24-32-03

COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
40176-4 / 40176-7
Title Page –
24-32-03
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April 15/2002
Original Issue Date: July 30/75
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
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RECORD OF REVISIONS
REVISION
No.
1
2
3
ISSUE
DATE
INSERTED
DATE
BY
07/30/75 07/30/75
09/30/98 09/30/98
04/15/02 04/15/02
REVISION
No.
ISSUE
DATE
INSERTED
DATE
BY
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REV. No.
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ISSUE
DATE
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SERVICE BULLETIN LIST
NUMBER
BRIEF DESCRIPTION
TYPE AFFECTED
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COMPONENT MAINTENANCE MANUAL
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LIST OF MAJOR REPAIRERS
TRADE NAME
For a complete list contact Saft
ADDRESS
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40176-4 / 40176-7
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LIST OF EFFECTIVE PAGES
CONTENT
PAGE
CONTENT
PAGE
1
2
REVISION
DATE
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TESTING AND FAULT
ISOLATION (Cont’d)
1014
REVISION
DATE
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TITLE PAGE
RECORD OF REVISIONS
1
2
Apr 15/2002
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SCHEMATIC AND
WIRING DIAGRAMS
2001
2002
Apr 15/2002
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RECORD OF
TEMPORARY REVISIONS
1
2
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DISASSEMBLY
SERVICE BULLETIN LIST
1
2
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3001
3002
3003
3004
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LIST OF MAJOR REPAIR
STATIONS
1
2
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CLEANING
LIST OF EFFECTIVE
PAGES
1
2
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4001
4002
4003
4004
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CHECK
TABLE OF CONTENTS
1
2
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TABLE OF
ILLUSTRATIONS
1
2
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INTRODUCTION
1
2
3
4
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5001
5002
5003
5004
5005
5006
5007
5008
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REPAIR
6001
6002
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DESCRIPTION AND
OPERATION
1
2
3
4
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ASSEMBLY
7001
7002
7003
7004
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TESTING AND FAULT
ISOLATION
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
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FITS AND CLEARANCES
8001
8002
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SPECIAL TOOLS,
FIXTURES AND
EQUIPMENT
9001
9002
9003
9004
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ILLUSTRATED PARTS
LIST
10001
10002
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40176-4 / 40176-7
CONTENT
PAGE
REVISION
DATE
INTRODUCTION
10003
10004
10005
10006
Apr 15/2002
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VENDOR CODE INDEX
10007
10008
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BLANK
ALPHA NUMERICAL
INDEX
10009
10010
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DETAILED PARTS LIST
10011
10012
10013
10014
10015
10016
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STORAGE AND
SHIPPING
15001
15002
15003
15004
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
TABLE OF CONTENTS
PAGE
Intro Page 1
Intro Page 1
Intro Page 1
Intro Page 1
Intro Page 2
Intro Page 3
Intro Page 3
Intro Page 4
INTRODUCTION
1 – General
2 – How to Use the Manual
3 – Measure
4 – Units of Measure
5 – Abbreviations
6 – Definition
7 – Disposal
DESCRIPTION AND OPERATION
1 – Description
OP Page 1
OP Page 1
TESTING AND FAULT ISOLATION
1 – General
2 – Testing
3 – Charge
4 – Electrolyte level and adjustment
5 – Discharge
6 – Temperature Sensor Testing
7 – Fault Isolation
1001
1001
1001
1004
1006
1007
1008
1009
SCHEMATIC AND WIRING DIAGRAMS
1 – General
2 – Sensor Schematic
2001
2001
2001
DISASSEMBLY
1 – General
2 – Safety
3 – Risks
4 – Safety Measures
5 – Disassembly
3001
3001
3001
3001
3001
3002
1 – General
2 – Equipment
3 – Materials
4 – Cleaning procedure
5 – Lubrication
4001
4001
4001
4001
4001
4003
1 – General
2 – Maintenance in workshop
5001
5001
5001
1 – General
2 – Equipment
3 – Repairs
6001
6001
6001
6001
CLEANING
CHECK
REPAIR
TOC Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
ASSEMBLY
1 – General
2 – Assembly procedures
7001
7001
7001
1 – General
2 – Torque Specifications
8001
8001
8001
FITS AND CLEARANCES
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 – General
2 – Special tools, fixtures and equipment
3 – Consumables
9001
9001
9001
9004
ILLUSTRATED PARTS LIST
1 – Introduction
2 – Vendor Code Index
3 – Alpha-Numeric Index
4 – Detailed Parts List
10001
10003
10007
10009
10011
SPECIAL PROCEDURES
NOT APPLICABLE
REMOVAL
NOT APPLICABLE
INSTALLATION
NOT APPLICABLE
SERVICING
NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION
1 – General Storage Information
2 – Preparation for Storage
3 – Active Stand-By Storage
4. – Trickle Charging
5 – Inactive Long-Term Storage
6 – Preparation for Use after Storage
7 – Packing and Transporting
REWORK (Service Bulletin Instructions)
15001
15001
15001
15001
15003
15004
15004
15004
NOT APPLICABLE
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
TABLE OF ILLUSTRATIONS
Figure
1
40176-4 / 40176-7 Battery
PAGE
OP Page 3
Figure
2
Identification plate
OP Page 3
Figure
3
Overall dimensions
OP Page 4
Figure
1001
Insulation Test
1002
Figure
1002
Insulation Test Parameters
1003
Figure
1003
Electrolyte Level Adjustment
1006
Figure
1004
Functional Test Flow
1009
Figure
2001
Sensor Schematic 40176-4
2001
Figure
2002
Sensor Schematic 40176-7
2001
Figure
5001
Periodic Check
5003
Figure
5002
Regular Check
5005
Figure
5003
General Overhaul
5008
Figure
7001
Liner Spacer Kit Installation
7002
Figure
7002
Cell Installation
7003
Figure
8001
Torque Specifications
8001
Figure
9001
Vent-Valve Wrench (T01)
9002
Figure
9002
Syringe with Nozzle (T02)
9002
Figure
9003
Equalizing Resistor (T03)`
9002
Figure
9004
Cell Extraction Tool (T04)
9003
Figure
9005
Vent-Valve Testing Tool
9003
Figure
IPL 1
40176-4 / 40176-7 Battery & Cell Hardware Configurations
10013-10015
Figure
15001
Charge Retention
15002
Figure
15002
Return to Service Procedures
15004
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COMPONENT MAINTENANCE MANUAL
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INTRODUCTION
1.
2.
3.
General
A.
This manual is written to the ATA Specification 100 and the AECMA Simplified English
standards. S.I. units of measure are used in this manual, with imperial units (U.S.) in
parenthesis.
B.
This manual describes maintenance on components in a workshop. It does not describe
maintenance on components when they are installed in the aircraft.
C.
Only approved technicians with the necessary skills should perform maintenance as
described in this manual.
D.
Aircraft Maintenance Task Oriented Support System (AMTOSS) is not supported in this
manual.
E.
This manual contains the following:
- Technical data for components
- Maintenance and repair procedures for components
- An Illustrated Parts List (IPL) with data for parts and components. Parts are identified in all
sections of the manual by the IPL figure 1 item number.
F.
Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY
procedures is accomplished by performing the procedures in the manufacturing facility.
How to use this manual
A.
Verify this manual contains information applicable to your model battery. Look for the model
number on the Title Page.
B.
If you need to identify a part of find a part number, refer to the IPL, which has an introduction
chapter detailing the procedure.
C.
The instructions in this manual must be used for maintenance of all components. Read all
the applicable WARNING and CAUTION notations before you perform work on the
component.
Measures
Measures given in this manual are taken from the original manufacturing drawings. Quantities are
given in S.I. units followed by U.S. imperial units in parenthesis.
INTRO Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
4.
Units of Measure
A.
S.I. Units
A
Ah
C1A
C1Ah
g
N
N·m
Pa
VDC
°C
%
W
mm
B.
U.S. Units (Imperial)
Ft
In
Lb
Lb●in
Lb●ft
InHg
Psi
°F
C.
Ampere
Ampere hour
Battery rated current
Battery rated capacity for one hour
Gram
Newton
Newton-Meter
Pascal
Volt direct-current
Degree Celsius
Per cent
Ohm
Millimeter
Foot
Inch
Pound
Inch pound
Foot pound
Inches of mercury
2
Pounds per in
Degree Fahrenheit
Multiplying Prefixes
m
m
Da
k
M
Micro
Milli
Deca
Kilo
Mega
INTRO Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
5.
Abbreviations
The abbreviations given below may be used in this manual:
AECMA
ATA
DIA
FIG.
IPL
Max.
MFR
Min.
No.
OD
P/N
PARA
REF.
S/A
TBD
V
6.
The European Association of Aerospace Industries
Air Transport Association of America
Diameter
Figure
Illustrated Parts List
Maximum
Manufacturer
Minimum
Number
Outside Diameter
Part Number
Paragraph
Refer to
Subassembly
To Be Defined
Voltage
Definition
This paragraph describes the notations used in this manual.
A.
WARNINGS call attention to the use of materials, procedures, or limits that must be followed
to avoid personal injury. Warnings will appear directly above the procedure they apply to.
B.
