Component Maintenance Manual With Illustrated Parts List

(F6177)
12 rue Sadi Carnot - 93170 Bagnolet - France

Tél. (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
www.saftbatteries.com
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
2778-14
Page 1
Revision n°. 3
Initial issue: 1997 24-30-00 Mar 03/2009
COMPONENT MAINTENANCE MANUAL
2778-14
This document and all information contained herein are the property of
Saft. Its use is restricted solely to the maintenance of Saft batteries and
may under no circumstances be used for any other manufacturer's prod-
ucts. No person may, in whole or in part, duplicate, use or disclose this
information for any other purpose without the prior written consent of
Saft.
Page 2
24-30-00 Mar 03/2009
2778-14
RECORD OF REVISION
Rev. Inserted Issue Inserted

Issue date Rev. n°
n° Date By date Date By
1 Oct 03/1997 Oct 03/07 Saft
2 Mar 27/1998 Mar 27/1998 Saft
2 Mar 03/2009 Mar 03/2009 Saft
ROR
Page 1
24-30-00 Mar 03/2009
2778-14
PAGE INTENTIONALLY LEFT BLANK
24-30-00 BLANK
2778-14
RECORD OF TEMPORARY REVISION
Temp rev. Inserted Removed

Issue date Page n°
n° Date By Date By
RTR
Page 1
24-30-00 Mar 03/2009
2778-14
24-30-00 BLANK
2778-14
SERVICE BULLETIN LIST
Incorporation into
Service bulletin
CMM Title
Number Rev. Date Rev.
SBL
Page 1
24-30-00 Mar 03/2009
2778-14
24-30-00 BLANK
2778-14
LIST OF EFFECTIVE PAGES
TITLE PAGE 1 Mar 03/2009 TESTING AND FAULT 1001 Mar 03/2009
2 Blank ISOLATION 1002 Mar 03/2009
1003 Mar 03/2009
RECORD OF REVI- 1 Mar 03/2009 1004 Mar 03/2009
SIONS 2 Blank 1005 Mar 03/2009
1006 Mar 03/2009
RECORD OF TEMPO- 1 Mar 03/2009 1007 Mar 03/2009
RARY REVISIONS 2 Blank 1008 Mar 03/2009
1009 Mar 03/2009
SERVICE BULLETIN 1 Mar 03/2009 1010 Mar 03/2009
LIST 2 Blank 1011 Mar 03/2009
1012 Mar 03/2009
LIST OF EFFECTIVE 1 Mar 03/2009
PAGES 2 July 01/2008 SCHEMATIC AND 3001 Mar 03/2009
WIRING DIAGRAM 3002 Blank
TABLE OF CON- 1 Mar 03/2009
TENT 2 Mar 03/2009 DISASSEMBLY 3001 Mar 03/2009
3 Mar 03/2009 3002 Mar 03/2009
4 Mar 03/2009 3003 Mar 03/2009
3004 Blank
LIST OF ILLUSTRA- 1 Mar 03/2009
TIONS 2 Mar 03/2009 CLEANING 4001 Mar 03/2009
4002 Mar 03/2009
INTRODUCTION 1 Mar 03/2009 4003 Mar 03/2009
2 Mar 03/2009 4004 Blank
3 Mar 03/2009
4 Mar 03/2009 INSPECTION/CHECK 5001 Mar 03/2009
5 Mar 03/2009 5002 Mar 03/2009
6 Mar 03/2009 5003 Mar 03/2009
7 Mar 03/2009 5004 Mar 03/2009
8 Mar 03/2009 5005 Mar 03/2009
5006 Mar 03/2009
DESCRIPTION AND 1 Mar 03/2009 5007 Mar 03/2009
OPERATION 2 Mar 03/2009 5008 Mar 03/2009
3 Mar 03/2009 5009 Mar 03/2009
4 Blank 5010 Mar 03/2009
5011 Mar 03/2009
5012 Blank
LEP
Page 1
24-30-00 July 01/2008
2778-14
LIST OF EFFECTIVE PAGES
REPAIR 6001 Mar 03/2009 DETAILED 10011 July 01/2008
6002 Mar 03/2009 PARTS LIST 10012 July 01/2008
10013 July 01/2008
ASSEMBLY 7001 Mar 03/2009 10014 July 01/2008
7002 Mar 03/2009 STORAGE (INCLU- 15001 Mar 03/2009
7003 Mar 03/2009 DING TRANSPORTA- 15002 Mar 03/2009
7004 Blank TION) 15003 Mar 03/2009
15004 Mar 03/2009
FITS AND CLEA- 8001 Mar 03/2009
RANCES 8002 Blank
SPECIAL TOOLS, 9001 Mar 03/2009

