(V9052)

711 Industrial Blvd Valdosta, GA 31601 - USA

Tel: (1) 229-245-2331 Fax: (1) 229-247-8486

COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST

AIRCRAFT BATTERY
401176-9

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 (V9052)
711 Industrial Blvd Valdosta, GA 31601 - USA
Tel: (1) 229-245-2331 Fax: (1) 229-247-8486

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RECORD OF REVISIONS

REVISION ISSUE INSERTED REVISION ISSUE INSERTED

No. DATE DATE BY No. DATE DATE BY

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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE BY DATE BY

REV. No. NUMBER DATE REMOVED

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SERVICE BULLETIN LIST

NUMBER BRIEF DESCRIPTION TYPE AFFECTED

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LIST OF APPROVED REPAIR STATIONS

TRADE NAME ADDRESS

For a complete list contact Saft

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LIST OF EFFECTIVE PAGES

CONTENT PAGE REVISION CONTENT PAGE REVISION

DATE DATE
TITLE PAGE 1 Dec 30/2003 TESTING AND FAULT 1014 BLANK
2 BLANK ISOLATION (Contd)

RECORD OF REVISIONS 1 Dec 30/2003 SCHEMATIC AND 2001 Dec 30/2003

2 BLANK WIRING DIAGRAMS 2002 BLANK
RECORD OF
TEMPORARY REVISIONS 1 Dec 30/2003 DISASSEMBLY 3001 Dec 30/2003
2 BLANK 3002 Dec 30/2003
3003 Dec 30/2003
SERVICE BULLETIN LIST 1 Dec 30/2003 3004 BLANK
2 BLANK
CLEANING 4001 Dec 30/2003
LIST OF APPROVED 1 Dec 30/2003 4002 Dec 30/2003
REPAIR STATIONS 2 BLANK 4003 Dec 30/2003
4004 BLANK
LIST OF EFFECTIVE 1 Dec 30/2003
PAGES 2 Dec 30/2003 CHECK 5001 Dec 30/2003
5002 Dec 30/2003
TABLE OF CONTENTS 1 Dec 30/2003 5003 Dec 30/2003
2 Dec 30/2003 5004 Dec 30/2003
5005 Dec 30/2003
TABLE OF 1 Dec 30/2003 5006 Dec 30/2003
ILLUSTRATIONS 2 BLANK 5007 Dec 30/2003
5008 Dec 30/2003
INTRODUCTION 1 Dec 30/2003
2 Dec 30/2003 REPAIR 6001 Dec 30/2003
3 Dec 30/2003 6002 BLANK
4 Dec 30/2003
ASSEMBLY 7001 Dec 30/2003
DESCRIPTION AND 1 Dec 30/2003 7002 Dec 30/2003
OPERATION 2 Dec 30/2003 7003 Dec 30/2003
3 Dec 30/2003 7004 BLANK
4 BLANK
FITS AND CLEARANCES 8001 Dec 30/2003
TESTING AND FAULT 1001 Dec 30/2003 8002 BLANK
ISOLATION 1002 Dec 30/2003
1003 Dec 30/2003 SPECIAL TOOLS, 9001 Dec 30/2003
1004 Dec 30/2003 FIXTURES AND 9002 Dec 30/2003
1005 Dec 30/2003 EQUIPMENT 9003 Dec 30/2003
1006 Dec 30/2003 9004 Dec 30/2003
1007 Dec 30/2003
1008 Dec 30/2003 ILLUSTRATED PARTS 10001 Dec 30/2003
1009 Dec 30/2003 LIST 10002 Dec 30/2003
1010 Dec 30/2003
1011 Dec 30/2003
1012 Dec 30/2003
1013 Dec 30/2003
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CONTENT PAGE REVISION CONTENT PAGE REVISION

DATE DATE
10013 Dec 30/2003
INTRODUCTION 10003 Dec 30/2003 10014 BLANK
10004 Dec 30/2003
10005 Dec 30/2003 STORAGE AND 15001 Dec 30/2003
10006 Dec 30/2003 SHIPPING 15002 Dec 30/2003
15003 Dec 30/2003
VENDOR CODE INDEX 10007 Dec 30/2003 15004 BLANK
10008 BLANK
ALPHA NUMERICAL
INDEX 10009 Dec 30/2003
10010 BLANK

DETAILED PARTS LIST 10011 Dec 30/2003

10012 Dec 30/2003

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TABLE OF CONTENTS

PAGE
INTRODUCTION 1
1 General 1
2 How to Use the Manual 1
3 Measure 1
4 Units of Measure 2
5 Abbreviations 3
6 Definition 3
7 Disposal 4

DESCRIPTION AND OPERATION 1

1 Description 1

TESTING AND FAULT ISOLATION 1001

1 General 1001
2 Testing 1001
3 Charge 1004
4 Electrolyte level and adjustment 1006
5 Discharge 1007
6 Temperature Sensor Testing 1008
7 Fault Isolation 1009

SCHEMATIC AND WIRING DIAGRAMS 2001

1 General 2001
2 Sensor Schematic 2001

DISASSEMBLY 3001
1 General 3001
2 Safety 3001
3 Risks 3001
4 Safety Measures 3002
5 Disassembly 3002

