.0V dc. Stop the discharge
when the battery terminal voltage reaches 20.0V dc and record the time.
NOTE: If a cell goes to zero volts or reverses polarity during the discharge,
short out the cell's terminals for the remainder of the discharge.
(4)
Residual Discharge
Discharge each cell in the battery to zero volts using the following procedures.
NOTE: It is not necessary to have a rest period between discharge and
residual discharge.
(a)
Continue to discharge the battery, and as each cell reaches 1.0V dc,
connect a 1.0 ohm (3.0 watt minimum) resistor across its terminals.
Leave the resistor in place until the cells reach 0.5V dc.
NOTE: Attach the resistors with alligator clips to make a firm connection.
(5)
(b)
As each cell reaches 0.5V dc, insert a shorting clip between its
terminals. Leave these clips on for 12-16 hours to allow the cells to
completely discharge and the battery to cool.
(c)
At completion of Residual Discharge procedure, remove the shorting
devices and recharge the battery in accordance with F(1)(b)2.
Second Discharge/Capacity Check
The purpose of this discharge procedure is to make sure that the initial battery
maintenance cycle (discharge and charge procedures) corrected the low
capacity and / or cell imbalance that existed in the battery when it was
removed from the aircraft. If the battery fails the capacity test then Special
Testing (F(6)) may be required.
(a)
Discharge the battery at one of the current rates shown in Figure 1005
until the battery reaches 20.0V dc.
NOTE:
It is important that the discharge current be continually
maintained at the selected value, and that the time of
discharge be measured accurately.
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1009
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
SECOND DISCHARGE / CAPACITY CHECK
DISCHARGE RATE
MINIMUM TIME FOR FIRST CELL TO
(AMPS)
DISCHARGE TO 1.0 VOLT
26.5
113.2 MINUTES
53.0
56.6 MINUTES
Discharge Rate
Figure 1005
(b)
Monitor individual cell voltages periodically during the discharge and
record the time at which the first cell reaches 1.0V dc. Stop the
discharge when the battery terminal voltage reaches 20.0 volts.
NOTE: If a cell goes to zero volts or reverses polarity during the
discharge, short out that cell's terminals per 3(F)(4)(a or b)
for the remainder of the discharge.
(c)
(6)
If the time until the first cell reaches 1.0V dc equals or exceeds the
values shown in Figure 1005, allow the battery to rest at least 2
hours.
Special Testing
These procedures are to be followed for a battery that does not meet
capacity or if the end of charge voltages are less than 1.55V dc during the
second charge.
NOTE:
If three cells are replaced during a service cycle or five cells are
replaced over the life of the battery, it is best to assume that all of
the original cells are in unsatisfactory condition due to length of
service, heat, overcharge, etc. and all of the cells should be
replaced.
NOTE:
For new battery or battery removed from aircraft, it is
recommended that if the battery requires Special Testing more
than 3 times all the cells must be replaced.
NOTE:
For battery from long term storage, several complete
charge/discharge cycles may be required to restore performance.
(a)
Discharge the battery to 20 volts at any rate up to a maximum of 53A.
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539CH1 and 5319CH1
(b)
Perform the residual discharge procedure on the battery using one of
the following steps:
1
Continue to discharge the battery, and as each cell reaches
1.0V dc, place a 1.0 ohm (3 watt minimum) resistor across its
terminals until the cell reaches 0.5V dc.
2
As each cell reaches 0.5V dc, insert a shorting clip between its
terminals. Leave shorting clips on for 12-16 hours to allow the
cells to completely discharge and the battery to cool.
(c)
Remove the shorting devices and fully charge the battery as outlined
in Figure 1003.
(d)
Continue to charge the battery at 0.1C for an additional 5 hours.
(e)
Monitor individual cell voltages every 15-30 minutes during the
additional overcharge and record voltage readings.
(f)
Mark for replacement any cell(s) that show a continual drop in voltage
or with an end of charge voltage of less than 1.55V dc. (See G. Cell
Replacement).
(g)
Discharge the battery and monitor cell voltages as follows:
NOTE: It is important the discharge current be continually
maintained at the selected value, and that the time of the
discharge be measured accurately.
(h)
1
After a rest of 1 to 12 hours, discharge the battery at one of the
current rates shown in Figure 1005 until the battery reaches
20.0V dc.
2
Monitor individual cell voltages periodically during the discharge
and record the time at which the cells reach 1.0V dc.
Using procedure G (Cell Replacement), replace those cells that have
an end of charge voltage less than 1.55V dc in accordance with
F(1)(c), or have a discharge time of less than the minimum specified
in Figure 1005.
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NOTE: If three cells are replaced during a service cycle or five cells
over the life of the battery are replaced, it is best to assume
that all of the original cells are in unsatisfactory condition due
to length of service, heat, overcharge, etc. and all of the cells
should be replaced.
