24 38 51 PDF
24 38 51 PDF
24 38 51 PDF
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
2758
24-38-51 edition 4
Apr 08/2013
Component Maintenance Manual
2758
This document and all information contained herein are the property of
Saft. Its use is restricted solely to the maintenance of Saft batteries and
may under no circumstances be used for any other manufacturer's prod-
ucts. No person may, in whole or in part, duplicate, use or disclose this
information for any other purpose without the prior written consent of
Saft.
24-38-51 Page 2
Apr 08/2013
Component Maintenance Manual
2758
RECORD OF REVISION
Inserted Inserted
Rev. n Issue date Rev. n Issue date
Date By Date By
1 Dec 89 Dec 89 Saft
Inserted Inserted
Rev. n Issue date Rev. n Issue date
Date By Date By
24-38-51 BLANK
Apr 08/2013
Component Maintenance Manual
2758
Incorporation into
Service bulletin
CMM Title
Number Rev. Date Rev.
24-38-51 BLANK
Apr 08/2013
Component Maintenance Manual
2758
TABLE OF CONTENTS
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
2. Website - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
3. Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
4. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
4-1. Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
4-2. Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
4-3. Chemical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
5. Aircraft Conversions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
6. Ground Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
7. Placing a new battery in service - initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
8. Battery Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
8-1. Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
9. Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
10. End of life cells - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
11. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
11-1. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
11-2. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
11-3. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-5
11-4. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-5
DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4. Disassembly procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-1. Removing the cover (050) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-2. Removing the cells (320) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-3. Removing the vent valves (325) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-4. Removing the connector (200) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-5. Disassembly of the battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-3. Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
4. Light Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
4-1. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
5. Thorough Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
5-1. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
6. Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4002
INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2. Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-1. Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-2. Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-3. General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
3. Recording - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
4. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
6. Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5002
6-1. Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
6-2. Insulation check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
6-3. Nut tightness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-4. Polarization test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-5. Residual discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-6. Adjust electrolyte level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-7. Supplementary test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5005
7. Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5006
7-1. Cell shorting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
7-2. Capacity check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
8. General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5008
8-1. Component inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
8-2. Replacement of faulty components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
8-3. Vent valve test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
9. Return to Service After Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5010
ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
4. Battery Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7002
4-1. Installation of the liner spacer kit (130) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7002
4-2. Installation of the vent valve (325) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003
24-38-51 BLANK
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Component Maintenance Manual
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LIST OF ILLUSTRATIONS
24-38-51 BLANK
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Component Maintenance Manual
2758
INTRODUCTION
1. General
This manual provides the information necessary for an experienced shop technician to maintain Saft nickel-cadmium batteries.
It describes construction of the battery, as well as techniques used to operate, maintain, repair, overhaul, and generally care
for the battery. Following these instructions will enhance the ability to obtain optimum performance and maximum life from Saft
batteries.
All aircraft batteries require checking and maintenance in order to make sure they are safe when installed and they perform
their required functions especially in emergency conditions on board the aircraft. Maintenance checks also permit any prob-
lems to be identified and corrected. The maintenance interval is the period for which correct operation is assured with a low
probability of failure and allows high levels of MTBUR and MTBF to be achieved. Apart from the question of safety, the avoid-
ance of failure on board the aircraft, with consequent costly impact on delays, reduces operational costs.
Every effort has been made to provide complete and accurate instructions. If a situation should arise that is not adequately
described in this manual, please contact Saft via the internet at www.saftbatteries.com or at one of the following addresses:
Saft America Inc. (V09052) Saft (F6177)
711 Industrial Boulevard 12, rue Sadi Carnot
Valdosta, Georgia 31601 - USA 93170 Bagnolet - France
Tel: +1 (229) 247-2331 Tel: +33 (0) 1 49 93 19 18
Fax: +1 (229) 247-8486 Fax: +33 (0) 1 49 93 19 56
2. Website
All Saft technical documentation, distributors and repair shops can be found at www.saftbatteries.com.
3. Definitions
Warnings call attention to use of materials, procedures, or limits, which must be followed precisely to avoid injury to persons.
Cautions call attention to procedures which must be followed to avoid damage to equipment.
Notes call attention to procedures which make the job easier.
4. Safety
Caution: Except for those steps that require the battery to be charged, do all steps on discharged batteries (refer to
Residual discharge paragraph) to avoid the possibility of electric shock. Tighten vent-valves (325) prior to be-
ginning discharge. Battery cells deliver very high current when short-circuited. Exercise caution. Remove rings,
watches, necklaces, metallic belts or other jewelry to avoid electric shock.