CAUTIONS call attention to procedures that must be followed to avoid damage to the
equipment.
C.
NOTES call attention to procedures that make the job easier or include special information
that pertains to the procedure.
INTRO Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
7.
Disposal
Ni-Cdâ batteries contain:
- Nickel
- Cadmium
- Potassium Hydroxide
Local legislation concerning disposal or recovery must be followed. For more information,
contact your local Saft supplier.
INTRO Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
DESCRIPTION AND OPERATION
1.
Description
A.
General
The alkaline battery has 20 vented nickel-cadmium VP400KH cells with welded polyamide
cases.
The battery is connected to the aircraft system and can be used:
- To start the engine or the APU used in the aircraft system.
- On the ground, to supply electrical power to the aircraft.
- In flight, if a malfunction or a failure occurs in the onboard power supply system.
NOTE:
The 28 VDC electrical system charges the battery onboard aircraft
The figure and item numbers in this chapter correspond to those in the ILLUSTRATED
PARTS LIST.
B.
Characteristics
(1)
Technical data
Nominal Voltage
Rated capacity C1Ah
Main Power Connector
Consumable volume of electrolyte
Maximum dimensions of the battery
case
- Length (base)
- Width (base)
- Height
Battery maximum weight
NOTE:
24 V
36 Ah
(see note below for more info)
Connector compliant with ISO 5064/II or
MS 3509
3
3
25 cm (1.525 in ) per cell
248 mm (9.76 in)
256 mm (10.08 in)
264 mm (10.39 in)
37.7 Kg (83 lb)
Current values can be expressed in: 36 A = 1C1A,
18 A = 0.5C1A, and 3.6 A = 0.1C1A for this 36 C1Ah battery.
OP Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(2)
Operational characteristics
- Operating temperature: -40°C to +71°C (-40°F to +160°F)
(3)
Electrical characteristics
Below is a listing of values used to service the battery:
Item
1 C1A
0.5 C1A
0.1 C1A
C.
Value
36 A
18 A
3.6 A
Used For
Charge / Discharge
Charge
Charge
Detailed Description
The battery has 20 VP400KH (13) cells housed in a stainless steel case (box) (1).
The case (box) (1) is lined with liners and spacers (kit (43)). The cells are kept upright by a
molded silicone elastomer pad fastened to the cover that presses against the top of the cells.
Cells are interconnected by rigid, nickel-plated copper links (22 thru 27).
The main power connector (28) connects the battery to the aircraft.
The cover (2) that can be removed is attached to the case (1) by four latches.
OP Page
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40176-4 / 40176-7
40176-4 / 40176-7 Battery
Figure 1
Identification Plate (typical – may not be specific to this battery)
Figure 2
OP Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
305 mm
12.00 in
Includes
handles &
bracket
257 mm
10.11 in
248 mm
9.76 in
253 mm
9.96 in
Overall Dimensions
(drawing may not be representative of specific battery)
Figure 3
OP Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
TESTING AND FAULT ISOLATION
1.
General
This chapter provides the tests and inspections required to determine the condition of a unit removed
for maintenance (scheduled or unscheduled). The table in section 7 (Fault Isolation) can be used to
assist in isolating and detecting faults noted during the maintenance process.
2.
Testing
A.
Equipment
(1)
Standard tools
- Standard mechanics tools
- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron
- Compressed air with manometer (0.1 to 1 bar (1.45 to 14.5 psi))
(2)
Special tools
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
- Discharge bench: constant current 0-50 A
- Power supply: 0-45 V, range 0-50 A
(3)
Instruments
- A multimeter, range 2 V to 50 V, 1% accuracy
- A megohmeter, range 0-50 MW @250 VDC, 3% accuracy
(4)
Environmental conditions for testing
- Ambient temperature: 20°C ± 15°C (68°F ± 27°F)
- Pressure: 85 to 106 Kpa (25.1 to 31.3 inHg)
- Relative humidity < 85%
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
B.
Precautions
Maintenance should be performed regularly per the aircraft manufacturer’s recommendations,
or as specified in this manual. The following precautions should be observed to insure the
proper operation of the battery:
- Do not install the battery in an aircraft that is too hot (>60°C (140°F)).
- Carefully follow aircraft installation instructions to ensure good airflow.
- Verify the capacity of the battery at specified intervals.
- Charge the battery in a battery shop.
- Maintenance should be performed per instructions found in the CHECK chapter to verify:
ü
ü
ü
ü
D.
Level of electrolyte
Torque on the connection nuts
Correct onboard charging
Battery capacity
Testing procedures
(1)
Insulation test
(a)
Place the leads of the megohmeter as indicated below. Check from the outer
case (1) to each cell terminal. See Figure 1002 for information regarding
minimum values.
+
MW
-
Insulation Test
Figure 1001
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
250 KW
Unacceptable
2 MW
10 MW
Can wait until next
To be cleaned
maintenance
In battery maintenance shop
Cleaning Required
Cleaning
Recommended
OK
Minimum value after
cleaning and drying
Acceptable
Fault Isolation
Insulation Test Parameters
Figure 1002
(2)
(3)
Polarization Test
(a)
Charge the battery at 3.6 A for 1.5 hours
(b)
Keep the battery in open circuit condition for 1 hour
(c)
Measure the open circuit voltage of each cell
(d)
If the open circuit voltage of any cell is 0 V (or negative polarity), perform a
Special Test (refer to paragraph (4)) and repair if necessary.
(e)
If every cell has an open circuit voltage that is greater than 0 volts, charge
the battery (refer to section 3).
Vent-Valve (20) Test
During charge, before putting the vent-valve (20) back onto the cells, verify proper
operation.
(a)
Install the vent-valve (20) with its O-ring (21) on the end of a testing
apparatus (Refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT – Fig
9005).
(b)
Connect the apparatus to a supply of compressed air through an adjustable
reducing valve.
(c)
Adjust the pressure to 0.5 bar (7.25 psi) and put the vent-valve into a
container of water. Air bubbles will come out when the valve opens. If there
are no bubbles, increase the pressure until you see bubbles and note the
pressure.
(d)
Decrease the pressure slowly to 0.1 bar (1.45 psi) and note the pressure at
which the bubbles stop.
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(4)
(e)
Reject all vent-valves that have an opening pressure greater than 0.7 bar (10
psi) and/or remain open at a pressure less than 0.14 bar (2 psi).
(f)
Install the vent-valve (20) (Refer to ASSEMBLY).
Special Test
CAUTION:
(a)
If the battery is discharged, charge the battery fully (refer to section 3) then
continue to step (b). If already charged, continue to step (b).
(b)
Continue to charge the battery at 3.6 A for an additional 5 hours, regularly
recording the voltage of each cell.
NOTE:
3.
WHEN YOU CHARGE THE BATTERY MORE THAN NECESSARY,
YOU DECREASE THE LIFE OF THE CELLS. PERFORM THIS
SPECIAL TEST ONLY WHEN SPECIFIED IN SECTION CHECK.
The temperature of cells that have damaged separators will
increase significantly and continuously, and the voltage will
continually decrease (over 0.1 V).
(c)
At the end of the additional 5-hour charge, mark any cell with a voltage less
than 1.50 V for replacement.
(d)
With current still flowing, adjust the electrolyte in all cells.
(e)
Discharge the battery down to 0 V (Initial and Residual discharges) (Refer to
section 5)
(f)
Replace any defective cells (Refer to DISASSEMBLY and ASSEMBLY).
(g)
Charge the battery (Refer to section 3).
Charge
A.
Flight Charge
The battery charge is normally maintained onboard by the electrical system or a dedicated
onboard charger.
NOTE:
The decrease of water from the cells is in direct proportion to the overcharge
the battery receives.
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
B.
Ground Charge
The following charging procedures are to be carried out in an appropriately equipped
workshop.
CAUTION:
REMOVE THE COVER TO CHARGE THE BATTERY. THIS IS TO MAKE
SURE THAT HYDROGEN GAS WILL NOT COLLECT IN THE BATTERY
CASE.
CAUTION:
WHEN THE BATTERY IS CHARGED IN EXCESS OF THE TIMES AND
RATES LISTED IN THE TABLE BELOW, THE LIFE OF THE CELLS IS
DECREASED.
(1)
Constant current charge
(a)
To charge a fully discharged battery, perform one of the Main Charge
procedures listed in the table below followed by a corresponding Final
Charge procedure.
CONSTANT CURRENT CHARGE
Main Charge
3.6 A (0.1 C1A) until 30.0 V as battery voltage
Min: 10 hr
Times:
Max: 12 hr
18 A (0.5 C1A) until 31 V as battery voltage
Min: 2 hr
Times:
Max: 2 hr 30 min
36 A (1C1A) until 31.4 V as battery voltage
Min: 1 hr
Times:
Max: 1 hr 15 min
NOTE:
Final Charge (overcharge)
3.6 A (0.1C1A) for 4 hours
All cells must be above 1.50 V at end of
charge
3.6 A (0.1C1A) for 4 hours
All cells must be above 1.50 V at end of
charge
3.6 A (0.1C1A) for 4 hours
All cells must be above 1.50 V at end of
charge
If during the Main Charge, the battery has not increased to the required voltage in the
maximum charge time, proceed to the Final Charge. Do not continue to charge the
battery at the high rate. If at the end of the Final Charge, all cells are not above the
required voltage, refer to Fault Isolation.
