SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
NICKEL-CADMIUM BATTERY
43B050LB01
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
RECORD OF REVISIONS
REV
NO.
1
2
3
4
5
ISSUE
DATE
09/01/71
08/15/76
12/12/97
06/15/98
08/17/01
INSERT
DATE
09/01/71
08/15/76
12/12/97
06/15/98
BY
REV
NO.
ISSUE
DATE
INSERT
DATE
BY
GE
GE
Saft
Saft
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV NO
PAGE
NUMBER
ISSUE DATE
BY
INSERT
DATE
BY
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
REVISION NUMBER
DATE BULLETIN
INCORPORATED INTO
MANUAL
PRODUCT IMPROVEMENTS
Product Improvements have been incorporated using service bulletins entered in the
service bulletin list. Service bulletin highlights are as follows:
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
LIST OF EFFECTIVE PAGES
SUBJECT
Title
PAGE
T-1
T-2
DATE
Aug 17/01
Blank
Record of Revisions RR-1
RR-2
Aug 17/01
Blank
Record of Temporary RTR-1
Revisions
RTR-2
Dec 12/97
Blank
Service Bulletin List
SBL-1
SBL-2
Dec 12/97
Blank
List of Effective
Pages
LEP-1
LEP-2
Aug 17/01
Blank
Table of Contents
TC-1
TC-2
Dec 12/97
Blank
Introduction
INTRO-1
INTRO-2
Aug 17/01
Blank
Description and
Operation
1
2
Dec 12/97
Dec 12/97
Testing and Fault
Isolation
101
102
103
104
Dec
Dec
Dec
Dec
301
302
Dec 12/97
Dec 12/97
401
402
403
404
Dec 12/97
Dec 12/97
Dec 12/97
Blank
Disassembly
Cleaning
12/97
12/97
12/97
12/97
SUBJECT
Check
PAGE
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
DATE
Dec 12/97
Dec 12/97
Dec 12/97
Dec 12/97
Dec 12/97
Dec 12/97
Dec 12/97
Dec 12/97
June 15/98
Aug 17/01
June 15/98
June 15/98
June 15/98
June 15/98
June 15/98
June 15/98
Repair
601
602
Dec 12/97
Dec 12/97
Assembly
701
702
703
704
705
706
Dec 12/97
Dec 12/97
June 15/98
June 15/98
June 15/98
Blank
Fits and Clearances
801
802
June 15/98
Blank
Special Tools
901
902
Dec 12/97
Blank
Illustrated Parts List
1001
1002
1003
1004
1005
1006
1007
1008
Dec
Dec
Dec
Dec
Aug
Aug
Aug
Aug
12/97
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17/01
17/01
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
TABLE OF CONTENTS
Paragraph Title
Page
Description and Operation
1
Testing and Fault Isolation
101
Automatic Testing Requirements (ATLAS)
N/A
Disassembly
301
Cleaning
401
Check
501
Repair
601
Assembly
701
Fits and Clearances
801
Special Tools, Fixtures, and Equipment
901
Illustrated Parts List
1001
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
INTRODUCTION
The instructions in this manual provide the information necessary for an experienced shop
technician to perform shop type repair with no specialized training.
The manual is divided into separate sections:
1.
2.
3.
4.
5.
6.
Title Page
Record of Revision
List of Effective Pages
Table of Contents
Introduction
Procedures and IPL
Sections
The disassembly, repair, and assembly sections generally contain only specific instructions
to be used on the equipment covered herein. Most standard aerospace practices are not
described herein.
An explanation of the use of the Illustrated Parts List (IPL) is provided in the introduction to
that section.
Every effort has been taken to provide complete and accurate component maintenance
instructions. However, if a situation should arise that is not adequately covered by this
manual, please contact SAFT America Inc. for specific information. Saft can be contacted
at the following addresses:
Saft America, Inc.
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Telephone:
(229) 247-2331
FAX:
(229) 247-8486
Saft
12 Avenue Sadi Carnot
93170 Bagnolet
France
Telephone: 33 1 49 93 19 18
FAX: 33 1 49 93 19 56
Verification:
Testing / Fault Isolation
Disassembly
Assembly
June 30, 1997
June 30, 1997
June 30, 1997
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
DESCRIPTION AND OPERATION
1.
Description
The Nickel Cadmium Battery (SAFT America Inc. type 43B050LB01 and General
Electric type 43B050LB01) provides power to the standby system. It is a nickelcadmium type with sintered plate construction, and uses a potassium hydroxide
electrolyte. The battery consists of a case and cover, eleven (11) cell assemblies,
and a temperature sensor assembly.
2.
Operation
The battery is charged on the aircraft by an on-board charger. The charge control
thermistor provides a signal to the charger to compensate the charge according to the
battery temperature.
Nickel-Cadmium Battery
Figure 1
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
Voltage:
Nominal
12.0 Volts
Weight
63 pounds (28.58 kg) maximum
Dimensions (Maximum):
Height
Length
Width
Number of Cell Assemblies
10.30 inches (261.62 mm)
11.56 inches (293.62 mm)
7.65 inches (194.31 mm)
11
Cell Model
Saft-Type 43B050AC01-2
Rated Capacity
Venting Pressure
Cell Assembly Case Material
Battery Case Material
50 Ampere-hours at 1-hour rate
2 to 10 psi (0.14 to 0.7 bar)
Polyamide
Nylon coated steel
Electrolyte
Potassium Hydroxide
Leading Particulars
Figure 2
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
TESTING AND FAULT ISOLATION
1.
Testing
Testing operations are described in the chapter entitled CHECK.
2.
Fault Isolation
The information presented below is a guide in locating a cause of malfunction and
isolating a possible remedy to the problem.
FAULT
Zero battery voltage
PROBABLE CAUSE
Loose main connector
REMEDY
Tighten or replace connector
Broken or loose terminal
links
Tighten or replace links
Battery completely
discharged
Recharge (CHECK)
Check insulation resistance
(CHECK).
Check temperature sensor
assembly (CHECK)
Zero Voltage on cell
Short circuited cell
Replace with new cell
Low cell voltage at end of
charge
Separator damage
Replace with new cell
Overflowing electrolyte
Electrolyte level too high
Clean battery, run electrical
tests, adjust level
(CHECK)
Relief valves loose or
damaged
Tighten or replace valves,
clean, recondition, run
electrical tests, adjust
electrolyte level
(CHECK)
Cell reversed during high
rate discharge
Check aircraft charger
voltage, run electrical tests
(CHECK)
Overcharge at too high a rate Check aircraft charger
voltage, run electrical tests
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COMPONENT MAINTENANCE MANUAL
43B050LB01
FAULT
PROBABLE CAUSE
REMEDY
(CHECK)
Excessive use of water
Loss of battery capacity
Low cell capacity
Leaky cells, defective cells or Inspect for and replace
vent valves
defective cells or valves
Overcharging too long or at
high temperatures
Check aircraft charger
voltage or ground charging
system
Defective thermistor
Check temperature sensor
assembly (CHECK)
Cell imbalance
Electrolyte level too low
Run electrical tests (CHECK)
Run electrical tests, adjust
electrolyte level
(CHECK)
In service charging
malfunction
Run electrical tests, check
aircraft charger (CHECK)
Normal wear from long
service
Abnormally high cell voltage Dry cell
at beginning of charge
Low voltage output
Replace with new cell
(CHECK)
Add 5 to 10 cm3 of distilled
water, adjust electrolyte level
at end of charge (CHECK)
Check cell performance for
permanent damage
Continuous demand without Run electrical tests
charging
(CHECK)
In service charger
malfunction
Run electrical tests (CHECK)
check aircraft charger, check
temperature sensor assy.
