COMPONENT MAINTENANCE MANUAL
43BO34LB03
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
43BO34LB03
Saft Part Number 021904-000
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Title Page-Page 1
July 21, 2003
Original Issue Date: May 5/70
COMPONENT MAINTENANCE MANUAL
43BO34LB03
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Original Issue Date: May 5/70
COMPONENT MAINTENANCE MANUAL
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RECORD OF REVISIONS
REV
NO.
1
2
3
4
5
6
ISSUE
DATE
05/05/70
10/15/97
07/01/98
04/11/00
09/23/02
07/21/03
INSERT
DATE
05/05/70
10/15/97
07/01/98
04/11/02
09/23/02
07/21/03
BY
REV
NO.
ISSUE
DATE
INSERT
DATE
BY
GE
Saft
Saft
Saft
Saft
Saft
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RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV NO
PAGE NUMBER
ISSUE DATE
BY
INSERT
DATE
BY
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SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
A00027
01-02
REVISION NUMBER
G
1
DATE BULLETIN
INCORPORATED INTO MANUAL
07/14/98
09/04/03
PRODUCT IMPROVEMENTS
Product improvements are incorporated using service bulletins and entered in the service bulletin list.
Product improvement highlights are as follows:
Service Bulletin 01-02 Revision 1 identifies the mandatory replacement of cap screws with hex head bolts
and the addition of a liner kit.
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LIST OF EFFECTIVE PAGES
SUBJECT
Title Page
PAGE
T–1
T–2
DATE
July 21/03
July 21/03
Record of
Revisions
RR – 1
RR – 2
July 21/03
July 21/03
Record of
Temporary
Revisions
RTR – 1
RTR – 2
July 21/03
July 21/03
Service Bulletin
List
SBL – 1
SBL – 2
July 21/03
July 21/03
List of Effective
Clearances
LEP – 1
LEP – 2
July 21/03
July 21/03
Table of Contents TC – 1
TC – 2
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July 21/03
Introduction
INTRO – 1
INTRO – 2
INTRO – 3
INTRO – 4
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July 21/03
July 21/03
July 21/03
1
2
July 21/03
July 21/03
Description and
Operation
Testing and Fault 1001
Isolation
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
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July 21/03
July 21/03
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July 21/03
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July 21/03
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July 21/03
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SUBJECT
Disassembly
PAGE
3001
3002
3003
3004
DATE
July 21/03
July 21/03
July 21/03
July 21/03
Cleaning
4001
4002
4003
4004
July 21/03
July 21/03
July 21/03
July 21/03
Check
5001
5002
5003
5004
5005
5006
5007
5008
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
Repair
6001
6002
July 21/03
July 21/03
Assembly
7001
7002
July 21/03
July 21/03
Fits and
Clearances
8001
8002
July 21/03
July 21/03
Special Tools
9001
9002
July 21/03
July 21/03
Illustrated Parts
10001
10002
10003
10004
10005
10006
10007
10008
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
July 21/03
Storage and
Shipping
150001
150002
150003
150004
July 21/03
July 21/03
July 21/03
July 21/03
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TABLE OF CONTENTS
INTRODUCTION
1 – General
2 – How to Use the Manual
3 – Measures
4 – Units of Measure
5 – Abbreviations
6 – Definition
7 – Disposal
DESCRIPTION AND OPERATION
1 – Description
2 – Operational Characteristics
3 – Electrical Characteristics
4 – Detailed Description
TESTING AND FAULT ISOLATION
1 – General
2 – Testing
3 – Charge
4 – Electrolyte level and adjustment
5 – Discharge
6 – Temperature Sensor Testing (if applicable)
7 – Re-Entry Point
8 – Fault Isolation
SCHEMATIC AND WIRING DIAGRAMS
PAGE
Intro Page 1
Intro Page 1
Intro Page 1
Intro Page 1
Intro Page 2
Intro Page 3
Intro Page 3
Intro Page 3
OP Page 1
OP Page 1
OP Page 2
OP Page 2
OP Page 2
1001
1001
1001
1005
1006
1008
1009
1009
1011
NOT APPLICABLE
1 – General
2 – Safety
3 – Risks
4 – Safety Measures
5 – Disassembly
3001
3001
3001
3001
3001
3002
1 – General
2 – Equipment
3 – Materials
4 – Cleaning procedure
5 – Lubrication
4001
4001
4001
4001
4001
4003
1 – General
2 – Maintenance in Workshop
5001
5001
5001
DISASSEMBLY
CLEANING
CHECK
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
1 – General
2 – Equipment
3 – Repairs
6001
6001
6001
6001
1 – General
2 – Assembly Procedures
7001
7001
7001
1 – General
2 – Torque Specifications
3 – Fits and Clearances
8001
8001
8001
8001
REPAIR
ASSEMBLY
FITS AND CLEARANCES
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 – General
2 – Special Tools, Fixtures and Equipment
3 – Consumables
9001
9001
9001
9002
ILLUSTRATED PARTS LIST
1 – Introduction
2 – Vendor Code Index
4 – Detailed Parts List
10001
10002
10005
10007
SPECIAL PROCEDURES
NOT APPLICABLE
REMOVAL
NOT APPLICABLE
INSTALLATION
NOT APPLICABLE
SERVICING
NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION
1 – General Storage Information
2 – Preparation for Storage
3 – Active Stand-By Storage
4 – Trickle Charging
5 – Inactive Long-Term Storage
5 – Preparation for Use after Storage
6 – Packing and Transporting
REWORK (Service Bulletin Instructions)
15001
15001
15001
15001
15003
15003
15004
15004
NOT APPLICABLE
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
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 is a workshop. It does not describe
maintenance on components when they are installed in the aircraft.
C. Only approved technicians with the necessary skills should perform maintenance as described
in this manual.
D. Aircraft Maintenance Task Oriented Support System (AMTOSS) is not supported in this
manual.
E. This manual contains the following:
•
•
•
Technical data for components
Maintenance and repair procedures for components
An Illustrated Parts List (IPL) with data for parts and components. Parts are identified
in all sections of the manual by the IPL figure 1 item number.
F. Verification of DISASSEMBLY, TESTING, AND FAULT ISOLATIONS, 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 you model battery. Look for the model
number on the Title Page.
B. If you need to identify a part or 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 notation before you perform work on the component.
3.
Measures
A. 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 parentheses.
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43BO34LB03
4.
Units of Measure
A.
S.I. Units
A
Ah
C1A
C1Ah
g
N
N•m
Pa
VDC
°C
%
Ω
mm
B.
U.S. Units (Imperial)
ft
in
lb
Lb●in
Lb●ft
InHg
Psi
°F
C.
Ampere
Ampere hour
Battery rated current
Battery rated capacity for one hour
Gram
Newton
Newton-Meter
Pascal
Volt direct-current
Degree Celsius
Per cent
Ohm
Millimeter
Foot
Inch
Pound
Inch pound
Foot pound
Inches of mercury
Pounds per in2
Degree Fahrenheit
Multiplying Prefixes
µ
m
Da
k
M
Micro
Milli
Deca
Kilo
Mega
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5.