(b)
For a battery not fully discharged or when the level of charge is unknown:
1
Discharge at 36 A (1C1A) down to 20 V (refer to section 5)
2
Charge: Refer to B (1)(a) for constant current charging instructions.
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(2)
4.
Other types of Charging: In addition to the constant current method of charging,
other methods that fully charge the battery can be used. HOWEVER, IN EVERY
CASE, CELL VOLTAGE CHECKS (V > 1.5 V) AND ELECTROLYTE
ADJUSTMENTS MUST BE CARRIED OUT USING A FINAL CHARGE AT
CONSTANT CURRENT: 3.6 A AT 0.1C1A. If specific instructions are not given in the
charger operating manual, Saft should be contacted before charging.
Electrolyte Check and Adjustment
The easiest tool to use to adjust the level of the electrolyte is a plastic syringe (T02) with a plastic
nozzle on the conical end.
The length of the nozzle that goes into the cell must be 20 mm (0.79 in). This is the distance
necessary between the seat of the vent-valve (20) and the electrolyte (refer to Figure 1003).
3
NOTE:
3
The maximum consumable amount of electrolyte for this battery is 25 cm (1.525 in )
per cell (refer to DESCRIPTION AND OPERATION).
Electrolyte Level Adjustment
Figure 1003
CAUTION:
DO NOT USE ACID OR ACIDULATED WATER TO ADJUST THE ELECTROLYTE
LEVEL IN NICKEL-CADMIUM BATTERIES. A VERY SMALL QUANTITY OF ACID
IS SUFFICIENT TO CAUSE PERMANENT DAMAGE. USE ONLY DISTILLED OR
DEIONIZED WATER (M01) (Refer to SPECIAL TOOLS, FIXTURES AND
EQUIPMENT)
A.
Insert the nozzle into the cell until the nozzle rests on the seat of the vent-valve opening. Pull
the syringe plunger up. If the level is not sufficient, the syringe tube stays empty when you
pull the plunger up. If there is too much electrolyte, the electrolyte is removed by the syringe
until the level aligns with the end of the nozzle. Discard any liquid drawn into the syringe
when leveling, do not reuse the liquid in other cells.
B.
If in check 4.A there is no liquid removed by the syringe, the level is not sufficient. Perform
the following to adjust the electrolyte:
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(1)
Add a measured amount (5 ml) of distilled or deionized water (M01) into the syringe
and inject it into the cell. Keep record of how much distilled or deionized water (M01)
is being injected into the cell during this procedure.
NOTE:
(2)
5.
The amount of distilled or deionized water (M01) required to level the
first cell will serve as a guide to the amount required for the
remaining cells in the battery. However, each cell must be adjusted
individually to ensure the correct level is achieved in each cell.
Repeat check 4.A to check for correct level.
Discharge
A.
Initial Discharge and Capacity Test
The initial discharge can also be used to determine the capacity of the battery. The battery
should be discharged at a rate equal to its rated capacity.
(1)
For Initial Discharge (from aircraft or storage):
(a)
Discharge the battery at 1C1A down to 20 V, monitoring the time from the
start of the discharge to the time the battery voltage (at the main terminals)
reaches 20 V.
The time should be greater than 30 minutes. If not, one of the following may
be the cause:
- There was a discharge performed after the last use of the battery onboard
the aircraft
- The aircraft charger may not be functioning properly
- If the battery was left idle for a time, self-discharge occurred
- The battery cells may be imbalanced and need servicing
(2)
For Capacity Test
(a)
Discharge the battery at 1C1A, monitoring the time from the start of the
discharge to the time any of the cells voltage falls below 1 V. Mark the time
any cell in the battery reads below 1 V.
Each cell in the battery should maintain a voltage higher or equal to 1 V for a
full 60 minutes of discharge at 1C1A (refer to Discharge Table). If one or
more cells should fall below 1 V in less than 60 minutes, refer to Section 7
(FAULT ISOLATION).
NOTE:
Repeating the charge and full discharge of a battery that
does not pass capacity test may recover lost capacity.
However, if the capacity continues to decline, refer to Section
7 (FAULT ISOLATION).
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40176-4 / 40176-7
Battery Type
40176-4
40176-7
B.
Discharge Table
1C1A Discharge Rate
36
36
Minimum Time
60 Min
60 Min
Residual Discharge
The Residual Discharge will clear the battery of all “residual” energy left in the battery after
the Initial Discharge or the Capacity Test. This procedure is to be performed after the battery
has been discharged to 1 V per cell.
(1)
6.
As each cell is discharged to 1 V, connect a resistor approximately 1 W 3 W (T03)
across the cell terminals and continue to discharge each cell in the battery. Keep
these resistors in position for 12 to 16 hours, allowing the battery to cool.
Temperature Sensor and Heater Control Thermostat Testing
Testing of the temperature sensor and heater control thermostat may require the use of a climatic
chamber or other device that will allow raising or lowering the temperature of components in the
temperature sensor.
Refer to the SCHEMATIC AND WIRING DIAGRAM section for information on the specific layout of
the temperature sensor.
A.
B.
Testing of the sensor (both 40176-4 & 40176-7)
(1)
Perform the following tests at the temperature specified.
(2)
This sensor is normally open at room temperature.
Test
Thermostat
Pins
1-2
Required Values
> 1 MW (normally open) @ 21.1°C ±2°C (70°F ±5°F)
Thermostat
1-2
< 1 MW (close on rise) @ 60°C (140°F) (stabilized temp)
Thermostat
1-2
> 1 MW (open again on fall) @ 51.6°C (125°F) (stabilized temp)
Heater Control Thermostat Test (40176-7 only)
(1)
Perform the following tests at the temperature specified.
(2)
The heater control thermostat is normally open at room temperature.
Test
Thermostat
Pins
3-4
Required Values
> 1 MW (normally open) @ 21.1°C ±2°C (70°F ±5°F)
Thermostat
3-4
< 1 MW (close on fall) @ below -1.1°C (30°F) (stabilized temp)
Thermostat
3-4
> 1 MW (open again on rise) @ 10°C (50°F) (stabilized temp)
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7.
Fault Isolation
Box or cells
damaged
Yes
See para. 7.C (5)
More than
usual added in
all cells
No
Salt or
electrolyte
traces
Yes
See para. 7.B (1)
No
Yes
See para. 7.C (1)
More than 25%
average added in
1 cell
Yes
See para. 7.B (2)
No
No
Electrolyte in
the case
Yes
See para. 7.C (2)
1 or more cells
voltage different
by >0.1V
Yes
See para. 7.B (3)
No
No
Metallic parts
corroded
Yes
See para. 7.C (3)
Voltage of 1
cell <1.50 V
No
Battery voltage
=0V
Yes
See para. 7.B (4)
Yes
See para. 7.B (5)
Yes
See para. 7.C(4)
No
Yes
See para. 7.A (1)
Capacity test
<100% C1Ah
No
No
1 or more cells
=0V
Yes
See para. 7.B (7)
Link or nut is
overheated
No
No
1 or more cells
<0V
Yes
See para. 7.B (5)
No
Cell to case
insulation <
250KW
Yes
See para. 7.A(3)
Perform a General
Overhaul to detect
and repair any
battery fault noted
No
Functional Test Flow
Figure 1004
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40176-4 / 40176-7
A.
Battery Electrical Faults
PROBLEM
(1) Zero battery open-circuit
voltage
(2) Zero volts with the battery set
to “discharge”
PROBABLE CAUSE
(a) Defective electrical
connection (no contact made).
CORRECTION
Check electrical contacts, links
and torque of nuts (refer to FITS
AND CLEARANCES).
(b) Link loose or broken
Verify the nuts have the proper
torque (refer to FITS AND
CLEARANCES).
Perform an Insulation Test and
recharge the battery (refer to
TESTING AND FAULT
ISOLATION).
(a) Battery fully discharged
(b) Battery circuit open or
connection defective
(c) One or more cells dry
(3) Low insulation
B.
(a) Leakage of electrolyte
Examine the connection and
links. Verify the terminal nuts
have proper torque (refer to FITS
AND CLEARANCES).
See section B (Cell faults).
Check electrolyte level (refer to
TESTING AND FAULT
ISOLATION).
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING). Perform an
electrolyte level check (refer to
TESTING AND FAULT
ISOLATION).
Cell Faults
PROBLEM
(1) Excessive water
consumption.
PROBABLY CAUSE
(a) Excessive charge or charging
at high temperatures.
CORRECTION
Examine the cause of the
excessive charge. If necessary,
adjust the maintenance interval.
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PROBLEM
(2) The variation of water
consumption in individual cells
exceeds ±25% of the average
consumption for all cells.
PROBABLE CAUSE
(a) More than 25% than the
average: cell leakage
CORRECTION
Perform an Insulation Test.