(i)
(7)
G.
In order to place a new battery in service, or to return a battery with
prior service, after the Special Testing and Cell Replacement (G., if
required) procedure(s) have been completed, the battery must be
allowed to cool (see F. NOTE:).
Polarization Test
(a)
Charge the battery at 0.1C for 1.5 hours.
(b)
Keep the battery in open circuit for 1 hour.
(c)
Measure the open circuit voltage of each cell. If any cell is zero (0) V
or negative polarity, perform Special Testing. If all cells are above
zero (0) V, continue with maintenance as specified.
Cell Replacement
A cell marked for replacement must be removed and replaced following an
additional Discharge and Residual Discharge in accordance with F(1)(b) and
F(2), respectively. (See the DISASSEMBLY and ASSEMBLY sections for the
appropriate procedures.) Before installing the replacement cell perform the
following procedure:
(1)
Connect a 1 ohm (3 watt minimum rating) resistor across the replacement
cells terminals.
(2)
With the 1 ohm resistor connected, monitor the cell voltage; when the cell
voltage drops below 1.0V dc, a shorting jumper can be safely connected.
(3)
Leave jumpers in place at least 30 minutes.
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
4. Fault Isolation
Fault isolation information is presented in Figure 1006 as a guide in locating a cause of
malfunction and isolating the cause to a specific component.
TROUBLE
Zero battery voltage
PROBABLE CAUSE
Loose main connector
Broken or loose terminal
links
Battery completely
discharged
REMEDY
Tighten or replace
connector
Tighten or replace links
Recharge (TESTING AND
FAULT ISOLATION 3.F(1))
Check insulation resistance
(CHECK 1.B.)
Zero Voltage on cell
Low cell voltage at end of
charge
Overflowing electrolyte
Short circuited cell
Separator damage
Check connector harness
assembly (TESTING AND
FAULT ISOLATION
3.C. & D.)
Replace with new cell
Replace with new cell
Electrolyte level too high
Clean battery, run electrical
tests, adjust level (TESTING
AND FAULT ISOLATION
3.F.)
Relief valves loose or
damaged
Tighten or replace valves,
clean, recondition, run
electrical tests, adjust
electrolyte level (TESTING
AND FAULT ISOLATION
3.F.)
Fault Isolation Chart
Figure 1006 (Sheet 1 of 5)
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
TROUBLE
Overflowing electrolyte
Excessive use of water
Loss of battery capacity
PROBABLE CAUSE
Cell reversed during high
rate discharge
REMEDY
Check aircraft charger
voltage, run electrical tests
(TESTING AND FAULT
ISOLATION 3.F.)
Overcharge at too high a
rate
Check aircraft charger
voltage, run electrical tests
(TESTING AND FAULT
ISOLATION 3.F.)
Inspect for and replace
defective cells or valves
Leaky cells, defective cells
or vent valves
Overcharging too long or at
high temperatures
Check aircraft charger
voltage or ground charging
system
Defective thermistor
Check connector harness
assembly (TESTING AND
FAULT ISOLATION 3.C.&
D)
Cell imbalance
Run electrical tests
(TESTING AND FAULT
ISOLATION 3.F.)
Run electrical tests, adjust
electrolyte level (TESTING
AND FAULT ISOLATION
3.F.)
Electrolyte level too low
In service charging
malfunction
Run electrical tests,
(TESTING AND FAULT
ISOLATION 3.F.), check
aircraft charger
Thermostat failure
Check and / or replace
connector harness assy.
(TESTING AND FAULT
ISOLATION 3.C. & D)
Fault Isolation Chart
Figure 1006 (Sheet 2 of 5)
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
TROUBLE
Low cell capacity
Abnormally high cell voltage
at beginning of charge
Low voltage output
PROBABLE CAUSE
Normal wear from long
service
Dry cell
Continuous demand without
charging
In service charger
malfunction
REMEDY
Replace with new cell
Add 5 to 10 cc of distilled
water, adjust electrolyte
level at end of charge
(TESTING AND FAULT
ISOLATION 3.F.(2))
Check cell performance
(TESTING AND FAULT
ISOLATION 3.F.(6)) for
permanent damage
Run electrical tests
(TESTING AND FAULT
ISOLATION 3.F.)
Run electrical tests
(TESTING AND FAULT
ISOLATION 3.F.)