CLEANING 4001
1 General 4001
2 Equipment 4001
3 Materials 4001
4 Cleaning procedure 4001
5 Lubrication 4003

CHECK 5001
1 General 5001
2 Maintenance in workshop 5001

REPAIR 6001
1 General 6001
2 Equipment 6001
3 Repairs 6001

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ASSEMBLY 7001
1 General 7001
2 Assembly procedures 7001

FITS AND CLEARANCES 8001

1 General 8001
2 Torque Table 8001

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

1 General 9001
2 Special tools, fixtures and equipment 9001
3 Consumables 9004

ILLUSTRATED PARTS LIST 10001

1 Introduction 10003
2 Vendor Code Index 10007
3 Alpha-Numeric Index 10009
4 Detailed Parts List 10011

SPECIAL PROCEDURES NOT APPLICABLE

REMOVAL NOT APPLICABLE

INSTALLATION NOT APPLICABLE

SERVICING NOT APPLICABLE

STORAGE (INCLUDING TRANSPORTATION 15001

1 General Storage Information 15001
2 Preparation for Storage 15001
3 Active Stand-By Storage 15001
4 Inactive Long-Term Storage 15003
5 Preparation for Use after Storage 15003
6 Packing and Transporting 15003

REWORK (Service Bulletin Instructions) NOT APPLICABLE

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TABLE OF ILLUSTRATIONS

PAGE
Figure 1 401176-9 Battery OP 3
Figure 2 Identification plate OP 4
Figure 3 Overall dimensions OP 5
Figure 1001 Insulations Test 1002
Figure 1002 Insulation Test Parameters 1003
Figure 1003 Electrolyte Adjustment 1006
Figure 1004 Functional Test Flow 1009
Figure 2001 Sensor Schematic 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 Polyamide key for vent-valve (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 IPL1 401176-9 Battery 10011
Figure 15001 Charge Retention 15002
Figure 15002 Topping Up Charge Guide 15003
Figure 15003 Return to Service Procedure 15003

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INTRODUCTION

1. 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 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 used 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.

2. 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.

3. 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.

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4. Units of Measure

A. S.I. Units

A Ampere
Ah Ampere hour
C1A Battery rated current
C1Ah Battery rated capacity for one hour
g Gram
N Newton
Nm Newton-Meter
Pa Pascal
VDC Volt Direct-Current
C Degree Celsius
% Per cent
Ohm
Mm Millimeter

B. U.S. Units (Imperial)

ft Foot
in Inch
lb Pound
Lbin Inch pound
Lbft Foot pound
InHg Inches of mercury
Psi Pounds per in3
F Degree Fahrenheit

C. Multiplying Prefixes

Micro
m Milli
Da Deca
K Kilo
M Mega

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5. Abbreviations

The abbreviations given below may be used in this manual:

AECMA The European Association of Aerospace Industries

ATA Air Transport Association of America
DIA Diameter
FIG. Figure
IPL Illustrated Parts List
Max. Maximum
MFR Manufacturer
Min. Minimum
No. Number
OD Outside Diameter
P/N Part Number
PARA Paragraph
REF. Refer to
S/A Subassembly
TBD To Be Defined
V Voltage

6. 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.

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7. Disposal

Ni-Cd batteries contain:

- Nickel
- Cadmium
- Potassium Hydroxide

Local legislation concerning disposal or recovery must be followed. For more information,
contact your local Saft supplier.

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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:

- 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 28VDC 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 24 V
Rated capacity C1Ah 40 Ah
Noted as 40 C1Ah for 40 C1Ah
(see note below for more info)
Battery main connector Connector compliant with ISO 5064/II or
MS 3509
Electrolyte Solution of potassium hydroxide
Consumable volume of electrolyte 25 cm3 (1.525 in3) per cell
Maximum dimensions of the battery
case
- Length (base) 247.45 mm (9.74 in)
- Width 266.7 mm (10.50 in)
- Height 261.9 mm (10.31 in)
Battery maximum weight 36.5 Kg (80.5 lb)

NOTE: Current values can be expressed in: 40A = 1C1A,

20A = 0.5C1A, and 4.0A = 0.1C1A for this 40 C1Ah battery.

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(2) Operational characteristics

- Operating temperature: -40C to +71C (-40F to +160F)

(3) Electrical characteristics

Below is a listing of values used to service the battery:

Item Value Used For

1 C1A 40 A Charge / Discharge
0.5 C1A 20 A Charge
0.1 C1A 4.0 A Charge

C. Detailed Description

The battery has 20 VP400KH (170) cells housed in an epoxy coated steel case (box) (10).

The case (box) (10) is lined with liners and spacers (supplied in a kit (270)). 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 (100 thru
140).

The main power connector (30) connects the battery to the aircraft.

The cover (20) that can be removed is attached to the case (10) by four latches.

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401176-9 Battery
Figure 1

Identification Plate
Figure 2
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261.9 mm 304.8 mm
10.31 in 12.00 in

247.45 mm 266.7 mm
9.74 in 10.50 in
Overall Dimensions
Figure 3

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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 0-50A

- Power supply: 0-45V, range 0-50A

(3) Instruments

- A multi-meter, range 2 V 50 V, 1% accuracy

- A megohmeter, range 0-50 M @250 VDC, 3% accuracy

(4) Environmental conditions for testing

- Ambient temperature: 20C 15C (68F 27F)

- Pressure: 85 to 106 Kpa (25.1 to 31.3 inHg)
- Relative humidity 85%

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B. Precautions

Maintenance should be performed regularly, per the aircraft manufacturers 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, >60C (140F).
- 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:

Level of electrolyte
Torque on the connection nuts
Correct onboard charging
Battery capacity

D. Testing procedures

(1) Insulation test

(a) Place the leads of the megohmeter as indicated below. Check from the outer
case (10) to each cell terminal. See Figure 1002 for information regarding
minimum values.