Abbreviations
The abbreviations given below may be used in this manual:
AECMA
ATA
DIA
FIG.
IPL
Max.
MFR
Min.
No.
OD
P/N
PARA
REF.
S/A
TBD
V
6.
The European Association of Aerospace Industries
Air Transport Association of America
Diameter
Figure
Illustrated Parts List
Maximum
Manufacturer
Minimum
Number
Outside Diameter
Part Number
Paragraph
Refer to
Subassembly
To Be Defined
Voltage
Definition
This paragraph describes the notations used in this manual.
7.
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.
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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43BO34LB03
8.
Shop Verification
Testing and Fault Isolation……………..………………………………….Date:
TBD
Disassembly…………………………………………………………………Date:
TBD
Assembly…………………………………………………………………….Date:
TBD
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43BO34LB03
DESCRIPTION AND OPERATION
1
Description
A.
General
The Nickel Cadmium Battery (Saft type 43B034LB03 and General Electric type
43B034LB03) is used to start the APU and act as a standby power source when normal DC
power fails. It is a nickel-cadmium type with sintered plate construction, and uses a
potassium hydroxide electrolyte. The battery consists of a case, cover, and eleven (11) cell
assemblies.
B
Operation
The battery is kept charged on the aircraft by an on-board charger. The aircraft charger is
designed to reduce overcharging by regulating the duration of charge current. To
compensate for battery temperature changes, the charge rate is controlled by a temperature
sensor located under the battery. The batteries are located on trays under the floor in the
pilot’s compartment.
C
Characteristics
1.
Technical Data
Voltage: Nominal
14.0 Volts
Weight
19.55 kg (43 pounds) maximum
Dimensions (Maximum):
Height
Length
Width
252.50 mm (10.10 inches)
179.00 mm (7.16 inches)
217.50 mm (8.70 inches)
Number of Cell Assemblies
11
Cell Model
Rated Capacity
Saft-Type 34AC14-2
(Can also be marked 43B034AC14-2 or
43B034AC14-G2
35 Ah (1-hour rate)
Cell Consumable Electrolyte
36 cm3
Venting Pressure
N/A
Cell Assembly Case Material
Plastic
Battery Case Material
Nylon coated steel
Electrolyte
Potassium Hydroxide
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43BO34LB03
Temperature Range:
Discharging
Charging
Non-Operating
-17.77°C (0°F) to 57.22°C (135°F)
-17.77°C (0°F) to 57.22°C (135°F)
-53.89°C (-65°F) to 73.89°C (165°F)
Altitude Range
0 to 40,000 Feet
Humidity
100% within above temperature and
altitude limits
Electrolyte indicator
External sight gauge in each cell
Leading Particulars
Figure 1
2.
Operational Characteristics
•
3.
Operating temperature: -40°C to +71°C (-40°F to + 160°F)
Electrical Characteristics
Below is a listing of values used to service the battery:
Item
1 C1A
Value
35 Amps
Used For
Charge / Discharge
0.5 C1A
17.5 Amps
Charge
0.1 C1A
3.5 Amps
Charge
Charge/Discharge
Figure 2
4.
Detailed Description
The batteries have 11 cells housed in a nylon coated steel case.
The case is lined with liners and spacers supplied in a kit. 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.
The removable cover is attached to the case by four latches.
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TESTING AND FAULT ISOLATION
1.
General
This chapter provides the tests and inspection required to determine the condition of a unit
removed for maintenance (scheduled or unscheduled). The table in section 1000 (Fault Isolation)
can be used to assist in isolating and detecting faults noted during the maintenance process.
2.
Testing
A.
Equipment
(1)
Standard tools
- Standard mechanics tools
- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron
- Compressed air with manometer (0.1 to 1 bar (1.45 to 14.5 psi))
(2)
Special tools
When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS,
FIXTURES AND EQUIPMENT, identifies them.
- Discharge bench: constant current 0 - 50 A
- Power supply: 0 - 45 V, range 0 - 50 A
(3)
Instruments
- A multimeter, range 2 V to 50 V, 1% accuracy
- A megohmeter, range 0 - 50 MΩ @250 VDC, 3% accuracy
(4)
Environmental conditions for testing
- Ambient temperature: 20°C ± 15°C (68°F ± 27°F)
- Pressure: 85 to 106 Kpa (25.1 to 31.3 In Hg)
- Relative humidity ≤ 85%
B.
Precautions
Maintenance should be performed regularly per the aircraft manufacturer’s
recommendations, or as specified in this manual. The following precautions should be
observed to insure the proper operation of the battery:
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- Do not install the battery in an aircraft that is too hot (> 60°C (140°F)).
- Carefully follow aircraft installation instructions to ensure good airflow.
- Verify the capacity of the battery at specified intervals.
- Charge the battery in a battery shop.
- Maintenance should be performed per instructions found in the CHECK chapter to
verify:
Level of electrolyte
Torque on the connection nuts
Correct onboard charging
Battery capacity
C.
Testing procedures
(1)
Insulation test
(a) Place the leads of the megohmeter as indicated in figure 1001.
Check from the outer case (20) to each cell terminal. See Figure
1002 for information regarding minimum values.
+
MΩ
-
Figure 1001
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43BO34LB03
250 KΩ
Unacceptable
2 MΩ
10 MΩ
Can wait until next
To be cleaned
maintenance
In battery maintenance shop
Cleaning Required
Cleaning
Recommended
OK
Minimum value after
cleaning and drying
Acceptable
Fault Isolation
Insulation Test Parameters
Figure 1002
(2)
(3)
Polarization Test
(a)
Charge the battery at 3.5 A for 1.5 hours
(b)
Keep the battery in open circuit condition for 1 hour
(c)
Measure the open circuit voltage of each cell
(d)
If the open circuit voltage of any cell is 0 V (or negative polarity), perform a
Special Test (refer to paragraph (4)) and repair if necessary.
(e)
If every cell has an open circuit voltage that is greater than 0 volts, charge the
battery (refer to section 3).
Vent Valve Pressure Test
Check the operation of the vent valves as follows:
(a)
Prepare a fixture from PVC pipe and fittings with an end adapter configured on
the inside to match the vent valve locking mechanism.
(b)
Screw the valve (100) with its o-ring (110) into the adapter end of the pressure
test fixture.
(c)
Attach the fixture to a compressed air line through an adjustable pressurereducing valve.
(d)
Immerse valve (100) and end of fixture in water, and slowly raise the pressure.
Make sure the valve opens between 0.14 to 0.7 bar (2 to 10 psi).
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(e)
Reuse only those vent valves (100) found to open in 0.14 to 0.7 bar (2 to 10
psi) range. Re-soak vent valves that do not open at 0.7 bar (10 psi) until they
do open (refer to Cleaning). Discard vent valves (100) which are not gas tight
at low pressure.
NOTE: The Vent Valve Test is not required if the full set of used vent valves is replaced by a
brand new one each year during the General Overhaul or when there is evidence of
electrolyte overflow.