Check aircraft charger
Check connector harness
assy. (TESTING AND
FAULT ISOLATION 3.C &
D)
Loose terminal connectors
Torque to spec., run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Main connector loose,
burned, pitted
Clean or replace, tighten run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Fault Isolation Chart
Figure 1006 (Sheet 3 of 5)
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
TROUBLE
Low voltage output
Excess foaming on charge
after adding water
PROBABLE CAUSE
Defective cell or cell with
reversed polarity
Cell to Case current leakage Discharge, disassemble,
clean, replace defective
cells and / or insulation, run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Electrolyte concentration
Discharge, run electrical
low
tests (TESTING AND
FAULT ISOLATION 3.F)
Excessive foaming out of
vent valve on charge
Electrolyte contaminated by
oil or grease
Tarnished or burned
terminal connectors
Corroded connectors
Loose terminal nuts and
links
Acid atmosphere
Burned or pitted main
battery cables
Deformed cell case
REMEDY
Replace defective cell, run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Discharge, replace
contaminated cells, run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Clean or replace hardware,
tighten to specified torque
Check room, eliminate acid
source
Inadequate greasing
Clean and lubricate properly
Mechanical damage to
protective nickel-plating
Improperly mated or loose
connection
Charger failure
Replace damaged hardware
Clean, repair or replace
parts to mate properly
Discharge, disassemble
install new cell (TESTING
AND FAULT ISOLATION
3.F)
Check aircraft charger
Fault Isolation Chart
Figure 1006 (Sheet 4 of 5)
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TROUBLE
Deformed cell case
PROBABLE CAUSE
Connector harness assy
failure
Deformed cell case
Damaged separator or
internal shorting
Inoperative vent valve
Distorted battery case
Overheating, lack of
ventilation, or major
explosion due to unusually
high ambient temperatures,
improper maintenance, too
high charge rate, charger
failure
Make sure the operation of
the vent valve and replace if
necessary (TESTING AND
FAULT ISOLATION 3.E)
Discharge, disassemble,
replace all damaged parts
with new parts or replace
entire battery; check entire
ventilation system; check
aircraft or ground charging
system
Loose terminal nuts and
links
Make sure all connections
are tight
Temperature sensor assy
failure
Resistance insulation failure
REMEDY
Check and / or replace
temperature sensor assy
(TESTING AND FAULT
ISOLATION 3.C & D)
Discharge disassemble,
install new cell (TESTING
AND FAULT ISOLATION
3.F)
Excessive spewing of
electrolyte, or water inside
battery case
Check and / or replace
temperature sensor assy
(TESTING AND FAULT
ISOLATION 3.C & D)
Discharge, disassemble,
clean, replace defective
insulation and / or cells, run
electrical tests (TESTING
AND FAULT ISOLATION
3.F)
Fault Isolation Chart
Figure 1006 (Sheet 5 of 5)
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
DISASSEMBLY
1.
General
Prior to disassembly, see TESTING and FAULT ISOLATION to determine condition of
the battery, cause, and remedy of malfunction. Disassemble only to the extent
necessary to effect repair and replacement.
NOTE: The ( ) part identification numbers herein are IPL Figure 1 numbers.
2.
Detailed Instructions
WARNING: BATTERY CELL ASSEMBLIES DELIVER VERY HIGH CURRENTS
WHEN SHORT-CIRCUITED. EXERCISE CAUTION. REMOVE RINGS,
WATCHES OR OTHER JEWELRY FROM HANDS AND ARMS.
COMPLETELY DISCHARGE BATTERY PRIOR TO DISASSEMBLY
(SEE TESTING AND FAULT ISOLATION PARAGRAPHS F(1) AND
F(2)).
WARNING: USE CARE NOT TO TILT BATTERY WHILE VENT VALVES ARE
LOOSENED; CONTACT WITH ELECTROLYTE WITH SKIN CAN
CAUSE SEVERE BURNS.
CAUTION: BATTERY MUST BE COMPLETELY DISCHARGED IN ACCORDANCE
WITH TESTING PARAGRAPH F(3) AND F(4) BEFORE CELL
ASSEMBLIES CAN BE REMOVED.
A.
Remove cover (20, IPL Fig 1) by opening latches and lifting cover from case (10).
B.
Remove the hold-down pad (30) and insulator (40).
C.
Remove the cell assemblies (260) from the battery case (10) as follows:
(1)
Using the vent valve wrench (Fig 9001), loosen the vent valves (350, IPL
Fig 1) of all cells to relieve any pressure; then re-tighten vent valves (use
only finger pressure on wrench when installing).
(2)
Remove nuts (340) and washers (330) from terminals of cell assemblies
(260).
(3)
Remove intercell terminal links (140) through (180) from terminals of cell
assemblies (260).
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
(4)
D.
E.
Using cell puller (Fig 9001), remove cell assemblies (260) from the battery
case (10) by tightening the cell puller to cell terminals and removing cell
with a steady straight up pull.
Remove the connector harness assembly (190) as follows:
(1)
Remove the thermostat mounting nuts (80) from the thermostat plate (60).
(2)
Remove the temperature sensor connector mounting screws (250) and lift
the temperature sensor harness assembly (190) out of the battery case
(10).