(CHECK)
Loose terminal connectors
Torque to spec., run
electrical tests (CHECK)
Main connector loose,
burned, pitted
Clean or replace, tighten run
electrical tests (CHECK)
Defective cell or cell with
Replace defective cell, run
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COMPONENT MAINTENANCE MANUAL
43B050LB01
FAULT
PROBABLE CAUSE
reversed polarity
REMEDY
electrical tests (CHECK)
Cell to Case current leakage Discharge, disassemble,
clean, replace defective cells
and / or insulation, run
electrical tests (CHECK)
Excess foaming on charge
Electrolyte concentration low Discharge, run electrical
after adding water
Tests (CHECK)
Excessive foaming out of
Electrolyte contaminated by Discharge, replace
vent valve on charge
oil or grease
contaminated cells, run
electrical tests (CHECK)
Tarnished or burned terminal Loose terminal nuts and links Clean or replace hardware,
connectors
tighten to specified torque
Corroded connectors
Acid atmosphere
Check room, eliminate acid
source
Inadequate greasing
Clean and lubricate properly
Mechanical damage to
protective nickel-plating
Burned or pitted main battery Improperly mated or loose
cables
connection
Deformed cell case
Charger failure
Temperature sensor assy.
Failure
Deformed cell case
Distorted battery case
Damaged separator or
internal shorting
Replace damaged hardware
Clean, repair or replace parts
to mate properly
Discharge, disassemble
install new cell, check aircraft
charger
Check and / or replace
temperature sensor assy.
(CHECK)
Discharge disassemble,
install new cell (CHECK)
Inoperative vent valve
Verify the proper operation of
the vent valve and replace if
necessary (CHECK)
Overheating, lack of
ventilation, or major
explosion due to unusually
high ambient temperatures,
improper maintenance, too
high charge rate, charger
Discharge, disassemble,
replace all damaged parts
with new parts or replace
entire battery; check entire
ventilation system; check
aircraft or ground charging
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
FAULT
PROBABLE CAUSE
failure
REMEDY
system(CHECK, DISASSEMBLY, ASSEMBLY)
Loose terminal nuts and links Make sure all connections
are tight
Temperature sensor assy.
Failure
Resistance insulation failure Excessive spewing of
electrolyte, or water inside
battery case
Check and / or replace
temperature sensor assy.
(CHECK, REPAIR)
Discharge, disassemble,
clean, replace defective
insulation and / or cells, run
electrical tests (CHECK)
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
DISASSEMBLY
1.
General
Prior to disassembly, see CHECK for testing procedures and refer to TESTING and
FAULT ISOLATION to determine condition of the battery, cause, and remedy of
malfunction. Disassemble only to the extent necessary to effect repair and
replacement.
NOTE:
2.
The ( ) part identification numbers herein are IPL, Figure 1 item
numbers.
Detailed Instructions
WARNING: BATTERY CELL ASSEMBLIES DELIVER VERY HIGH CURRENTS
WHEN SHORT-CIRCUITED. EXERCISE CAUTION. REMOVE
RINGS, WATCHES OR OTHER JEWELRY FROM HANDS AND
ARMS. COMPLETELY DISCHARGE BATTERY PRIOR TO
DISASSEMBLY (CHECK)
CAUTION:
BATTERY MUST BE COMPLETELY DISCHARGED IN
ACCORDANCE WITH (CHECK) BEFORE CELL ASSEMBLIES CAN
BE REMOVED.
A.
Remove cover (50) by opening latches and lifting cover from case (10).
B.
Remove the cell assemblies (240) from the battery case (10) as follows:
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE
LOOSENED OR REMOVED; CONTACT OF ELECTROLYTE WITH
SKIN CAN CAUSE SEVERE BURNS.
NOTE:
Prior to any disassembly of the cells, refer to CHECK.
(1)
Using the vent valve wrench (20), loosen the vent valves (250) of all
cells to relieve any pressure; then retighten vent valves.
(2)
Remove terminal screws (160, 270), lock washers (170, 280) and
washers (180, 290) from cell assemblies (240).
(3)
Remove intercell terminal links (300) through (320) from cell
assemblies (240).
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(4)
Remove cell assemblies (240) from the battery case (10) using Saft
cell puller (P/N 022056-000) with a steady straight up pull.
NOTE:
C.
Do not attempt further disassembly of the cell subassembly.
Cells are nonrepairable items and must be replaced with a
factory new cell if defective.
Main battery connector
(1)
Remove the attaching screw (200,210,220) connecting wire of
temperature sensor assembly (190) from main battery connector (130)
(2)
Remove screws (150) from main battery connector (130)
(3)
Remove main battery connector (130)
D.
Remove foam fillers (60, 110, 80) from battery case (10)
E.
Remove foam filler (90) from the center partition of the battery case (10) by
pushing the foam filler (90) downward and then grasping the foam filler (90) at
the bottom and removing from the left or right side through the gap between
the bottom of the partition and the battery case (10).
F.
Remove foam filler (70) from battery case (10)
G.
Remove nut (190.10) and washer from the sensor assembly connector (190).
H.
Remove sensor assembly (190) from battery case (10) by the following:
(1)
Gently remove the temperature sensor plate from its mounting position
being careful not to bend out of shape
(2)
Push the sensor connector through the battery case
(3)
Slide the sensor wires connected to the connector through the cut out
in the battery case partition and remove through the top of the battery
case.
I.
Remove foam filler (100) from battery case (10)
J.
Remove bottom liner (120) from either the left or right side of the battery case
(10)
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COMPONENT MAINTENANCE MANUAL
43B050LB01
CLEANING
1.
General
A.
The following items are required to perform the cleaning procedures
(equivalent substitutes can be used):
Stiff bristle brush (nonmetallic)
Dry compressed air source, less than 20 psi (1.4 bar).
Safety goggles
Lubricant (non acid petroleum jelly)
Soft, clean cloth (two required)
Isopropyl alcohol or degreasing agent
Running water
Soap
Distilled or deionized water
2.
Assembled Battery
CAUTION:
DISCHARGE BATTERY PRIOR TO DISASSEMBLY IN
ACCORDANCE WITH CHECK
NOTE:
The ( ) part identification numbers herein are IPL, Figure 1 item
numbers.
A.
The following procedures are for an assembled battery with battery cover (50)
removed.
CAUTION:
B.
Using the vent valve wrench (20), make sure that the vent valves (250) of all
cell assemblies (240) are closed. Do not overtighten.
CAUTION:
C.
