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<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

<strong>SAFT</strong><br />

<strong>ELECTRIC</strong> <strong>STORAGE</strong> <strong>BATTERY</strong><br />

<strong>Gulfstream</strong> <strong>Aerospace</strong><br />

P/N 1159SCAV519-1<br />

<strong>SAFT</strong> <strong>BATTERY</strong> TYPE<br />

5317CH-1<br />

P/N 023805-000<br />

COMPONENT MAINTENANCE MANUAL<br />

WITH<br />

ILLUSTRATED PARTS LIST<br />

24-34-01<br />

R/R-1<br />

Aug 30 96


REVISION<br />

DATE<br />

ISSUE<br />

DATE<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

RECORD OF REVISIONS<br />

BY REVISION<br />

DATE<br />

ISSUE<br />

DATE<br />

BY<br />

24-34-01<br />

R/R-1<br />

Aug 30 96


TEMPORARY<br />

REV. NO.<br />

PAGE<br />

NUMBER<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

RECORD OF TEMPORARY REVISIONS<br />

ISSUE<br />

DATE<br />

BY DATE<br />

REMOVED<br />

BY<br />

24-34-01<br />

T/R-1<br />

Aug 30 96


SUBJECT PAGE DATE<br />

Title T-1 Aug 30/96<br />

Record of<br />

Revisions<br />

Record of<br />

Temporary<br />

Revisions<br />

List of<br />

Effective Pages<br />

Table of<br />

Contents<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

LIST OF EFFECTIVE PAGES<br />

R/R-1 Aug 30/96<br />

TR-1 Aug 30/96<br />

LEP-1 Aug 30/96<br />

T/C-1<br />

T/C-2<br />

Introduction Intro-1<br />

Intro-2<br />

Description of<br />

Operation<br />

Testing and<br />

Troubleshooting<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7/8<br />

101<br />

102<br />

103<br />

104<br />

105<br />

106<br />

107<br />

108<br />

109<br />

110<br />

111<br />

112<br />

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Aug 30/96<br />

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Aug 30/96<br />

Disassembly 301 Aug 30/96<br />

SUBJECT PAGE DATE<br />

302 Aug 30/96<br />

Cleaning 401<br />

402<br />

Inspection 501<br />

502<br />

503<br />

504<br />

505/506<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Repair 601/602 Aug 30/96<br />

Assembly and<br />

Storage<br />

Tools and<br />

Special<br />

Equipment<br />

Illustrated Parts<br />

List<br />

701<br />

702<br />

703<br />

704<br />

705/706<br />

901<br />

902<br />

903/904<br />

Intro-1001-<br />

1 Intro-<br />

1001-2<br />

Intro-1001-<br />

3<br />

1001<br />

1001-0<br />

1001-1<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

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Aug 30/96<br />

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Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

Aug 30/96<br />

24-34-01<br />

LEP-1<br />

Aug 30 96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

TABLE OF CONTENTS<br />

SUBJECT PAGE<br />

DESCRIPTION AND OPERATION<br />

1. Description 1<br />

2. Operation 6<br />

TESTING AND TROUBLESHOOTING<br />

1. Testing 101<br />

DISSASSEMBLY<br />

1. Disassembly 301<br />

CLEANING<br />

1. Cleaning the Valves 401<br />

2. Cleaning the Cells 401<br />

3. Cleaning the Case 402<br />

4. Cleaning the Hardware 402<br />

INSPECTION<br />

1. Visual Inspection 501<br />

2. Checking a Valve 501<br />

3. Checking Upper and Lower Nuts for Tightness 502<br />

4. Checking the Connector Receptacle 502<br />

5. Checking the Temperature Sensor Harness Assembly 502<br />

6. Checking the Temperature Sensor Harness Assembly 502<br />

REPAIR<br />

1. Case 601<br />

2. Cells 601<br />

24-34-01<br />

TABLE OF CONTENTS - PAGE 1<br />

Aug 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

SUBJECT PAGE<br />

ASSEMBLY AND <strong>STORAGE</strong><br />

1. Assembly 701<br />

2. Storage 702<br />

FITS AND CLEARANCES<br />

TOOLS AND SPECIAL EQUIPMENT 901<br />

ILLUSTRATED PARTS LIST<br />

1. Introduction Intro-1001<br />

2. Illustrated Parts List 1001<br />

24-34-01<br />

TABLE OF CONTENTS - PAGE 2<br />

Aug 30/96


1. General<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

INTRODUCTION<br />

This component maintenance manual has been prepared in compliance with ATA<br />

specification No. 100 by the (AIR TRANSPORT ASSOCIATION OF AMERICA). Its<br />

purpose is to describe the procedures, applied in the manufacturer's shops to<br />

enable a technician, unfamiliar with the component, to return it to operating<br />

condition or perform an overhaul of the component.<br />

The operations described must be carried out in maintenance shops using special<br />

tools and test equipment.<br />

This manual does not cover standard techniques, maintenance intervals nor details<br />

which are likely to vary depending on the shop facilities available.<br />

2. Format<br />

A. The page numbering system of the manual consists in using a page number<br />

block for each section as follows. As concerns small basic items of<br />

equipment, more than one section can be covered on the same page.<br />

1-100 DESCRIPTION AND OPERATION<br />

101-200 TESTING AND TROUBLESHOOTING<br />

201-300 (NOT ASSIGNED)<br />

301-400 DISASSEMBLY<br />

401-500 CLEANING<br />

501-600 INSPECTION<br />

601-700 REPAIR<br />

701-800 ASSEMBLY AND <strong>STORAGE</strong><br />

801-900 FITS AND CLEARANCES<br />

901-1000 TOOLS AND SPECIAL EQUIPMENT<br />

1001-1100 ILLUSTRATED PARTS LIST<br />

24-34-01<br />

INTRODUCTION - PAGE 1<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

B. In general, all values are expressed in units of International System of<br />

Measurement (meter, kilogram, second) or multiples and sub-multiples of<br />

same.<br />

In some particular cases more appropriate units are employed.<br />

3. Revision<br />

With each revision issued for the manual, detailed instructions are supplied crossreferring<br />

to the page numbers concerned for insertion and deletion. The revised,<br />

added or deleted material is indicated by the letter R printed in the margin.<br />