Disassembly of the cell assemblies (260) is restricted to replacing defective Orings (270) of the cell terminal seals. After replacing the O-rings, the lower
terminal nuts must be torqued to 5 ±1 Nm (44 ± 9 lb-in) prior to cleaning.
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE OR
REMOVED; CONTACT OF ELECTROLYTE WITH CAN CAUSE
SEVERE BURNS.
NOTE: Prior to any disassembly of the cells, refer to CHECK and TESTING.
(1)
Using the vent valve wrench (Fig 9001), loosen and remove the vent valves
(350) from the cells.
(2)
Remove O-rings (360) from the vent valves (350).
NOTE: Do not attempt further disassembly of the cell subassembly. Cells
are non repairable items and must be replaced as a unit if
defective.
F.
Remove the battery connector receptacle (90) from the battery case (10) by
removing screws (100).
G.
Remove connector receptacle gasket (130) from the battery case (10).
H.
Remove all spacers (50) from the battery case (10).
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
CLEANING
1.
General
A.
The following items are required to perform the cleaning procedures (equivalent
substitutes can be used):
Stiff bristled brush (nonmetallic)
Dry compressed air source, less than 20 psi (1.4 bar)
Safety goggles
Lubricant (non-acid petroleum jelly)
Soft, clean cloth (two required)
Isopropyl alcohol (or non petroleum based) degreasing agent
Running water
Soap
Distilled or de-ionized water
NOTE: The ( ) part identification numbers herein are IPL Figure 1 numbers.
2.
Assembled Battery
CAUTION: DISCHARGE BATTERY PRIOR TO CLEANING IN ACCORDANCE
TESTING PARAGRAPHS F(3) AND F(4).
A.
The following procedures are for an assembled battery with battery cover (20,
IPL Fig 1), hold down pad (30), and formed insulator (40) removed.
CAUTION: VENT VALVES MUST BE CLOSED TO PREVENT DIRT AND
FOREIGN MATTER FROM ENTERING CELLS DURING
CLEANING. VENT VALVES SHOULD BE CLOSED AT ALL TIMES
(TO AVOID EXPOSURE TO CO2), EXCEPT AS DIRECTED
OTHERWISE HEREIN. OVER EXPOSURE TO CO2 WILL AFFECT
BATTERY PERFORMANCE OVER TIME.
B.
Using vent valve wrench (093365-000), make sure that the vent valves (350, IPL
Fig 1) of all cell assemblies (260) are closed and secure. Do not over-tighten.
CAUTION: DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS. CELLS
MAY BE DAMAGED BY SUCH ACTION.
C.
Remove white deposits (potassium carbonate) from tops of all cell assemblies
(260) using a stiff bristled nonmetallic brush.
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539CH1 and 5319CH1
WARNING: TO PREVENT INJURY WHEN USING COMPRESSED AIR,
DIRECT STREAM AWAY FROM BODY. USE SAFETY GOGGLES TO
PREVENT EYE INJURIES FROM FINE DUST PARTICLES.
3.
D.
Disperse residual dust and particles from the battery with blasts of clean, dry,
compressed air not over 1.4 bar (20 psi).
E.
Coat cell assembly terminal nuts (340) and all intercell terminal links (140 through
180) with a light film of non-acid petroleum jelly. Silicone coatings are not
suitable due to the alkaline electrolyte.
F.
Clean the exterior surfaces of the battery cover (20) and battery case (10) using
a soft, clean cloth, moistened with water. Dry with compressed air or a dry, clean
cloth.
Disassembled Battery
A.
Remove greasy residue from battery connector receptacle (90) with isopropyl
alcohol or degreasing agent.
B.
After ensuring that the vent valves (350) are closed, wash each cell (260) in
running water. Do not allow any water to enter the cell. Dry with compressed air
or a dry, clean cloth.
C.
Wash the battery case (20), cover insulator (40), spacers (50), gasket (130), and
cell hardware (280 through 340) in warm, soapy water to remove dirt and salt
deposits. A plastic scraper or a stiff bristled brush (nonmetallic) may be used to
aid in the removal of heavy deposits. Rinse away all soap, and dry with
compressed air or a dry, clean cloth.
D.
Remove the vent valves (350) from the cell subassemblies (260), and submerge
them and the O-rings (360) in a clean container of distilled or deionized water.
This treatment will dissolve any salt deposits which may have accumulated in the
vents of the valves or around the O-ring seat. Cover the cells (260) with a damp,
clean cloth, or take other precautions to prevent any foreign particles from falling
into the cells while the valves are removed.
NOTE: The length of time vent valves are removed from the cell assemblies
should be kept to a minimum. Over exposure of the electrolyte to the
atmosphere will affect battery performance due to CO2 contamination.
E.