FIXTURES, 9002 Mar 03/2009
EQUIPMENT 9003 Mar 03/2009
AND CONSUMABLES 9004 Mar 03/2009
9005 Mar 03/2009
9006 Blank
ILLUSTRATED 10001 Mar 03/2009

PARTS LIST 10002 Blank
INTRO IPL 10003 Mar 03/2009

10004 Mar 03/2009
10005 Mar 03/2009
10006 Mar 03/2009
10007 Mar 03/2009
10008 Mar 03/2009
ALPHA NUMERICAL 10009 Mar 03/2009

INDEX 10010 Mar 03/2009
LEP
Page 2
24-30-00 July 01/2008
2778-14
TABLE OF CONTENT
RECORD OF REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
B. How to Use the Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
C. Associated Publications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
D. Revision and updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
E. CMM Page Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
F. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
G. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
H. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
I. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
J. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
K. Verifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
L. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
M. Disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
B. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
C. Detailed description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
2. Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
A. reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004
E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1006
3. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1006
A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1006
C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1006
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1006
E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1008
4. Discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1008
A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1008
C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1008
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1008
5. Fault isolation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1009
TOC
Page 1
24-30-00 Mar 03/2009
2778-14
TABLE OF CONTENT
A. Battery electrical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1009
B. Cell faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1009
C. Physical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1011
D. Vent valve faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1012
DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
B. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
C. Risks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
D. Safety measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
2. Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002
E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3003
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
2. Cleaning of a unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4003
INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2. Maintenance steps in workshop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5002
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
REPAIR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
2. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
A. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
B. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
C. Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
3. Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6001
REPAIR N°1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002

4. Changing a cover gasket- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002
B. Detailed procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002
TOC
Page 2
24-30-00 Mar 03/2009
2778-14
TABLE OF CONTENT
ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
2. Assembly procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7002
E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7004
FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001

1. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
A. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES - - - - - - - - - - - - - - - - 9001

1. Special tools, fixtures and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9001
A. Special tools table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9001
2. Consumables material - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9005
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
B. How to Use the illustrated Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
C. Numerical Index (NI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
D. Detailed Parts List (DPL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
E. Updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10005
VENDOR LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10007
ALPHA NUMERICAL INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10009
DETAILED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011
STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
B. Storage room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
C. Temperature conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
2. Storage procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002
E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15004
3. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15004
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15004
TOC
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LIST OF ILLUSTRATIONS
INTRO-1 Recyclable Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1 Identification plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
3 Overall dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1001 Preliminary Functional Tests - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003
1002 Insulation Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004
1003 Insulation Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004
1004 Cell connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1007
2001 Sensor electrical schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2001
5001 Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
5002 Level adjustment with a syringe and calibrated nozzle - - - - - - - - - - - - - - - - - - - - 5005
5003 Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
5004 General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5010
9001 Polyamide key for vent valve (T01) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
9002 Syringe with nozzle (T02) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
9003 Equalizing resistor (T03) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
9004 Cell extraction tool (T04) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9003
10001 2778-14 BATTERY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011
15001 Short term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
LOI
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INTRODUCTION
TASK 24-30-00-871-801-A01
1. Introduction
A. General
(1) This component maintenance manual (CMM) agrees with the Air Transport Association
(ATA) iSpec 2200, and it is written in AECMA Simplified English (European Association of
Aerospace Industries).
(2) This CMM gives the procedures necessary to do simple checks and replacement of parts
and components. It also gives the procedures for maintenance. The maintenance proce-
dures given in this CMM are only for approved persons with the necessary skills.
(3) This CMM gives the shop maintenance procedures of the component.
(4) This CMM uses the identification of the tasks and subtasks which is defined in the Mainte-
nance Task Oriented Support System (MTOSS). The maintenance tasks and other data
have special MTOSS numbers for the use of Electronic Data Processing (EDP). The user of
the manual can ignore the MTOSS numbers.
(5) This manual contains:
- the technical data for the component,
- the maintenance and repair procedures for the component,
- an Illustrated Parts List (IPL) with the data for the component parts. The parts are iden-
tified in all the Page Blocks of the manual, by the IPL Figure and the item number.
(6) A check of the DISASSEMBLY, TESTING and ASSEMBLY procedures in the workshop.
B. How to Use the Manual
(1) Make sure the manual contains the applicable data for your component. Look for the part
number on the Title Page.
(2) To identify a part or to find a part number, refer to the IPL, which has an Introduction to show
the procedure.
(3) You must use the instructions in this manual, for all the maintenance steps of a component.
Read all the applicable WARNINGS and CAUTIONS before you do the work on the compo-
nent.
(4) When you use consumable materials, these materials are identified by a code number which
is listed in the Consumable Materials Table.
(5) When you use special tools, these tools are identified by a code number which is listed in
the Special Tools Table.
(6) For the tightening torque values of the parts, refer to the Table of Tightening Torques.
C. Associated Publications
Not applicable.
D. Revision and updating
This manual is revised periodically and may be the subject of update which refers to modifica-
tions made on the equipment. Detailed instructions relative to the insertion of withdrawal of pag-
es accompany each update.
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E. CMM Page Blocks
(1) The information for each component in the CMM is divided into specific Page Blocks. Each
Page Block has its own specified subject matter and its own specified page numbering.
These Page Blocks have these titles:
ACTUAL
PAGEBLOCKS PAGENUMBER DATE BY
VERIFICATIONS
Description and 0001 to 0999
Operation
Testing and Fault 1001 to 1999
Isolation
Schematics and Wir- 2001 to 2999
ing Diagrams
Disassembly 3001 to 3999
Cleaning 4001 to 4999
Inspection/Check 5001 to 5999
Repair 6001 to 6999
Assembly 7001 to 7999
Fits and Clearances 8001 to 8999
Special Tools, Fix- 9001 to 9999
tures, Equipment
and Consumables
Illustrated Parts List 10001 to 10999
Special Procedure 11001 to 11999 Not applicable
Removal 12001 to 12999 Not applicable
Installation 13001 to 13999 Not applicable
Servicing 14001 to 14999 Not applicable
Storage (including 15001 to 15999
Transportation)
Rework (Service 16001 to 16999 Not applicable
Bulletin Instructions)
(2) Description and Operation