VENT VALVES MUST BE CLOSED TO PREVENT DIRT AND
FOREIGN MATTER FROM ENTERING CELLS DURING CLEANING.
VENT VALVES SHOULD BE CLOSED AT ALL TIMES (TO AVOID
EXPOSURE TO CO2), EXCEPT AS DIRECTED OTHERWISE
HEREIN.
DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS. CELLS MAY
BE DAMAGED BY SUCH ACTION.
Remove white deposits (potassium carbonate) from tops of all cell
assemblies (240) using a stiff non-metallic bristle brush.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
WARNING: TO PREVENT INJURY WHEN USING COMPRESSED AIR, DIRECT
STREAM AWAY FROM BODY. USE SAFETY GOGGLES TO
PREVENT INJURY TO EYES FROM FINE DUST PARTICLES.
3.
D.
Disperse residual dust and particles from the battery with blasts of clean, dry,
compressed air not over 20 psi (1.4 bar).
E.
Lightly coat cell assembly screws (160, 270) and all intercell terminal links
(300 through 320) with a light film of non acid petroleum jelly. Silicone
coatings are not suitable due to the alkaline electrolyte.
F.
Clean the exterior surfaces of the battery cover (50) and battery case (10)
using a soft, clean cloth, moistened with water. Dry with compressed air or a
dry, clean cloth.
Disassembled Battery
CAUTION:
DISCHARGE BATTERY PRIOR TO DISASSEMBLY IN
ACCORDANCE WITH CHECK
A.
Remove greasy residue from battery connector receptacle (130) with
isopropyl alcohol or degreasing agent.
B.
After assuring that the vent valves (250) are closed, wash each cell (240) in
running water. Do not allow any water to enter the cell. Dry with
compressed air or a dry, clean cloth.
C.
Wash the battery case, cover insulation, liners, connector gasket, and cell
hardware in warm, soapy water to remove dirt and salt deposits. A plastic
scraper or a stiff bristle brush (non-metallic) may be used to aid in the
removal of heavy deposits. Rinse away all soap, and dry with compressed air
or a dry, clean cloth.
NOTE:
ENSURE THAT FOAM LINERS ARE COMPLETELY DRY.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
D. Remove the vent valves (250) from the cell subassemblies (240) and submerge
the vent valves (250) and the O-ring (260) in a clean container of distilled or
deionized water. This treatment will dissolve any salt deposits which may have
accumulated in the vents of the valves or around the o-ring seat. Cover the cells
(240) with a damp, clean cloth, or take other precautions to prevent any foreign
particles from falling into the cells while the valves are removed.
NOTE:
E.
The length of time vent valves are removed from the cell assemblies
should be kept to a minimum.
After cleaning, test the vent valves in accordance with CHECK.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
CHECK
1.
General
This section contains battery functional tests and maintenance requirements. Test
procedures are written in a step-by-step format.
NOTE:
2.
The ( ) part identification numbers herein are IPL, Figure 1 item numbers.
Scheduled Maintenance
A.
Regular Check: At 1000 hours or 6 months, perform the following:
NOTE:
These periods are given as an indication; modify in accordance
with operational experience.
NOTE:
Maintenance checks may be combined if operating hours do not
meet times listed.
(1)
Discharge the battery at 50 A down to a voltage of 11 V at the battery
terminals.
(a)
Measure and record the time from the start of discharge to the
moment 11 V is reached.
(2)
Continue with a residual discharge by connecting a resistor of
approximately 1 W (3 W) across each cell. (Resistors with clips
attached to their leads can be easily attached to the cell terminals.)
(3)
Leave resistors in place overnight.
(4)
Remove all the resistors.
(5)
Charge the battery (Section 3).
(6)
Adjust the electrolyte level in the cells (Section 3).
(7)
Perform a capacity check (Section 3.C).
(a)
Discharge the battery again at 50 A.
(b)
Measure the terminal voltage of each cell.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(c)
(8)
Record the time that is needed for the first cell to reach 1.0 V
and the battery terminal voltage to reach 11.0 V.
Conclusions to be drawn from the above tests:
(a)
(b)
The battery is functioning properly if:
1
The first discharge required more than 30 minutes.
2
The second discharge required at least 51 minutes for
the first cell to reach 1.0 V.
3
Each individual cell voltage during the last 15 minutes of
charge at 5.0 A is at least 1.5 V (accuracy ±0.5%)
4
The quantity of distilled water added to each cell is
approximately equal to or less than 25 cm3 (1.55 in3).
5
If the duration of the first discharge is less than 30
minutes but the second discharge time is correct (at least
51 min) it may be concluded that the battery is in good
condition but was not fully charged when removed from
the aircraft (this may be due to insufficient recharge on
board and/or discharge resulting from unexpected use of
the battery after landing.)
The battery must be given a General Overhaul if:
1
The duration of the second discharge is less than 51
minutes or if any cell has a voltage of less than 1 volt or
reversed polarity before 51 minutes of discharge.
2
Individual cell voltages measured during the last 15
minutes of charge at 5.0 A are less than 1.50 V.
3
One or several cells required considerably (10-25%)
more or less distilled water than the other cells.
NOTE:
The consumption of water by a Saft nickelcadmium cell is proportional to the
overcharge that it has received.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
NOTE:
C.
The fact that one or more cells of the same
battery consume noticeably more or less
water than other indicates a defect:
a
High consumption is generally caused by leakage.
b
Low consumption is caused by separator damage.
c
Consumption is considered to be abnormal when it
is 10-25% more or less than average.
(9)
Charge the battery (Section 3).
(10)
Return battery to service.
General Overhaul
In addition to the electrical tests described in the Regular Check, the General
Overhaul includes a systematic disassembly and cleaning of all components
of the battery. It must be carried out at 2000 hours or at least once a year.
(1)
Disassemble the battery (DISASSEMBLY).
(2)
Clean the battery (CLEANING).
(3)
Test the battery
(a)
Box:
1
(b)
Nuts, links, and spring washers:
1
(c)
Straighten the box sides and flatten out any minor dents
with a hard rubber mallet.
Discard and replace any corroded or damaged
components.
Spacers:
1
Discard and replace all defective components.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(d)
Connector:
1
3.
Ensure that the connector is in good condition, both inner
and outer surfaces. Replace if the connector contacts
show any signs of corrosion, burning, or arcing.
Battery Charging, Electrolyte Level Adjustment and Capacity Test
NOTE:
A.
The success of these tests depends very much upon keeping the
battery cool. High temperature, during a discharge procedure and
particularly during a charge procedure, will result not only in poor
equalization but in a shortened life for the battery. For best results, the
ambient temperature must be 60°F to 80°F (15.6° C to 26.7°C) . The
battery temperature at the start of a charge procedure must be at room
temperature 60°F to 80°F (15.6°C to 26.7°C). A 12 hour rest is
required following a discharge procedure. There is not a required rest
period between completion of a charge and the start of dicharge
procedures.
Charge
CAUTION:
ATTEMPTING TO CHARGE BATTERIES WITH LOW
ELECTROLYTE LEVELS IN ANY CELL MAY CAUSE DAMAGE
TO THAT CELL.