Caution: Do not tilt the battery while doing maintenance, any contact of skin with electrolyte can cause severe burns.
Safety rules are different from one country to another. Always follow local safety regulations.
There are three types of risks.
4-1. Physical
- Handling: the battery is heavy. When you lift it, bend your legs and not your back.
- Use protective shoes.
4-2. Electrical
- Do not wear rings, watches, chains, belt buckles, necklaces or any other metallic objects.
- Use insulated tools.
4-3. Chemical
- For a complete listing of hazards, refer to the MSDS available on Saft's website at www.saftbatteries.com. Electrolyte
is very corrosive and can damage the skin: use gloves and an apron. If it touches the skin, flush affected part with
water and neutralize with an acetic solution, vinegar or lemon juice, or with a boric acid solution at 10% concentration.
- Electrolyte is very dangerous for eyes, use protective goggles. If the electrolyte comes in contact with the eyes, flush
them with water for at least 15 minutes and immediately call a doctor.
- Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit. Call a doctor im-
mediately.
- Skin contact with nickel can cause chronic eczema.
- Inhalation of cadmium oxide can cause dry throat, headaches, vomiting, chest pain. If inhaled, remove to fresh air. If
not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately.
5. Aircraft Conversions
Saft aircraft batteries come in a wide variety of configurations that are approved for installation on selected aircraft. When re-
placing a lead-acid battery with a Saft nickel-cadmium aircraft battery, it is vitally important to clean all mounting and holding
fixtures in the aircraft prior to installation. All traces of acid and salt should be removed by washing with a neutralizing agent
such as sodium bicarbonate (baking soda) in water. Once the area has been fully cleaned and prepared, the surface should
be painted with an alkaline resistant paint. This preparation should ensure that your new Saft battery will not be harmed by
sulfuric acid residue.
6. Ground Applications
Your Saft battery can be used in such ground applications as starting gas turbine generators, ground mobile equipment, or in
shop testing equipment. The same principles used in flight operations apply when the battery is used in ground applications.
Ventilation of the battery during ground use can be accomplished through a ventilation system or by simply removing the cover
(only in a well-ventilated area). Check with your local authorities for regulations in effect for your area.
8. Battery Ratings
8-1. Capacity
Nickel-cadmium batteries are rated in terms of capacity in ampere-hours (Ah) (rated capacity).
Capacity is the quantity of electricity, usually expressed as ampere-hours (Ah) available from a cell/battery. The rated capacity
of aircraft batteries is defined according to international standards (EN2570, IEC 60952 and RTCA DO 293) under specific con-
ditions for a fully charged battery.
A battery rated for 1C1Ah indicates that the battery is rated at a value based upon a discharge time of 1 hour at 23C 3C
(73.4F 5.4F).
9. Recycling
All batteries eventually lose their ability to perform and are eligible for scrap and recycling. Saft takes environmental matters
seriously and advocates proper recycling of nickel-cadmium batteries and their components. To that end, Saft operates recy-
cling facilities in both Europe and North America.
Nickel-cadmium batteries contain nickel, cadmium, and potassium hydroxide and should be disposed of properly. In all cases,
rely on local and national regulations for proper battery disposal and/or shipping to an appropriate recycling location.
You can find the nearest recycling collection point on our website at www.saftbatteries.com.
11. Measurements
The measurements which are given in this manual come from the original manufacturer drawings.
This CMM uses the Systeme International (S.I.) units for quantities and values. It also gives the imperial units in parentheses.
A Ampere
Ah Ampere hours
C1A Rated current
C1Ah Rated capacity for an hour
g Gram
min Minute
N Newton
N.m Newton meter
Pa Pascal
VDC Volt direct current
C Degree Celsius
% Per cent
Ohm
ft Foot
in Inch
inHg Inch of mercury
lb Pound
lbf.in Pound force inch
F Degree Fahrenheit
Micro
m Milli
da Deca
k Kilo
M Mega
1 in 25,4 mm
1 in 6,4516 cm
1 lbf 4,4482 N
1 oz 28,3495 g
1 inHg 3,3864 kPa
1 lb 0,4536 kg
1 gal (U.S.) 3,7854 l/min
1 lbf.in 0,1130 N.m
1 lbf.ft 1,3558 N.m
11-4. Abbreviations
The abbreviations given below are used in this manual:
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1. Description
1-1. General
The batteries are connected to the aircraft system:
- According to the aircraft manufacturer, to start the engine or the APU.