This Page Block gives general data.
It gives a mechanical description and an electrical description.
It gives a description of the configuration and operation of the component.
(3) Testing and Fault Isolation
(a) It contains special tests and procedures which you must do to find the condition of a com-
ponent. The general test procedure is given in the FAULT ISOLATION TABLE. For each
test, this table refers to a special procedure which gives all the parameters which you
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2778-14
must set. It also gives all the parameters for which you must do a check.
(b) The pressure values in the tests are gage-pressure values.
(c) Before you use any of the measuring instruments, make sure that they are in correct op-
erating condition and that they are calibrated.
(d) Do a check for pneumatic system tightness, if this is applicable.
(e) You must do the tests in a room at ambient temperature +23 °C ± 5 °C (73 °F ± 9 °).
(4) Schematic and Wiring Diagrams
This Page Block contains all the schematic diagrams and the wiring and interconnecting di-
agrams of the cards.
It also contains the diagrams of:
- chassis wiring, modules, and sub-assemblies
- external connector interconnections in the component.
(5) Disassembly
(a) This Page Block gives step-by-step disassembly instructions in a correct sequence, and
it refers to the figure item numbers from the IPL illustration(s), when they are applicable.
Identify the type of fault, to know how much the extent of disassembly is necessary (do
this to prevent disassembly/reassembly work that is not necessary). The procedure given
below is when full disassembly is necessary.
(b) Put the component on a clean workbench, in a dust-free and moisture-free room. Move
all the parts carefully, and prevent corrosion and impact damage to them after disassem-
bly.
NOTE: Always discard all the seals and gaskets during disassembly.
Discard the washers, the nuts and the screws during disassembly if they are
damaged.
(6) Cleaning
(a) This Page Block gives a step-by-step description of the cleaning operations for the com-
ponent and its parts.
(b) Always use the recommended procedures for the component parts of the unit.
(7) Inspection / Check
(a) This Page Block gives the full check procedures which are necessary during shop main-
tenance.
(b) Discard all the defective parts if the document does not give a repair procedure.
(c) Do all the inspections/checks on the cleaned parts.
(8) Repair
This Page Block contains the full repair procedures and specifications which are necessary
to repair a worn or damaged part. As specified in the INSPECTION/CHECK section, you
must reject the defective parts if the document does not give a repair procedure. Replace
the defective parts with new parts.
(9) Assembly
(a) This Page Block gives step-by-step assembly instructions in a correct sequence, which
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2778-14
refer to the figure item numbers from the IPL illustration(s), if applicable.
(b) Put the component on a clean workbench, in a dust-free and moisture-free room. More
all the parts carefully, and prevent corrosion and impact damage to them.
(c) Be sure to remove the storage protection coating from all the new parts before assembly.
Clean the new part if necessary.
(10) Fits and Clearances
(a) This Page Block gives a table and some figures which gives the fits and clearances data
and the torque values for assembly. It also gives the permitted wear for in-service / ser-
vice, and the manufacturer’s design wear-tolerances.
(b) Fits and Clearances Table
1 The identifiers in column (1) show the location of the clearance or the dimension that
you must measure..
2 The identifiers in column (2) identify the parts in the IPL (Figure + Item number).
3 Column (3) gives the initial manufacturing dimensions and clearances.
4 In-service Wear Limits (Columns 4).
a The maximum limits are the maximum wear limits. If the part is in these limits then
it is serviceable.
b If the parts have more wear than the specified limits, you must repair or replace them.
(c) Torque Values
1 All torque values in this manual are shown in the Table of Tightening Torques. The parts
are identified by the figure number and the item number of the IPL.
(d) Spring Data
1 The technical data for all springs used in the unit are shown in the Table of Spring Data.
The parts are identified by the figure number and the item number of the IPL.
(11) Special Tools, Fixtures, Equipment and Consumables
(a) This Page Block shows all the special tools, the fixtures, the equipment and the consum-
ables which are necessary to do the maintenance actions which are given in the other
page blocks.
(b) All the items shown are identified in this manual by a standard code number: Txx for
Tools, Fixtures and Equipment and Mxx for Consumable Materials.
(12) Illustrated Parts List
This Page Block contains the full list of all the parts of the component (For the detailed de-
scription, refer to the IPL INTRO).
(13) Special Procedures
This Page Block contains the tasks which are given in other Page Blocks of the manual, but
which are necessary because of other maintenance tasks. The tasks are self-contained re-
pairs or preventive maintenance.
(14) Removal
This Page Block gives the procedure for the removal of modules/sub-assemblies from com-
plex modular components.
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(15) Installation
This Page Block gives the procedure for the installation of modules/sub-assemblies in com-
plex modular components.
(16) Servicing
This Page Block gives the self-contained tasks which are necessary because of other
maintenance tasks.
(17) Storage
This Page Block gives the requirements for preparation for transportation, for special han-
dling, for packaging, for storage and for preservation: these requirements are for the com-
ponent after assembly or test.
(18) Rework
This Page Block gives the rework procedures which are necessary for in-service compo-
nents.
F. Measurements
(1) The measurements which are given in this manual come from the original manufacturing
drawings.
(2) This CMM uses the “Systeme International” (S.I.) units for quantities and values. It also gives
the imperial units in parentheses.
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G. Units of Measure
(1) I.S. Units
A Ampere
Ah Ampere hours
C1A Rated current
C1Ah Rated capacity for an hour
g Gram
min Minute
N Newton
N.m Newton meter
Pa Pascal
VDC Volt direct current
°C Degree Celsius
% Per cent
Ω Ohm
(2) U.S. Units
ft Foot
in Inch
inHg Inchs of mercury
lb Pound
lbf.in Pound force inch
°F Degree Fahrenheit
(3) Multiplying Prefixes
μ Micro
m Milli
da Deca
k Kilo
M Mega
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H. Measurement Conversion Table
(1) From I.S. Measurement to U.S. Standard System
1 kPa 0.1450 psi