(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)
If the battery is discharged, charge the battery fully (refer to section 3) then
continue to step (b). If the battery is already charged, continue to step (b).
(b)
Continue to charge the battery at 3.5 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 5)
(f)
Replace any defective cells (Refer to DISASSEMBLY and ASSEMBLY).
(g)
Charge the battery (Refer to section 3).
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 (90) over the life of the battery are replaced, it is recommended that all
cells in the battery be replaced (DISASSEMBLY, ASSEMBLY).
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3.
Charge
A.
Flight Charge
The battery charge is normally maintained onboard by the electrical system or a dedicated onboard
charger.
NOTE: The decrease in the amount of water in the cells is in direct proportion to the
overcharge the battery receives.
B.
Ground Charge
The following charging procedures are to be carried out in an appropriately equipped workshop.
CAUTION: REMOVE THE COVER TO CHARGE BATTERY. THIS IS TO MAKE SURE THAT
HYDROGEN GAS WILL NOT COLLECT IN THE BATTERY CASE.
CAUTION: WHEN THE BATTERY IS CHARGED IN EXCESS OF THE TIMES AND RATES
LISTED IN THE TABLE BELOW, THE LIFE OF THE CELLS IS DECREASED.
(1)
Constant current charge
(a)
To charge a fully discharged battery, perform one of the Main Charge
procedures listed in the table below followed by the corresponding Final
Charge procedure.
CONSTANT CURRENT CHARGE
Main Charge
Final Charge (overcharge)
0.1 C1A 3.5 A
until 16.5 V as battery voltage
Minimum time: 10 hr
0.1C1A for 4 hours
3.5 A
Times:
Maximum time: 12 hr
0.5 C1A 17.5 A
until 16.8 V as battery voltage
Minimum time: 2 hr
Times:
Maximum time: 2 hr 30 min
1C1A 35.0 A
until 17.5 V as battery voltage
Minimum time: 1 hr
Times:
Maximum time: 1 hr 15 min
All cells must be above 1.50 V at end of charge
0.1C1A for 4 hours
3.5A
All cells must be above 1.50 V at end of charge
0.1C1A for 4 hours
3.5 A
All cells must be above 1.50 V at end of charge
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NOTE: If during the Main Charge, the battery has not increased to the required voltage in the
maximum charge time, proceed to the Final Charge. Do not continue to charge the battery at
the high rate. If at the end of the Final Charge, all cells are not above the required voltage,
refer to Fault Isolation.
(b)
(2)
4
For a battery not fully discharged or when the level of charge is unknown:
1
Discharge at 1C1A down to 20 V (refer to Discharge section 5)
2
Charge: Refer to B (1)(a) for constant current charging instructions.
Other types of Charging: In addition to the constant current method of charging, other
methods that fully charge the battery can be used. HOWEVER, IN EVERY CASE,
CELL VOLTAGE CHECKS (U > 1.5 V) AND ELECTROLYTE ADJUSTMENTS MUST
BE CARRIED OUT USING A FINAL CHARGE AT CONSTANT CURRENT: 3.6 A AT
0.1 C1A. If specific instructions are not given in the charger operating manual, Saft
should be contacted before charging.
Electrolyte Level Adjustment
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT CAPS ARE LOOSENED OR
REMOVED; CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE SEVERE BURNS.
CAUTION: BATTERY MUST BE FULLY CHARGED BEFORE ADJUSTING ELECTROLYTE
LEVEL.
(1)
To perform the electrolyte leveling procedure, the indicator level assembly (P/N
21961-000) must be modified per the following instructions and Fig 1005:
(a)
Measure 44.45 mm (1.750 inches) from the tip of the tube and make a mark.
(b)
Drill a 2.38 mm (3/32-inch) hole through one side of the tube at the mark as
shown in Figure 1005.
(2)
Before the adjustment of the electrolyte level, remove the vent cap assemblies (100)
with the vent-valve wrench (180) supplied with the unit. Immerse the vent cap
assembly (100) in distilled or deionized water and let them soak to dissolve any salts.
Cover the cell (90) with a clean damp cloth to prevent entry of foreign matter.
Remove the cloth only while checking electrolyte level.
(3)
Use the following procedure to level the electrolyte:
NOTE: Use only distilled or demineralized water. The water in each cell must be adjusted
individually to the correct level.
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(a)
With the tip of the indicator level resting on the bottom of the baffle as shown in
Figure 1005, fully squeeze the bulb of the indicator level and release.
(b) If the indicator level remains empty, follow step (c) and (d) to achieve the correct
level. If electrolyte is drawn into the bulb, repeat step (a) until no more liquid is
drawn into the indicator level. This is when the correct level has been reached.
Expel any excess liquid into a container for later disposal.
(c) Draw a small amount (about 5 cm3) of the distilled water into the indicator level
and inject it into the cell assembly (90).
(d) With the tip of the indicator level resting on the bottom of the baffle as shown in
Figure 1005, fully squeeze the bulb of the indicator level and release. At the
point when no more liquid is drawn into the indicator level when the bulb is
released, the correct level for that cell has been reached. Expel any excess
liquid into a container for later disposal.
2.38 mm
Position of Syringe in Cell Vent Seat
Figure 1005
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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 (noted on the battery label).
(1)
For Initial Discharge (from aircraft or storage):
(a)
Discharge the battery at 1C1A down to 11 V, monitoring the time from the start
of the discharge to the time the battery voltage (at the main terminals) reaches
11 V.
(b)
The time should be greater than 30 minutes. If not, one of the following may be
the cause:
There was a discharge performed after the last use of the battery onboard
the aircraft
The aircraft charger may not be functioning properly
If the battery was left idle for a time, self-discharge occurred
The battery cells may be imbalanced and need servicing
(2)
For Capacity Test
(a)
Discharge the battery at 1C1A, monitoring the time from the start of the
discharge to the time any of the cells voltage falls below 1 V. Mark the time any
cell in the battery reads below 1 V.
Each cell in the battery should maintain a voltage higher or equal to 1 V for a
full 60 minutes of discharge at 1C1A (refer to Discharge Table). If one or more
cells should fall below 1 V in less than 60 minutes, refer to Section 1000
(FAULT ISOLATION).
NOTE: Repeating the charge and full discharge of a battery that does not pass capacity test may
recover lost capacity. However, if the capacity continues to decline, refer to Section 1000
(FAULT ISOLATION).
DISCHARGE RATE
(AMPS)
DISCHARGE TIMES
MINIMUM TIME FOR FIRST CELL TO DISCHARGE
TO 1 VOLT
8.75
17.5
35
204.0 MINUTES
102.0 MINUTES
51.0 MINUTES
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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.
(1) As each cell is discharged to 1 V, connect a resistor approximately 1 Ω 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.
C.
Battery Cover Gasket Resistance (Insulation Test)
(1)
Measure the resistance with an ohmmeter between the case (20) and the cover (30)
by taking measurements at random locations at least one inch (25 mm) apart. The
resistance value must exceed 200 kΩ. Should the value be <200 kΩ, the gasket should to
be replaced.