Insulation Test
Figure 1001

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250 K 2M 10 M
Can wait until next
Unacceptable To be cleaned OK
maintenance

In battery maintenance shop Minimum value after

cleaning and drying
Cleaning Required Cleaning
Recommended Acceptable
Fault Isolation

Insulation Test Parameters

Figure 1002

(2) Polarization test

(a) Charge the battery at 4.0 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 0V (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).

(3) Vent valve (250) test

During charge, before putting the vent valve (250) back onto the cells, verify proper
operation.

(a) Install the vent valve (250) with its O-ring 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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(e) Reject all vent valves that have an opening pressure greater than 0.7 bar (10
psi) and/or close at a pressure less than 0.14 bar (2 psi).

(f) Install the vent-valve (250) (Refer to ASSEMBLY).

(4) Special Test

CAUTION: 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.

(a) Charge the battery fully (refer to section 3).

(b) Continue to charge the battery at 4.0 A for an additional 5 hours, regularly
recording the voltage of each cell.

NOTE: 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 4)

(f) Replace any defective cells (Refer to DISASSEMBLY and ASSEMBLY).

(g) Charge the battery (Refer to section 3).

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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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 procedures listed in
the table below.

CONSTANT CURRENT CHARGE

Main Charge Final Charge (overcharge)
4.0 A (0.1 C1A) until 30.0 V as
battery voltage
4.0 A (0.1C1A) for 4 hours
Min: 10 hr
Times:
Max: 12 hr
20 A (0.5 C1A) until 31V as battery
voltage
4.0 A (0.1C1A) for 4 hours
Min: 2 hr
Times:
Max: 2 hr 30 min
40 A (1C1A) until 31.4 V as battery
voltage
4.0 A (0.1C1A) for 4 hours
Min: 1 hr
Times:
Max: 1 hr 15 min
NOTE: If the battery voltage does not increase above the required value
in the maximum charge time, refer to TESTING AND FAULT
ISOLATION. Do not continue to charge the battery at the high
rate.

(b) For a battery not fully discharged or when the level of charge is unknown:

1 Discharge at 40A (1C1A) down to 20 V (refer to section 5)

2 Charge: Refer to B (1)(a) for constant current charging instructions.

(2) Reflex Charging: For more information, contact your local Saft representative.

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4. 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 (250) and the electrolyte (refer to Figure 1003).

NOTE: The maximum consumable amount of electrolyte for this battery is 25 cm3
(1.525 in3) per cell (refer to DESCRIPTION AND OPERATION).

Electrolyte Level Adjustment

Figure 1003

WARNING: 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 (5ml) 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: The amount of distilled or deionized water (M01) required to level the
first cell will serve as an approximate 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.

(2) Repeat check 4.A to check for correct level.

5. 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 40 A 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 40 A, 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 51 minutes of discharge at 40 A. If one or more cells should fall below
1 V in less than 51 minutes, refer to Section 7 (FAULT ISOLATION).

B. 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.

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(1) Once each cell is discharged to 1 V, connect a resistor approximately 1 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.

6. Temperature Sensor Testing

Testing of the temperature sensor 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. Testing of the sensor

(1) Perform the following tests at 25C (77F).

Test Pins Required Values

Thermistor T1 & Fixed Resistor A-B R = 30.1 K 10%
Fixed Resistor A-C R = 100 10%
Thermistor T1 B-C R = 30 K 10%
Thermistor T2 & Fixed Resistor D-E R = 30.1 K 10%
Fixed Resistor D-F R = 100 10%
Thermistor T2 E-F R 30 K 10%

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7. Fault Isolation

Box or cells Yes More than

See para. 7.C (5) Yes
damaged usual added in See para. 7.B (1)
all cells
No No

Salt or Yes
electrolyte See para. 7.C (1) More than 25% Yes
average added in
See para. 7.B (2)
traces
1 cell
No
No

Electrolyte in Yes
See para. 7.C (2) 1 or more cells Yes
the case See para. 7.B (3)
voltage different
by >0.1V
No
No

Metallic parts Yes

See para. 7.C (3) Voltage of 1 Yes
corroded See para. 7.B (4)
cell <1.50 V

No
No

Battery voltage Yes

See para. 7.A (1) Capacity test Yes
=0V See para. 7.B (5)
<100% C1Ah

No
No

1 or more cells Yes

See para. 7.B (7) Link or nut is Yes
=0V See para. 7.C(4)
overheated
No
No
Yes
1 or more cells
See para. 7.B (5)
<0V

No

Cell to case Yes

Perform a General
insulation < See para. 7.A(3) Overhaul to detect
250K and repair any
battery fault noted
No

Functional Test Flow

Figure 1004

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A. Battery Electrical Faults

PROBLEM PROBABLE CAUSE CORRECTION

(1) Zero battery open-circuit (a) Defective electrical Check electrical contacts, links
voltage connection (no contact made). 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).
(2) Zero volts with the battery set (a) Battery fully discharged Perform an Insulation Test and
to discharge recharge the battery (refer to
TESTING AND FAULT
ISOLATION).