24-34-01<br />

INTRODUCTION - PAGE 2<br />

AUG 30/96


1. Description<br />

A. General<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

DESCRIPTION AND OPERATION<br />

The electrical storage battery supplies the aircraft with 25.2 V D.C. until the<br />

generators operate or in case of generator output drop.<br />

It also enables direct or indirect starting of the propulsion engine(s).<br />

The battery assembly comprises 21 nickel cadmium series mounted storage<br />

cells contained in a metallic box which accommodates a connector receptacle<br />

and accommodates an additional connector receptacle which is connected to<br />

the temperature sensor/charge control harness assembly.<br />

B. Characteristics<br />

(1) Dimensions and weight<br />

OVERALL DIMENSIONS mm (in.) MAX WEIGHT<br />

IN kg (lb)<br />

MAX LENGTH MAX WIDTH MAX HEIGHT<br />

317 mm<br />

(12.48 in.)<br />

248 mm<br />

(9.76 in.)<br />

(2) Technical features<br />

265 mm<br />

(10.43 in.)<br />

43.1 kg<br />

(95 lb.)<br />

Alkaline, spill-proof, nickel cadmium battery, 25.2 V D.C., 53<br />

Amp hour.<br />

Connector receptacle complying with MS 3509 or equivalent.<br />

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PAGE 1<br />

AUG 30/96


Cell<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Very thin, plastic bonded cadmium oxide negative<br />

plates, and nickel-hydrate impregnated positive plates.<br />

Composite separator made of synthetic fiber. Ternary<br />

electrolyte (chemically pure potassium hydroxide<br />

aqueous solution).<br />

Polyamide boxes and covers assembled by<br />

thermowelding.<br />

Nickel-plated copper output terminals. Sealing around<br />

the terminals is provided by preformed packings (O-<br />

Rings).<br />

Removable polyamide safety valve located in the center<br />

of the cover.<br />

Nominal capacity (C1) = 53 Ah (at the one hour discharge<br />

rate).<br />

Special characteristics<br />

Two thermostats (T1 & T2) in series with a resistor (R1)<br />

connected to the positive post of the main battery<br />

receptacle. One thermistor fitted to a special mounting<br />

plate. A series resistor (R2) connected to the negative<br />

post of the main battery receptacle. A connector<br />

receptacle located under the main connector receptacle<br />

provides electrical interface with the on board charger.<br />

Operating temperature of the thermostats T1 and T2:<br />

Open on temperature rise at 68°C (154°F).<br />

Thermistor registers 2460 Ohms at 23°C (73.4°F).<br />

R1 and R2 register 32.4K Ohms each.<br />

Temperature sensor/charge control auxiliary connector<br />

complies with MS 24264 R 12 B 12 SN<br />

24-34-01<br />

PAGE 2<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

C. Detailed description (See Fig. 1)<br />

This comprises:<br />

a case assembly (10)<br />

complete cover (20) with an insulating gasket made of silicone elastomer<br />

bonded to the to the inner face.<br />

(a) Box<br />

(2) Storage cells<br />

The case assembly is provided with two vent pipes, four spring<br />

fasteners, and two lifting handles.<br />

An identification plate.<br />

The front face of battery P/N 1159SCAV519-1 supports the base plate<br />

of the connector receptacle connected to the temperature<br />

sensor/charge control harness assembly.<br />

(b) Cover<br />

The cover (20) is laterally provided with four catches intended for<br />

attachment to the box, and with a bar, notched at both ends, intended<br />

for battery mounting through tie-rods secured to a rack.<br />

The twenty one electrical storage cells (30) are arranged in two rows of eight and<br />

one row of five within the battery case.<br />

Each storage cell is equipped with a safety valve (120) fitted with a preformed<br />

packing (130).<br />

The storage cell terminals are made up of two threaded nickel-plated copper rods.<br />

24-34-01<br />

PAGE 3<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Each storage cell terminal is fitted with:<br />

a preformed packing (40),<br />

a flat washer (50),<br />

two Belleville washers (60),<br />

a preformed washer indicating polarity (+) (70) or (-) (80),<br />

a terminal lower nut (90),<br />

a Belleville washer (100),<br />

a terminal nut (110).<br />

a vent valve assembly (120)<br />

(3) Accessories<br />

The accessories are used to secure the storage cells in the form of a<br />

liner spacer kit (290).<br />

There are:<br />

six end liners,<br />

two notched side liners,<br />

four intermediate liners inserted between the three rows of<br />

storage cells,<br />

twenty two links (140, 150, 160) ensuring series-connection of<br />

storage cells and connection to the main connector receptacle,<br />

24-34-01<br />

PAGE 4<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

NOTE: ITEM NUMBERS ARE THOSE SHOWN<br />

IN IPL, FIG. 1<br />

Description<br />

Figure 1<br />

24-34-01<br />

PAGE 5<br />

AUG 30/96


2. Operation<br />

(4) Connector Receptacle<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Main connector receptacle (170) is secured to the box by four Sems<br />

screws (190).<br />

The temperature sensor/charge control auxiliary connector receptacle<br />

is secured to the box by four screws (230) and four locking nuts (240).<br />

A. Principle of Operation<br />

The battery plates store electrical power supplied by a charging source, and<br />

supply power when the battery is connected to a load circuit, i.e. when it<br />

discharges.<br />

During charge, nickel hydroxide Ni (0H)2 of the positive plates is oxidized and<br />

is transformed into superior hydroxide NO O OH; cadmium hydroxide Cd<br />

(OH)2 of the negative plates is reduced and is transformed into cadmium<br />

metal (Cd). Reverse reactions take place during discharge and active<br />

materials return to their initial state. The electrolyte (ternary hydroxide<br />

solution) does not undergo any significant chemical change.<br />

For a battery with a given volume, the nominal capacity of the battery<br />

discharged in 1 hour is determined by the quantity of electricity (Ah) the<br />

battery can supply.<br />

The efficiency of the battery, in terms of quantity of electricity, is 71.5%. This<br />

means that, in order for a 53 Ah battery to supply 100% of its capacity, it must<br />

store a quantity of electricity of 74.2 Ah, i.e. 140% of C1 .<br />

It is only on this condition that complete chemical transformation of the active<br />

materials takes place.<br />

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PAGE 6<br />

AUG 30/96


B. Operation in normal use<br />

(1) Charging in normal use<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Charging the battery on the aircraft is ensured by an on board<br />