After cleaning, test the vent valve assemblies (350) to ensure they operate within
the correct pressure range in accordance with TESTING E.
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
CHECK
1.
Assembled Battery
The following procedure are for an assembled battery with battery cover (20, IPL Fig
1), hold-down pad (30), and formed insulator (40) removed.
A.
Visually inspect battery for evidence of damage or electrolyte leakage. If damage
to any part is visible, refer to REPAIR and/or TESTING AND FAULT ISOLATION
for applicable procedures.
B.
Check battery insulation resistance, using the following procedure:
NOTE: A breakdown in electrical insulation between the cells and the battery
case will result in a "leakage" current, which, over a period of time, can
discharge the battery.
(1)
Set up the analog multi-meter (volt, ohm, amp) and meter leads for a
measurement of 250mA.
(2)
Connect the negative lead from the meter to the battery container.
(3)
Touch the positive lead from the meter to the positive terminal of the
battery and then to the positive terminal of each cell.
(4)
If, while performing the above, there is any deflection of the needle from
zero, the insulation should be considered defective. Disassemble and
clean the battery (see DISASSEMBLE and CLEANING).
(5)
If, after cleaning the battery and assuring that everything is dry, a leakage
current is still indicated by a deflection of the needle, one or more cells is
defective. Isolate and replace the defective cell(s) in accordance with
TESTING AND FAULT ISOLATION. Figure 105.
(6)
As an alternative to the above test: after completely reassembling the
battery, measure the insulation resistance between the block of cells and
the metal box. The value measured must be at least 10M ohm under a
250Vdc continuous using a megohmmeter.
C. Check that the torque on each upper terminal nut (340) and (320) is 13 ± 1 Nm
(115 ± 9 lb-in).
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
D.
2.
Check all ventilation openings to make sure that they are clean and clear.
Disassembled Battery
A.
Visually check each cell carefully for evidence of electrolyte leakage, cracks,
corrosion, burns, holes, or cross-threaded terminals. Excessive salt around a
terminal post indicates leakage.
B.
Visually check each cell vent valve assembly (350, IPL Fig 1) for defective Orings, cracks, or other physical damage. Replace defective O-rings (360).
Suspect vent valves should be tested before being discarded in accordance with
TESTING E.
C.
Inspect intercell terminal links (140 through 180) for bends, tarnish, loss of nickel
plating, corrosion, or burns. Tarnish can be polished off with a fine wire brush.
Replace any defective intercell links.
D.
Spaces (50) should be clean and free of cracks or holes. Replace any that are
defective.
CAUTION: A DEFECTIVE BATTERY CONNECTOR RECEPTACLE CAN
CAUSE DANGEROUS OVERHEATING.
NOTE: A defective battery connector receptacle can cause battery discharge, as
well as in service low voltage.
E.
Check the battery connector receptacle (90) for evidence of arching, corrosion,
cracks, or cross threaded terminals. Using the insulation resistance check
procedure in paragraph 1.B(1) and 1.B(4) above, check the insulation between
the positive pin and the connector shell and the negative pin and connector shell.
Discard any receptacle that is found to have any of the above noted damage or
fails the insulation test. Replace with factory new.
F.
Visually check the temperature sensor harness assembly (190) as follows:
(1)
Inspect electrical connector for bent or loose pins, corrosion, cracks, faulty
wire connections, and evidence of arcing. Any evidence of the above
conditions, however minor, is grounds for rejection. Discard the damaged
unit and replace with factory new.
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
(2)
Inspect charge control thermistor and thermostat for damage, loose or
broken wire connections, cracks, dents, or other physical defects. Any
evidence of the above conditions, however minor, is grounds for rejection.
Discard the damaged unit and replace with factory new.
(3)
Visually check all wiring damage to insulation, cracked or broken wire, and
other physical defects. Any evidence of the above conditions, however
minor, is grounds for rejection. Discard the damaged unit and replace with
factory new.
NOTE: Temperature sensor harness assembly (190) is a non repairable
item, and should be discarded if defective.
G.
Check all small hardware items for damage.
H.
Check battery cover (20) and battery case (10) for damage (see REPAIR).
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
REPAIR
1.
Temperature sensor harness assembly
If any part of the temperature sensor harness assembly (190, IPL Fig 1) is damaged,
the entire assembly must be replaced (see CHECK and TESTING).
2.
Cell Assembly
NOTE: If three cells are replaced during a service cycle or five cells are replaced over
the life of the battery, it is best to assume that all of the original cells are in
unsatisfactory condition due to length of service, heat, overcharge, etc. and all
of the cells should be replaced.
3.
A.
Repair to cell assembly (260) is limited to replacement of defective hardware
(270 through 340) and the vent valve assembly (350). Defects to the cell itself
will be corrected by cell replacement.
B.
