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 24-31-07 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 24-31-07 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: 24-31-07 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 24-31-07 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 24-31-07 TOC Page 1/TOC Page 2 Blank Jul 28/10 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 24-31-07 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 24-31-07 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 24-31-07 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 24-31-07 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 24-31-07 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 24-31-07 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: 24-31-07 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. 24-31-07 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. 24-31-07 1006 Jul 28/10 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. 24-31-07 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. 24-31-07 1008 Jul 28/10 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. 24-31-07 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. 24-31-07 1010 Jul 28/10 COMPONENT MAINTENANCE MANUAL 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. 24-31-07 1011 Jul 28/10 COMPONENT MAINTENANCE MANUAL 539CH1 and 5319CH1 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. 24-31-07 1012 Jul 28/10 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) 24-31-07 1013 Jul 28/10 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) 24-31-07 1014 Jul 28/10 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) 24-31-07 1015 Jul 28/10 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) 24-31-07 1016 Jul 28/10 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) 24-31-07 1017/1018 Blank Jul 28/10 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). 24-31-07 3001 Jul 28/10 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). 24-31-07 3002 Jul 28/10 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. 24-31-07 4001 Jul 28/10 COMPONENT MAINTENANCE MANUAL 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. 24-31-07 4002 Jul 28/10 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). 24-31-07 5001 Jul 28/10 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. 24-31-07 5002 Jul 28/10 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). 24-31-07 5003/5004 Blank Jul 28/10 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. 24-31-07 6001/6002 Blank Jul 28/10 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. 24-31-07 7001 Jul 28/10 COMPONENT MAINTENANCE MANUAL 539CH1 and 5319CH1 Cell and Spacer Installation Figure 7001 24-31-07 7002 Jul 28/10 COMPONENT MAINTENANCE MANUAL 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 24-31-07 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). 24-31-07 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 Jul 28/10 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 24-31-07 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) 24-31-07 10003 Jul 28/10 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