NOTE: If the gasket has come loose from the cover, it must be removed, cleaned, and
bonded to the cover (REPAIR).
6.
Temperature Sensor Testing
These batteries are not equipped with an auxiliary temperature sensor. For temperature
monitoring, consult the Aircraft Maintenance Manual or the aircraft OEM.
7.
Re-entry Point
To continue maintenance, allow the battery to cool then proceed per Figure 1001 starting at “*”
(reentry point).
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43BO34LB03
NEW
OR
FROM
LONG TERM
STORAGE
REMOVED
FROM
AIRCRAFT
CHECK CELL NUT
TORQUE
CHECK CELL NUT
TORQUE
INITIAL
DISCHARGE
CHARGE
RESIDUAL
DISCHARGE
INSULATION
TEST
ADJUST
ELECTROLYTE
CELL
VOLTAGE
> 1.50 V
VENT
CAP
CLEANING
CELL
VOLTAGE
< 1.50 V
*
INITIAL
DISCHARGE
LEVEL
ELECTROLYTE
PASS
FAIL
CHARGE
CONTINUE
AT RESIDUAL
DISCHARGE
UNDER
“REMOVED
FROM
AIRCRAFT”
ADJUST
ELECTROLTYE
INSULATION
TEST
CHECK CELL
NUT TORQUE
CHARGE
SPECIAL
TESTING
CELL
VOLTAGE
> 1.50 V
*
CELL
VOLTAGE
< 1.50 V
SECOND
DISCHARGE
PASS
FAIL
CHARGE
LEVEL
ELECTROLYTE
CHECK CELL NUT
TORQUE
RESIDUAL
DISCHARGE
SPECIAL
TESTING
PLACE IN
SERVICE
RETURN TO
SERVICE
NOTES: Record all discharge data in battery log book.
Testing procedures are contained in TESTING AND FAULT ISOLATION
*
* = Reentry point from SPECIAL TESTING
Test procedure Block Diagram
Figure 1001
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8.
Fault Isolation
A.
Battery Electrical Faults
PROBLEM
(1) Zero battery open-circuit
voltage
(2) Zero volts with the battery set
to “discharge”
PROBABLE CAUSE
(a) Defective electrical
connection (no contact made).
CORRECTION
Check electrical contacts, links
and torque of nuts (refer to FITS
AND CLEARANCES).
(b) Link loose or broken
Verify the nuts have the proper
torque (refer to FITS AND
CLEARANCES).
Perform an Insulation Test and
recharge the battery (refer to
TESTING AND FAULT
ISOLATION).
(a) Battery fully discharged
(b) Battery circuit open or
connection defective
(c) One or more cells dry
(3) Low insulation
B.
(a) Leakage of electrolyte
Examine the connection and
links. Verify the terminal nuts
have proper torque (refer to FITS
AND CLEARANCES).
See section B (Cell faults).
Check electrolyte level (refer to
TESTING AND FAULT
ISOLATION).
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING). Perform an
electrolyte level check (refer to
TESTING AND FAULT
ISOLATION).
Cell Faults
PROBLEM
(1) Excessive water
consumption.
PROBABLY CAUSE
(a) Excessive charge or
charging at high temperatures.
CORRECTION
Examine the cause of the
excessive charge. If necessary,
adjust the maintenance interval.
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PROBLEM
(2) The variation of water
consumption in individual cells
exceeds ±25% of the average
consumption for all cells.
PROBABLE CAUSE
(a) More than 25% than the
average: cell leakage
CORRECTION
Perform an Insulation Test.
Disassemble and replace faulty
components as necessary
(b) 25% (or less) than the
average: cell(s) with damaged
separators
Perform the Special Test (refer
to TESTING AND FAULT
ISOLATION). Replace cells if
necessary
(c) Previous maintenance was
not performed or performed
incorrectly
Note the cell location and check
the level of water consumption
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 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
(5) Low capacity cell (the cell
shows a reversed voltage or a
correct polarity voltage of less
than 1 V after a discharge at
1C1A for the specified period of
time).
(6) Cell with an excessively
swollen case.
(7) Cell with zero voltage when
the battery circuit is open
(b) The cell has reached its end
of serviceable life.
(a) Usual wear after long service
life.
(b) Unusual operation, operating
at high temperatures or with low
electrolyte.
(a) Cell operated with low
electrolyte level; deterioration of
separators and damaged plates
(a) Short-circuited cell.
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY)
Perform the Special Test (refer
to TESTING AND FAULT
ISOLATION). If necessary,
replace the cell(s).
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY).
Replace the cell (refer to
DISASSEMBLY and
ASSEMBLY).
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C.
Physical Faults
PROBLEM
(1) Leakage of electrolyte.
(2) Electrolyte found in the
battery case.
(3) Corrosion on the links.
PROBABLE CAUSE
(a) Incorrect adjustment of
electrolyte level
CORRECTION
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(b) Cell polarity incorrect during
high-rate discharge (for example,
during the engine start).
Investigate the cause of the
excessive discharge.
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(c) Excessive overcharge or high
overcharge at high
temperatures.
Investigate the cause of
excessive charge. If necessary,
adjust the maintenance interval.
Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING).
(a) Damaged cell case
Replace the cell if necessary.
Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
(b) Leakage of electrolyte
Perform an electrolyte level
check and disassemble and
clean the battery (refer to
DISASSEMBLY and
ASSEMBLY)
Make sure the battery test
bench, test room, and storage
areas contain no materials that
can release acid fumes.
(a) Operation in acid
environment
(b) Mechanical damage to the
nickel plating
(4) The links show signs of
overheating
(a) Loose terminal nuts
(5) Case Deformed
(a) Physical damage
(b) Swollen cells
Replace the damaged links
(refer to DISASSEMBLY and
ASSEMBLY)
Verify the torque on the nuts
(refer to FITS AND
CLEARANCES)
Disassemble and straighten
case (refer to DISASSEMBLY
and ASSEMBLY)
Replace the cell if necessary.
Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
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D.
Vent-valve Faults
PROBLEM
(1) Valve open pressure > 0.7
bar (10 psi) or stays closed
(2) Valve stays open at a
pressure < 0.14 bar (2 psi).
PROBABLE CAUSE
(a) Clogged valve
(a) Pierced valve
CORRECTION
Clean the valve (refer to
CLEANING).
Replace the valve if cleaning is
not successful.
Replace the valve
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DISASSEMBLY
1.
General
WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A COMPLETELY
DISCHARGED BATTERY (REFER TO TESTING AND FAULT ISOLATION)
Refer to the TESTING AND FAULT ISOLATION chapter to determine the malfunction and
necessary level of disassembly required.
The figures and item numbers used in this chapter correspond to those of the ILLUSTRATED
PARTS LIST (IPL).
2.
Safety
The safety regulations are different from one country to another. Check local regulations for those
that apply.
3.
Risks
There are three types of risks involved in nickel-cadmium battery maintenance:
A.
Physical
•
•
B.