chargers supplied by one (or several) AC generator(s).<br />

NOTE: When a battery, in which the active materials have been<br />

fully transformed, is subjected to an extended charging<br />

operation, the battery becomes overcharged. The<br />

current passing through the assembly gives rise to the<br />

electrolysis of the electrolyte water into its two elements:<br />

oxygen and hydrogen. The rate of decomposition is 1<br />

cm 3 (0.061 cu. in.) of water for an overcharge of 3 Ah.<br />

Water consumption in overcharging conditions is<br />

therefore proportional.<br />

(2) Discharging<br />

The nominal capacity C1 of the battery corresponds to the 1 hour rate<br />

of discharge; that is, the battery can supply a 53 amp current for 1<br />

hour, when it is at 100% state of charge.<br />

However, the battery can, without danger, supply currents greatly<br />

exceeding the nominal discharge current. For instance, a battery with<br />

a 53 Ah nominal capacity can supply, in peak conditions, currents<br />

about twenty times its nominal rating.<br />

24-34-01<br />

PAGE 7/8<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

TESTING AND TROUBLESHOOTING<br />

NOTE: Tools and special equipment to be used are listed under "Tools and<br />

Special Equipment".<br />

1. Testing<br />

A. Setting into service<br />

(1) Ground maintenance<br />

(a) Operating voltage<br />

The nominal charging voltage for 21-cell batteries is 31.5 V<br />

D.C. at 20C (68F). An end-of-charge current matching the<br />

water consumption is obtained at this voltage level.<br />

In case the water consumption is excessive during the<br />

service cycle, i.e. more than 88 cm 3 ( 5.39 cu.in.) per cell<br />

[see para. B . (3) (b) ], check the voltage above, or the usual<br />

temperature of the batteries in service (see aircraft<br />

Maintenance Manual).<br />

(b) Insulation<br />

Electrolyte condensation or overflowing may reduce the<br />

value of the insulation between the battery electrical circuit<br />

(connector receptacle disconnected and the box.<br />

The value of the insulation under 250 V D.C. should be<br />

greater than 10 megohms.<br />

(c) Charge condition<br />

The battery can be charged in flight up to 100%. When this<br />

state is reached, the open-circuit voltage is about 31.5 V<br />

D.C.<br />

24-34-01<br />

PAGE 101<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

When the off-load voltage of the battery after an idle period<br />

is greater than 25.5 V D.C., it can be deemed at least 50%<br />

charged. If required (see aircraft maintenance manual),<br />

perform fast-charging [see para. A (2) (c) ].<br />

(d) Maintenance periods<br />

Maintenance on the aircraft is defined by the corresponding<br />

specifications. The workshop maintenance periods and<br />

removal conditions are covered in the aircraft manuals and<br />

determined by the users, taking account of the operating<br />

conditions.<br />

The maintenance operations can be broken down as follows:<br />

the complementary fast-charging operations above,<br />

Charging and topping up of the electrolyte level including :<br />

residual discharge [see para. B. (2) (a) ],<br />

fast charging as per the procedure mentioned in paragraph<br />

A. (2) (c) 1st method,<br />

topping up the of electrolyte level and valve cleaning [see<br />

para. B. (3) (b)]<br />

visual inspection of the thermostat (see "Inspection"),<br />

Reconditioning, including:<br />

residual discharge,<br />

balancing as required,<br />

complete charging and topping up of the electrolyte levels,<br />

valve cleaning<br />

checking the thermostat for operation,<br />

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<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

checking the capacity (discharge and complementary<br />

checks as required),<br />

final charging after checking the insulation,<br />

Overhaul, including:<br />

disassembling the battery,<br />

cleaning,<br />

inspection,<br />

assembling the battery.<br />

This operation is to be performed during reconditioning, after<br />

the capacity check and before the final charging.<br />

It is either scheduled or to be performed when cells are to be<br />

replaced.<br />

(2) Charging in workshop<br />

(a) General conditions<br />

Equipment required :<br />

battery charger,<br />

valve wrench.<br />

CAUTION: CHARGING SHOULD BE PERFORMED ONLY IN<br />

CLEAN AND VENTILATED PREMISES WHICH<br />

ARE NOT USED FOR LEAD BATTERIES (ACID<br />

ATMOSPHERE).<br />

REMOVE THE COVER OF THE <strong>BATTERY</strong> AND<br />

LOOSEN, BUT DO NOT REMOVE, THE VALVES<br />

(USING THE WRENCH), ALLOWING THE<br />

GASES PRODUCED TO BE DISSIPATED<br />

WITHOUT PLACING THE ELECTROLYTE IN<br />

CONTACT WITH THE AMBIENT AIR (RISKS OF<br />

CARBONATION).<br />

24-34-01<br />

PAGE 103<br />

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<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

NOTE: After charging a discharged battery for 5 min., and some or all of the<br />

individual cell voltages indicate greater than 1.5 V D.C. [see para. B.<br />

(3)] add 10 to 15 cm 3 of distilled water to these cells. The high<br />

voltage reading may be a result of being dry.<br />

When this can be foreseen, it is advisable to check the voltages of<br />

each cell at the beginning of the charging operation.<br />

During charge, and particularly near the end of the charging period, a<br />

production of foam may occur. This phenomenon is generally due to:<br />

the presence of greasy matter inside the cell (for instance, grease<br />

or oil which could have accidentally ingressed through the valve<br />

clearing hole),<br />

excessive reduction of the specific gravity of the free electrolyte<br />

above the plates. This can happen particularly when distilled water<br />

is added to a cell having consumed all (or even more than) its<br />

content of water reserve. In this case, it is necessary to add a<br />

large volume of distilled water, which does not immediately mix<br />

with the concentrated electrolyte remaining in the cell.<br />

To stop this phenomenon, it is generally sufficient to interrupt the<br />

charging operation and to perform a discharge allowing the electrolyte<br />

to mix. The next charging operation will further improve electrolyte<br />

dispersion and the phenomenon should then disappear.<br />

In the case where the foam is formed by the contact with greasy matter<br />

inside the cell, practically nothing can be done except preventing the<br />

foam from spreading over the covers and flowing between the cells.<br />

This can easily be performed by fitting a water-absorbent cotton pad in<br />

place of the valve.<br />

(b) Slow-rate low-current charging<br />

For a new battery or after removing a discharged battery from storage;<br />

charge the battery at 5.3 amps constant current for 10-12 hours to<br />

obtain 30 V D. C. As measured across the terminals, then continue<br />

with the same rate<br />

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<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

5.3 A for 4 additional hours. Charging can be performed in two<br />

periods provided that the first period lasts at least 8 hours.<br />

Do not interrupt the charging operation for the last 5 hr. (to ensure<br />

normal topping up of the electrolyte levels).<br />

(c) Fast-rate charging (discharged battery)<br />

This charging operation is performed at two successive regulated<br />

current rates :<br />

First method<br />

First charge at 26.5 A up to 32.5 V D.C. (2 hr.40 min. maximum<br />

depending on the actual capacity of the battery), then charge at<br />

5.3 A for 4 hr. (the voltage is then about 35 V D.C.)<br />

Second method<br />

First charge at 53 A up to 32.9 V D.C. (1 hr. 15 min. max.<br />

depending on the actual capacity of the battery), then charge at<br />

5.3 A for 4 hr. (the voltage is then about 35 V D.C.).<br />

NOTE: The high current phase is limited by the voltage, in order not to<br />

overload (or underload) batteries with excessively different capacities<br />

and to completely charge the battery in about 6 hr.<br />

(d) Charging a battery whose charge is unknown<br />

Applicable when a complement of charge is needed, or if the battery<br />

has not been used for a period of less than 2 months, if it is not<br />

possible to perform complete recycling :<br />

charge at 5.3 A until the voltage reaches 32.5<br />

24-34-01<br />

PAGE 105<br />

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B. Recycling<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

or charge at 26.5 A until the voltage reaches 35 volts.<br />

or charge at 53 A until the voltage reaches 35 volts.<br />

(1) Equipment and product required<br />

(a) Equipment<br />

Battery charger.<br />

D.C.voltmeter, 0 to 3 V/0 to 40 V, class 0.5.<br />

Stopwatch/Timer<br />

20 resistors (1 ohm approx.10W min. each) fitted at both ends<br />

with "alligator" clips.<br />

Plastic syringe fitted with a cylindrical adaptor and a stop. (P/N<br />

20916-1)<br />

Valve wrench. (P/N 93365 see Fig. 902)<br />

(b) Product<br />

Distilled water.<br />

(2) Residual discharge and rebalancing<br />

(a) Residual discharge<br />

After removing the battery for scheduled maintenance or after in<br />

flight detection of a fault, discharge the unit as follows:<br />

24-34-01<br />

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<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Discharge 100% of C1 at a constant current, i.e. 53 A (or 50%<br />