Disassemble and replace faulty
components as necessary
(b) 25% (or less) than the
average: cell(s) with damaged
separators
Perform the Special Test (refer
to TESTING AND FAULT
ISOLATION). Replace cells if
necessary
Note the cell location and check
the level of water consumption
versus other cells at the next
maintenance interval
3
(3) A cell has an unusually high
(a) Dry cell
Add 5 cm of distilled or
voltage at the start of the charge
deionized water (M01) to the cell.
Do not add more unless voltage
continues to be exceptionally
high. Level electrolyte at final
level at the end of charge (refer
to TESTING AND FAULT
ISOLATION).
NOTE: If a cell is charged with low electrolyte levels, it may cause overheating and permanent
damage to the cell and adjacent cells.
Replace the cell (refer to
(a) The cell was operated at
(4) A cell has an unusually low
DISASSEMBLY and
temperatures and charge rates
voltage at the end of the Final
ASSEMBLY)
outside the limits, and the
Charge (less than 1.50 V)
separator is damaged
(c) Previous maintenance was
not performed or performed
incorrectly
(5) Low capacity cell (the cell
shows a reversed voltage or a
correct polarity voltage of less
than 1 V after a discharge of 60
minutes at 1C1A).
(6) Cell with an excessively
swollen case.
(7) Cell with zero voltage when
the battery circuit is open
(b) The cell has reached its end
of serviceable life.
(a) Usual wear after long service
life.
(b) Unusual operation, operating
at high temperatures or with low
electrolyte.
(a) Cell operated with low
electrolyte level; deterioration of
separators and damaged plates
(a) Short-circuited cell.
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY)
Perform the Special Test (refer
to TESTING AND FAULT
ISOLATION). If necessary,
replace the cell(s).
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY).
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY).
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C.
Physical Faults
PROBLEM
(1) Leakage of electrolyte.
(2) Electrolyte found in the
battery case.
(3) Corrosion on the links.
PROBABLE CAUSE
(a) Incorrect adjustment of
electrolyte level
CORRECTION
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(b) Cell polarity incorrect during
high-rate discharge (for example,
during the engine start).
Investigate the cause of the
excessive discharge.
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(c) Excessive overcharge or high
overcharge at high temperatures.
Investigate the cause of
excessive charge. If necessary,
adjust the maintenance interval.
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(a) Damaged cell case
Replace the cell if necessary.
Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
(b) Leakage of electrolyte
Perform an electrolyte level
check and disassemble and
clean the battery (refer to
DISASSEMBLY and
ASSEMBLY)
Make sure the battery test
bench, test room, and storage
areas contain no materials that
can release acid fumes.
(a) Operation in acid
environment
(b) Mechanical damage to the
nickel plating
(4) The links show signs of
overheating
(a) Loose terminal nuts
(5) Case Deformed
(a) Physical damage
(b) Swollen cells
Replace the damaged links (refer
to DISASSEMBLY and
ASSEMBLY)
Verify the torque on the nuts
(refer to FITS AND
CLEARANCES)
Disassemble and straighten case
(refer to DISASSEMBLY and
ASSEMBLY)
Replace the cell if necessary.
Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
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D.
Vent-valve Faults
PROBLEM
(1) Valve open pressure > 0.7
bar (10 psi) or stays closed
(2) Valve stays open at a
pressure <0.14 bar (2 psi).
PROBABLE CAUSE
(a) Clogged valve
(a) Pierced valve
CORRECTION
Clean the valve (refer to
CLEANING).
Replace the valve if cleaning is
not successful.
Replace the valve
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SCHEMATIC AND WIRING DIAGRAMS
1.
General
This chapter gives all electrical schematics of the battery temperature sensor
2.
Sensor Schematic
1
2
3
4
5
Sensor Schematic 40176-4
Figure 2001
1
2
3
4
5
Sensor Schematic 40176-7
Figure 2002
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DISASSEMBLY
1.
General
WARNING:
DISASSEMBLY SHOULD ONLY BE PERFORMED ON A COMPLETELY
DISCHARGED BATTERY (REFER TO TESTING AND FAULT ISOLATION)
Refer to the TESTING AND FAULT ISOLATION chapter to determine the malfunction and necessary
level of disassembly required.
The figures and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2.
Safety
The safety regulations are different from one country to another. Check local regulations for those
that apply.
3.
Risks
There are three types of risks involved in nickel-cadmium battery maintenance:
A.
Physical
- Handling: Lift with your legs and not your back
- Wear protective shoes
B.
Electrical
- Don’t wear rings, watches, chains, or belt buckles
- Use insulated tools
C.
Chemical
- Electrolyte is very corrosive and may cause severe burn to the skin: wear gloves and apron.
- Contact with the eyes is very dangerous; wear protective goggles.
4.
Safety Measures
- The electrolyte is caustic and can cause severe burns. If electrolyte comes in contact with the skin,
flush the affected area with water and neutralize the solution with acetic solution, vinegar, lemon
juice, or with boric acid solution at 10% concentration.
- If the electrolyte comes in contact with the eyes, flush with water for at least 15 minutes and contact
a physician.
- Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the
solution with water or milk. Contact a physician immediately.
- Contact with nickel can cause chronic eczema.
- Inhalation of cadmium oxide can cause a dry throat, cough, headaches, vomiting, or pain in the
chest. Persons having inhaled cadmium oxide fumes must get fresh air, take oxygen, or have
artificial respiration. Contact a physician as soon as possible.
- Potash can cause eczema.
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5.
Disassembly
A.
Equipment
(1)
Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eyewash.
- Protective apron
(2)
Special tools
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
B.
Disassembly procedure
WARNING:
(1)
DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY
DISCHARGED BATTERY (TESTING AND FAULT ISOLATION).
Remove the cover (2)
(a)
Remove the cover by pulling up the tab on the latches that attach the cover
(2) to the case (1) and lifting the cover upward.
CAUTION:
REMOVE THE VENT-VALVE (20) ONLY FOR CLEANING OR LEVELING
ELECTROLYTE. OVEREXPOSURE TO ATMOSPHERE WILL CAUSE
DETRIMENTAL CHEMICAL CHANGES IN THE ELECTROLYTE.
(2)
Remove the vent-valve (20)
(a)
Unscrew the vent-valve (20) with the special tool (T01).
(b)
Remove the vent-valve (20) with its o-ring (21).
CAUTION:
(3)
IN ORDER TO AVOID SHORT-CIRCUIT, REMOVE THE LINKS
ATTACHED TO THE CELL AND ADJACENT CELLS.
Remove a cell (13)
(a)
Remove the nuts (11) and the belleville or spring washers (12) that attach the
links to the cell.
(b)
Remove all links (22 thru 27)
(c)
Fully engage the end of the special threaded tool (T04) onto one of the cell
terminals. Pull up to remove the cell.
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(4)
(5)
(6)
Remove the main power connector (28)
(a)
Remove the nuts (11) and belleville or spring washers (12).
(b)
Remove the screws (29) and washers (if equipped) (30).
(c)
Remove the connector (28) with the gasket (not numbered).
Remove the temperature sensor (4, 5)
(a)
Remove the connector (28) (refer to section (4))
(b)
Remove the attaching nut (8) and O-ring (9).
(c)
Remove the nuts (11), belleville or spring washers (12), and brackets that
hold down any part of the temperature sensor.
(d)
Disconnect (cut) any tie straps (not shown) holding parts of the temperature
sensor (if applicable).
(e)
Remove the sensor (4, 5) with the O-ring (9) from the inside of the case (1).
Disassembly of a complete battery
(a)
Remove the cover (2) (refer to Section (1)).
(b)
Remove the cells (13) (refer to Section (3)).
(c)
Remove the liner-spacer kit (43) by pulling out the liners and spacers, making
sure to mark them to ensure correct placement during assembly.
(d)
Remove the connector (28) (refer to Section (4)).
(e)
Remove the sensor (4, 5) and O-ring (9) (refer to Section (5)).
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CLEANING
1.
General
This chapter provides instructions for the cleaning and preservation of the battery components.
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2.
Equipment
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eyewash.
- Protective apron.
- Compressed air
3.
Materials
CAUTION:
DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. SOME
CHEMICALS CAN DEGRADE METAL PARTS CAUSING PREMATURE FAILURE.
- Ordinary water.
- Distilled or deionized water (M01).
- Neutral soap (M02).
- Non-fluffy swab.
- Non-wire brush.
- Rubbing alcohol (isopropyl)
4.
Cleaning Procedure
WARNING:
A.
BE CAREFUL WHEN HANDLING ELECTROLYTE AND AVOID SPLASHING.
ELECTROLYTE IS A STRONG CAUSTIC AGENT AND CAN CAUSE SEVERE
BURN. ALWAYS WEAR FACE AND EYE PROTECTION (PREFERABLY A
TRANSPARENT FACE MASK), RUBBER GLOVES AND LONG-SLEEVED
CLOTHING. IN CASE OF CONTACT WITH SKIN, FLUSH WITH WATER. IN
CASE OF CONTACT WITH EYES, FLUSH WITH WATER FOR AT LEAST 15
MINUTES AND SEEK MEDICAL ATTENTION.
Light Cleaning
(1)
Remove the cover (2).
CAUTION:
(2)
TO PREVENT SHORT-CIRCUIT, USE A RUBBER TUBE OR AN
INSULATED NOZZLE TO DISPENSE COMPRESSED AIR.