Electrical
•
•
C.
Don’t wear rings, watches, chains, or belt buckles
Use insulated tools (the use of open end or box end wrenches is prohibited)
Chemical
•
•
4.
Handling: Lift with your legs and not your back
Wear protective shoes
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.
Safety Measures
•
•
•
•
The electrolyte is caustic and can cause severe burns. If electrolyte comes in contact with
the skin, flush the affected area with water and neutralize the solution with acetic solution,
vinegar, lemon juice, or with boric acid solution at 10% concentration.
If the electrolyte comes in contact with the eyes, flush with water for at least 15 minutes
and contact a physician.
Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit.
Dilute the solution with water or milk. Contact a physician immediately.
Contact with nickel or potash can cause chronic eczema.
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•
5.
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.
Disassembly
A.
Equipment
(1)
Standard tools
•
•
•
•
•
•
(2)
Standard mechanic’s tools.
Safety gloves.
Protective goggles.
Safety shoes.
Eyewash.
Protective apron
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 cover (30) by opening latches and lifting cover from marked case (20).
(2)
Main battery connector-receptacle
(3)
(a)
Remove screws (70) from main battery connector receptacle (60).
(b)
Remove bolts (140) from terminals and remove intercell connector links (150).
(c)
Remove battery connector receptacle (60).
Remove the cell assembly (90) from the marked case (20) as follows:
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT CAPS ARE LOOSENED OR
REMOVED: CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE SEVERE BURNS.
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(a) Using the vent wrench (180), loosen the vent cap assembly (100) of each cell
assembly (90) to relieve any pressure; then re-tighten vent cap assembly (100).
(b)
Remove bolts (140), lock washers (130) and flat washers (120) from the cell
assemblies (90).
(c)
Remove intercell connector links (150, 160 & 170) from cell assemblies (90).
(4) Remove cell assemblies (90) from the marked case (20) using the cell puller (P/N
022056-000) with a steady, straight upward pull.
NOTE: Cell removal is easier if the center cell in each row is the first removed.
NOTE: Do not attempt further disassembly of the cell assembly. Cells are non-repairable
items and must be replaced if defective.
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CLEANING
1.
General
This chapter provides instructions for the cleaning and preservation of the battery components.
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED
PARTS LIST (IPL).
2.
Equipment
•
•
•
•
•
3.
Safety gloves.
Protective goggles.
Safety shoes.
Eyewash.
Protective apron.
Materials
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS
THAT CONTAIN CHLORIDES. SOME CHEMICALS CAN DEGRADE METAL PARTS
CAUSING PREMATURE FAILURE.
•
•
•
•
•
•
4.
Ordinary water.
Distilled or deionized water (M01).
Neutral soap (M02).
Non-fluffy swab.
Non-wire brush.
Rubbing alcohol (isopropyl)
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 (30)
CAUTION: TO PREVENT SHORT-CIRCUIT, USE A RUBBER TUBE OR AN
INSULATED NOZZLE TO DISPENSE COMPRESSED AIR.
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(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 (if installed).
(3)
Battery Connector Receptacle (60)
(a)
B.
Clean connector pins with rubbing alcohol to clean off any accumulated grease
and/or dirt. Inspect the pins for damage, which includes 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.
Thorough Cleaning
WARNING: TO AVOID ELECTRIC SHOCK, 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 cap assembly (100) which must be cleaned while cells are in the
case.
(a)
Cell Assemblies (90)
1
Make sure the vent cap assembly (100) is tight.
CAUTION: DO NOT SOAK THE CELLS IN WATER. TAP WATER ENTERING THE
CELL WILL CONTAMINATE ELECTROLYTE.
(b)
2
To easily remove all the electrolyte and mineral salts from the terminals,
cover, and sides of the cell cases, clean in distilled or de-ionized water
(M01) with a soft brush.
3
Rub the cell with a cloth and let dry.
Case (20) and handle (if equipped)
1
(c)
Bolts (14), flat washers (120), and lock washers (130), and intercell connector
links (150, 160, 170)
1
(d)
Clean with light soap (M02) and water, rub with a cloth and let dry.
Clean in distilled or de-ionized water (M01) with a soft brush and let dry.
Insulation Shim (80) and Liner Spacer kit (190)
1
Clean in warm water with a soft brush and let dry. Inspect for rips, tears,
warping, or heat damage. Replace liners that are damaged.
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(e)
Temperature Sensor
Not applicable
CAUTION: CLEANING OF THE VENT-VALVE (100) MUST BE DONE WHEN THE
CELLS (90) ARE ASSEMBLED IN THE CASE (20).
(f)
Vent Cap Assembly (100)
1
Remove the vent cap assembly (100) (refer to DISASSEMBLY) during the Final
Charge (refer to TESTING AND FAULT ISOLATION) at 0.1C1A.
2
Place a swab or soft cloth over the cell opening to keep out unwanted material.
3
Soak the vent cap assembly (100) 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 48.89°C (120°F).
(g)
Battery Connector Receptacle (60)
1
5.
Clean connector pins with rubbing alcohol to clean off any accumulated grease
and/or dirt. Inspect the pins for damage; pits, cracks, or scratches, that allow
copper to show through the nickel plating. Replace connectors that are
damaged with a Saft factory new unit.
Lubrication
When the battery is clean (with the vent-valve installed), put a thin layer of mineral vaseline (M04)
or light oil on the terminals and on the links. Use of a paintbrush will make this procedure easier.
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CHECK
1.
General
The checks in this chapter are necessary to use the batteries in flight and on the ground. The
maintenance procedures in this chapter should be carried out in a battery shop. The three types of
maintenance that will be detailed in this chapter are:
•
•
•
2.
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.
Maintenance in workshop
A.
Equipment
(1)
Standard tools
•
•
•
•
•
•
(2)
Standard mechanic’s tools
Safety gloves
Protective goggles
Safety shoes
Eyewash
Protective apron
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
•
•
•
•
B.
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 MΩ (voltage 250 VDC), accuracy 3%
Conditions
•
•
•
Ambient temperature: 20°C ± 15°C (68°F ± 27°F)
Pressure: 85 to 106 Kpa (25.1 to 31.3 InHg)
Relative humidity ≤ 85%
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C.
Periodic Check
If the electrolyte consumption exceeds the maximum consumable amount between two Regular
Checks, this Period Check may be performed to adjust the electrolyte. Maintenance should be
performed using Fig 5001 as a guide and will include the following steps:
•
•
•
•
•
•
•
•
•
Clean the battery.
Check the torque on bolts (140).
Perform an Insulation Test.
Measure the battery voltage.
Discharge the battery.
Charge the battery.
Clean the vent cap assemblies (100).
Adjust the electrolyte.
Check the torque on bolts (140).
(1)
Remove the cover (30).
(2)
Perform a Light Cleaning (refer to CLEANING).
(3)
Check the torque on all bolts (140) (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 11.55 V, perform a polarization test (refer to TESTING AND FAULT
ISOLATION).