C1, 26.5 A), and note the time necessary to obtain a voltage of<br />

21 V D.C. across the battery terminals. The current should<br />

automatically or manually be regulated. When the voltage<br />

across the terminals passes between 22 and 21 V D.C. (in other<br />

words, if sudden voltage drops occur), measure the voltage of<br />

each cell in order to detect and localize imbalance. If the V<br />

between cells is practically nil (normal battery), let the battery<br />

cool down before performing a new charging operation and<br />

topping up of levels [see para. (3) ].<br />

(b) Reconditioning<br />

As soon as the voltage of one or several cell(s) drops below 1 V<br />

D.C., or, as a limit, when the voltage across the terminals of the<br />

battery reaches 21 V D.C., stop discharging (and note the<br />

discharge duration). Continue the discharge. Use a 1-ohm<br />

resistor to shunt each cell and keep the resistors in place for 16<br />

to 24 hr.<br />

In these conditions, each cell will discharge at a slow rate<br />

through its individual resistor without danger or reversing the<br />

polarities.<br />

NOTE: The complimentary checks covered in paragraph (4) (b)<br />

provide a means of classifying the cells after their capacity; this<br />

in not covered at this stage.<br />

(3) Complete charging and topping up of the electrolyte level<br />

(a) Charging<br />

Charge the battery as per paragraph A. (2) (b) or A. (2) (c) to<br />

ensure complete charging to 140% of the available capacity.<br />

This charging provides a quantity of electricity equal to 140% of<br />

the capacity of the battery. During the final stage, a certain<br />

quantity of water from the electrolyte is decomposed and will<br />

have to be replaced as per the following operation.<br />

At the end the 4hr. overcharge, the electrolyte is at its maximum<br />

level (presence of H2 and 0 bubbles on and between the plates)<br />

and the voltage of the battery is 33 to 33.6 V D.C. [between 15<br />

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Component Maintenance Manual<br />

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and 25C (59 and 77F) ]. The individual voltages of the cells<br />

should be homogeneous and about 1.6 V D.C.<br />

(b) Topping up the electrolyte level<br />

During the last charging hour, as close as possible to the end of<br />

charge, and keeping the charge at 5.3 A, add distilled water to<br />

top up the level of the liquid in each cell.<br />

NOTE: In case of simultaneous recharging of several batteries,<br />

consider the time required to top up their levels. If necessary,<br />

extend the charging time by a few minutes so as to complete<br />

this operation.<br />

Checking the level as described below is valid only if it is<br />

performed at the end of charging, while the current flows.<br />

CAUTION: IF THIS ADJUSTMENT IS NOT PERFORMED AS PER THESE<br />

SPECIFICATIONS, THE CELLS WILL OVERFLOW.<br />

The level of the electrolyte should be 20mm below the valve seat (the<br />

valve and valve seal should be removed to obtain accurate<br />

measurement).<br />

To adjust the level, after removing each valve, use a plastic syringe<br />

whose adapter is provided with a tube and a stop; the end of the<br />

syringe should be a 20mm (0.79 in.) below the valve seat (see Fig.<br />

101).<br />

By maintaining the stop shoulder in contact with the valve seat, and by<br />

pulling the syringe piston, checking for correct topping up is<br />

immediate.<br />

if the level is too low, the syringe piston will come up "dry",<br />

any excess fluid will be sucked into the syringe until the level<br />

coincides with the tip of the tube.<br />

If the volume of water added to any cell is greater than 88cc, check<br />

the conditions of use [see para. A. (1) (a)]. For new batteries with a<br />

normally correct level, the volume of added water should not exceed<br />

88cc.<br />

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Component Maintenance Manual<br />

1159SCAV519-1<br />

TOPPING UP WITH A SYRINGE FITTED WITH CALIBRATED ADAPTER<br />

FIGURE 101<br />

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Component Maintenance Manual<br />

1159SCAV519-1<br />

NOTE: Clean the valves (see "Cleaning", para.1) while the levels are<br />

being adjusted. Leave the cells unplugged for as short as time<br />

as possible.<br />

CAUTION: NEVER USE ACID OR A SOLUTION OF ACID AND WATER<br />

TO ADJUST CELL LEVELS IN NICKEL-CADMIUM<br />

BATTERIES. ANY TRACE OF ACID, HOWEVER SMALL,<br />

WILL PERMANENTLY DAMAGE THE <strong>BATTERY</strong>. ONLY USE<br />

EQUIPMENT WHICH HAS NEVER BEEN USED FOR LEAD<br />

BATTERIES. AVOID USING CHEMICALLY PURIFIED WATER<br />

WHICH CONTAINS ACID OR CHLORINATED ELEMENTS.<br />

(4) Checking the thermostat for operation (see "Inspection").<br />

(5) Capacity check<br />

(a) Discharge<br />

Within 24 hours after charging and topping up the level,<br />

discharge the battery down to 1 volts per cell [see para. (2) (a) ].<br />

Note the discharge duration and the time when some cells drop<br />

below 1 V D.C. Stop discharging when reaching 21 V D.C.<br />

across the battery terminals.<br />

Conclusions to be drawn from the above test :<br />

the battery is correct if the duration of the first discharge of the<br />

battery [see para. (2) (a) ]. is greater than 30 min. If using the<br />

discharge current of C1 or 60 min. if using the discharge<br />

current of 0.5C1, and the duration the second discharge is at<br />

least equal to 1 hr. 100% charge using C1 or 122 min. using<br />

0.5C1,<br />

if the duration of the first discharge is less than 30 min. using<br />

the discharge current of C1 or 60 min. using the discharge of<br />

0.5C1, and the duration of the second discharge is correct (1<br />

hr. at C1 or 122 min. at 0.5C1, minimum), the condition of the<br />

battery is correct, but it is not completely charged and the<br />

operating conditions should be checked,<br />

if some cells remain shorted during discharge, discard them.<br />

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Component Maintenance Manual<br />

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if the duration of the second discharge is less than 1 hr. At<br />