Blow (with compressed air) across the tops of the cells to remove all dust and light
traces of mineral salts from the battery. Using a clean cloth, wipe off all temperature
sensor components.
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(3)
Main Power Connector (28).
(a)
B.
Clean connector pins with rubbing alcohol to clean off any accumulated
grease and/or dirt. Inspect the pins for damage; pits, cracks, or scratches,
that allow copper to show through the nickel plating. Replace connectors
that are damaged with a Saft factory new unit.
Thorough Cleaning
WARNING:
(1)
TO AVOID ELECTRIC SHOCK, DISASSEMBLY SHOULD ONLY BE
PERFORMED ON A FULLY DISCHARGED BATTERY (REFER TO
TESTING AND FAULT ISOLATION).
Disassemble the battery (refer to DISASSEMBLY) and then clean all components
except the vent-valve (20) which must be cleaned while cells are in the case.
(a)
Cells (13)
1
Make sure the vent-valve (20) is tight.
2
Remove lower terminal nut (14), polarity washer (15,16), belleville or
spring washers (17), flat washer (18), and clean in warm water if
necessary.
3
Inspect the terminal o-ring (19) for cracks, breaks or leakage and
clean in warm water. Replace if necessary.
4
Reassemble the dry hardware onto the cell and torque the lower
terminal nut (14) per FITS AND CLEARANCES.
CAUTION:
(b)
5
To easily remove all the electrolyte and mineral salts from the
terminals, cover, and sides of the cell cases, clean in warm water
with a soft brush.
6
Rub the cell with a cloth and let dry.
Case (1) and handle (if equipped)
1
(c)
Clean with light soap (M02) and water, rub with a cloth and let dry.
Nuts, belleville or spring washers, flat washers, and links
1
(d)
DO NOT SOAK THE CELLS IN WATER. TAP WATER
ENTERING CELL WILL CONTAMINATE ELECTROLYTE.
Clean in warm water with a soft brush and let dry.
Liner-spacer kit (43)
1
Clean in warm water with a soft brush and let dry.
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(e)
Temperature Sensor (4, 5)
1
CAUTION:
(f)
1
Remove the vent-valve (20) (refer to DISASSEMBLY) during the
Final Charge (refer to TESTING AND FAULT ISOLATION) at
0.1C1A.
2
Place a swab or soft cloth over the cell opening to keep out
unwanted material.
3
Soak the vent-valve (20) for 1-2 hours in a container of distilled or
deionized water to dissolve mineral salts from the vent-valve hole.
To facilitate the cleaning process the water may be warmed
to 50°C (122°F).
Main Power Connector (28)
1
5.
CLEANING OF THE VENT-VALVE (20) MUST BE DONE WHEN
THE CELLS ARE ASSEMBLED IN THE CASE (1).
Vent-valve (20)
NOTE:
(g)
Wipe all parts with a damp cloth and let dry.
Clean connector pins with rubbing alcohol to clean off any
accumulated grease and/or dirt. Inspect the pins for damage; pits,
cracks, or scratches, that allow copper to show through the nickel
plating. Replace connectors that are damaged with a Saft factory
new unit.
Lubrication
When the battery is clean (with the vent-valve installed), put a thin layer of mineral vaseline (M04) or
light oil on the terminals and on the links. Use of a paintbrush will make this procedure easier.
.
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CHECK
1.
General
The checks in this chapter are necessary to use the batteries in flight and on the ground. The
maintenance procedures in this chapter should be carried out in a battery shop. The three types of
maintenance that will be detailed in this chapter are:
- Periodic Check: adjustment of the electrolyte levels.
- Regular Check: electrical functional testing, adjustment of electrolyte, and capacity test.
- General Overhaul: disassembly, full cleaning, assembly and Regular Check.
2.
Maintenance in workshop
A.
Equipment
(1)
Standard tools
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eyewash.
- Protective apron.
(2)
Special tools
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
(3)
Instruments
- Power supply 0-45 V, 0-50 A
- Discharge bench, constant current 0-50 A
- Multi-meter, range 2 V and 50 V, accuracy 1%
- Megohmeter, range 0-50 MW (voltage 250 VDC), accuracy 3%
B.
Conditions
- Ambient temperature: 20°C ± 15°C (68°F ± 27°F)
- Pressure: 85 to 106 Kpa (25.1 to 31.3 InHg)
- Relative humidity < 85%
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C.
Periodic Check
If the electrolyte consumption exceeds the maximum consumable amount between two
Regular Checks, this Period Check may be performed to adjust the electrolyte. Maintenance
should be performed using Fig 5001 as a guide and will include the following steps:
- Clean the battery.
- Check the torque on nuts (11).
- Perform an Insulation Test.
- Measure the battery voltage.
- Discharge the battery.
- Charge the battery.
- Clean the vent valves (20).
- Adjust the electrolyte.
- Check the torque on nuts (11).
(1)
Remove the cover (2).
(2)
Perform a Light Cleaning (refer to CLEANING).
(3)
Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES).
(4)
Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION).
(5)
Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test (refer to TESTING AND FAULT
ISOLATION).
(6)
Perform an Initial Discharge at 36 A down to 20 V at the battery terminals, and allow
the battery to cool (refer to TESTING AND FAULT ISOLATION).
(7)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(8)
During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (20) (refer to CLEANING).
(9)
Level the electrolyte (refer to TESTING AND FAULT ISOLATION).
(10)
Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES).
Page
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April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
Periodic Check
Check Torque
on all nuts
Light Cleaning
Dust Only
Yes
No
No
Electrolyte Traces
Cell to Case
Insulation Test
> 2 Megohms
Yes
Total Voltage > 21V
At main power connector
No cells with reversed polarity
No
General Overhaul
Yes
Polarization Test
Initial Discharge
Fault Isolation
No
Special Test
Additional charge with up to
5 hr overcharge
Yes
Charge
For standard product
all cells > 1.50V
Yes
Vent Valve Cleaning
For standard product
all cells > 1.50V
No
No
General Overhaul
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Yes
Check Torque
on all nuts
Battery Accepted
Periodic Check
Figure 5001
Page
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April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
D.
Regular Check
After six months, or according to aircraft manufacturer’s specifications, perform this check
following the different procedures indicated in Figure 5002.
- Perform a Light Cleaning.
- Check the torque on all nuts (11).
- Measure the voltage of the battery.
- Perform an Initial Discharge.
- Perform a Residual Discharge.
- Perform an Insulation Test.
- Test the temperature sensor.
- Charge the battery.
- Clean the vent-valves (20).
- Adjust the electrolyte.
- Perform a Capacity Test.
- Charge the battery.
- Check the torque on all nuts (11).
(1)
Remove the cover (2).
(2)
Perform a Light Cleaning (refer to CLEANING).
(3)
Check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
(4)
Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test.
(5)
Perform an Initial Discharge at 36 A down to a voltage of 20 V at the battery
terminals. Monitor the time from the start of the discharge to the time the battery
reaches 20 V (refer to TESTING AND FAULT ISOLATION).
(6)
Perform a Residual Discharge (refer to TESTING AND FAULT ISOLATION).
(7)
Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION).
(8)
Test the temperature sensor (4, 5). This will likely require partial disassembly (refer
to TESTING AND FAULT ISOLATION and DISASSEMBLY).
(9)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(10)
During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (20) (refer to CLEANING).
(11)
Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(12)
Perform a Capacity Test (Refer to TESTING AND FAULT ISOLATION).
(13)
Re-check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(14)
Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Regular Check
Check Torque
on all nuts
Light Cleaning
Dust Only
Yes
Total Voltage > 21 V
At main power connector
No cells with reversed polarity
No
No
Electrolyte Traces
Yes
Polarization Test
General Overhaul
Initial Discharge
Residual Discharge
1 Ohm - 3W Min Resistor
12-16 hours on all cells
No
Cell to Case
Insulation Test
> 2 Megohms
Yes
Test Temperature
Yes
Sensor
No
No
Charge
For standard product
all cells > 1.50V
Yes
Vent Valve Cleaning
Fault Isolation
No
Special Test
Additional charge with up to
5 hr overcharge
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Yes
Yes
For standard product
all cells > 1.50V
No
Clean Vent Valves if applicable
Capacity Test
(Initial Discharge)
Yes
Adjust electrolyte at end of charge
Check Torque
on all nuts
No
General Overhaul
No
Charge
For standard product
all cells > 1.50V
Adjust Electrolyte
at end of charge
Battery Accepted
Yes
Regular Check
Figure 5002
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
E.
General Overhaul
The General Overhaul includes electrical tests contained in the Regular Check. It also
includes disassembly and cleaning of all components. Perform the General Overhaul every
12 months, or according to aircraft manufacturer’s instructions following the procedures
indicated in Figure 5003.
- Check the torque on all nuts (11).
- Measure the voltage of the battery in open circuit at the main terminals.
- Perform an Initial Discharge.
- Perform a Residual Discharge.
- Disassemble the battery completely.
- Perform a Thorough Cleaning.
- Test the Temperature Sensor.
- Check torque on lower nuts (14).
- Assemble the battery.
- Perform an Insulation Test.
- Charge the battery.
- Clean the vent-valves (20) and test.