(b) Battery circuit open or Examine the connection and

connection defective links. Verify the terminal nuts
have proper torque (refer to FITS
AND CLEARANCES).

See section B (Cell faults).

(c) One or more cells dry Check electrolyte level (refer to
TESTING AND FAULT
ISOLATION).
(3) Low insulation (a) Leakage of electrolyte Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING). Perform an
electrolyte level check (refer to
TESTING AND FAULT
ISOLATION).

B. Cell Faults

PROBLEM PROBABLY CAUSE CORRECTION

(1) Excessive water (a) Excessive charge or charging Examine the cause of the
consumption. at high temperatures. excessive charge. If necessary,
adjust the maintenance interval.

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PROBLEM PROBABLE CAUSE CORRECTION

(2) The variation of water (a) More than 25% than the Perform an Insulation Test.
consumption in individual cells average: cell leakage Disassemble and replace faulty
exceeds 25% of the average components as necessary
consumption for all cells.
(b) 25% (or less) than the Perform the Special Test (refer
average: cell(s) with damaged to TESTING AND FAULT
separators ISOLATION). Replace cells if
necessary

(c) Previous maintenance was Note the cell location and check
not performed or performed the level of water consumption
incorrectly versus other cells at the next
maintenance interval
(3) A cell has an unusually high (a) Dry cell Add 5 cm3 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.
(4) A cell has an unusually low (a) The cell was operated at Replace the cell (refer to
voltage at the end of the final temperatures and charge rates DISASSEMBLY and
charge (less than 1.50 V) outside the limits, and the ASSEMBLY)
separator is damaged

(b) The cell has reached its end

of serviceable life.
(5) Low capacity cell (the cell (a) Usual wear after long service Replace the cell (refer to
shows a reversed voltage or a life. DISASSEMBLY and
correct polarity voltage of less ASSEMBLY)
than 1 V after a discharge of 51
minutes at 1C1A). (b) Unusual operation, operating Perform the Special Test (refer
at high temperatures or with low to TESTING AND FAULT
electrolyte. ISOLATION). If necessary,
replace the cell(s).
(6) Cell with an excessively (a) Cell operated with low Replace the cell (refer to
swollen case. electrolyte level; deterioration of DISASSEMBLY and
separators and damaged plates ASSEMBLY).
(7) Cell with zero voltage when (a) Short-circuited cell. Replace the cell (refer to
the battery circuit is open DISASSEMBLY and
ASSEMBLY).

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C. Physical Faults

PROBLEM PROBABLE CAUSE CORRECTION

(1) Leakage of electrolyte. (a) Incorrect adjustment of Disassemble and clean the
electrolyte level battery (refer to DISASSEMBLY
and CLEANING).

(b) Cell polarity incorrect during Investigate the cause of the

high-rate discharge (for example, excessive discharge.
during the engine start). Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).

(c) Excessive overcharge or high Investigate the cause of

overcharge at high temperatures. excessive charge. If necessary,
adjust the maintenance interval.
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).

(2) Electrolyte found in the (a) Damaged cell case Replace the cell if necessary.
battery case. 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)
(3) Corrosion on the links. (a) Operation in acid Make sure the battery test
environment bench, test room, and storage
areas contain no materials that
can release acid fumes.

(b) Mechanical damage to the Replace the damaged links (refer

nickel plating to DISASSEMBLY and
ASSEMBLY)
(4) The links show signs of (a) Loose terminal nuts Verify the torque on the nuts
overheating (refer to FITS AND
CLEARANCES)
(5) Case Deformed (a) Physical damage Disassemble and straighten case
(refer to DISASSEMBLY and
ASSEMBLY)

(b) Swollen cells Replace the cell if necessary.

Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)

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D. Vent-valve Faults

PROBLEM PROBABLE CAUSE CORRECTION

(1) Valve open pressure > 0.7 (a) Clogged valve Clean the valve (refer to
bar (10 psi) or stays closed CLEANING).

Replace the valve if cleaning is

not successful.
(2) Valve stays open at a (a) Pierced valve Replace the valve
pressure < 0.14 bar (2 psi).

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SCHEMATIC AND WIRING DIAGRAMS

1. General

This chapter gives all electrical schematics of the battery temperature sensor

2. Sensor Schematic

VIOLET
A
WHITE
B
BLACK
C
VIOLET
D
WHITE E
BLACK F

Sensor Schematic
Figure 2001

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DISASSEMBLY

1. General

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).

WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A COMPLETELY DISCHARGED

BATTERY (REFER TO TESTING AND FAULT ISOLATION)

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

- Dont 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.

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4. Safety Measures

- The electrolyte is caustic and can cause sever 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.

5. Disassembly

A. Equipment

(1) Standard tools

- Standard mechanics 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: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY DISCHARGED

BATTERY (REFER TO TESTING AND FAULT ISOLATION).

(1) Remove the cover (20)

(a) Remove the cover by pulling up the tab on the latches that attach the cover
(20) to the case (10) and lifting the cover upward.