(6)
Perform an Initial Discharge at 1C1A down to 11 V at the battery terminals, and allow
the battery to cool (refer to TESTING AND FAULT ISOLATION).
(7)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(8)
During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the ventvalves (100) (refer to CLEANING).
(9)
Level the electrolyte (refer to TESTING AND FAULT ISOLATION).
(10)
Check the torque on all bolts (140) (refer to FITS AND CLEARANCES).
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Periodic Check
Check Torque
on all nuts
Light Cleaning
Dust Only
Yes
No
No
Electrolyte Traces
Total Voltage > 21V
At main power connector
No cells with reversed polarity
No
General Overhaul
Cell to Case
Insulation Test
> 2 Megohms
Yes
Yes
Polarization Test
Initial Discharge
Fault Isolation
No
Special Test
Additional charge with up to
5 hr overcharge
Yes
Charge
For standard product
all cells > 1.50V
Yes
Vent Valve Cleaning
For standard product
all cells > 1.50V
No
No
General Overhaul
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Yes
Check Torque
on all nuts
Battery Accepted
Periodic Check
Figure 5001
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D.
Regular Check
After six months, or according to aircraft manufacturer’s specifications, perform this check following
the different procedures indicated in Figure 5002.
•
•
•
•
•
•
•
•
•
•
•
•
Perform a light cleaning.
Check the torque on all bolts (140).
Measure the voltage of the battery.
Perform an Initial Discharge.
Perform a Residual Discharge.
Perform an Insulation Test.
Charge the battery.
Clean the vent cap assemblies (100).
Adjust the electrolyte.
Perform a Capacity Test.
Charge the battery.
Check the torque on all bolts (140).
(1)
Remove the cover (30).
(2)
Perform a Light Cleaning (refer to CLEANING).
(3)
Check the torque on all bolts (140) (refer to FITS AND CLEARANCES).
(4)
Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 11.55 V, perform a polarization test.
(5)
Perform an Initial Discharge at 1C1A down to a voltage of 11 V at the battery
terminals. Monitor the time from the start of the discharge to the time the battery
reaches 11 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)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(9)
During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the ventvalves (100) (refer to CLEANING).
(10)
Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(11)
Perform a Capacity Test (Refer to TESTING AND FAULT ISOLATION).
(12)
Re-check the torque on all bolts (140) (refer to FITS AND CLEARANCES).
(13)
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
Dust Only
Yes
Total Voltage > 21 V
At main power connector
No cells with reversed polarity
No
No
Electrolyte Traces
Yes
Polarization Test
General Overhaul
Initial Discharge
Residual Discharge
1 Ohm - 3W Min Resistor
12-16 hours on all cells
No
Cell to Case
Insulation Test
> 2 Megohms
Yes
No
Test Temperature
Yes
Sensor
No
Charge
For standard product
all cells > 1.50V
Yes
Vent Valve Cleaning
Fault Isolation
No
Special Test
Additional charge with up to
5 hr overcharge
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Yes
Yes
For standard product
all cells > 1.50V
No
Clean Vent Valves if applicable
Capacity Test
(Initial Discharge)
Yes
Adjust electrolyte at end of charge
Check Torque
on all nuts
No
General Overhaul
No
Charge
For standard product
all cells > 1.50V
Adjust Electrolyte
at end of charge
Battery Accepted
Yes
Regular Check
Figure 5002
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
E.
General Overhaul
The General Overhaul includes electrical tests contained in the Regular Check. It also
includes disassembly and cleaning of all components. Perform the General Overhaul every
12 months, or according to aircraft manufacturer’s instructions, following the procedures
indicated in Figure 5003.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the torque on all bolts (140).
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.
Assemble the battery.
Perform an Insulation Test.
Charge the battery.
Clean the vent cap assemblies (100) and test.
Adjust the electrolyte.
Perform a Capacity Test.
Check the torque on all bolts (140).
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 bolts (140) (refer to TESTING AND FAULT ISOLATION).
(2)
Measure the voltage of the battery at the main terminals. If the voltage is less than
11.55 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION).
(3)
Perform an Initial Discharge at 1C1A down to 11 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)
Thoroughly clean the battery (refer to CLEANING) and inspect components.
(a)
Verify the cells show no signs of leakage.
(b)
Remove any small dents from the marked case (20).
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(7)
Assemble the battery (refer to ASSEMBLY).
(8)
Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value
measured after a Thorough Cleaning should be at least 10 MΩ.
(9)
Charge the battery (refer to TESTING AND FAULT ISOLATION).
(10)
During the Final Charge, clean and test the vent cap assemblies (100) (refer to
CLEANING and TESTING AND FAULT ISOLATION).
(11)
Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(12)
Perform a Capacity Test (refer to TESTING AND FAULT ISOLATION).
(13)
Check the torque on all bolts (140) (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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COMPONENT MAINTENANCE MANUAL
43BO34LB03
General Overhaul
Total Voltage > 21V
At main power connector
No cells with reversed polarity
Check Torque
on all nuts
Residual Discharge
1 Ohm Resistor
12 hours on all cells
Initial Discharge
Polarization Test
Disassembly
and Thorough Cleaning
Visual Inspection
Temperature Sensor Test
Check - Disassembled Battery
Assembly
No
Cell to Case
Insulation Test
> 10 Megohms
Yes
Charge
For standard product
all cells > 1.50V
No
Yes
Vent Valve Cleaning/Test
Fault Isolation
Yes
No
Adjust Electrolyte
during last 15 minutes of
charge with constant
current flowing
< 25% difference in
electrolyte levels
Special Test
Complete charge with
Additional charge with up to
5 hr overcharge
Yes
No
For standard product
All cells > 1.50V
Capacity Test
Yes
Check Torque
on all nuts
No
Full Discharge
Replace faulty components
and return to charge
No
Charge
For standard product
all cells >1.50V
Adjust Electrolyte
at end of charge
Battery Accepted
Yes
General Overhaul
Figure 5003
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
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 are:
•
A.
Re-affixing the Cover Gasket (40).
Cover Gasket
The Cover Gasket (40) can only be re-glued one time.
(1)
Remove the Cover Gasket (40) completely.
(2)
Clean all traces of glue from the Cover (30).
(3)
Apply the glue (M03) to the flat side of the Cover Gasket (40).
(4)
Let dry for 2 hours in a dry place (or as specified by manufacturer’s instructions).
(5)
Place Cover Gasket (40) on the bottom of the Cover (30) and press firmly to seat.
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COMPONENT MAINTENANCE MANUAL
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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
•
•
•
•
•
•
B.
Standard mechanic’s tools
Safety gloves
Protective goggles
Safety shoes
Eyewash
Protective apron
Installation of the Temperature Sensor
Not applicable
This section contains assembly instructions necessary after disassembly and/or repair.
NOTE:
C.
The () part identification numbers herein are IPL, Figure 1 item numbers.
Cells
(1)
Install cells assembly (90) using the following procedure:
(a)
Place one cell assembly (90) into the front of the marked case (20).
(b)
Lay one intercell connector link (150) from the closest battery connector
receptacle (60) terminal to the cell assembly (90) terminal.