(1)
Prior to charging the battery, remove the cover (50) and loosen (do not
remove) all vent valves (250). Ensure that the shorting spring has
been removed from the connector adapter (130).
(2)
Charge the battery using one of the procedures that follow:
NOTE:
(a)
Check individual cell voltages at the beginning of the
charge. If any cell indicates an immediate voltage rise
above 1.50 volts, add about 10 cm3 of distilled or
demineralized water through the vent valve opening of
that cell.
Charge battery at 5.0 A until the voltage reaches 16.5 V. Then,
continue charging battery at the 5.0 A rate for 4 additional
hours. The total charge time must be at least 14 hours, but not
more than 16 hours.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(b)
Charge the battery at 25 A for at least 2 hours but not more than
2 hours and 30 minutes until the battery voltage has reached
17.05 V. Then, charge at 5.0 A for 4 additional hours.
Procedure (a): 5.0 A (0.1 C1A) until
battery reaches 16.5 V
Time:
Minimum:
10 hours
Maximum:
12 hours
Procedure (b): 25.0 A (0.5 C1A) until
battery reaches 17.05 V
Time:
Minimum:
2 hours
Maximum:
2 hours 30 min.
Figure 505
(3)
+ Completion of charge 5.0
Amps (0.1 C1A) for 4 hours
at end of charge with all
cells ³1.50 V. Total charge
not to exceed 16 hours.
+ Completion of charge 5.0
Amps (0.1 C1A) for 4 hours
at end of charge with all
cells ³1.50 V. Total charge
not to exceed 6.5 hours.
During the last 15 minutes of charge at 5.0 A, measure each cell's
voltage. Mark for replacement any cell(s) with an end of charge
voltage of less than 1.5 V. Then, adjust electrolyte level while charging
battery at 5.0 A.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
NEW
R E M O VE D
FR O M
A IR C R A FT
C H E C K CE L L N U T
TO RQ UE
(C H E C K )
C H EC K C EL L N U T
TO R Q U E
(CH E C K )
CHECK
C E LL V O L TA G E S
CHARGE
(C H E CK )
IN IT IA L
D IS C H A RG E
(C H EC K )
AD JUS T
E LE C T R O L Y TE
(C H E C K )
R E SID U A L
D IS C H A RG E
(C H EC K )
A L L C EL LS
> 1.5 0 V
*
A N Y CE L L
<1 .5 0V
R E C H AR G E
(C H EC K )
INIT IA L
DIS C H A R G E
(C H EC K )
GOOD
REST
10 - 12 HR S.
CHARGE
(C H E C K )
AL L C E LLS
> 1.5 0 V
N O -G O O D
P R O C EE D
TO
S P EC IA L
T E ST ING
S P E CIA L
T E ST ING
(C H E C K )
A D JU S T
E LE C T R O L Y TE
(C H E CK )
IN S U LA T IO N
CHECK
(C H E C K )
C H E C K C E L L N UT
TO RQ UE
(C H E C K )
PL A CE IN
S E R V IC E
SE C O N D
DIS C H A RG E
(C H EC K )
GOOD
*
A N Y CE L L
<1 .5 0V
NOT GOOD
CH A R G E
(C H E C K )
L EV E L
E LE C TR O L YT E
(C H E C K )
AL L C E LL S
> 1.5 0 V
AN Y C EL L
<1 .5 0V
INS U L AT IO N
CHECK
(C H E C K )
S P E CIA L
T E S T ING
(C H E C K )
*
C H EC K C EL L N U T
TO RQ UE
(C H E C K )
RETURN TO
S E R VIC E
NO T E S : R ec ord a ll disch arge da ta in b a ttery lo g b o o k. * = R e en try p oint fro m SP E C IA L T E S T IN G
Test procedure Block Diagram
Figure 506
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Dec 12/97
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
B.
Electrolyte Level Adjustment
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE
LOOSENED OR REMOVED; CONTACT OF ELECTROLYTE
WITH SKIN CAN CAUSE SEVERE BURNS.
CAUTION:
(1)
BATTERY MUST BE FULLY CHARGED BEFORE ADJUSTING
ELECTROLYTE LEVEL.
To perform the electrolyte leveling procedure, the indicator level
assembly (P/N 21961-000) included in the battery maintenance kit
(P/N 23249-000) must be modified per instructions below .
(a)
Measure 1 3/8 inches (34.93 mm) from the tip of the tube and
make a mark.
(b)
Drill a 3/32 inch (2.38 mm) hole through one side of the tube at
the mark as shown in Figure 508.
(2)
Before the adjustment of the electrolyte level, remove the vent valves
(250) with the special, plastic vent valve wrench (20) supplied with the
unit. Immerse the valves (250) and their o-rings (260) in distilled or
deionized water, and let them soak to dissolve any salts. Cover the
cells (240) with a clean damp cloth to prevent entry of foreign matter.
(3)
Remove the cloth only while checking electrolyte level. Check the
liquid level in the cell (240) by inserting the modified indicator level
(P/N 21961-000) into the cell opening until the tip of the tube rests on
the bottom of the plastic baffle inside the cell (Figure 508). Squeeze
the ball and check for any liquid in the indicator level. If the liquid level
is too low, the indicator level will remain empty, indicating that the hole
in the tube did not reach the liquid in the cell. Any excess liquid in the
cell will be drawn into the indicator level until the electrolyte is level with
the hole in the tube. This is the correct level for the electrolyte.
(4)
If the electrolyte is low, use the following procedure to fill the cell
(240) to the correct level:
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COMPONENT MAINTENANCE MANUAL
43B050LB01
NOTE:
Use only distilled or demineralized water. The
3
quantity (in cm ) of distilled water required to fill
the cell (240) to the correct level will serve as an
approximate guide to the amount required for the
remaining cells (240). The water in each cell
(240), however, must be adjusted individually to
the correct level.
(a)
Draw an amount of the distilled water into the indicator level and
inject it into the cell (240).
(b)
With the tip of the indicator level resting on the bottom of the
baffle as shown in Figure 508, fully squeeze the bulb of the
indicator level and release.
(c)
If the indicator level remains empty, repeat steps (a) and (b) to
achieve the correct level.
(d)
At the point in step (b) when some excess liquid is drawn into
the indicator level, the correct level for that cell has been
reached. Expel the excess liquid into a container for later
disposal.
2.38 mm
34.93 mm
Position of Syringe in Cell Vent Seat
Figure 508
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(C)
Initial Discharge (Capacity Test)
The purpose of this discharge procedure is to determine the initial capacity of
a new/stored battery or the electrical characteristics of a battery when it is
removed from the aircraft; either for routine maintenance or for investigation
of a malfunction. The results of this initial discharge will determine the steps
that should be taken.
(1)
Discharge the battery at one of the current rates shown in Figure 509
until the battery reaches 11 V.
NOTE:
(2)
Monitor individual cell (240) voltages periodically during the discharge,
and record the time at which the first cell (240) reaches 1.0 V. Stop
the discharge when the battery voltage reaches 11 V.
NOTE:
(3)
It is important that the discharge current be continually
maintained at the selected value, and that the time of
discharge be measured accurately.