(2) Remove the vent valve (250)

(a) Unscrew the vent valve (250) with the special tool (T01).

(b) Remove the vent valve (250) with its o-ring.

NOTE: Remove the vent valve (250) only for cleaning or leveling electrolyte.

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CAUTION: IN ORDER TO AVOID SHORT-CIRCUIT, REMOVE THE LINKS

ATTACHED TO THE CELL AND ADJACENT CELLS.

(3) Remove a cell (170)

(a) Remove the nuts (150) and the belleville washers (160) that attach the links
to the cell.

(b) Remove all links (100 thru 140)

(c) Fully engage the end of the special threaded tool (T03) onto one of the cell
terminals. Pull up to remove the cell.

(4) Remove the main power connector (30)

(a) Remove the nuts (150) and belleville washers (160).

(b) Remove the screws (40).

(c) Remove the connector (30) with the gasket (50).

(5) Remove the temperature sensor (60)

(a) Remove the connector (refer to section 4)

(b) Remove the attaching screws (70) and washers (80).

(c) Remove the nuts (150), belleville washers (160), 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.

(e) Remove the sensor (60) with the gasket (90) from the outside of the case
(10).

(6) Disassembly of a complete battery

(a) Remove the cover (20) (refer to Section 1).

(b) Remove the cells (170) (refer to Section 3).

(c) Remove the liner-spacer kit (270) by pulling out the liners and spacers,
making sure to mark them to ensure correct placement during assembly.

(d) Remove the connector (30) (refer to Section 4).

(e) Remove the sensor (60) and gasket (90) (refer to Section 5).

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CLEANING

1. General

This chapter provided 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

- Ordinary water.
- Distilled or deionized water (M01).
- Neutral soap (M02).
- Non-fluffy swab.
- Non-wire brush.
- Rubbing alcohol (isopropyl)

4. Cleaning Procedure

WARNING: 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.

A. Light Cleaning

(1) Remove the cover (20)

CAUTION: TO PREVENT SHORT-CIRCUIT, USE A RUBBER TUBE OR AN

INSULATED NOZZLE TO DISPENSE COMPRESSED AIR.

(2) 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

(a) Clean connector pins with rubbing alcohol to clean off any accumulated
grease and/or dirt. Inspect the pins for any pits, cracks, or scratches that
allow copper to show through the nickel plating. Replace connectors that are
damaged with a Saft factory new unit.

B. Thorough Cleaning

WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY

DISCHARGED BATTERY (REFER TO TESTING AND FAULT
ISOLATION).

(1) Disassemble the battery (refer to DISASSEMBLY) and then clean all components
except the vent valve (250) which must be cleaned while cells are in the case.

(a) Cells

1 Make sure the vent valve (250) is tight.

2 Remove lower terminal nut (180), polarity washer (190,200),

belleville washers (210) or belleville washers (220), flat washer (230),
and clean in warm water if necessary.

3 Inspect the terminal o-ring (240) for cracks, breaks or leakage.

Replace if necessary.

4 Reassemble the hardware onto the cell and torque the lower terminal
nut (180) per FITS AND CLEARANCES.

CAUTION: DO NOT SOAK THE CELLS IN WATER

5 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.

6 Rub the cell with a cloth and let dry.

(b) Case (10) and handle (if equipped)

1 Clean with light soap (M02) and water, rub with a cloth and let dry.

(c) Nuts, belleville washers, and links

1 Clean in warm water with a soft brush and let dry.

(d) Liner-spacer kit (270)

1 Clean in warm water with a soft brush and let dry.

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(e) Temperature Sensor (60)

1 Wipe all parts with a damp cloth and let dry.

CAUTION: CLEANING OF THE VENT-VALVE (250) MUST BE DONE WHEN

THE CELLS ARE ASSEMBLED IN THE CASE (10).

(f) Vent valve (250)

1 Remove the vent valve (250) (refer to DISASSEMBLY).

2 Place a swab or soft cloth over the cell opening to keep out
unwanted material.

3 Soak the vent valve (250) for 1-2 hours in a container of distilled or
deionized water to dissolve mineral salts from the vent valve hole.

NOTE: To facilitate the cleaning process the water may be warmed

to 48.89C (120F).

(g) Main Power Connector

1 Clean connector pins with rubbing alcohol to clean off any

accumulated grease and/or dirt. Inspect the pins for any pits, cracks,
or scratches that allow copper to show through the nickel plating.
Replace connectors that are damaged with a Saft factory new unit.

5. 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 mechanics 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 M (voltage 250 VDC), accuracy 3%

B. Conditions

- Ambient temperature: 20C 15C (68F 27F)

- 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 (150).
- Perform an Insulation Test.
- Measure the battery voltage.
- Discharge the battery.
- Charge the battery.
- Clean the vent valves (250).
- Adjust the electrolyte.
- Check the torque on nuts (150).

(1) Remove the cover (20).

(2) Perform a light cleaning (refer to CLEANING).

(3) Check the torque on all upper terminal nuts (150) (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 40 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, clean the vent valves (250) (refer to CLEANING).

(9) Level the electrolyte (refer to TESTING AND FAULT ISOLATION).

(10) Check the torque on all upper terminal nuts (150) (refer to FITS AND
CLEARANCES).