When inspection reveals electrolyte leakage from the cell at the vent hole
opening, replace the defective O-ring (360) as follows:
(1)
Using the vent-valve wrench (P/N 093365-000), loosen and remove the
vent valve (350) from the cell assembly (260).
(2)
Cover the cell with a damp, clean cloth to prevent any foreign particles from
falling into the cell.
(3)
Remove the defective O-ring (360) from the vent valve (350), and install a
new O-ring onto the valve.
(4)
Remove the damp, clean cloth from the cell, and insert the vent valve
assembly (350) into the cell assembly (260). Using the vent valve wrench
(P/N 093365-000), tighten the vent valve securely in place. To ensure they
are tightened properly, use only finger pressure on the wrench.
(5)
Clean cell assembly (260) in accordance with CLEANING.
Physical damage
When necessary, remove minor dents in the battery cover (20) and battery case (10)
using a hard rubber mallet. Polish out minor pits or scratches using a fine grain
abrasive sanding/polishing cloth.
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
ASSEMBLY
1.
General
This section contains assembly instructions necessary after disassembly and repair.
2.
Liners
NOTE: Make sure all components are clean and dry before re-assembly.
Install liners (50, IPL Fig 1), temperature sensor harness assembly (190), and cell
assemblies (260) into the battery case (10), using the following steps. Refer to Figure
7001 and 7002.
A.
Insert one edge of bottom spacer into battery case (10) from either the left or
right side, then slide the spacer under the cell partition.
B.
Reinstall temperature sensor harness assembly (190) as follows:
C.
(1)
Insert the temperature sensor harness assembly connector into its
mounting hole on the case (10) and reinstall the connector mounting
screws (250).
(2)
Insert the thermostat liner (60) and thermostat liner assembly on the inside
face of the center partition, taking care to align the holes in the liner with
the hole in the partition.
(3)
Insert the thermostat plate (70) in back of spacer assembly so that the
spacer assembly is between the thermostat plate (70) and the thermostat
liner, which is against the partition.
(4)
Pass the thermostat-end of temperature sensor harness assembly (190)
through the hole in the partition, liner, and spacer assembly.
(5)
Attach the thermostat to the thermostat plate (70) with thermostat mounting
nuts (80). Torque to approximately 1.1 Nm (10 lb-in).
Install the center row spacers and cell subassemblies in accordance with the
following steps:
HINT: It is often easier to install the center cell of a row last. Observe polarity.
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
Cell and Spacer Installation
Figure 7001
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539CH1 and 5319CH1
(1)
Install spacers in place on inside of cell partition, as shown in Figure 7001.
(2)
Apply a small amount of non-acid petroleum jelly to the threads of the cell
terminals.
(3)
Install side and end spacers into the center partition of battery case (see
Figure 7001).
(4)
Install five cell subassemblies (260) into positions 4, 5, 6, 9, and 10 in the
center partition of battery case (10). Be sure to maintain the proper cell
arrangement and polarity orientation (see Figure 7002). Install the charge
control thermistor plate between cells 6 and 9, as shown in Figure 7002.
(5)
Install a cell assembly (260) into positions 13 in the center partition of the
battery case. Insertion of the last cells is sometimes difficult, and may be
assisted by pushing down on the terminals with a small block of soft wood.
NOTE: Spacers (50) are used as required to ensure the center row cells
are retained securely in place. As indicated in Figure 7001, the
maximum quantity to be used is as shown. When installed it shall
be necessary to exert approximately 30 lbs of upward force to
remove a cell from the assembly.
Cell Number and Polarity Orientation
Figure 7002
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7003
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
D.
Install the left and right side row of cells and spacers in accordance with the
following steps, and as shown (see Figure 7001).
(1)
Install spacers into the battery case (10) as shown in Figure 7001.
(2)
Install the left and right end spacers into the battery case (10), as shown in
Figure 7001.
(3)
Install six cell assemblies (260) in the left hand side of the battery case, be
sure to maintain the proper cell arrangement and polarity orientation (see
Figure 7002).
(5)
Install the remaining row cell assemblies (260) into the battery case. Be
sure to maintain the proper cell arrangement and polarity orientation (see
Figure 7002). Insertion of the last cell on each side is sometimes difficult,
and can be assisted by pushing down on the terminals with a small block of
soft wood.
NOTE: Spacers are used as required to ensure the left and right hand row
of cells are retained securely in place. The maximum quantity to
be used is shown in Figure 7001. It shall be necessary to use a
force of approximately 30 lb-ft to remove the center cell of a row
when assembly is complete.
(6)
3.
Torque the lower terminals nuts (320) of the cell assemblies (260) to 5 ± 1
Nm (44 ± 9 lb-in).
Battery Connector Receptacle
Install battery connector receptacle (90) into the battery case (10) follows:
A.