If a cell (240) goes to zero volts or reverses polarity
during the battery discharge, short out the cell's (240)
terminals for the remainder of the discharge.
If the "weakest" cell (240) fails to meet the required minimum
discharge time shown in Figure 509, proceed to Special Tests.
INITIAL DISCHARGE (Capacity Test)
DISCHARGE RATE
MINIMUM TIME FOR FIRST CELL TO
(AMPS)
DISCHARGE TO 1.0 VOLT
25
104 MINUTES
50
51 MINUTES
Discharge Rate
Figure 509
(4)
Residual Discharge
Discharge each cell (240) in the battery to zero volts using one of the
following procedures:
NOTE:
It is not necessary to have a rest period between
discharge and residual discharge.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(a)
Continue to discharge the battery, and as each cell (240)
reaches 1.0 V, connect a 1.0 W (3.0 watt minimum) resistor
across its terminals. Leave the resistors in place for 16 hours to
allow the cells (240) to completely discharge and the battery to
cool.
NOTE:
(b)
4.
Attach the resistors with alligator clips to make a
firm connection.
Continue to discharge the battery, and as the battery reaches
10 V, insert a shorting clip between the main terminals. Leave
this clip on for 16 hours to allow the battery to completely
discharge and cool.
Testing
A.
Test Conditions
Conduct all tests with the battery temperature at 60°F to 80°F
(15.6°C to 26.7°C).
B.
Test Equipment
Refer to Table 901(B) for test equipment recommendations.
C.
Connector and Sensor Assembly
(1)
Identification of the Connector and Sensor Assembly
Prior to performing testing on the Connector and Sensor Assembly,
you must determine which style sensor is installed in the battery. The
identification can be accomplished in two ways:
(a)
Visually
NOTE:
1
The connector and sensor assembly must be
removed to be visible for this identification.
When viewing the connector in its normal mounting
position, the original style connector and sensor
assembly (190) (GE P/N 139C2495ABG1), will have two
wires exiting the potting compound on top of the sensor
mounting bracket.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
2
(b)
When viewing the connector in its normal mounting
position, the newer style connector and sensor assembly
(7) (P/N 022036-000) will have two wires exiting the
potting compound on the bottom of the sensor mounting
bracket.
Electrically
Using an ohmmeter, connect one lead to pin C of the connector
(7) and the other lead to pin E. The reading on the ohmmeter
will determine which style connector is present.
(2)
1
If the original style sensor is present the ohmmeter
should show open circuit (no movement of the needle
toward zero)
2
If the newer style sensor is present, the ohmmeter should
show a resistance value of 2 kW ±20 W.
Testing of the Connector and Sensor Assembly
(a)
Testing the original style sensor (GE P/N 139C2495ABG1)
This test is designed only to detect open circuit or short circuit
conditions in the connector and sensor assembly. It does not
verify full operation of the sensor. The procedure can be
accomplished without disassembly of the battery. Full operation
of the sensor can be verified by completing the testing
procedure in 4.C.(2)(c).
NOTE:
If the sensor fails any part of the following tests,
the sensor must be replaced with an original SAFT
replacement (P/N 022036-000).
NOTE:
The voltmeter range is to be between 1,000 ohms
and 20 kW per volt.
1
Measure and note the battery voltage. The battery
voltage must be at least 13 volts to perform this test.
2
Connect pin E of the sensor connector to the negative
terminal of the battery using a jumper cable.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
(b)
3
Connect pin C of the sensor connector to the negative
terminal of the voltmeter.
4
Connect the positive terminal of the voltmeter to the
positive terminal of the battery. Note the reading on the
voltmeter.
5
If the voltmeter reading in step 4 is greater than 1 volt,
the circuit is not open. If the difference between the
voltage reading in step 1 and the voltage reading in step
4 is greater than 1 volt, a short circuit does not exist.
6
Using an ohmmeter, measure the resistance between pin
G of the sensor connector and the positive terminal of the
battery. The reading should be 1 kW ±10%.
Testing of the new style Connector and Sensor Assembly
(P/N 022036-000)
This test is designed to check the components of the Connector
and Temperature Assembly. This procedure can be
accomplished without disassembly of the battery. Full operation
of the sensor can be verified by the completion of the testing
procedures in 4.C.(2)(c).
(c)
1
Measure the resistance between Pin C of the connector
and Pin E. The resistance will be 2 kW +20 ohms.
2
Measure the resistance between Pin G of the connector
and the positive terminal of the battery. The resistance
will be 1000 W +100 ohms.
3
Measure the resistance between Pin C of the connector
assembly and the battery case, then between Pin E of
the sensor connector and the battery case. Each of
these readings should be greater than 20 MW.
Low temperature testing of the Connector and Sensor Assembly
This test should be used for both the original style sensor and
the newer style sensor. Disassembly of the battery and removal
of the Connector and Sensor Assembly is required for this
procedure.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
1
Remove the sensor assembly from the battery
(DISASSEMBLY).
2
Connect the sensor assembly as indicated in the circuit
diagram of Figure 511.
3
Adjust the variable resistor to obtain a current of 17.5
mA.
4
Immerse the sensor unit (NOT THE CONNECTOR) in a
mixture of ice and water that is contained in a glass or
plastic container.
5
Allow the sensor to remain in the ice and water mixture
for 10 minutes while stirring the mixture. Readjust
current if necessary to maintain 17.5 mA.
6
Note the voltage between pin “C” and pin “E”. To be
acceptable, the voltage measurement must be between
11.09 and 11.28 volts.
R1
1000 W
R2
200 W
+
A
PIN C
TEM PER A TU R E
SEN SO R
A SSEM BLY
A P P R O X IM A T E L Y
30 V D C
PO W ER SU PPLY
-
V
P IN E
Circuit Diagram, Temperature Sensor
Figure 511
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COMPONENT MAINTENANCE MANUAL
43B050LB01
D.
Vent Valve Pressure Test
Check the operation of the vent valves as follows:
E.
(1)
Prepare a fixture from PVC pipe and fittings with an end adapter
configured on the inside to match the vent valve locking mechanism.
(2)
Affix the valve (250) with its o-ring (260) into the adapter end of the
pressure test fixture.
(3)
Attach the fixture to a compressed air line through an adjustable
pressure-reducing valve.
(4)
Immerse valve (250) and end of fixture in water, and slowly raise the
pressure. Make sure the valve opens between 2 to 10 psi (0.14 to 0.7
bar).
(5)
Reuse only those vent valves (250) found to open in the 2 to 10 psi
(.014 to 0.7 bar) range. Re-soak vent valves that do not open at 10 psi
(0.7 bar) until they do open (refer to Cleaning). Discard vent relief
valves (250) which are not gas tight at low pressure.
Battery Insulation Resistance
NOTE:
A BREAKDOWN IN ELECTRICAL INSULATION BETWEEN
THE CELLS AND THE BATTERY CASE (10) WILL RESULT IN
“LEAKAGE” CURRENT, WHICH OVER TIME WILL
DISCHARGE THE BATTERY.
(1)
Set up the analog multi-meter (volt, ohm, amp) and meter leads for a
measurement of 250 mA.