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Periodic Check

Check Torque
Light Cleaning
on all nuts

Yes
Dust Only
Cell to Case
No No
Insulation Test
> 2 Megohms
Electrolyte Traces
Yes

Total Voltage > 21V

General Overhaul No
At main power connector
No cells with reversed polarity
Yes

Polarization Test Initial Discharge

Fault Isolation
No Charge
For standard product
all cells > 1.50V
Special Test
Additional charge with up to Yes
5 hr overcharge Yes

For standard product Vent Valve Cleaning

all cells > 1.50V
Adjust Electrolyte
No during last 15 minutes of
No charge with constant
current flowing
General Overhaul
< 25% difference in
electrolyte levels

Yes

Check Torque
on all nuts

Battery Accepted

Periodic Check
Figure 5001
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D. Regular Check

After six months, or according to aircraft manufacturers specifications, perform this check
following the procedures indicated in Figure 5002.

- Perform a light cleaning.

- Check the torque on all nuts (150).
- 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 (250).
- Adjust the electrolyte.
- Perform a Capacity Test.
- Charge the battery.
- Check the torque on all nuts (150).

(1) Remove the cover (20).

(2) Perform a light cleaning (refer to CLEANING).

(3) Check the torque on all nuts (150) (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 40 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 (60). 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, clean the vent valves (250) (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 (150) (refer to FITS AND CLEARANCES).

(14) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
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Regular Check
Check Torque
on all nuts
Light Cleaning
Yes Total Voltage > 21 V
Dust Only No At main power connector
No No cells with reversed polarity
Electrolyte Traces
Yes

Polarization Test Initial Discharge

General Overhaul

Residual Discharge
1 Ohm - 3W Min Resistor
12-16 hours on all cells
Cell to Case
Insulation Test
No > 2 Megohms Yes
Test Temperature
No Sensor Yes Charge
For standard product
No all cells > 1.50V

Yes

Vent Valve Cleaning

Fault Isolation Adjust Electrolyte
during last 15 minutes of
charge with constant
No current flowing
Special Test
Additional charge with up to < 25% difference in
5 hr overcharge electrolyte levels
Yes Yes
For standard product
all cells > 1.50V No Capacity Test
(Initial Discharge)
Clean Vent Valves if applicable
Yes
Adjust electrolyte at end of charge Check Torque
on all nuts
No

General Overhaul
Charge
For standard product
No all cells > 1.50V

Adjust Electrolyte
at end of charge

Battery Accepted Yes

Regular Check
Figure 5002

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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 manufacturers instructions, following the procedures
indicated in Figure 5003.

- Check the torque on all nuts (150).

- 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 (180).
- Assemble the battery.
- Perform an Insulation Test.
- Charge the battery.
- Clean the vent valves (250) and test.
- Adjust the electrolyte.
- Perform a Capacity Test.
- Check the torque on all nuts (150).
- 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 (150) (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 40 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 (10).

(7) Test the Temperature Sensor (60) (refer to TESTING AND FAULT ISOLATION).

(8) Assemble the battery (refer to ASSEMBLY).

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(9) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value
measured after a Thorough Cleaning should be at least 10 M.

(10) Charge the battery (refer to TESTING AND FAULT ISOLATION).

(11) During the final charge, clean and test the vent valves (250) (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 (150) (refer to FITS AND CLEARANCES).

(15) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).

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General Overhaul

Total Voltage > 21V

At main power connector Check Torque
No cells with reversed polarity on all nuts
Residual Discharge
Initial Discharge 1 Ohm Resistor
12 hours on all cells
Polarization Test

Disassembly
and Thorough Cleaning

Visual Inspection
Assembly Temperature Sensor Test
Check - Disassembled Battery

Cell to Case
Insulation Test
No > 10 Megohms Yes Charge
For standard product
all cells > 1.50V
No
Yes
Vent Valve Cleaning/Test

Adjust Electrolyte
during last 15 minutes of
Fault Isolation charge with constant
No current flowing
< 25% difference in
Special Test
electrolyte levels
Complete charge with
Additional charge with up to
Yes
5 hr overcharge
Yes No
Capacity Test
For standard product
Yes
All cells > 1.50V
Check Torque
on all nuts
No

Full Discharge
Charge
Replace faulty components For standard product
and return to charge No all cells >1.50V

Adjust Electrolyte
at end of charge

Yes
Battery Accepted

General Overhaul
Figure 5003

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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 (not shown) can only be re-glued one time.

(1) Remove the Cover Gasket (not shown) completely.

(2) Clean all traces of glue from the cover (20).

(3) Apply the glue (M03) to the flat side of the cover (20).

(4) Let dry for 2 hours in a dry place (or as specified by manufacturers instructions).

(5) Place Cover Gasket (not shown) on the bottom of the cover (20) and press firmly to
seat.

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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 mechanics tools

- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron

B. Installation of the Temperature Sensor (60)

(1) Insert the sensor (60) with the gasket (90) and attach with screws (70) and washers
(80).

NOTE: 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.

C. Installation of the Connector (30)

(1) Insert the main power connector (30) with the gasket (50) into position in the battery
case (10) and attach with screws (40).

D. Installation of the liner spacer kit (270)

(1) Insert the bottom liner into the bottom of the case (10).