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(c)
Press down firmly on the battery connector-receptacle end of the link (150) and
measure the distance between the top of the cell terminal and the bottom edge
of the link.
(d)
If this distance exceeds 0.03 inches (0.75mm), remove the link (150) and the
cell and install an insulation shim (80) in the bottom of the case (20). Repeat
steps 1 through 4 until the gap is less than 0.03” (0.75mm).
CAUTION: DO NOT HAMMER CELLS INTO THE BATTERY CASE. THIS MAY
DAMAGE CELLS.
(e)
Place the rest of the cells and shims into the case (20) using IPL Figure 1 as a
guide to ensure proper polarity is achieved.
NOTE: For easiest assembly, insert the cell in the middle of the row last.
(2)
Install intercell connector links (150, 160, & 170) per IPL Figure 1.
(3)
Install flat washers (120), lock washers (130) and bolts (140).
NOTE: Screw threads should be lightly greased prior to installation.
(4)
Torque bolts (140) per Figure 8001.
(5)
Coat the cell hardware (screws, links and terminals) with a light film of non-acid
petroleum jelly. Silicone coatings are not suitable due to the alkaline electrolyte.
(6)
Install the cover (30) onto the marked case (20) and secure in place by fastening the
latches.
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43BO34LB03
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.
Figure / Item Number
IPL 1
140
Torque Value
8.3 Nm (72 ± 2 lb-in)
Description
Bolt
IPL 1
70
2.3 Nm (20 lb-in)
Screw, Sems
IPL 1
210
.23 Nm (2 lb-in)
Screw, (attaching parts)
Torque Values
Figure 8001
3.
Fits and Clearances Table
No fits and clearances required.
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1
General
This chapter provides pertinent specifications for any special tools that may be needed during
battery maintenance. It also supplies a listing of consumable items that may be useful during
normal servicing, repair, and use.
2.
Special Tools, Fixtures and Equipment
CODE
T01
FIGURE
9001
QTY
1
PART
NUMBER
004414-001
DESCRIPTION
Vent-Valve Wrench
Syringe, 20 cm3
T02
9002
1
021961-000
T03
9003
1
N/A
T04
9004
1
022056-000
USE
-DISASSEMBLY
-CLEANING
-CHECK
-ASSEMBLY
(1.22 in3)
-TESTING AND
FAULT ISOLATION
-CHECK
Equalizing
Resistors
1Ω 3 Watt
-TESTING AND
FAULT ISOLATION
-CHECK
Cell Extraction Tool
-DISASSEMBLY
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3.
Consumables
NOTE:
Equivalent alternatives may be used.
A
D
I
I
R
S
L
CODE
DESIGNATION PART
NUMBER AND
SPECIFICATION
MANUFACTURER
OR SUPPLIER
I
T
N
E
E
S
T
C
M02
Soap (non-abrasive – mild
household)
Local Vendor
M03
Neoprene Glue (alkali
resistant)
Local Vendor
M04
Mineral Vaseline
Local Vendor
NATO: S 743
F: AIR 3565
US: SLP 236
UK: DEF 2333
S
H
S
E
E
C
M
K
L
R
E
E
A
P
N
A
I
I
N
R
G
S
S
S
T
E
O
M
R
B
A
L
G
Y
E
X
X
Y
E
M01
C
L
D
Distilled or deionized water;
clear, colorless, odorless
while boiling, resistivity
>30 KΩ/cm
5 < pH < 7
Absence of organic and
reducing substances.
Reducing agent content
(expressed in weight of
oxygen) < 30 mg/l (test with
permanganate). Total of
ions: SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
A
B
O
A
C
X
X
X
X
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COMPONENT MAINTENANCE MANUAL
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ILLUSTRATED PARTS LIST
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
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:
•
•
•
•
•
B.
C.
Introduction
Equipment Designator Index (EDI)
Numerical Index
Detailed Parts List (DPL)
Vendor Code Index
How to use the Illustrated Parts List
(1)
To find the illustration for a part if the part number is known, refer to the
Numerical Index and look for the part number and the corresponding figure and
item number. Refer to the Detailed Parts List and look for the figure and item
number found in the Numerical Index for that part to verify it is the part specified.
(2)
To determine the part number of a given part, refer to the Illustrated Parts List
figures. Note the item number of the illustrated part and refer to the Detailed
Parts List that indicates the part number and identification.
Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and
electronic components of the items listed. If applicable, they are listed in alphanumeric
order.
D.
Numerical Index (NI)
In this index, part numbers are classified in the following order:
Classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
The first row ordering is:
•
•
•
Hyphen
Alpha from A to Z (except for “O” and “I” which will be considered zero and one)
Numbers from 0-9
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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.
E.
Detailed Parts List (DPL)
(1) Figure and Item Number
Each assembly, sub-assembly, and component designated a part number and included
in the part list is given a callout number.
The figure number linked to the item number is shown on the first line at the top of each
page.
Assemblies, sub-assemblies, and numbered parts included in the list but not illustrated
are identified by a hyphen (-) preceding the item number.
The letter “R” shown in the index before the item number refers to a modified item of the
Detailed Parts List.
(2) Manufacturer’s Part Number
A manufacturer’s part number is given to each part and/or assembly, whether illustrated
or not. To help our customers, we have included a second column giving the equivalent
Saft France and Saft America part numbers for parts having an equivalent.
(3) Indenture
The parts list is represented with indenting showing the relationship of parts and
assemblies to their next higher assemblies as follows:
1234567
Assembly
Attaching parts for assembly
. Detailed parts for assembly
. Sub-assembly
. Attaching parts for sub-assembly
. . Detailed parts for sub-assembly
. . Attaching parts for sub-assembly
. . . Detailed parts for sub-sub-assembly
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43BO34LB03
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 (*).
(4)
Effectivity Code
An alphanumeric index indicates the effectivity of sub-assemblies and detailed parts list
in relation to the next higher assembly (ies) or sub-assembly (ies).
When the part is applicable to all effective products, the usage column remains blank.
The usage code for assemblies and detailed parts refer to the figure/item number of
the next higher assembly(ies) or subassembly(ies).
Example: Effectivity 1A, 1B, 1C is written 1ABC.
(5)
Units Per Assembly
The units per assembly column show the quantity of units required for one next higher
assembly.
In some cases, the information is replaced by the abbreviations REF (reference) or AR
(as required).
F.
Abbreviations
The following abbreviations may be used in this section:
ALT FROM P/N XXX
AR
ASSY
DPL
EDI
EFF
FIG.
IPL
LH
NHA
NP
OPT P/N
P/N
POST SB
PRE SB
REF
RH
SUPSD BY
SUPSDS
Interchangeable part
As required
Assembly
Detailed Parts List
Electronic Data Interchange
Effectivity
Figure
Illustrated Parts List
Left-Hand
Next-Higher Assembly
Not-Procurable
Optional Part Number
Part Number
Post Service Bulletin
Pre Service Bulletin
Reference
Right-Hand
Superseded by
Supersedes
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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.