C1 (less than 122 min. At 0.5C1), or if the voltage of some<br />

cells is less than 1 V D.C. within 1 hour of discharge (122<br />

min. At 0.5C1 ), the battery should undergo a more complete<br />

overhaul. Perform the complementary checks [see para.<br />

(b)].<br />

(b) Complementary checks<br />

The capacity supplied by the battery is :<br />

53 A • number of minutes before 21 V D.C. / 60 = Number of<br />

Ampere-hours (Ah), or divide by 122 if using 0.5C1<br />

If the capacity is not greater than 53 Ah, or if the voltage of each cell<br />

rises too quickly during charging, drops, or is excessively low at the<br />

end of charge, some cells may have been insufficiently balanced, the<br />

volume of added water is insufficient, or the cell separators are<br />

damaged.<br />

Repeat the balancing operations more accurately by discharging at<br />

10 A.<br />

Meanwhile, regularly measure and note the voltage of each cell,<br />

observing the sequence of measurement. Locate and shunt the cells<br />

whose voltage drops below 1 to 0.9 V D.C. using a 1-ohm (10 W)<br />

resistor.<br />

Stop discharging at the latest when the voltage reaches 10 V across<br />

the battery terminals. Keep the shunts in place as described in<br />

paragraph (2) (b).<br />

Repeat the remaining operations: slow-rate charging [see para. A. (2)<br />

(b)], checking the levels [see para. (3) (b)] and a new test discharge<br />

[see para (a)].<br />

Regularly check the voltage of each cell during the first and last hour<br />

of charging.<br />

At the end of this test, discard the following cells whose operation is<br />

defective:<br />

cells not reaching 1.2 V D.C. after 5 min. Charging,<br />

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cells whose voltage is less than 1.5 V D.C. at the end of 5.3 A<br />

charging,<br />

cells whose voltage is greater than 1.78 V D.C. at the end of<br />

charging [at 20C (68 F)],<br />

cells whose voltage still falls below 1 V D.C. before 1 hr's.<br />

discharge, (122 min. at 0.5C1) when the last test discharge is<br />

performed.<br />

NOTE: A more accurate procedure intended to discard the defective cells<br />

consists in extending the end of charge described in paragraph A. (2)<br />

(b) for 4 to 5 hr. under 5.3 A and localizing the cells whose voltage<br />

falls below 1.5 V D.C.<br />

(c) Replacing cells<br />

Replacing cells requires disassembly and reconditioning of the battery.<br />

After replacing the cells, perform a fast-rate charging [see para. A. (2)<br />

(c) ].<br />

The capacity of the replacement cells and remaining cells should be<br />

approximately the same, to avoid creating new unbalance. Only a<br />

small number of new cells can be installed in a battery comprised of<br />

average cells. It is advisable to series-connect average cells to obtain<br />

balanced batteries.<br />

The tests as described in paragraph (b), together with an accurate<br />

control of the voltage rise of the cells during charging, allow for<br />

qualitative classification and thus economical use of the cells.<br />

(6) Final charging<br />

Check for insulation [see para. A. (1) (b) ] before performing this<br />

charging operation prior to setting into service. Perform a fast-range<br />

charging [see para. A. (2) (a) and A. (2) (c) ].<br />

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Component Maintenance Manual<br />

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DISASSEMBLY<br />

NOTE: See "Testing and Troubleshooting" to determine the condition of the<br />

unit or the most likely cause of faulty operation.<br />

Tools and special equipment to be used are listed under "Tools and Special Equipment".<br />

1. Disassembly (See IPL, Fig. 1)<br />

Remove cover (20) .<br />

CAUTION: MAKE SURE THAT THE <strong>BATTERY</strong> IS COMPLETELY DISCHARGED<br />

BEFORE PERFORMING THE FOLLOWING OPERATIONS.<br />

Remove terminal nuts (110), spring washers (100), and rigid links (140,and<br />

150) interconnecting cells (30).<br />

Detach the temperature sensor harness assembly (220) ring terminals from<br />

the connector adapter (170) interconnecting links (160) by removing the two<br />

screws (270) and lock nuts (280).<br />

Extract the first cell in each row using wrench. (P/N 17556 see Fig. 901) The<br />

remaining cells may be removed by hand thereafter.<br />

Remove the liner spacers (300).<br />

Unscrew the four attaching sems screws (190), and remove connector<br />

receptacle (170) ; recover preformed packing (180).<br />

Remove cell valves (120) using wrench 93365 (use the two lugs provided to<br />

facilitate unlocking); recover preformed packing (130).<br />

Remove the four screws (230) and four locking nuts (240) retaining the<br />

temperature sensor harness assembly (220).<br />

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Remove the temperature sensor harness assembly (220) through the<br />

opening in liner and spacer bracket.<br />

Disassemble the temperature sensor harness assembly (220) from the plate<br />

and stud assembly (250) by removing the four retaining lock nuts (260).<br />

Remove the temperature sensor harness assembly (220).<br />

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1. Cleaning the valves<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

CLEANING<br />

CAUTION: THE USE OF GASOLINE, CHLORINATED SOLVENT OR ANY<br />

OTHER SOLVENT IS STRICTLY PROHIBITED.<br />

Remove the valves and soak them for a sufficient time to dissolve any salts that are<br />

present in a container filled with distilled water or, if not available, with very clean<br />

and non-acid water.<br />

The purpose of this dipping operation is to dissolve the salts likely to accumulate<br />

within the valve clearing ports.<br />

While the valves are immersed, take all appropriate precautions to prevent foreign<br />

matter from falling inside the cells, and to avoid the reaction of the electrolyte in<br />

contact with the ambient air.<br />

Before fitting back the valves on the cells, check them for operation (see<br />

"Inspection").<br />

2. Cleaning the cells<br />

Two cleaning procedures can be used :<br />

cleaning with well-filtered compressed air,<br />

cleaning by washing.<br />

A. Cleaning with compressed air<br />

NOTE: To avoid any short-circuit, blow with a rubber hose or a pipe fitted with<br />

an insulating adaptor.<br />

Thoroughly blow on the cell covers, in order to expel outside the box the dust and<br />

the salts likely to have accumulated on the covers.<br />

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B. Cleaning by washing (cells removed)<br />

3. Cleaning the box<br />

This procedure is more rational and consists in washing the terminals,<br />

covers and cell walls with warm water and a smooth non-metallic<br />

brush, in order to remove any trace of potassium or salts.<br />

Before cleaning, make sure that the cell vent valves are installed and<br />

secure.<br />

Never immerse the cells in water.<br />

Wipe each cell, then let in dry in ambient air.<br />

Do not submerge or force water in vent valve area.<br />

Wash with water and let dry in the ambient air after wiping.<br />

4. Cleaning the nuts, links, spring washers, endplates and sideplates<br />

Clean with warm water and a brush, and let dry in ambient air.<br />

Discard any corroded or mechanically defective part.<br />

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INSPECTION<br />

NOTE: Tools and special equipment to be used are listed under "Tools and<br />

Special Equipment".<br />

1. Visual inspection<br />

Inspect the box on the outside and make sure that it does not show any trace<br />

of impact.<br />

Check the cells for condition, in order to detect any electrolyte seepage<br />

around the terminals, traces of shorting, corrosion by potassium, cover lifting,<br />

cracked cells, etc.<br />

Discard and replace any corroded or damaged parts.<br />

2. Checking a valve<br />

Remove the valve.<br />

Screw the valve fitted with its seal on a manifold fitted with an appropriate<br />

adapter.<br />

Connect this tube to an adjustable pressure reducing valve and then to a<br />

compressed air line or a compressed air cylinder.<br />

Adjust the pressure to 0.5 bar (7.25 psi) and dip the valve in a container filled<br />

with water. If the valve is in good condition, air bubbles should come off.<br />