- On the ground, to provide power before electrical power is supplied to the aircraft systems.
- In flight, if a malfunction or a failure occurs in the power supply system
2. Technical data
2-1. Characteristics
The most important characteristics are indicated in the table below.
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3. Description
NOTE: The item numbers are those of the detailed parts list chapter.
The 2758 Saft nickel-cadmium battery consists of a stainless steel box (020), containing 20 individual cells VHP230KA-3.
These cells are connected in series to obtain 24 V nominal. Individual cells are enclosed in a container that provides insulation,
allowing them to be fitted side-by-side in the battery box. Interconnection of cells is via rigid, highly conductive, nickel-plated
copper links (270 to 310). Each link is held in place by nickel-plated copper nuts (350) on the cells terminals. Inside the battery
box, individual cells are held in place by partitions, liners and spacers (130), and a cover complete (050).
The connector (200) connects the battery to the aircraft DC power.
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The cover (050), which can be removed, is attached to the box (020) by four latches.
Cover complete
Connector
Box
Range plate
4. Operation
4-1. Temperature
Although Saft nickel-cadmium batteries are capable of operating in a wide temperature range [-40C (-40F) to +71C
(+160F)], optimum performance is obtained between +5C (+41F) and +45C(+113F). Charging is inefficient at tempera-
tures below -30C (22F) and is not recommended above 57C (135F). Charging must be stopped at temperatures above
+71C (+160F).
Unless otherwise stated, charge and discharge testing should be done when the battery temperature is between +15C and
+ 30C.
4-2. Maintenance
All maintenance, including charging, discharging, should be done specifically in accordance with the instructions contained in
this manual.
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5. Charge
5-1. Constant Current Charge
Starting with a discharged battery.
- Remove the cover complete (050).
- Loosen, but do not remove, all vent-valves (325).
- Charge using one of the methods shown in the table below.
NOTE: Check cell voltage at the beginning of the charge. If any cell indicates an immediate voltage rise above 1.5 V,
add 5 cm3 of distilled or deionized water to that cell.
- During the last 15-30 minutes of the overcharge cycle, Adjust electrolyte level.
Final charge
Main charge
(overcharge)
Criteria of end of charge Minimum voltage
Current and duration
Current Time voltage at the end of charge
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1. Introduction
This chapter gives the tests and inspections required to find the cause of a fault condition of the unit either removed for un-
scheduled maintenance or during scheduled maintenance. The test procedure is given in the tables below. For each test refer
to the indicated procedures which specify all necessary information.
(2) Zero volt with the battery (a) Battery fully discharged Do an insulation check (refer to Insulation
set to "discharge" check). Charge the battery (refer to
Charge).
(b) Battery circuit open or contacts Examine the contacts and links.
defective Make sure the terminal nuts are tight
(refer to INSPECTION/CHECK).
Refer to related subsequent steps.
(2) Water decrease in cell(s) (a) More than 30% or more than the Check for cell leakage (refer to INSPEC-
is very different from the average : cell leakage. TION/CHECK)
other cells in the battery.
(b) 30% (or less) of the Do the Supplementary test (refer to
average: cell(s) with damaged separa- INSPECTION/CHECK). If necessary,
tor(s). replace the cell(s).
(c) Previous maintenance has not Note the cell location and check the level of
been done. water consumption versus other cells at the
next maintenance.
(3) A cell has a higher voltage (a) Dry cell. When the defect occurs, add 5 cm3 (5 ml)
at the start of charge than is of distilled water to the cell. Do not adjust
defined in para. Charge chap- more accurately until the end of the charge.
ter Description and operation.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can cause the temperature
to increase too much.
(4) A cell has a lower voltage (a) The cell was operated at tempera- Do the Supplementary test (refer to
at the end of charge than is tures and charge rates outside the lim- INSPECTION/CHECK). Replace the cell
defined in para. Charge chap- its, and the separator is damaged. (refer to DISASSEMBLY, ASSEMBLY AND
ter Description and operation. Storage (including transportation)).
(b) Usual wear after long operation
(5) Low capacity cell. (a) insufficient balancing Do the Supplementary test (refer to
INSPECTION/CHECK). Repeat Charge,
discharge at 23 A and Cell shorting up to
three times.
(b) Usual wear after long operation. Replace the cell (refer to DISASSEMBLY,
ASSEMBLY AND Storage (including trans-
portation)).