- Adjust the electrolyte.
- Perform a Capacity Test.
- Check the torque on all nuts (11).
- Charge the battery and perform a final electrolyte adjustment.
NOTE:
If three cells are replaced during a single maintenance cycle, or five cells
over the life of the battery, Saft recommends that all cells be changed or the
battery be replaced.
(1)
Check the torque on all nuts (11) (refer to TESTING AND FAULT ISOLATION).
(2)
Measure the voltage of the battery at the main terminals. If the voltage is less than
21 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION).
(3)
Perform an Initial Discharge at 36 A down to 20 V (refer to TESTING AND FAULT
ISOLATION).
(4)
Perform a Residual Discharge with resistor clips (T03) down to 0 V (refer to TESTING
AND FAULT ISOLATION).
(5)
Disassemble the battery completely (refer to DISASSEMBLY).
(6)
Perform a Thorough Cleaning (refer to CLEANING) and inspect components.
(a)
Verify the cells show no signs of leakage.
(b)
Remove any small dents from the case (1).
(7)
Test the Temperature Sensor and Heater Control Thermostat (4, 5) (refer to
TESTING AND FAULT ISOLATION).
(8)
Assemble the battery (refer to ASSEMBLY).
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(9)
Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value
measured after a Thorough Cleaning should be at least 10 MW.
(10)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(11)
During the Final Charge, clean and test the vent-valves (20) (refer to CLEANING and
TESTING AND FAULT ISOLATION).
(12)
Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(13)
Perform a Capacity Test (refer to TESTING AND FAULT ISOLATION).
(14)
Check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
(15)
Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
General Overhaul
Total Voltage > 21V
At main power connector
No cells with reversed polarity
Check Torque
on all nuts
Residual Discharge
1 Ohm Resistor
12 hours on all cells
Initial Discharge
Polarization Test
Disassembly
and Thorough Cleaning
Visual Inspection
Temperature Sensor Test
Check - Disassembled Battery
Assembly
No
Cell to Case
Insulation Test
> 10 Megohms
Yes
Charge
For standard product
all cells > 1.50V
No
Yes
Vent Valve Cleaning/Test
Fault Isolation
Yes
No
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Special Test
Complete charge with
Additional charge with up to
5 hr overcharge
Yes
No
For standard product
All cells > 1.50V
Capacity Test
Yes
Check Torque
on all nuts
No
Full Discharge
Replace faulty components
and return to charge
No
Charge
For standard product
all cells >1.50V
Adjust Electrolyte
at end of charge
Battery Accepted
Yes
General Overhaul
Figure 5003
Page
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April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
REPAIR
1.
General
Defective parts for which no repair instructions are given shall be rejected and replaced by Saft
factory new parts only.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2.
Equipment
A.
Special Tools
When special tools are used in this chapter, a code number that can be found in SPECIAL
TOOLS, FIXTURES AND EQUIPMENT, identifies them.
B.
Standard Tools
Standard mechanics tools.
C.
Materials
Neoprene glue (M03)
3.
Repairs
The only authorized repair(s) applicable to this unit:
- Re-affixing the Cover Gasket (not shown).
A.
Cover Gasket
The Cover Gasket (3) can only be re-glued one time.
(1)
Remove the Cover Gasket (3) completely.
(2)
Clean all traces of glue from the cover (2).
(3)
Apply the glue (M03) to the flat side of the cover (2).
(4)
Let dry for 2 hours in a dry place (or as specified by manufacturer’s instructions).
(5)
Place Cover Gasket (3) on the bottom of the cover (2) and press firmly to seat.
Page
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40176-4 / 40176-7
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
ASSEMBLY
1.
General
Battery assembly is to be performed in a clean, dry room where all parts are protected from any
impact from other parts or tools. Any protective layers applied to replacement parts must be removed
prior to assembly.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2.
Assembly Procedures
A.
Equipment
(1)
Special Tools
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
(2)
Standard Tools
- Standard mechanic’s tools
- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron
B.
Installation of the Temperature Sensor (4, 5)
(1)
Insert the sensor (4, 5) with the O-ring (9) and attach with nut (8).
NOTE:
C.
Installation of the Main Power Connector (28)
(1)
D.
Lay the remaining portion of the sensor to the side of the case, these
components will be attached either during or after the cells are
installed.
Insert the main power connector (28) with the gasket (not numbered) into position in
the battery case (1) and attach with screws (29) and washers (if equipped)(30).
Installation of the liner spacer kit (43)
(1)
Insert the bottom liner into the bottom of the case (1).
(2)
Follow the assembly shown in Fig 7001, inserting liners and spacers in each position.
NOTE:
Additional liners and spacers may be necessary to keep cells (13)
tight in the case (1).
Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
Liner Spacer Kit Installation
Figure 7001
E.
Installation of Cells (13)
(1)
Torque all lower terminal nuts (14) (refer to FITS AND CLEARANCES).
(2)
Cells should be installed in rows. Install all but the center cell in each row according
to their polarity as found in Fig. 7002. Make sure to install any liners and spacers
(refer to Fig 7001) and/or temperature sensor plates (as applicable) that are needed
in between the cells at this time.
(3)
Carefully position the last cell (13) in each row and insert the cell (13) by pressing on
the terminals with a piece of soft wood. This cell should be difficult to insert, requiring
25-30 lb-ft of pressure to seat. If the cell is too loose, install additional liners and
spacers (43). If the cell is too difficult to insert, remove a liner or spacer (43) as
needed. Never lubricate the cells to facilitate assembly.
(4)
Lightly lubricate all links (22-27), belleville or spring washers (12), nuts (11), and cell
terminals with a mineral vaseline (M04) or light oil using a paintbrush.
(5)
Install the links (22-27), belleville or spring washers (12), and nuts (11).
(6)
Torque all nuts (11) (refer to FITS AND CLEARANCES).
Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
¢ Negative
Polarity
Polarity
+
˜ Positive Polarity
Polarity -
Cell Installation
Figure 7002
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FITS AND CLEARANCES
1.
General
The FITS AND CLEARANCES section provides torque specifications for any components requiring a
specific torque value, or clearance values for moving parts that require specific clearance distance.
2.
Torque Specifications
IMPORTANT: The values provided in the torque table (Fig 8001) are “lube torque” values. All
threads should be lightly lubricated with mineral vaseline (M04) or light oil prior to installation and
applying torque.
IPL FIG
ITEM
NOMENCLATURE
(FROM IPL)
TORQUE VALUE (lubricated)
N●m ±10%
Lb●in ±10%
11
Upper Terminal Nut
10
87
14
Lower Terminal Nut
5
43.5
8
Temperature Sensor Nut
0.2
2
Torque Specifications
Figure 8001
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1
General
This chapter provides pertinent specifications for any special tools that may be needed during battery
maintenance. It also supplies a listing of consumable items that may be useful during normal
servicing, repair, and use.
2.
Special Tools, Fixtures and Equipment
CODE
FIGURE
QTY
PART
NUMBER
(where
applicable)
F6177
PART
NUMBER
(where
applicable)
V09052
DESCRIPTION
USE
T01
9001
1
015528
093382-000
Vent-Valve Wrench
-DISASSEMBLY
-CLEANING
-CHECK
-ASSEMBLY
T02
9002
1
016544
020915-004
Syringe w/20 mm
Nozzle
-TESTING AND
FAULT ISOLATION
-CHECK
T03
9003
1
164829
Equalizing
Resistors
1W 3 Watt
-TESTING AND
FAULT ISOLATION
-CHECK
T04
9004
1
013169
Cell Extraction tool
M10
-DISASSEMBLY
017556-000
Page
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April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
Vent-Valve Wrench (T01)
Figure 9001
Syringe with Nozzle (T02)
Figure 9002
Equalizing Resistor (T03)
Figure 9003
Page
24-32-03
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
Cell Extraction Tool M10 (T04)
Figure 9004
Vent-Valve Testing Tool
Figure 9005
Page
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
3.
Consumables
NOTE:
CODE
Equivalent alternatives may be used.
DESIGNATION PART
NUMBER AND
SPECIFICATION
MANUFACTURER
OR SUPPLIER
A
I
R
L
I
N
E
T
E
S
T
C
O
D
E
M01
Distilled or deionized water;
clear, colorless, odorless
while boiling, resistivity
>30 KW/cm
5 < pH > 7
Absence of organic and
reducing substances.
Reducing agent content
(expressed in weight of
oxygen) < 30 mg/l (test with
permanganate). Total of
2+
ions: SO4 Cl < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
M02
Soap (non-abrasive – mild
household)
Local Vendor
M03
Neoprene Glue (alkali
resistant)
Local Vendor
M04
Mineral Vaseline
Local Vendor
X
D
I
S
A
S
S
E
M
B
L
Y
C
H
E
C
K
C
L
E
A
N
I
N
G
R
E
P
A
I
R
S
T
O
R
A
G
E
X
X
X
X
X
NATO: S 743
F: AIR 3565
US: SLP 236
UK: DEF 2333
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S
E
M
B
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ILLUSTRATED PARTS LIST
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40176-4 / 40176-7
ILLUSTRATED PARTS LIST
1.
Introduction
A.
General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed
parts of the unit.