VENDOR CODE INDEX
Vendor Code
NAME / ADDRESS
Vendor Code
NAME / ADDRESS
V09052
Saft
711 Industrial Boulevard
Valdosta, GA 31601
USA
F6177
Saft
156 Avenue de Metz
93230 Bagnolet
France
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
30
40
170
90
160
180
150
190
50
150
20
60
80
70
140
100
130
110
120
90
Aircraft Battery
Figure 1
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
ILLUSTRATED PARTS LIST
FIG.
ITEM
1-10
20
30
40
50
60
PART
AIRLINE STOCK
NUMBER
NUMBER
43B034LB03
022114-000
022469-000
022155-000
093422-000
022473-000
70
093616-000
80
90
100
110
120
130
140
150
160
170
180
190
-200
-210
-220
-230
013357-048
021903-000
021915-000
012536-000
005798-000
092862-000
093819-000
009357-003
009357-001
014368-003
004414-000
025090-000
093704-000
022105-000
022297-000
092508-001
NOMENCLATURE
12345
Battery, Aircraft
. Case, Marked
. Cover
.. Gasket, Cover
. O-Ring
. Receptacle, Battery Connector
Attaching Parts
. Screw, Sems
***
. Insulation Shim
. Cell Assembly (marked 34AC14-2)
.. Vent Cap Assembly
… O-Ring
. Washer, Flat
. Washer, Lock
. Bolt, Hex Head
. Link, Intercell Connector
. Link, Intercell Connector
. Link, Intercell Connector
. Vent Wrench
. Kit, Liner and Spacer
. Stopper
.. Screw
. Dust Cap
. Spring, Shorting
UNITS
PER
ASSY
ref
1
1
1
1
1
4
1
11
1
1
2
2
2
4
7
1
1
1
1
1
1
1
- Denotes item not shown
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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.
A nickel-cadmium battery storage location should be free of acid, dust, or dampness. No corrosive
liquids or gases should be stored in the same room. Temperatures may range from -60°C (-76°F)
to +60°C (+140°F) without harming the battery. The most desirable range for storage is between
0°C (32°F) to + 30°C (+86°F).
2.
3.
Preparation for Storage
A.
In-service batteries to be stored for less than 90 days should undergo completion of the
Regular Check or General Overhaul and be left in an airworthy status. See Section 5
(CHECK).
B.
In-service batteries to be stored longer than 90 days should be discharged and placed in a
container suitable to the duration of storage.
C
Factory new batteries may be stored as received for a period of up to 24 months. Longer
storage duration requires placement in sealed packaging prior to storage.
Active Stand-by Storage
Active stand-by storage is to be used when the battery must be charged and ready for service
onboard an aircraft in a short period of time. The length of time that a battery will retain a minimum
capacity (80%) will vary dependent upon the ambient temperature of the storage environment
(refer to Figure 15001). For storage longer than 90 days, see procedures for Inactive Storage.
NOTE: Saft vented-cell aircraft batteries may be stored charged, ready for service in the normal,
upright or vertical position.
NOTE: Nickel-cadmium batteries automatically self-discharge at about 0.25% per day at 20°C
(68°F).
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
100
AVAILABLE CAPACITY (%C1Ah)
90
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) (41°F)
Temp. (15°C) (59°F)
Temp. (25°C) (77°F)
Temp. (35°C) (95°F)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
Disch. (0%C1Ah)
0
20
60
10
30
40
50
60
70
80
90
Days
Charge Retention
Figure 15001
A.
Storage at < 20°C (68°F).
(1)
Place fully-serviced, airworthy battery into proper storage for a period not to
exceed 90 days.
(2)
After 90 days (on the 91st day), the battery must receive an electrolyte level
verification. See Section 1 (TESTING AND FAULT ISOLATION).
(3)
After electrolyte leveling, the battery can be returned to storage for another
period not to exceed 90 days.
(4)
It is possible to repeat Steps 2 and 3 a maximum of two times (three 90 day
intervals).
(5)
If the battery has not been installed into an aircraft after three 90 day intervals, it
must undergo completion of the Regular Check or General Overhaul as required.
See Section 5 (CHECK).
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43BO34LB03
B.
Storage at > 20°C (68°F).
(1) Storage duration is dependent upon ambient temperature. Minimum acceptable
available capacity retention may not be less than 80%.
(2) Refer to Figure 15001 to determine the maximum number of days a battery can be
stored before maintenance is required.
(3) Place a fully-serviced, airworthy battery into proper storage for a period not to exceed
the maximum number of days determined in step 2.
(4) One day past the maximum number of storage days, the battery must receive an
electrolyte level verification. See Section 1 (TESTING AND FAULT ISOLATION).
(5) The battery can then be returned to storage for a period not to exceed the maximum
duration for the ambient storage temperature.
(6) It is possible to repeat steps 4 and 5 a maximum of two times (three storage
intervals).
(7) If the battery has not been installed into an aircraft after three storage intervals, it must
undergo completion of the Regular Check or General Overhaul as required. See
Section 5 (CHECK).
4.
Trickle Charging
The principle of trickle charging is to keep a battery in active stand-by condition by continuously
charging the battery in an over-charge condition. Saft does not recommend this method,
however some operators take responsibility for its use.
WARNING:
USE OF A TRICKLE CHARGER WILL CONSUME WATER OVER TIME.
FAILURE TO VERIFY ELECTROLYTE LEVEL PRIOR TO INSTALLATION
MAY RESULT IN PREMATURE BATTERY FAILURE.
Example: If a 40 Ah battery remains on a continuous trickle charge of 3 mA/Ah for one month,
the total consumption of water is 35 cm3/cell.
The operator must adjust the electrolyte level before placing the battery onboard the aircraft.
Otherwise, the risk of a battery incident exists; cells dry out before the normal end of the
maintenance interval.
5.
Inactive Long-term Storage
Saft nickel-cadmium aviation batteries can be stored in the original cardboard packaging for a
period of two years, and up to 10 years in sealed packaging under the following conditions:
A.
Ambient temperature of 20°C ± 15°C (+68°F ± 27°F)
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COMPONENT MAINTENANCE MANUAL
43BO34LB03
6.
B.
Humidity less than 70%
C.
Normal upright, vertical position
D.
Atmosphere free of dust, dirt, vibration or corrosive agents.
Preparation for Use After Storage (other than Active Stand-by Storage)
STORAGE TIME
Less than 3 months
More than 3 months
7.
SERVICE PROCEDURE
Perform a Periodic Check (CHECK - Fig 5001)
Perform a Regular Check (CHECK - Fig 5002)
Return to Service Procedures
Figure 15002
Packing and Transporting
The normal packing for shipment of Saft nickel-cadmium batteries is with fiberboard or injected
foam packing enclosed in fiberboard or wooden outer containers. For overseas shipments,
wrapping in sealed plastic is recommended. Precautions must be taken to keep batteries upright
while in transit. All markings and documentation should conform to current IATA regulations
(UN2795 or UN2800 as applicable) governing the shipment of vented nickel-cadmium batteries.
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