If there are no bubbles, increase pressure until the air escapes, then<br />

gradually decrease pressure to 0.5 bar (7.25 psi) and note the value for<br />

which the air stops escaping.<br />

Discard any valve whose operating pressure is greater than 0.7 bar (10 psi)<br />

after this "lifting" operation is performed, and replace the valve by a duly<br />

tested spare valve. Also discard any valve whose operating pressure is less<br />

than 0.14 bar (2 psi).<br />

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Component Maintenance Manual<br />

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Install the valve using wrench p/n 93365. (see Fig. 902)<br />

Check the packing (O-Ring) for condition.<br />

3. Checking the nuts for tightness<br />

Check that all nuts are correctly tightened:<br />

lower terminal nuts; torque 60 ± 8 in. lbs. (6.8 Nm)<br />

upper terminal nuts; torque after assembly: 113 in. lbs. (13 Nm)<br />

4. Checking the connector receptacle<br />

Check the connector receptacle pins for condition; replace the connector receptacle<br />

if the pins show any trace of arcing or excessive oxidization.<br />

5. Visual inspection of the temperature sensor harness assembly<br />

Visually check the temperature sensor harness and auxilliary connector receptacle<br />

for condition.<br />

Check in particular that:<br />

the thermistor is secure to the mounting plate,<br />

the connecting leads or cable between the connector receptacle and the<br />

various components are not damaged.<br />

6. Checking the thermostat<br />

A. Functional check (see Fig. 501)<br />

Dip the thermostats in a 0.5 liter (0.109 Imp. Gal; 0.132 US Gal.)<br />

beaker, three quarters full of water. Make sure that the thermostats<br />

are not in contact with the container walls.<br />

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Dip a thermometer in the container, being careful to place the bulb of<br />

the thermometer in the immediate vicinity of the thermostat.<br />

Connect the test circuit (ohmmeter or closed circuit detector) to the<br />

connector receptacle contact #8 and the positive ring terminal of the<br />

harness assembly.<br />

Gradually heat the container water, being careful to maintain the water<br />

at a temperature close to 140F (60C) for about 10 minutes. This is<br />

necessary to bring all thermostat components to the same temperature<br />

as the water.<br />

Continue to heat the water gradually and note on the thermometer the<br />

temperature at which the thermostat operates. (Opens on temperature<br />

rise)<br />

Thermostat opening is indicated by the ohmmeter pointer moving from<br />

32.4K to the infinity position or by the light exstinguishing on the<br />

closed-circuit detector.<br />

Thermostat operation is correct if the temperature noted is within<br />

138.6F (59.2C) and 169.4F(76.3C).<br />

As soon as the thermostats open, stop heating the water and place the<br />

.5 liter (0.109 Imp. Gal; 0.132 US Gal.) beaker in a 1 liter (0.219 Imp<br />

Gal.; 0.264 US Gal.) container.<br />

Slowly pour cold water into the larger container until the water level is<br />

the same in the two containers.<br />

Note the temperature at which the thermostat contacts close (falling<br />

temperature). When the contacts close, the ohmmeter pointer<br />

resumes the 32.4K position or the closed circuit detector indicater<br />

illuminates.<br />

Thermostat operation is correct if the difference between the opening<br />

and closing temperatures is between 7.2F and 18F (4C and 10C).<br />

In the case of operating temperatures recorded not being within<br />

tolerance limits, perform the above tests again.<br />

Remove the thermostats from the container and dry thoroughly.<br />

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B. Testing the thermistor<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Connect an ohm meter to pins #11 and #12.<br />

The ohmmeter shall indicate 2460 ± 10% at 73F (23C).<br />

C. Testing the resistors<br />

Connect an ohmmeter to pin #8 of the connector receptacle and<br />

positive ring terminal of harness assembly.<br />

The ohmmeter shall indicate 32.4K ± 10% at 73F (23C).<br />

Connect an ohmmeter to pin #9 of the connector receptacle and the<br />

negative ring terminal of the harness assembly.<br />

The ohmmeter shall indicate 32.4K ± 10% at 73F (23C).<br />

D. Testing the shunt<br />

Connect an ohmmeter to pins #4 and #6 of the connector receptacle.<br />

The ohmmeter shall indicate zero ohms at all temperatures.<br />

E. Insulation test<br />

Using a megohmmeter, measure the insulation of each pin of the<br />

connector receptacle and the outer metal shell.<br />

The insulation resistance shall be greater than or equal to 30M <br />

under 250 Volts D.C.<br />

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CHECKING THE THERMOSWITCH<br />

FIGURE 501<br />

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1. Box<br />

2. Cells<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

REPAIR<br />

Straighten out the sides of the box and remove any dents which have been<br />

produced following impact.<br />

Repair essentially consists in the replacement of cells acknowledged defective (see<br />

"Testing and Troubleshooting", para. 1.B.(4)(c). New cells must first be discharged<br />

(see "Testing and Troubleshooting", para. 1.B.(2) (a)).<br />

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Component Maintenance Manual<br />

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ASSEMBLY AND <strong>STORAGE</strong><br />

NOTE: The products to be used are listed under "List of Products".<br />

1. Assembly<br />

Tools and special equipment to be used are listed under "Tools and<br />

Special Equipment".<br />

NOTE: In case cells must be replaced, see "Testing and Troubleshooting",<br />

para. 1.B.(4)(c).<br />

Secure the two series mounted thermostats to the thermostat mounting plate<br />

(250) with four locking nuts (260) through the opening provided in the<br />

insulator plate. Install this assembly in the case assembly by threading the<br />

temperature sensor harness assembly through the spacer bracket of the<br />

case assembly.<br />

Apply a small amount of silicone sealant (General Electric RTV 108 or<br />

equivalent) to the harness connector O-Ring and mating surface.<br />

Install the thermostat connector receptacle from the inside of the box and<br />

secure it with four screws (230) and four lock nuts (240). Place the<br />

remainder of the temperature sensor harness assembly outside the box.<br />

Apply a small amount of silicone sealant (General Electric RTV 108 or<br />

equivalent) to the connector receptacle gasket (180).<br />

Install connector receptacle (170), fitted with its preformed packing (180), and<br />

secure with four Sems screws (190).<br />

Preposition the two notched insulator plates, and intermediate insulator<br />

plates between the three rows of the case assembly. Place end plate<br />

insulators in position as individual cell rows are occupied by installed cells.<br />