(2)
Connect the negative lead from the meter to the battery container.
(3)
Touch the positive lead from the meter to the positive terminal of the
battery and then to the positive terminal of each cell (240).
(4)
If while performing the above, there is any deflection of the needle
from zero the insulation should be considered defective. Disassemble
and clean the battery (DISASSEMBLE and CLEANING).
(5)
If, after cleaning the battery and assuring that everything is dry, a
leakage current is still indicated by a deflection of the needle, one or
more cells (240) is defective. Isolate and replace the defective cell(s)
(240) (DISASSEMBLY, ASSEMBLY).
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COMPONENT MAINTENANCE MANUAL
43B050LB01
(6)
F.
5.
As an alternative to the above test: after completely reassembling the
battery, measure the insulation resistance between the block of cells
(240) and the metal box (10). The value measured must be at least
10 MW under 250 V continuous using an ohmmeter.
Polarization Test
(1)
Charge the battery at 5.0 A for 1.5 hour.
(2)
Leave the battery in open circuit condition for 1 hour.
(3)
Measure the open voltage of each cell (240).
(a)
If the cell (240) open voltage is 0 V or reversed carry out a
special test and proceed to repair.
(b)
If every cell (240) presents an open voltage above 0 V, charge
the battery.
Special Testing
These procedures are to be followed if deemed necessary per Fig 506.
A.
Discharge the battery per one of the methods in Figure 509.
NOTE:
It is not necessary to monitor time.
B.
Perform the residual discharge procedure described in Section 3.C.
C.
Charge the battery using one of the methods in Figure 505.
D.
Perform an additional overcharge period of 4 hours at 0.1C1A (5.0 amps).
During this overcharge procedure, measure each cell voltage every 15-20
minutes making notation of each reading. Mark for replacement any cell that
expresses a drop in voltage during this overcharge procedure, or any cell with
an end of charge voltage less than 1.5 V.
NOTE:
A drop in voltage during overcharge indicates a defect in the
gas barrier that is neither recoverable nor repairable. Cells with
this condition must be replaced with factory new cells
(DISASSEMBLY, ASSEMBLY).
NOTE:
If three cells (240) over the life of the battery are replaced it is
best to assume that all of the original cells are in unsatisfactory
condition and should be replaced.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
E.
In order to place battery in service after the Special Testing procedure has
been completed, the battery must be allowed to cool. Then, follow Figure 506
starting at "*" (reentry point).
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COMPONENT MAINTENANCE MANUAL
43B050LB01
REPAIR
1.
Temperature Sensor Assembly
NOTE:
The ( ) part identification numbers are IPL, Figure 1 item numbers.
If any part of the temperature sensor assembly (190) is damaged, the entire
assembly must be replaced. (CHECK).
2.
Cell Assembly
A.
Repair to cell assembly (240) is limited to replacement of defective vent valve
o-ring (260) and the complete valve assembly (250).
NOTE:
Replacement of the o-ring (260) is limited to the large o-ring on the
outside of the vent valve seat (250). The small o-ring visible through
the see through vent valve is not replaceable.
NOTE:
Replacement of complete cell (240) assemblies must be with a factory
new cell (240).
B.
When inspection reveals electrolyte leakage from the cell (240) at the vent
hole opening, replace the defective o-ring (260) as follows:
(1)
Using the vent-valve wrench (20), loosen and remove the vent valve
(250) from the cell assembly (240).
(2)
Cover the cell (240) with a damp, clean cloth to prevent any foreign
particles from falling into the cell (240).
(3)
Remove the defective o-ring (260) from the vent valve (250), and
install a new o-ring (260) onto the valve.
(4)
Remove the damp, clean cloth from the cell (240), and insert the vent
valve (250) into the cell assembly (240). Using the vent valve wrench
(20), tighten the vent valve (250) securely in place. To ensure they are
tightened properly, use only finger pressure on the wrench.
(5)
Clean cell assembly (240) in accordance with CLEANING.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
3.
Physical damage
When necessary, remove minor dents in the battery cover (50) and battery case (10)
using a hard rubber mallet.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
ASSEMBLY
1.
General
This section contains assembly instructions necessary after disassembly and repair
with the battery case positioned such that the receptacle adapter port and auxiliary
connector port are facing the technician.
2.
Liners and Temperature Sensor Assembly
NOTE:
The ( ) part identification numbers herein are IPL, Figure 1 item
numbers.
Install liner (120), foam fillers (60 through 110), temperature sensor assembly (190),
and cell assemblies (240) into the battery case (10), using the following steps. Refer
to Figure 703.
NOTE:
Make sure all components are clean and dry before re-assembly.
A.
Insert one edge of bottom liner (120) into battery case (10) from either the left
or right side, then slide the liner under the cell (240) partition.
B.
Insert foam filler (100), 2 each, into battery case (10)
C.
Insert sensor assembly (190) into battery case (10). Ensure that the sensor
plate is on the outside of the partitions of the battery case (10) and the
dimples on the sensor plate mate with the holes in the battery case (10)
partitions.
D.
Insert foam filler (70) into battery case (10)
E.
Insert sensor connector (190) through hole in battery case (10). Ensure that
the two wire leads from the sensor plate are placed in the indention of foam
filler (70) and the third wire lead of the sensor assembly that has the
compression lug attached is free.
(1)
Install washer and nut (190.10) to the sensor connector and torque to
40 +2 lb-in (5 +0.25 Nm)
F.
Insert foam filler (90) in between center partition of battery case (10) from
below the partition and push upward.
G.
Insert the remaining foam fillers (60, 80, 100) into battery case (10).
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COMPONENT MAINTENANCE MANUAL
43B050LB01
H.
Insert main battery connector (130) with gasket (140) attached. Insert screws
(150) and torque to 20 +1 lb-in (2.5 +0.12 Nm)
(1)
3.
Insert the remaining wire from the sensor assembly (190) to the main
connector (130) using washer (210), lock washer (220) and pan head
screw (200). Torque pan head screw (200) to 10 +0.5 lb-in
(1.2 +0.06 Nm).
Cells
A.
Install cells (240) making sure of correct polarity per Figure 703.
B.
Install intercell links (300, 310, 320) per Figure 703.
C.
Install washer (180, 290), lock washer (170, 280) and screws (160, 270)
(IPL Fig 1).
WARNING: DO NOT CROSSTHREAD TERMINAL SCREWS
(1)
Torque screws (160, 270) to 96 +4.8 lb-in (11.9 Nm +0.6 Nm)
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COMPONENT MAINTENANCE MANUAL
43B050LB01
#7
#6
#8
#5
#9
#4
#10
#3
#11
#2
#1
Cell Number and Polarity Orientation
Figure 703
D.
4.
Install the battery cover (50) onto the battery case (10) and secure in place by
fastening the latches.
Storage
Store battery assembly as follows:
A.
Storage area humidity should not be more than 90 percent.
B.
Battery may be exposed to temperature within the range of -67°F to 140°F
(-55°C to 60°C).
CAUTION:
MAXIMUM ACCUMULATED EXPOSURE TO TEMPERATURE
ABOVE 120°F (49°C) SHOULD NOT EXCEED 30 DAYS.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
C.