(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 (170) tight
in the case (10).
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1 required on 1 on bottom
each end row,
up to 9 can be
placed to fit
1 on each
properly
partition

1 on front
partition

Liner Spacer Kit Installation

Figure 7001

F. Installation of Cells (170)

(1) Torque all lower terminal nuts (180) (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 (170) in each row and insert the cell (170) 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 (270). If the cell is too difficult to insert, remove a liner or spacer (270)
as needed. Never lubricate the cells to facilitate assembly.

(4) Lightly lubricate all links (100-140), belleville washers (160), nuts (150), and cell
terminals with a mineral vaseline (M04) or light oil using a paintbrush.

(5) Install the links (100-140), belleville washers (160), and nuts (150).

(6) Torque all nuts (150) (refer to FITS AND CLEARANCES).

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Negative
PolarityPolarity
+
z 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 NOMENCLATURE TORQUE VALUE (lubricated)

ITEM (FROM IPL) Nm Lbin
150 Upper Terminal Nut 10 87

180 Lower Terminal Nut 5 43.5

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

PART PART
NUMBER NUMBER
CODE FIGURE QTY (where (where DESCRIPTION USE
applicable) applicable)
F6177 V09052
DISASSEMBLY
CLEANING
T01 9001 1 015528 093382-000 Vent-Valve Wrench
CHECK
ASSEMBLY

TESTING AND
Syringe w/20mm
T02 9002 1 016544 020915-004 FAULT ISOLATION
Nozzle
CHECK

TESTING AND
Equalizing Resistors
T03 9003 1 164829 FAULT ISOLATION
1 3 Watt
CHECK

Cell Extraction tool

T04 9004 1 013169 017556-000 DISASSEMBLY
M10

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Vent-Valve Wrench (T01)

Figure 9001

Syringe with Nozzle (T02)

Figure 9002

Equalizing Resistor (T03)

Figure 9003

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Cell Extraction Tool M10 (T04)

Figure 9004

Vent-Valve Testing Tool

Figure 9005

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3. Consumables

NOTE: Equivalent alternatives may be used.

A
I D
R I A
C
L S S S
L R
I A C S T
DESIGNATION PART T E E
MANUFACTURER N S H E O
CODE NUMBER AND E A P
OR SUPPLIER E S E M R
SPECIFICATION S N A
S E C B A
T I I
M K L G
N R
C B Y E
G
O L
D Y
E
Distilled or deionized water;
clear, colorless, odorless
while boiling, resistivity >30
K/cm
5 < pH < 7
Absence of organic and
reducing substances.
M01 X X
Reducing agent content Local Vendor
(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

Soap (non-abrasive mild

M02 Local Vendor X
household)

Neoprene Glue (alkali

M03 Local Vendor X
resistant)

NATO: S 743
M04 Mineral Vaseline F: AIR 3565 X X
US: SLP 236
UK: DEF 2333

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ILLUSTRATED PARTS LIST

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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. 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.

C. 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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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) Manufacturers Part Number

A manufacturers 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 (*).

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(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 Interchangeable part

AR As required
ASSY Assembly
DPL Detailed Parts List
EDI Electronic Data Interchange
EFF Effectivity
FIG Figure
IPL Illustrated Parts List
LH Left-Hand
NHA Next-Higher Assembly
NP Not-Procurable
OPT P/N Optional Part Number
P/N Part Number
POST SB Post Service Bulletin
PRE SB Pre Service Bulletin
REF Reference
RH Right-Hand
SUPSD BY Superseded by
SUPSDS Supersedes

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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 from 10 to 10 makes it possible to add new
items between the old ones in the appropriate order of the breakdown. With the
addition of more than nine new items, a new number 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.

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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

V09052 Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Phone: (1) 229-247-2331
Fax: (1) 229-247-8486

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ALPHANUMERIC INDEX

PART NUMBER AIRLINE FIGURE INDEX TOTAL

V09052 STOCK NUMBER NUMBER NUMBER REQUIRED

009384-000 IPL Fig 1 50 1

011013-000 IPL Fig 1 90 1
015575-000 IPL Fig 1 100 14
015576-000 IPL Fig 1 110 3
015577-000 IPL Fig 1 120 2
015578-000 IPL Fig 1 130 1
015579-000 IPL Fig 1 150 42
015579-000 IPL Fig 1 180 2
015602-000 IPL Fig 1 170 20
015926-000 IPL Fig 1 140 1
015957-000 IPL Fig 1 250 1
019756-000 IPL Fig 1 60 1
020430-000 IPL Fig 1 20 1
021798-000 IPL Fig 1 10 1
021870-000 IPL Fig 1 230 2
021871-000 IPL Fig 1 210 4
022138-000 IPL Fig 1 30 1
022228-000 IPL Fig 1 160 42
022369-000 IPL Fig 1 270 1
023388-001 IPL Fig 1 190 1
023388-002 IPL Fig 1 200 1
091180-008 IPL Fig 1 260 1
091181-002 IPL Fig 1 240 2
091924-000 IPL Fig 1 80 4
092178-008 IPL Fig 1 70 4
093616-000 IPL Fig 1 40 4

- Item not illustrated

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DETAILED PARTS LIST

150
20
160

170

270

150

160

30 10

40 100
110
50
120
80

70 140
130
60
90
401176-9 BATTERY
IPL FIGURE 1 (PAGE 1 OF 2)
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180 180
190,200 190,200
210
250 220
210
250 260 230
230
260
240
240