Install cells, strictly complying with polarities (see Fig. 701).<br />

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Install the temperature sensor thermistor/plate assembly between cells #6<br />

and #9 in the center row of cells. (See Fig. 701)<br />

HINT: Installing the center row of cells first, with the thermistor/plate<br />

assembly, and installing the center cell of each row last after all other<br />

cells have been put in place eases assembly.<br />

NOTE: Install a sufficient number of end plate insulators to obtain<br />

approximately 30 lbs of pull to remove individual cells.<br />

Check the torque on the cell lower terminal nuts [60 in. lbs.(6.8 Nm)].<br />

Install intercell connector links (140, and 150).<br />

Secure the negative and positive leads of the temperature sensor<br />

harness assembly to intercell connector links (160) with screws (270)<br />

and lock nuts (280).<br />

Install the intercell connector link (160) on the receptacle adapter and<br />

cell #1 and #21.<br />

Secure the intercell connector links with nuts (110), and washers<br />

(100).<br />

Tighten the nuts using a torque wrench [torque: 113 in lbs.(13 Nm)].<br />

Lightly coat the exposed areas of the terminals, nuts, and intercell<br />

connector links with non acid petroleum jelly or neutral light machine<br />

oil.<br />

Measure the insulation resistance value [see "Testing and<br />

Troubleshooting", para. .A.(1)(b)].<br />

Charge the battery [see "Testing and Troubleshooting", para. 1.B.(5)].<br />

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2. Storage<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

A. Preparing the battery for storage<br />

After re-establishing the electrolyte level [see "Testing and<br />

Troubleshooting", para. 1.B.(3)], discharge the battery with a constant<br />

current of 26.5 A until the voltage across the terminals falls to 21 V<br />

D.C.<br />

Using non acid petroleum jelly or neutral light machine oil (non acid),<br />

lightly coat the exposed areas of the terminals, nuts, intercell<br />

connector links and connector receptacle contacts, and the metal parts<br />

which are likely to be damaged by atmospheric agents.<br />

Install the cover and place the battery in its normal upright position.<br />

B. Storage premises<br />

Store the equipment in a dust-free, dry area.<br />

C. Temperature requirements<br />

The battery can be stored between -60 and +60C (-76 to 140F).<br />

Optimum storage temperatures range from 0 to +30C (+32 to +86F).<br />

D. Storage life<br />

10 years from date of manufacture<br />

E. Packing<br />

The battery is usually packed in a fiberboard container with fiberboard<br />

spacers.<br />

For long term storage or overseas transportation, it is advisable to<br />

enclose the equipment in a plastic sealed envelope.<br />

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F. Transportation<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

It is important that all required precautions should be taken to<br />

transport the battery in its normal upright position. To this effect, the<br />

transportation container should bear the inscriptions "Top" and<br />

"Bottom". Consult IATA regulations on the transportation and handling<br />

of semi-sealed non spillable nickel cadmium batteries.<br />

G. Removal from storage<br />

Charge the battery at a slow or fast rate, as required (see "Testing and<br />

Troubleshooting")<br />

If difficulty occurs in charging a unit that has been in long term storage<br />

is experienced, it may be necessary to:<br />

1. Terminate the charge sequence where the difficulty occurs. (Voltage<br />

plateau or temperature rise.)<br />

2. Completely discharge the battery [see "Testing and Troubleshooting"<br />

para. 1.B.(2)(a)]<br />

3. Repeat the above charge/discharge sequence until the unit accepts a<br />

full charge and delivers its rated capacity or a reason for the difficulty<br />

is determined. (Loose hardware, defective component etc.)<br />

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1159SCAV519-1<br />

Cell Position (numerical designation) is determined by its position relative to the positive<br />

post of the main battery receptacle. i.e. the cell directly connected to the positive post of<br />

the battery receptacle is cell number 1. Follow the intercell connector path (from the<br />

positive post of the battery receptacle) to determine cell number.<br />

CONNECTION DIAGRAM<br />

FIGURE 701<br />

24-34-01<br />

PAGE 705/706<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

TOOLS AND SPECIAL EQUIPMENT<br />

NOTE: Equivalent items of equipment may be used in place of those listed.<br />

PART NUMBER DESCRIPTION<br />

17756<br />

Cell Extraction Tool (Fig. 901)<br />

93365<br />

Simpson 260<br />

(or equivalent)<br />

Amprobe AMB-4D<br />

(or equivalent)<br />

Valve Wrench (Fig 902)<br />

Multi-Meter<br />

Meg-Ohm Meter<br />

T<br />

E<br />

S<br />

T<br />

I<br />

N<br />

G<br />

X<br />

X<br />

X<br />

USE<br />

D<br />

I<br />

S<br />

A<br />

S<br />

S<br />

E<br />

M<br />

B<br />

L<br />

Y<br />

X<br />

R<br />

E<br />

P<br />

A<br />

I<br />

R<br />

X X<br />

X<br />

X<br />

C<br />

L<br />

E<br />

A<br />

N<br />

I<br />

N<br />

G<br />

X<br />

24-34-01<br />

PAGE 901<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

NOTE: ALL DIMENSIONS ARE IN MM<br />

CELL EXTRACTING WRENCH<br />

FIGURE 901<br />

24-34-01<br />

PAGE 902<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

NOTE: ALL DIMENSTIONS ARE IN INCHES<br />

VALVE WRENCH<br />

FIGURE 902<br />

24-34-01<br />

PAGE 903/904<br />

AUG 30/96


INTRODUCTION<br />

1. General<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

ILLUSTRATED PARTS LIST<br />

The Illustrated Parts List (IPL) is prepared in compliance with ATA 100. the IPL is<br />

intended to identify all the components of the unit.<br />

The Illustrated Parts List contains the following sections:<br />

Introduction<br />

Vendors Code List<br />

List of Circuit Symbols (if applicable)<br />

Alphanumeric Index of Manufacturer's Part Numbers<br />

Detailed Parts List<br />

2. How to Use Detailed Parts List<br />

The Detailed Parts List includes the nomenclature and illustrations of the unit<br />

components.<br />

The Detailed Parts List columns are arranged as follows:<br />

1st column : Fig. Item - Figure and Item Number.<br />

2nd column : Part Number - Manufacturer's Part Number.<br />

3rd column : Nomenclature.<br />

4th column : Usage Code - Effectivity.<br />

5th column : Units per Assy. - Quantity per next higher assembly.<br />

24-34-01<br />

INTRO 1001 - PAGE 1<br />

AUG 30/96


A. Figure and Item Numbers<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

The figure number, covering items listed, is indicated on the first line at the<br />

top of each page.<br />

Each part-numbered assembly, sub-assembly or item listed in the parts list is<br />

assigned an item number followed by a letter identifying the variant. The<br />

basic variant is lettered A.<br />

Assemblies, sub-assemblies and parts listed, but not illustrated, are identified<br />

by a dash (-) preceding the corresponding item numbers.<br />

A "lettered index" appearing before the item number is a cross reference to<br />

the illustration of the variant called out from the corresponding main figure.<br />