(d) The lower nut is not correctly tight- Torque the lower nut (refer to ASSEM-
ened. BLY chapter)
(2) Electrolyte found in the battery (a) Damaged cell case. Do a leak test of the cells (refer to
box. INSPECTION/CHECK).
Replace the cell if necessary and refer
to related subsequent steps.
(b) Leakage of electrolyte. Disassemble and clean the battery
(refer to INSPECTION/CHECK and
CLEANING).
Do an electrolyte level check (refer to
INSPECTION/CHECK).
(3) Corrosion on the links. (a) Operation in acidic air. Make sure the battery test bench and
the storage areas have no materials
which can give off acid fumes.
Replace the damaged links (refer to
(b) Mechanical damage to nickel plat- DISASSEMBLY, ASSEMBLY AND
ing. Storage (including transportation)).
(4) The links are too hot. (a) Loose terminals nuts. Make sure the nuts are torqued (refer
to INSPECTION/CHECK).
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DISASSEMBLY
1. Introduction
NOTE: Refer to the Testing and fault isolation chapter to identify the possible cause of a malfunction. This will give
the necessary level of disassembly.
The instructions found in this section are designed to allow the maintenance person to completely disassemble the battery for
the purpose of General Overhaul. However, some maintenance operations do not require complete disassembly. Disassemble
only to the extent necessary to effect appropriate repair or replacement.
2. Safety
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
3. Equipment
3-1. Standard tools
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
4. Disassembly procedures
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers and are using hypertext facility.
CLEANING
1. Introduction
The instructions in this chapter are for the general cleaning of your Saft aircraft battery. The instructions under Light Cleaning
are to be done each time the battery is removed from the aircraft, and can be accomplished with no disassembly of the battery.
The section Thorough Cleaning includes the instructions for the cleaning of a disassembled battery for the purpose of a Gen-
eral Overhaul.
2. Safety
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
3. Equipment
3-1. Standard tools
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
3-3. Consumables
When consumables are used in this chapter, they are identified by a code number listed in SPECIAL TOOLS, FIXTURES,
EQUIPMENT AND CONSUMABLES chapter.
4. Light Cleaning
On an assembled battery.
Caution: Do not use solvent, petroleum spirits, trichloroethylene or other products containing chloride for cleaning
the battery. The use of solvents may degrade the integrity of metal and plastic parts.
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
4-1. Procedure
Caution: To prevent injury when using compressed air, direct air stream away from the body. Use safety goggles to
prevent eye injury from airborne particles.
- Remove the battery cover complete (050).
- Check the battery vent tubes to ensure that they are clean and clear.
- Hand tighten the vent valves (325) with the Universal vent wrench (T01)
- Remove potassium carbonates (white deposits) from the top of all cells (320) using a stiff bristle, non-metallic brush.
- Disperse residual salts and dust particles from the battery using blasts of clean, dry compressed air.
- Coat all nuts (350) and links (270 to 310) with M02.
5. Thorough Cleaning
On a disassembled battery.
5-1. Procedure
Fully disassemble the battery (refer to DISASSEMBLY chapter).
5-1-1. Cells (320)
Make sure that the vent valve (325) is tight.
Caution: Do not soak the cells in water.
To easily remove all the electrolyte and mineral salts from the terminals, the cover and the sides of the cell cases: clean in
warm water with a soft brush.
Rub the cell with a cloth and let dry.
5-1-2. Box and cover (010) and handle (030 and 040)
Clean with lightly soapy water, rub with a cloth and let dry.
6. Lubrication
When the battery is clean (and after installation of the vent valve), coat all upper nuts (250) and links (270 to 310) with M02.
INSPECTION/CHECK
1. Introduction
1-1. General
This chapter includes the checks, the maintenance procedures and the functional tests that must be done to use Saft batteries
in flight and on the ground.
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
2. Maintenance intervals
The aircraft manufacturer is responsible for defining the usage and function for aircraft batteries installed in its aircraft.
NOTE: Maintenance steps must be completed in a battery shop.
Saft distinguishes between three types of maintenance
3. Recording
It is very important to record the battery check values (capacity, end of charge voltage, water consumption) as required in the
battery logbook for each maintenance. It is recommended that an operator tracks these maintenance data in order to verify
the interval is correct relative to that particular operation. These data may also allow the interval to be extended, with the agree-
ment of the competent authorities, if the data justify it .
4. Safety
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
5. Equipment
5-1. Standard tools
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES.