It includes the following sections:
- Introduction
- Equipment Designator Index (EDI)
- Numerical Index
- Detailed Parts List (DPL)
- Vendor Code Index
B.
C.
How to use the Illustrated Parts List
(1)
To find the illustration for a part if the part number is known, refer to the Numerical
Index and look for the part number and the corresponding figure and item number.
Refer to the Detailed Parts List and look for the figure and item number found in the
Numerical Index for that part to verify it is the part specified.
(2)
To determine the part number of a given part, refer to the Illustrated Parts List figures.
Note the item number of the illustrated part and refer to the Detailed Parts List that
indicates the part number and identification.
Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and
electronic components of the items listed. If applicable, they are listed in alphanumeric order.
D.
Numerical Index (NI)
In this index, part numbers are classified in the following order:
Classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
The first row ordering is:
- Hyphen
- Alpha from A to Z (except for “O” and “I” which will be considered zero and one)
- Numbers from 0-9
The part number column contains all part numbers included in the Detailed Parts List. Part
numbers that have been deleted or superceded from the Detailed Parts List are listed in the
Numerical Index and identified as deleted or superceded.
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40176-4 / 40176-7
E.
Detailed Parts List (DPL)
(1)
Figure and Item Number
Each assembly, sub-assembly, and component designated a part number and
included in the part list is given a callout number.
The figure number linked to the item number is shown on the first line at the top of
each page.
Assemblies, sub-assemblies, and numbered parts included in the list but not
illustrated are identified by a hyphen (-) preceding the item number.
The letter “R” shown in the index before the item number refers to a modified item of
the Detailed Parts List.
(2)
Manufacturer’s Part Number
A manufacturer’s part number is given to each part and/or assembly, whether
illustrated or not. To help our customers, we have included a second column giving
the equivalent Saft France and Saft America part numbers for parts having an
equivalent.
(3)
Indenture
The parts list is represented with indenting showing the relationship of parts and
assemblies to their next higher assemblies as follows:
1234567
Assembly
Attaching parts for assembly
. Detailed parts for assembly
. Sub-assembly
. Attaching parts for sub-assembly
. . Detailed parts for sub-assembly
. . Attaching parts for sub-assembly
. . . Detailed parts for sub-sub-assembly
The attaching parts are shown directly after the assembly of the part they attach.
They are listed under the same indenture number as the item they are attached to,
and are identified by the words “Attaching Parts”, followed by three asterisks (*).
Page 10004
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
(4)
Effectivity Code
An alphanumeric index indicates the effectivity of sub-assemblies and detailed parts
list in relation to the next higher assembly(ies) or sub-assembly(ies).
When the part is applicable to all effective products, the usage column remains blank.
The usage code for assemblies and detailed parts refer to the figure/item number of
the next higher assembly(ies) or subassembly(ies).
Example: Effectivity 1A, 1B, 1C is written 1ABC.
(5)
Units Per Assembly
The units per assembly column show the quantity of units required for one next
higher assembly.
In some cases, the information is replaced by the abbreviations REF (reference) or
AR (as required).
F.
Abbreviations
The following abbreviations may be used in this section:
ALT FROM P/N XXX
AR
ASSY
DPL
EDI
EFF
FIG
IPL
LH
NHA
NP
OPT P/N
P/N
POST SB
PRE SB
REF
RH
SUPSD BY
SUPSDS
Interchangeable part
As required
Assembly
Detailed Parts List
Electronic Data Interchange
Effectivity
Figure
Illustrated Parts List
Left-Hand
Next-Higher Assembly
Not-Procurable
Optional Part Number
Part Number
Post Service Bulletin
Pre Service Bulletin
Reference
Right-Hand
Superseded by
Supersedes
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
G.
Updating
(1)
General
When an item is revised, added or deleted, the letter “R” is shown in the right-hand
margin (the date of issue in the footer also changes).
(2)
Added Items
The basic sequence of the items given makes it impossible to add new items
between the old ones in the appropriate order of the breakdown. With the addition of
new items, a new number would be added at the end of the IPL.
(3)
Deleted Items
Should a part number be deleted, the information given in the Detailed Parts List is
deleted. The old part number will always remain in the Numerical Index.
(4)
New Figure Number
Whenever new illustrations are necessary, they are inserted in the appropriate place
within the manual. The new illustration will refer to the same parts list.
The new figure number is given with the basic figure number and a letter designation.
This letter precedes the item number in the parts list.
Page 10006
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COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
VENDOR CODE INDEX
VENDOR CODE
NAME — ADDRESS
F6177
Saft
12 avenue Sadi Carnot
93170 Bagnolet
France
Phone: (33) 1 49 93 19 18
Fax: (33) 1 49 93 19 56
Http:\\www.saftbatteries.com
V09052
Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Phone: (1) 229-247-2331
Fax: (1) 229-247-8486
Http:\\www.saftbatteries.com
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40176-4 / 40176-7
ALPHANUMERIC INDEX
1.
Listing by Saft France (F6177) part number.
PART NUMBER
F6177
PART NUMBER
V09052
012374
015266
015539
031282
057014
062007
062007
063412
080004
100078
100094
100094
100430
100431
100593
100693
100694
102227
105405
112965
112967
114767
114880
114881
116109
116112
116312
116390
116997
119083
- Item not illustrated
015575-000
015578-000
015577-000
015576-000
015579-000
015579-000
015602-000
015957-000
021870-000
091180-008
023388-002
023388-001
022078-000
093169-000
093169-000
015926-000
015945-000
015924-003
016420-000
016423-000
015949-000
021751-000
021752-000
AIRLINE
STOCK NUMBER
FIGURE
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
1&2
1&2
1&2
1&2
1&2
1&2
3
3
3
3
3
1&2
1&2
1&2
3
3
3
1&2
1&2
1&2
1&2
1&2
1&2
1&2
1&2
1&2
1&2
1&2
1
2
23
26
22
41
24
11
14
13
20
18
17
12
30
29
21
15
16
28
6
7
9
25
3
2
5
27
4
42
1
1
14
1
2
2
3
42
2
20
1
2
2
42
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Page 10009
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
2.
Listing by Saft (V09052) part number.
PART NUMBER
V09052
PART NUMBER
F6177
AIRLINE
STOCK NUMBER
FIGURE
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
1&2
1&2
1&2
1&2
1&2
1&2
**
23
24
22
26
11
14
1
14
3
2
1
42
2
13
20
2
25
3
4
20
1
1
1
1
1
5
27
43
1
1
18
1
1
1
1
1
2
17
4
28
12
15
1
42
1
16
1
21
1
19
2
6
7
29
1
1
4
009384-000
015575-000
015576-000
015577-000
015578-000
015579-000
015579-000
012374
057014
015539
015266
062007
062007
015602-000
063412
015924-003
015926-000
015945-000
015949-000
015957-000
114881
144767
114880
116312
080004
1&2
1&2
1&2
1&2
016420-000
016423-000
019736-000
021751-000
021752-000
021870-000
116109
116112
1&2
1&2
1&2
1&2
1&2
116997
119083
100078
021871-000
3
3
3
3
3
022078-000
022228-000
023388-001
102227
1&2
1&2
100693
023388-002
100694
091180-008
100593
091181-002
100594
3
3
3
3
093169-000
093169-000
093616-000
105405
105405
1&2
1&2
1&2
- Item not illustrated
Page 10010
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
DETAILED PARTS LIST
24 25
23
2
3
25
6
4
22 26
A
20
21
15
31
35 (2 max.)
36 (3 max.)
39 (2 max.)
38
37
32
37
33 (3 max.)
34
33 (3 max.)
34
31
32
35
36
11
12
14
16
17
18
19
10
31
A
4
11 12 42
143
41
29 30 28
8 9
40
40176-4 BATTERY
IPL FIGURE 1 (PAGE 1 OF 3)
Page 10011
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
24 25
23
2
5
4
27
A
3
25
6
22 27
7
20
21
15
31
35 (2 max.)
36 (3 max.)
39 (2 max.)
38
37
32
37
33 (3 max.)
34
33 (3 max.)
34
31
32
35
36
11
12
14
16
17
18
19
10
31
5
A
11 12 42
143
41
29 30 28
8 9
40
40176-7 BATTERY
IPL FIGURE 2
Page 10012
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
14
14
15
15
17
20
17
20
18
21
18
21
19
16
19
16
17
13
13
Saft Valdosta VP400KH Cell
V09052
Saft France VP400KH Cell
F6177
VP400KH CELL HARDWARE CONFIGURATIONS
IPL FIGURE 3
Page 10013
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
THIS PAGE INTENTIONALLY LEFT BLANK
Page 10014
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
DETAILED PARTS LISTING
FIGURE
AND
ITEM
PART NUMBER
F6177
EFF.