B. Manufacturer's Part Number<br />

Each of the assemblies, sub-assemblies and detail parts, illustrated or not, is<br />

assigned a manufacturer's part number.<br />

When the manufacturer's actual part number exceeds 15 characters, an<br />

equivalent assigned part number is listed in the "Part Number" column<br />

preceded by the following annotation:<br />

ORDER OVERLENGTH... MADE BY V...<br />

Both part numbers are listed in the Alphanumeric Index in their logical order;<br />

the actual overlength part number is cross-referenced to the assigned part<br />

number preceded by the annotation, "SEE...".<br />

C. Nomenclature<br />

The nomenclature is indented to show the relationship between the parts<br />

listed, as follows:<br />

1 2 3 4 5 6 7<br />

24-34-01<br />

INTRO 1001 - PAGE 2<br />

AUG 30/96


Assembly<br />

Detail parts for assembly<br />

Sub-assembly<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

Attaching parts and/or storage parts for sub-assembly<br />

+ + +<br />

Detail parts for sub-assembly<br />

Sub-sub-assembly<br />

Attaching parts and/or storage parts for sub-sub-assembly<br />

+ + +<br />

Detail parts for sub-sub-assembly etc.<br />

A vendor code is indicated for all items or articles not made by the prime<br />

manufacturer of the assembly.<br />

This vendor code or the abbreviation "NP" (nonprocurable) is placed at the<br />

extreme right-hand side of the first line of the nomenclature.<br />

D. Effectivity (Usage Code)<br />

An alphanumeric usage code indicates the applicability of sub-assemblies<br />

and detail parts to the next higher assembly(ies) or sub-assembly(ies).<br />

When the applicability is general, the usage code column is left blank.<br />

The usage code corresponds to the figure/item number of the next higher<br />

assembly(ies) or sub-assembly(ies), e.g., effectivity 1A, 1B, 1C is written<br />

1ABC.<br />

E. Units per Assembly<br />

The Units per Assy column shows the number of units required for the next<br />

higher assembly.<br />

In some cases, this information is replaced by the letter REF (reference) or<br />

AR (as required).<br />

24-34-01<br />

INTRO 1001 - PAGE 3<br />

AUG 30/96


3. Terms and Abbreviations Used<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

AR: As Required<br />

ATTACHING PARTS<br />

DELETED<br />

DET: Detail<br />

LH and RH: Left and Right<br />

MADE BY<br />

MADE FROM<br />

MATCHED PART<br />

MODIFIED PART<br />

NHA: Next Higher Assembly<br />

NP: Nonprocurable<br />

OPT TO: Optional Parts<br />

ORDER OVERLGTH MPN: Actual part number exceeding 15 characters<br />

OVERSIZE: Oversize repair parts<br />

POST SB: After applying Service Bulletin instructions<br />

R: Modified<br />

REF: For Reference<br />

SEE<br />

SEL FROM: Select from parts<br />

<strong>STORAGE</strong> PARTS<br />

SUPSD BY: Superseded by<br />

SPUSDS: Supersedes<br />

UNDERSIZE: Undersize repair parts<br />

4. Updating<br />

When an item is revised, added or deleted, the letter "R" is shown in the RH margin<br />

(the page date of issued changes).<br />

The letter "R" appears in the RH margin opposite the page number when all the item<br />

numbers are changed.<br />

24-34-01<br />

INTRO 1001 - PAGE 4<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

ILLUSTRATED PARTS LIST<br />

24-34-01<br />

PAGE 1001<br />

AUG 30/96


<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

<strong>BATTERY</strong> <strong>STORAGE</strong><br />

FIGURE 1<br />

24-34-01<br />

PAGE 1001-0<br />

AUG 30/96


FIG.<br />

ITEM<br />

1-001<br />

010<br />

020<br />

030<br />

-040<br />

-050<br />

-060<br />

-070<br />

-080<br />

-090<br />

100<br />

110<br />

120<br />

130<br />

140<br />

150<br />

160<br />

170<br />

180<br />

190<br />

200<br />

210<br />

220<br />

230<br />

240<br />

-250<br />

-260<br />

-270<br />

-280<br />

-290<br />

300<br />

PART<br />

NUMBER<br />

5317CH-1<br />

23837<br />

23840<br />

23456<br />

91180-2<br />

21870<br />

21971<br />

23382-1<br />

23382-2<br />

15579<br />

22228<br />

15579<br />

23619<br />

12536-2<br />

18567<br />

15575<br />

23904<br />

22078<br />

9384<br />

93616<br />

15579<br />

22228<br />

23850<br />

92178-8<br />

90064<br />

23870<br />

90064<br />

92830-4<br />

90063<br />

23872<br />

TBD<br />

-ITEM NOT ILLUSTRATED<br />

<strong>SAFT</strong> AMERICA INC.<br />

Component Maintenance Manual<br />

1159SCAV519-1<br />

1234567<br />

NOMENCLATURE<br />

<strong>BATTERY</strong>, <strong>STORAGE</strong><br />

.CASE, MARKED<br />

.COVER & PAD MARKED<br />

.CELL, <strong>BATTERY</strong>, <strong>STORAGE</strong><br />

..PACKING, PREFORMED<br />

..WASHER, FLAT<br />

..WASHER, BELLEVILLE<br />

..WASHER, POLARITY, (+) (Red)<br />

..WASHER, POLARITY, (-) (Blue)<br />

..NUT, HEX<br />

..WASHER, BELLEVILLE<br />

..NUT, HEX<br />

..VALVE, VENT, ASSY<br />

...PACKING, PREFORMED<br />

.INTERCELL CONNECTOR<br />

.INTERCELL CONNECTOR<br />

.INTERCELL CONNECTOR W/HOLE<br />

.CONNECTOR RECEPTACLE<br />

..GASKET, PREFORMED<br />

ATTACHING PARTS<br />

.SCREW, SEMS<br />

* * *<br />

.NUT, HEX, (17mm)<br />

.WASHER, BELLEVILLE<br />

.CONNECTOR & HARNESS ASSY<br />

ATTACHING PARTS<br />

.SCREW, BINDING HEAD<br />

.NUT, LOCKING<br />

* * *<br />

.PLATE & STUD ASSY<br />

..NUT, LOCKING<br />

.SCREW, FLAT<br />

.NUT, LOCKING<br />

.LINER, THERMOSTAT MOUNTING<br />

.KIT, LINER/SPACER<br />

USAGE<br />

CODE<br />

UNITS<br />

PER<br />

ASSY<br />

RF<br />

1<br />

1<br />

20<br />

2<br />

2<br />

4<br />

1<br />

1<br />

2<br />

2<br />

1<br />

1<br />

14<br />

6<br />

2<br />

1<br />

1<br />

4<br />

2<br />

2<br />

1<br />

4<br />

4<br />

1<br />

4<br />

2<br />

2<br />

1<br />

1<br />

24-34-01<br />

PAGE 1002-0<br />

AUG 30/96

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