6. Periodical check
yes
Visual Inspection OK? no yes
Insulation check OK
no
General overhaul
Nut tightness
no yes
Testing and fault isolation Charge OK
no yes
Supplementary test OK?
no
General overhaul
Nut tightness
with Replacement of faulty compo-
nents.
Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe-
cific intervals according to aircraft use, or if electrolyte consumption exceeds the approved consumption levels between 2 reg-
ular checks, do this periodical check according to the above figure.
NOTE: Time periods are given as a guideline. Modify in accordance with operational experience.
Periodic and Regular maintenance checks may be combined if operating hours permit.
NOTE: Whether or not the battery has been subject to disassembly and reassembly, before its issue to service and
installation, the tightness of all connector nuts / screws must be checked to verify that torque values corre-
- 3. Insert the syringe (T02) into the cell opening until the shoulder of the nozzle rests on the vent-valve seat .
20 mm (0.79 in)
- 4. Withdraw the plunger and check for any liquid in the syringe.
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.
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. In this case, replenish low electrolyte:.
- 5. Draw 5 cm3 of the distilled water (M01) into the syringe and inject it into the cell.
- 6. With the syringe nozzle remaining on the vent-valve (325) seat, slowly withdraw the plunger in the syringe.
- 7. If the syringe remains empty, repeat steps 5 and 6, counting the number of 5 cm3 injections required to achieve the
correct level. Record the amount of water added to each cell on the maintenance record.
- 8. At the point in step 6 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 disposal. Do not re-use the liquid removed from cells.
Check with local authorities for proper disposal of hazardous waste.
7. Regular check
Light Cleaning
REGULAR CHECK
yes no yes
Visual Inspection OK? Insulation check OK
no
no yes
Charge OK
yes
Supplementary test OK?
no
Vent valve cleaning
(refer to CLEANING)
Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe-
cific intervals according to aircraft use, or AFTER A MAXIMUM OF ONE YEAR of operation, test the battery according to the
above figure.
NOTE: Time periods are given as a guideline. Modify in accordance with operational experience. Periodic and Regular
maintenance checks may be combined if operating hours permits.
NOTE: Whether or not the battery has been subject to disassembly and reassembly, before its issue to service and
installation, the tightness of all connector nuts / screws must be checked to verify that torque values corre-
spond with those specified.
8. General overhaul
polarity
Nut tightness
Residual discharge
Charge and Adjust electro-
lyte level
DISASSEMBLY
Testing and fault isolation
Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe-
cific intervals according to aircraft use, or AFTER A MAXIMUM OF ONE YEAR of operation, test the battery according to the
above figure.
NOTE: Whether or not the battery has been subject to disassembly and reassembly, before its issue to service and
installation, the tightness of all connector nuts / screws must be checked to verify that torque values corre-
spond with those specified.
test Check
O-ring No distortion, split or cracks
air pressure < 0.14 bar (2 psi) Vent valve is closed
0.14 bar (2 psi) < air pressure < 0.7 bar (10 psi) Vent valve opens
ASSEMBLY
1. Introduction
This section covers basic battery assembly procedures. In all cases, when reassembling a battery, all components should be
clean and dry.
2. Safety
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES..
3. Equipment
3-1. Standard tools
Refer to chapter Standard tools in SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES..
4. Battery Assembly
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
G, F
D, E G, F
G, F
A
B
D, E
G, F
C
A
G, F
NOTE: You must assemble the D and E slotted spacers to keep the ventilating system of the box free.
NOTE: only the spacers F is mandatory, the spacers G are installed in order to adjust the fitting of the cells.
- Put the different spacers in position (Ref. fig.7001).
- Install the cells.
4-5. Recording
Fill out identification plate (080) if the box (020) has been changed.
Fill out the log book.
1. Introduction
The torque values below are lube torque values. The thread of the terminals and attaching nuts (or screws) should be lightly
greased with (M02) prior to assembly and applying torque.
2. Torque table
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1. Introduction
This chapter is divided into two parts:
- The first part provides the list of special tools, fixtures and equipments needed to do the steps listed in the other chapters.
- The second part provides the listing of consumable materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for tools, fixtures and equipment,
- Mxx for consumable materials.
2. Standard tools
The following items are recommended to do the procedures described in this manual. When necessary, equivalent substitutes
may be used.