Assemble connector receptacle gasket (130) to battery connector receptacle
(90).
B.
Insert terminals of battery connector receptacle (90) through the oval mounting
hole in the front of the battery case (10).
C.
Attach the battery connector receptacle (90) to the battery case (10) with screws
(100) and washer assemblies (110). Secure the receptacle by tightening the
screws (100) to approximately 2.2 ± 0.4 Nm (20 ± 4 lb-in).
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7004
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
4.
Complete Battery
A.
Install intercell terminal links (140 through 180) on the terminals of the cell subassemblies (260) and battery connector receptacle (90) as shown in Fig. 7002.
B.
Install the two wire lead/lug assemblies of the temperature sensor harness
assembly (190) on the terminal posts of the cell sub-assemblies (260) as shown
in Fig. 7001.
C.
Install nuts (120) and washers (110) onto the terminals of the cell assemblies
(260) and terminals of the receptacle adapter. Torque nuts (120) to 13 ±1 Nm
(115 ± 9 lb-in).
CAUTION: DO NOT CRIMP WIRE LEAD/LUG ASSEMBLIES OF THE
TEMPERATURE SENSOR HARNESS ASSEMBLY.
5.
D.
Install formed insulator (40) on top of the cells. Observe proper orientation.
E.
Install the hold down pad (30) onto the cell assemblies, being sure that each vent
hole mates properly with the cell assembly vent valve.
F.
Install the battery cover (20) onto the battery case (10) and secure in place by
fastening the latches.
Storage
Store battery assembly as follows:
NOTE: For more storage information, refer to Saft Technical Note TN01 Rev 5 dated
July 2008 or later revision. Contact Saft for the latest copy of this document.
A.
Storage area humidity should not be more than 90 percent.
B.
Battery may be exposed to temperature within the range of -55°C to 60°C
(-67°F to 140°F).
CAUTION: MAXIMUM ACCUMULATED EXPOSURE TO TEMPERATURE ABOVE
48.9°C (120°F) SHOULD NOT EXCEED 30 DAYS.
C.
Store the battery in a discharge state in accordance with TESTING 1.F(4). Install
a shorting device across the battery receptacle terminals (90).
D.
Battery should be stored in original shipping container in accordance with ATA300 specification.
24-31-07
7005/7006 Blank
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
FITS AND CLEARANCES
1.
Torque Table
Figure / Item Number
IPL Fig 1
340
IPL Fig 1
320
2.
Torque Value
13 ± 1 Nm (115 ± 9 lb-in)
5 ± 1 Nm (44 ± 9 lb-in)
Name, Location
Nut, Terminal, Upper
Nut, Terminal, Lower
Fits and Clearances Table
No fits and clearances required.
24-31-07
8001/8002 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.
Special Tools
A.
Battery Maintenance Kit
(1)
The Battery Maintenance Kit (SAFT P/N 416161) is required for
performance of the TESTING AND FAULT ISOLATION and
DISASSEMBLY procedures. The kit may be purchased from SAFT or a
SAFT authorized distributor.
The syringe (P/N 020916-001) is used in the electrolyte level adjustment
and the cell puller (P/N 017556-000) is used in cell removal. Spare
hardware, vent valves, and O-rings are provided.
(2)
The following items are the contents of the SAFT Battery Maintenance Kit.
Part Number
NA (1)
164829
416159
017556-000 (2)
413876
093365-000 (2)
416228
020915-002 (2)
416229
416231
020916-001 (2)
458469
416233
020916-002 (2)
416235
416236
Description
Syringe
Equalizing resistors (1Ω / 3W)
Cell extraction tool (M8/M10)
Universal vent wrench
Nozzle 12 mm
Nozzle 15 mm
Nozzle 20 mm
Nozzle 20 mm for MS valves
Nozzle 24 mm
Nozzle 33 mm
Nozzle 38 mm
Quantity
1
20
2
1
1
1
1
1
1
1
1
Note (1): Individual nozzle orders include a syringe
Note (2): Where two part numbers are listed, the parts are interchangeable
Battery Maintenance Kit
Figure 9001
24-31-07
9001/9002 Blank
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
ILLUSTRATED PARTS LIST
1.
Introduction
A.
Purpose
(1)
B.
This section provides illustrations and parts breakdown of the 539CH-1 and
5319CH1 batteries, which can be disassembled, repaired or replaced, and
reassembled.
Explanation and Usage of Section
(1)
Assembly Order Indenture System
The Indenture System used in the parts list shows the relationship of one
part to another. For a given item, the number of indentures depicts the
relationship of the item to the associated next higher assembly.
(2)
Effectively Code
Reference letters (A, B, C, etc.) are assigned in the EFF CODE column to
each top assembly. The reference letter of the applicable top assembly is
also shown in the EFF CODE column for each detail part and subassembly
except that no reference letter is shown for detail parts and subassemblies
used on all top assemblies.