Store the battery in a discharge state. Install a shorting spring across the
battery receptacle terminals of main battery connector (130).
D.
Battery should be stored in original shipping container in accordance with
ATA-300 specification. Mark on container: FRAGILE DO NOT DROP, and
on top of container: STORE THIS SIDE UP ONLY.
E.
Active stand-by storage
CAUTION:
NICKEL-CADMIUM BATTERIES AUTOMATICALLY SELFDISCHARGE AT APPROXIMATELY 0.25% PER DAY AT 68°F
(20°C)
CAUTION:
USE OF A BATTERY WITHOUT THE PROPER WATER
LEVEL WILL CAUSE SEVERE DAMAGE TO THE BATTERY
AND SHORTEN LIFE
(1)
Saft vented cell batteries may be stored charged, ready for service in
the normal, upright or vertical position.
(a)
F.
Battery may be kept in a charged condition for a maximum
period of 90 days after service in the following conditions:
1
Storage temperature of <68°F (20°C)
2
Atmosphere free of acid, dust and dampness
3
No corrosive liquids or gases stored in the same room
4
After 90 days the battery must be charged and the water
level checked in accordance with procedures found in
CHECK
Inactive long term storage
Saft batteries are best kept discharged in the same packing in which they were
shipped.
G.
Shelf Life
Saft vented cell batteries may be stored, in the normal, upright or vertical position,
charged or discharged for a period of up to 10 years without damage.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
H.
Preparation for service after storage (other than active standby storage)
(1)
Check all vent valves (110) for white salt deposits. If such deposits are
evident:
(a)
Remove, clean, and test (CHECK) the vent valves (110).
(b)
Reinstall the vent valves (110) in the cells.
(2)
The battery temperature should be allowed to equalize to a range of
60°F (15°C) to 90°F (32°C) before charging.
(3)
Charge the battery (CHECK).
(4)
Adjust the electrolyte level (CHECK).
(5)
Completely discharge (deep cycle) the battery (CHECK).
(6)
Recharge the battery (CHECK).
(7)
If difficulty is experienced in charging (i.e. voltage plateau or
temperature rise) a new or in-service battery that has been in long term
inactive storage, the following procedure will apply:
(a)
Terminate the charge sequence where the difficulty occurs.
(b)
Completely discharge (deep cycle) the battery (CHECK).
(c)
Repeat the above charge/discharge sequence until the unit
accepts a full charge and delivers its rated capacity.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
FITS AND CLEARANCES
1.
Torque Table
Figure / Item Number
Torque Value
IPL 1
270
96 +4.8 lb-in (11.03 + 0.5 Nm)
2.
40 +2 lb-in (5 +0.25 Nm)
Name, Location
Screw, Socket Head
IPL 1
190.10
Nut, Sensor
Assembly
Screw, Sems
IPL 1
150
20 + 1 lb-in (2.5 + 0.12 Nm)
IPL 1
160
96 +4.8 lb-in (11.03 + 0.5 Nm)
Screw, Socket Head
IPL 1
200
10 +0.5 lb-in (1.2 + 0.06 Nm)
Screw, Pan Head
Fits and Clearances Table
No fits and clearances required.
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COMPONENT MAINTENANCE MANUAL
43B050LB01
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.
Special Tools
A.
2.
Battery Maintenance Kit
(1)
The Battery Maintenance Kit (SAFT P/N 023249-000) is required for
performance of the CHECK and DISASSEMBLY procedures. The kit
may be purchased from SAFT or SAFT's authorized distributors.
(2)
The following items are included in the SAFT 023249-000 Battery
Maintenance Kit.
NOMENCLATURE
SAFT PART NUMBER
Cell Removal Tool
022056-000
Indicator Level (Modified by
021961-000
customer per Figure 508)
Vent Valve Wrench
004414-001
O-Ring, Vent Valve (22 ea.)
012536-002
Battery Maintenance Kit
Table 901(A)
Required Test Equipment
NOTE: Test equipment having equivalent specifications can be used.
NOMENCLATURE
APPLICATION
DC Power Supply, regulated, Check / Fault Isolation
0-50 amp
Multimeter (V, ohm, Amps)
Check / Fault Isolation
(this can be replaced by the
individual meters below)
DC Voltmeter, (precision
Check / Fault Isolation
±0.5%), 0V - 2V / 0V - 5V and
0V - 50V scales required
Volt-Ohmmeter
Check / Fault Isolation
Thermometer, Immersion
Check / Fault Isolation
Ohmmeter
Check / Fault Isolation
250V
Required Test Equipment
Table 901(B)
24-34-04
PAGE 901/902
Aug 17/01
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
ILLUSTRATED PARTS LIST
1.
Introduction
A.
Purpose
(1)
B.
This section provides illustration and parts breakdown of the
43B050LB01 battery, which can be disassembled, repaired or
replaced, and reassembled.
Explanation and Usage of Section
(1)
Assembly Order Indenture System
The Indenture System used in the parts list shows the relationship of one part
to another. For a given item, the number of indentures depicts the
relationship of the item to the associated next higher assembly.
(2)
Effectivity Code
Reference letters (A, B, C, etc.) are assigned in the EFF CODE column to
each top assembly. The reference letter of the applicable top assembly is
also shown in the EFF CODE column for each detail part and subassembly
except that no reference letter is shown for detail parts and subassemblies
used on all top assemblies.
(3)
Quantity Per Assembly
The UNITS PER ASSY column shows the total number of units required per
assembly, subassembly, or sub-subassembly as applicable. The letters REF
indicate the item is listed for reference purposes.
(4)
Parts Replacement Data
Interchangeability information will be provided in a future manual revision if it
becomes applicable.
(5)
Service Bulletin Incorporation
Service Bulletin incorporation information applicable to the parts list will be
provided in a future manual revision if it becomes applicable.
24-34-04
PAGE 1001
Dec 12/97
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
(6)
Items Not Illustrated
Items not illustrated are indicated by a dash ( - ) ahead of the item numbers in
the FIG. and ITEM NO. column.
(7)
Alpha Variant Item Numbers
(a)
(b)
(8)
Alpha variants A - Z (except I and O) are assigned to existing
item numbers when necessary to show:
1
Added items
2
Service Bulletin modifications
3
Configuration differences
4
Optional parts
5
Product improvement parts (non-service bulletin)
Alpha variant item numbers are not shown on the exploded view
when the appearance and location of the alpha variant item is
the same as the basic item.
Vendors
The vendor of all parts shown in the parts list is as follows:
Vendor Code
NAME / ADDRESS
V09052
Saft America Inc.