- Constant Current Power Unit (0-60 A)
- Constant Current Load Bank (0-60 A)
- Megohmmeter (0-50 M @ 250 V continuous)
- Precision Multimeter (Volt, , mA)
- Torque Wrench (Fully insulated) 0-15 N.m (0-133 lbf.in)
- Standard mechanics tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Stiff bristle brush (non-metallic)
- Small paintbrush (non-metallic)
- Dry, compressed air source [less than 1.4 bar (20 psi)]
- Soft, clean cloth (at least two required)
3. Special tools
NOTE: Equivalent tools can be used.
A special tool kit (P/N 416161) is available from Saft containing all special tools T01, T02, T03, and T04. The
tools are in a polypropylene box and each tool is insulated to ensure optimum safety for the technician.
F6177 V09052
CODE DESCRIPTION
P/N P/N
T01 Universal vent wrench 413876 093365-000
T02 Syringe assembly (with nozzle 20 mm (0.79 in)) 416231 020915-004
T03 1 3 W equalizing resistors 164829
T04 Universal cell extraction tool 416159
T05 Vent valve adapter for M8 valve - 025098-000
4. Consumables
NOTE: Equivalent alternatives can be used for list items.
This paragraph describes the consumables used in the OMM.
MANUFAC-
DESIGNATION TURER
PARTNUMBER OR SUPPLIER
CODE
AND (NAME,
SPECIFICATION ADDRESS,
CODE)
M01 Distilled or deionized water
clear, colorless, odorless while boiling, resistivity > 30 k/ Local vendor
cm
5 < pH < 7
Absence of organic and reducing substances. Reducing
agent content (expressed in weight of oxygen) < 30 mg/l
(test with permanganate).
Total of ions
SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
1. Introduction
1-1. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts of the unit in disassembly
sequence.
To find the illustration for a part if the part number is known, refer to the Alpha numerical index and look for the part number
and the corresponding figure and item number. Refer to the Detailed part list and look for the first figure and item number found
in the Alpha numerical index for that part. If this figure shows the part in a section or system of the equipment other than the
one necessary, refer to the other figure numbers listed in the Numerical Index.
To determine the part number of a given part, refer to the illustration showing the assembly including this part. Note the item
number of the illustrated part and refer to the Detailed part list which indicates its part number and identification.
The attaching parts are shown directly after the assembly of the part thereof. They are listed under the same indent number as
the item they are attached to, and are identified by the words "Attaching Parts" and are followed by three asterisks.
The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme right- hand side of the first line of
the parts list column.
1-3-2. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in relation to the next higher assem-
bly (ies) or sub-assembly (ies).
When the effectivity is fully applicable, the usage code column remains blank.
The use code for assemblies and detailed parts refers to the figure/item number of the next higher assembly (ies) or sub-as-
sembly (ies). Example: Effectivity 1A, 1B, 1C is written 1ABC.
1-3-3. Units per Assembly
The units per assembly column shows the quantity of units required for one next higher assembly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR
320
325
1. Introduction
1-1. General
Storage preparation and packaging makes sure that the equipment is protected against any attack by atmospheric agents.
The figure and item numbers are those of the ILLUSTRATED PARTS LIST chapter.
2. Storage procedure
2-1. Short term storage
2-1-1. Preparation of the battery for short term storage
Service the battery as scheduled (periodical check, regular check or general overhaul check). The battery is fully charged at
this step.
Lightly lubricate the nuts, the links, and all the components that can be damaged by atmospheric corrosion with M02.
Put the battery in its usual vertical position.
2-1-2. Periodic refresh charge
The battery can stay in storage for a period shorter than the 100
time necessary to reach 80% of capacity. This duration de- CHARGE RETENTION
Aircraft Ni-Cd battery
pends on storage temperature according to Figure 15001 :
for instance 60 days at 25C, with a maximum of 90 days.
If the storage has to be extended beyond this duration, per- 90
AVAILABLE CAPACITY (%C1Ah)
End of 80
25 C
Maximum
Curent charge
duration
voltage
30 C
2.3 A 30 V 2h
70 35 C
11.5 A 31 V 24 min
23 A 31.4 V 12 min 40 C
3. Transportation procedure
The battery is normally discharged before packing. If it is necessary to transport a charged battery, make sure that the output
terminals are protected against short circuit.
The battery should then be packed vertically in its original container. If the original container is not available, the international
and/or local packaging regulations applicable to the mode of transport and destination must be followed.
According to IATA/IMDG dangerous goods regulations, Nickel Cadmium aviation batteries as well as individual aviation Nickel
Cadmium cells must be shipped under the UN 2795 classification (wet, filled with alkali) according to packing instruction 801.