(3)
Quantity Per Assembly
The UNITS PER ASSY column shows the total number of units required
per assembly, per subassembly, and per sub-subassembly as applicable.
The letters REF indicate the item is listed for reference purposes.
(4)
Parts Replacement Data
Interchangeability information will be provided in a future manual revision if
it becomes applicable.
(5)
Service Bulletin Incorporation
Service Bulletin incorporation information applicable to the parts list will be
provided in a future manual revision if it becomes applicable.
24-31-07
10001
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
(6)
Items Not Illustrated
Items not illustrated are indicated by a dash ( - ) ahead of the item numbers
in the FIG. and ITEM NO. column.
(7)
Alpha Variant Item Numbers
(a)
(b)
(8)
Alpha variants A - Z (except I and O) are assigned to existing item
numbers when necessary to show:
1
Added items
2
Service Bulletin modifications
3
Configuration differences
4
Optional parts
5
Product improvement parts (non-service bulletin)
Alpha variant item numbers are not shown on the exploded view
when the appearance and location of the alpha variant item is the
same as the basic item.
Vendors
The vendor of all parts shown in the parts list is as follows:
Vendor Code
NAME / ADDRESS
Vendor Code
V09052
Saft America Inc.
F6177
711 Industrial Boulevard
Valdosta, GA 31601
USA
Phone:
229-247-2331
Fax:
229-247-8486
NAME / ADDRESS
Saft
12 Avenue Sadi Carnot
93170 Bagnolet
France
Phone:
33 1 49 93 19 18
Fax:
33 1 49 93 19 56
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10002
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
20
30
40
260
60
50
70
80
120
10 or 10A
110
100
90
130
Battery Exploded View Figure 1 (Sheet 1 of 4)
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10003
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COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
140
180
170
160
150
Battery, Exploded View
Figure 1 (Sheet 2 of 4)
24-31-07
10004
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
230
220
210
240
250
200
190
Battery, Exploded View
Figure 1 (Sheet 3 of 4)
24-31-07
10005
Jul 28/10
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
340
330
320
350
300 or 310
360
290
280
270
260
Battery, Exploded View
Figure 1 (Sheet 4 of 4)
24-31-07
10006
Jul 28/10
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
539CH1 and 5319CH1
ILLUSTRATED PARTS LIST
Fig
1
Index
Part Number
1
024147-000
1A
025920-000
10
10A
20
30
40
50
60
70
80
90
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
024190-000
025902-000
018552-003
024142-000
018559-000
018951-000
018737-000
018733-000
090064-000
022078-000
093616-000
022228-000
015579-000
009384-000
015575-000
015577-000
018567-000
018568-000
018569-000
024314-000
N/A
N/A
N/A
N/A
N/A
092178-008
024257-000
091181-002
021870-000
021871-000
023388-001
023388-002
015579-000
022228-000
015579-000
023619-000
012536-002
Nomenclature
1234567
.......
BATTERY, 539CH-1 (09052)
BA35-01 (V08748)
BATTERY, 5319CH1 (09052)
BA35-02 (V08748)
. Case, Marked
. Case, Marked
. Cover
. Pad, Hold Down
. Insulator, Formed Top
. Kit, Spacer
. Plate, Thermostat Mounting
. Liner, Thermostat Mounting
. Nut, Aux. Connector Mounting
. Connector, Adapter, Terminal
. Screw, Sems
. Washer, Belleville
. Nut, Hex, M10x1.25
. Gasket, Connector
. Link, Intercell - 0.125 X 0.750 X 1.334
. Link, Intercell - 0.125 X 0.750 X 1.452
. Link, Intercell - 0.125 X 0.750 X 1.476
. Link, Intercell - 0.125 X 0.750 X 2.023
. Link, Intercell - 0.118 X 0.668 X 2.331
. Connector Harness Assy
. . Thermostat, Temperature Sensing
. . Thermistor/Plate Assy
. . Terminal Lug, Negative
. . Terminal Lug, Positive
. . Connector, Auxiliary
. . Screw, Connector Mounting
. Cell, CVH531KA (with hardware)
. . O-Ring
. . Washer, Flat
. . Washer, Belleville
. . Washer, Polarity, Red (+)
. . Washer, Polarity, Blue (-)
. . Nut, Hex, M10x1.25
. . Washer, Belleville
. . Nut, Hex, M10x1.25
. . Valve, Vent
. . . O-Ring
Units
Use Unit Per
Code
Assy
RF
A
A
RF
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
1
1
4
1
4
2
2
1
5
2
10
1
3
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
4
20
2
2
4
1
1
2
2
2
1
1
N/A - Not available separately
24-31-07
10007/10008 Blank
Jul 28/10