711 Industrial Boulevard
Valdosta, GA 31601
USA
24-34-04
PAGE 1002
Dec 12/97
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
50
110
90
20
80
30
60
40
70
120
140
100
160
170
180
10
150
130
200
210
220
Battery, Exploded View
Figure 1 (Sheet 1 of 2)
24-34-04
PAGE 1003
Dec 12/97
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
190.10
250
190
270
300
280
290
260
310
240
320
Battery, Exploded View
Figure 1 (Sheet 2 of 2)
24-34-04
PAGE 1004
Dec 12/97
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
ILLUSTRATED PARTS LIST
FIG PART NUMBER
ITEM
1 43B050LB01
10 139C2480G13
20 162A7836P21
R
30 N76P16020
40 162A8080AEP74
50 149C1337G1
60 232A2201AFP21
70 232A2201AEP21
80 232A2201ADP22
90 232A2201AXP21
100 232A2201ADP21
110 232A2201ARP21
120 178A3377P46
130 162A8279G12
140 162A8089P21
150 N59P15006
190 139C2495ABG1
200 MS35233-26
NOMENCLATURE
12345
Nickel Cadmium Battery, 43B050LB01
. Case Assy Marked
(SUPSED BY Item 093422-000)
. Wrench, Vent Cap
(SUPSED BY Item 004414-001)
. Scr, Sltd Thk Scr Sst 10-32 X 1-1-2
(SUPSED BY Item 022105-000)
. Stopper (attaching parts)
(SUPSED BY Item 093704-000)
. Cover-Gasket Assembly
(SUPSED BY Item 022043-000)
. Filler
(SUPSED BY Item 022271-000)
. Filler
(SUPSED BY Item 021985-000)
. Filler
(SUPSED BY Item 022037-000)
. Filler
(SUPSED BY Item 022173-000)
. Filler
(SUPSED BY Item 022172-000)
. Filler
(SUPSED BY Item 022026-000)
. Insulation Shim
(SUPSED BY Item 013357-049)
. Receptacle and Term Assy (Attaching
Parts)
(SUPSED BY Item 022012-000)
. O-Ring
(SUPSED BY Item 093704-000)
. Scr, Sltd Ovh Crm Nkl Sst-Psvt
(8-32 X 3-8)
(SUPSED BY Item 093616-000)
. Connector and Sensor Assy (Attaching
Parts)
(SUPSED BY Item 022036-000)
. Scr, (V96906)(N186P13004)
(SUPSED BY Item 093015-003)
EFF
UNITS
CODE PER
ASSY
ref
1
1
1
1
1
1
1
1
1
2
1
AR
1
1
4
1
1
24-34-04
PAGE 1005
Aug 17/01
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
FIG PART NUMBER
ITEM
210 N400P7
220 MS35337-79
240 43B050AC01G2
250 123C9367G2
260 162A8089P23
270 N171P20010
280 N406P11
290 N400P11
300 162A7812P51
310 162A7812P52
320 162A7812P53
162A8080BAP1
147A7457P41
152B5024P21
MS35336-17
10a 093422-000
20a 004414-001
30a 022105-000
40a 093704-000
50a 022043-000
NOMENCLATURE
12345
. Washer, Flat (Crm Nkl SST-PSVT)(#6)
(SUPSED BY Item 092461-005)
. LK, Wash (V96906)(N406P7)
(SUPSED BY Item 092375-000)
. Cell 43B050AC01-G2
(SUPSED BY Item 021930-000)
.. Vent Cap Assy
(SUPSED BY Item 022221-000)
... O-Ring
(SUPSED BY Item 012536-002)
. Cap Scr Sch Chr Nkl Sst-Psvt
(1-4X28X5-8)
(SUPSED BY Item 093707-002)
. Lk Wash Spr -Psvt
(1-4-0.255X0.107X0.047)
(SUPSED BY Item 092456-000)
. Pw, Chr Nkl Sst-Psvt
(1-4-0.281X05.00X0.63)
(SUPSED BY Item 092488-000)
. Link
(SUPSED BY Item 022001-000)
. Link
(SUPSED BY Item 022002-000)
. Link (attaching parts for 18, 19, 20)
(SUPSED BY Item 022003-000)
. Spring Deleted
. Washer, Flat - Deleted
. Dust Cap Deleted
. LK Wash Tooth (V96906(N421P12)
Deleted
. Case Marked
(SUPERSEDES Item 139C2480G13)
. Wrench, Vent Cap
(SUPERSEDES Item 162A7836P21)
. Screw, Truss Head
(SUPERSEDES Item N76P16020)
. Stopper, Rubber
(SUPERSEDES Item 162A8080AEP74)
. Cover and pad
(SUPERSEDES Item 149C1337G1)
EFF
UNITS
CODE PER
ASSY
1
1
11
11
11
24
24
24
5
5
2
1
1
1
4
1
1
1
1
1
24-34-04
PAGE 1006
Aug 17/01
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
FIG PART NUMBER
ITEM
60a 022271-000
70a 021985-000
80a 022037-000
90a 022173-000
100a 022172-000
110a 022026-000
120a 013357-049
130a 022012-000
140a 093704-000
150a 093616-000
160a
170a
180a
190a
093707-002
092456-000
092488-000
022036-000
200a 093015-003
210a 092461-005
220a 092375-000
240a 021930-000
250a 022221-000
260a 012536-002
270a 093707-002
NOMENCLATURE
12345
. Foam Filler
(SUPERSEDES Item 232A2201AFP21)
. Foam Filler
(SUPERSEDES Item 232A2201AEP21)
. Foam Filler
(SUPERSEDES Item 232A2201ADP22)
. Foam Filler
(SUPERSEDES Item 232A2201AXP21)
. Foam Filler
(SUPERSEDES Item 232A2201ADP21)
. Foam Filler
(SUPERSEDES Item 232A2201ARP21)
. Liner Bottom
(SUPERSEDES Item 178A3377P46)
. Connector Adapter
(SUPERSEDES Item 162A8279G12)
.. Gasket
(SUPERSEDES Item 162A8089P21)
. Screw, Sems
(SUPERSEDES Item N59P15006)
. Screw, Socket Head
. Washer, Lock
. Washer
. Connector and Sensor Assembly
(SUPERSEDES Item 139C2495ABG1)
. Screw, Pan Head
(SUPERSEDES Item MS35233-26)
. Washer
(SUPERSEDES Item N400P7)
. Washer, Lock
(SUPERSEDES Item MS35337-79)
. Cell, 43B050AC01-2
(SUPERSEDES Item 43B050AC01-G2)
.. Valve, Vent
(SUPERSEDES Item 123C9367G2)
... O-ring
(SUPERSEDES Item 162A8089P23)
. Screw, Socket Head
(SUPERSEDES Item N171P20010)
EFF
UNITS
CODE PER
ASSY
1
1
1
1
2
1
1
1
1
4
2
2
2
1
1
1
1
11
1
1
22
24-34-04
PAGE 1007
Aug 17/01
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
43B050LB01
FIG PART NUMBER
ITEM
NOMENCLATURE
12345
280a 092456-000
. Washer, Lock
SUPERSEDES Item N406P11)
. Washer
(SUPERSEDES Item N400P11)
. Link
(SUPERSEDES Item 162A7812P51)
. Link
(SUPERSEDES Item 162A7812P52)
. Link
(SUPERSEDES Item 162A7812P53)
290a 092488-000
300a 022001-000
310a 022002-000
320a 022003-000
EFF
UNITS
CODE PER
ASSY
22
22
5
5
2
AR = As Required
24-34-04
PAGE 1008
Aug 17/01