CODE
UNITS
PER
ASSY
IPL Fig 1
116944
015920-000
Nickel-Cadmium Battery
(V09052) 015920-000 is Ref/Code
for Saft 40176-4 Battery
A
REF
IPL Fig 2
117481
016392-000
Nickel-Cadmium Battery
(V09052) 016392-000 is Ref/Code
for Saft 40176-7 Battery
(F6177) 117481 is Ref/Code for
Saft 40176-7 Battery
B
REF
1
116997
021751-000
. Case, 40176-4
A
1
1
119083
021752-000
. Case, 40176-7
B
1
2
116996
015924-003
. Cover 40176-4 / 40176-7
1
3
114880
015945-000
. Gasket, Cover
1
4
116312
015949-000
. Sensor, Temperature
A
1
5
116109
016420-000
. Sensor, Temperature, and Heater
Control Thermostat
B
1
6
105405
093169-000
. . Nut, Thermostat connecting
7
105405
093169-000
. . Nut, Thermostat connecting
8
112965
NP
. . Nut, Temperature Sensor
1
9
112967
NP
. . O-Ring, Temperature Sensor
1
V09052
10
AIRLINE
STOCK
NUMBER
NOMENCLATURE
1234567
1
B
1
Reserved for future use
11
062007
015579-000
. . Nut, Hex (upper)
42
12
100094
˜
. . Washer, Spring (F6177)
42
12
—
022228-000
. . Washer, Belleville (V09052)
42
13
063412
015602-000
. Cell, VP400KH (w/hardware)
20
14
062007
015579-000
. . Nut, Hex (lower)
2
15
100693
023388-002
. . Washer, Negative Polarity
1
16
100694
023388-001
. . Washer, Positive Polarity
1
17
100094
˜
. . Washer, Spring (F6177)
2
17
—
021871-000
. . Washer, Belleville (V09052)
4
18
100078
021870-000
. . Washer, Flat
2
19
100594
091181-002
. . O-Ring, Terminal
2
20
080004
015957-000
. . Valve, Vent
1
21
100593
091180-008
. . . O-Ring, Vent-Valve
1
22
015539
015577-000
. Link, Cell to Receptacle
2
Page 10015
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
FIGURE
AND
ITEM
PART NUMBER
F6177
V09052
AIRLINE
STOCK
NUMBER
NOMENCLATURE
EFF.
CODE
1234567
UNITS
PER
ASSY
23
012374
015575-000
. Link
14
24
057014
015576-000
. Link
3
25
144767
015926-000
. Link
1
26
015266
015578-000
. Link
A
1
27
116112
016423-000
. Link
B
1
28
102227
022078-000
. Connector, Main Power
1
29
100431
˜
. Screw, M4 x 10 (F6177) Cannot
be replaced with 093616-000
(attaching parts***) (used with (30))
4
29
—
093616-000
. Screw, Sems 8-32 (V09052)
Cannot be replaced with 0100431
(attaching parts***)
(no washer needed with this screw)
4
30
100430
. Washer, (F6177)
(attaching parts***)
(not required with 093616-000
(V09052) Sems Screw
4
31
NP
NP
.Liner (available in kit (43))
4
32
NP
NP
.Liner (available in kit (43))
3
33
NP
NP
.Liner (available in kit (43))
9
34
NP
NP
.Liner (available in kit (43))
3
35
NP
NP
.Liner (available in kit (43))
3
36
NP
NP
.Liner (available in kit (43))
4
37
NP
NP
.Liner (available in kit (43))
2
38
NP
NP
.Liner (available in kit (43))
2
39
NP
NP
.Liner (available in kit (43))
2
40
NP
NP
.Liner (available in kit (43))
1
41
031282
NP
. Plate, Instruction
2
42
411108
NP
. Plate, Identification
1
43
412240
019736-000
. Kit, Liner
1
**
NP
009384-000
. Gasket, Main Power Connector
1
NP – Not Procurable
- Item not illustrated
** Item not numbered
Page 10016
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
Storage and Transportation
1.
General Storage Information
CAUTION:
STORAGE FACILITIES FOR NICKEL-CADMIUM BATTERIES SHOULD BE
ENTIRELY SEPARATE FROM THOSE FOR LEAD ACID BATTERIES. FUMES
FROM LEAD ACID BATTERIES OR TRACES OF SULFURIC ACID ENTERING A
NICKEL-CADMIUM BATTERY CAN CAUSE PERMANENT DAMAGE.
A nickel-cadmium battery storage location should be free of acid, dust, or dampness. No corrosive
liquids or gases should be stored in the same room. Temperatures may range from -60°C (-76°F) to
+60°C (+140°F) without harming the battery. The most desirable range for storage is between 0°C
(32°F) to +30°C (+86°F).
2.
3.
Preparation for Storage
A.
In-service batteries to be stored for less than 90 days should undergo completion of the
Regular Check or General Overhaul and be left in an airworthy status. See Section 5
(CHECK).
B.
In-service batteries to be stored longer than 90 days should be discharged and placed in a
container suitable to the duration of storage.
C.
Factory new batteries may be stored as received for a period of up to 24 months. Longer
storage duration requires placement in sealed packaging prior to storage.
Active Stand-by Storage
Active stand-by storage is to be used when the battery must be charged and ready for service
onboard an aircraft in a short period of time. The length of time that a battery will retain a minimum
capacity (80%) will vary dependent upon the ambient temperature of the storage environment (refer
to Figure 15001). For storage longer than 90 days, see procedures for Inactive Storage.
NOTE:
Saft vented-cell aircraft batteries may be stored charged, ready for service in the
normal, upright or vertical position.
NOTE:
Nickel-cadmium batteries automatically self-discharge at about 0.25% per day at
20°C (68°F).
Page 15001
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
100
AVAILABLE CAPACITY (%C1Ah)
90
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) (41°F)
Temp. (15°C) (59°F)
Temp. (25°C) (77°F)
Temp. (35°C) (95°F)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
0
20
60
10
30
40
50
60
70
80
90
Days
Charge Retention
Figure 15001
A.
Storage at < 20°C (68°F).
(1)
Place fully-serviced, airworthy battery into proper storage for a period not to exceed
90 days.
(2)
After 90 days (on the 91 day), the battery must receive an electrolyte level
verification. See Section 1 (TESTING AND FAULT ISOLATION).
(3)
After electrolyte leveling, the battery can be returned to storage for another period not
to exceed 90 days.
(4)
It is possible to repeat Steps 2 and 3 a maximum of two times (three 90 day
intervals).
(5)
If the battery has not been installed into an aircraft after three 90 day intervals, it must
undergo completion of the Regular Check or General Overhaul as required. See
Section 5 (CHECK).
st
Page 15002
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
B.
4.
Storage at > 20°C (68°F).
(1)
Storage duration is dependent upon ambient temperature. Minimum acceptable
available capacity retention may not be less than 80%.
(2)
Refer to Figure 15001 to determine the maximum number of days a battery can be
stored before maintenance is required.
(3)
Place a fully-serviced, airworthy battery into proper storage for a period not to exceed
the maximum number of days determined in step 2.
(4)
One day past the maximum number of storage days, the battery must receive an
electrolyte level verification. See Section 1 (TESTING AND FAULT ISOLATION).
(5)
The battery can then be returned to storage for a period not to exceed the maximum
duration for the ambient storage temperature.
(6)
It is possible to repeat steps 4 and 5 a maximum of two times (three storage
intervals).
(7)
If the battery has not been installed into an aircraft after three storage intervals, it
must undergo completion of the Regular Check or General Overhaul as required.
See Section 5 (CHECK).
Trickle Charging
The principle of trickle charging is to keep a battery in active stand-by condition by continuously
charging the battery in an over-charge condition. Saft does not recommend this method, however
some operators take responsibility for its use.
WARNING:
USE OF A TRICKLE CHARGER WILL CONSUME WATER OVER TIME. FAILURE
TO VERIFY ELECTROLYTE LEVEL PRIOR TO INSTALLATION MAY RESULT IN
PREMATURE BATTERY FAILURE.
Example: If a 40 Ah battery remains on a continuous trickle charge of 3 mA/Ah for one month, the
3
total consumption of water is 35 cm /cell.
The operator must adjust the electrolyte level before placing the battery onboard the aircraft.
Otherwise, the risk of a battery incident exists; cells dry out before the normal end of the
maintenance interval.
Page 15003
24-32-03
April 15/2002
COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
5.
Inactive Long-term Storage
Saft nickel-cadmium aviation batteries can be stored in the original cardboard packaging for a period
of two years, and up to 10 years in sealed packaging under the following conditions:
6.
A.
Ambient temperature of 20°C ± 15°C (+68°F ± 27°F)
B.
Humidity less than 70%
C.
Normal upright, vertical position
D.
Atmosphere free of dust, dirt, vibration or corrosive agents.
Preparation for Use After Storage (other than Active Stand-by Storage)
STORAGE TIME
Less than 3 months
More than 3 months
7.
SERVICE PROCEDURE
Perform a Periodic Check (CHECK - Fig 5001)
Perform a Regular Check (CHECK - Fig 5002)
Return to Service Procedures
Figure 15002
Packing and Transporting
The normal packing for shipment of Saft nickel-cadmium batteries is with fiberboard or injected foam
packing enclosed in fiberboard or wooden outer containers. For overseas shipments, wrapping in
sealed plastic is recommended. Precautions must be taken to keep batteries upright while in transit.
All markings and documentation should conform to current IATA regulations (UN2795 or UN2800 as
applicable) governing the shipment of vented nickel-cadmium batteries.
Page 15004
24-32-03
April 15/2002