170
170

Saft Valdosta VP400KH Cell Saft France VP400KH Cell

V09052 F6177

401176-9 BATTERY
IPL FIGURE 1 (PAGE 2 OF 2)

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FIGURE PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

AND STOCK CODE PER
ITEM F6177 V09052 NUMBER 1234567 ASSY
IPL Fig 1 020412-000 Nickel-Cadmium Battery (V09052) REF
020412-000 is Ref/Code for Saft
401176-9 Model Battery
10 021798-000 . Case Marked 401176-9 1
20 020430-000 . Cover Marked 401176-9 1
30 022138-000 . Connector, Main Power 1
40 093616-000 . Screw, Sems (attaching parts***) 4
50 009384-000 . Gasket, Main Power Connector 1
60 019756-000 . Sensor, Temperature 1
70 092178-008 . Screw (attaching parts***) 4
80 091924-000 . Washer, Lock (attaching parts***) 4
90 011013-000 . Gasket, Temperature Sensor 1
100 0012374 015575-000 . Link 14
110 0057014 015576-000 . Link, Cross Formed 3
120 015577-000 . Link 2
130 0015266 015578-000 . Link 1
140 0114767 015926-000 . Link 1
150 0062007 015579-000 . Nut, M10 x 1.25 (upper) 42
160 0100094 022228-000 . Washer, Belleville (upper) 42
170 0063037 015602-000 . Cell, VP400KH 20
180 0062007 015579-000 . . Nut, M10 x 1.25 (lower) 2
190 0100694 023388-001 . . Washer, Red Polarity 1
200 0100693 023388-002 . . Washer, Blue Polarity 1
210 021871-000 . . Washer, Belleville (V09052 Cells) 4
220 0100094 . . Washer, Spring (F6177 Cells) 2
230 0100078 021870-000 . . Washer, Flat 2
240 0100594 091181-002 . . O-Ring, Terminal 2
250 0080004 015957-000 . . Valve, Vent 1
260 0100593 091180-008 . . . O-Ring, Vent-Valve 1
270 022369-000 . Kit, Liner 1

- Item not illustrated

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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.

The 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 -60C (-75F) to +60C
(+140F) without harming the battery. The most desirable range for storage is between 0C
(32F) to +30C (+86F).

2. 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 (discharged) (refer to
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 (unsealed for < 2 years, sealed for >2 <10 years).

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.

3. 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 (less than 90 days). 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). Saft recommends an active storage period of no more than 90
days before an appropriate check is performed on the battery. For storage longer than 90 days, see
procedures for Inactive Storage.

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100

90
AVAILABLE CAPACITY (%C1Ah)

80

CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5C) (41F) Disch. (0%C1Ah)
Temp. (15C) (59F) Disch. (0%C1Ah)
Temp. (25C) (77F) Disch. (0%C1Ah)
Temp. (35C) (95F) Disch. (0%C1Ah)

60
0 10 20 30 40 50 60 70 80 90

Days

Charge Retention
Figure 15001

A. Saft vented-cell aircraft batteries may be stored charged, ready for service in the normal
upright, or vertical position under the following conditions. Refer to Figure 15001 for the
approximate number of days a battery can be stored and retain a minimum of 80% capacity.

(1) Battery fully serviced and charged prior to storage.

(2) Storage temperature relative to number days of storage desired (see Fig 15001).

(3) Atmosphere free of acid, dust and dampness.

(4) No corrosive liquids or gases stored in the same room.

(5) After 90 days, a Periodic Check must be performed (Section 5 CHECK - see Fig
5001).

NOTE: Only two periodic checks can be performed 90 days apart, afterward a
Regular Check must be performed.

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CAUTION: THE BATTERY MAY BE TOPPED UP TWO TIMES. ON THE THIRD TIME, A
PERIODIC CHECK MUST BE PERFORMED. FAILURE TO PERFORM THE
PERIODIC CHECK MAY RESULT IN LOW WATER AND PERMANENT DAMAGE
TO THE BATTERY.

B. As an alternative to (A), the battery may be kept at any temperature below 35C (95F) and
be topped up after 30 days by charging until the battery has reached the voltage specified in
Fig 15002.

CHARGE RATE Voltage to Terminate charge for

VO-VP-VHP
0.1C1 Amps 1.5 V per cell
Topping Up Charge Guide
Figure 15002

4. Inactive Long-Term Storage

Saft Nickel-Cadmium Aviation Batteries can be stored discharged in the original cardboard packaging
for a period of two years, and up to 10 years in sealed packaging under the following conditions:

A. Airworthy condition

B. Ambient temperature of 20C 15C (+68F 27F)

C. Humidity less than 70%

D. Normal upright, vertical position

E. Atmosphere free of dust, dirt, vibration or corrosive agents.

5. Preparation for use after Inactive Long-Term storage (section 4.)

STORAGE TIME SERVICE PROCEDURE

Less than 3 months Perform a Periodic Check (CHECK - Fig 5001)
More than 3 months Perform a Regular Check (CHECK - Fig 5002)
Return to Service Procedures
Figure 15003

6. Packing and Transporting

The normal packing for shipment of Saft Ni-Cd 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 Ni-Cd batteries

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