1 cm 0.3937 in
1 cm² 0.1550 in²
1N 0.2248 lbf
1g 0.0353 oz
1 kg 2.2046 lb
1 mm 0.0394 in
1 N.m 8.8507 lbf/in
1 N.m 0.7376 lbf/ft
(2) From U.S. Standard System to I.S. Measurement
1 psi 6,8948 kPa

1 in 2,54 cm
1 in 25,4 mm
1 in² 6,4516 cm²
1 lbf 4,4482 N
1 oz 28,3495 g
1 inHg 3,3864 kPa
1 lb 0,4536 kg
1 gal (U.S.) 3,7854 l/min
1 lbf/in 0,1130 N.m
1 lbf/ft 1,3558 N.m
I. Temperature Conversion Table

(a) SI MEASUREMENT Degrees Celsius (°C)
Celcius = ( Fahrenheit – 32 ) × 0.555 5
(b) U.S. STANDARD SYSTEM Degrees Fahrenheit (°F)
Fahrenheit = ( Celcius × 1.8 ) + 32
J. Abbreviations
The abbreviations given below are used in this manual:
AECMA European Association of Aerospace Industries

ATA Air Transport Association of America
dia. diameter
fig. figure
ipl illustrated parts list
max. maximum
mfr manufacturer
min. minimum
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n° number
od outside diameter
p/n part number
para. paragraph
ref. refer to
s/a subassembly
TBD to be defined
V Voltage
K. Verifications
(1) The functions (tasks) which are given in this manual were verified by simulation. This com-
ponent maintenance manual is "shop verified" after all the functions (tasks) are actually
done on the equipment.
(2) We will revise this statement after all verifications are made.
(3) The list of Page Blocks gives the shop verifications which are actually made. We will revise
this statement after all verifications are made.
L. Definition
(1) This paragraph describes the warnings used in this manual.
(2) Warnings call attention to use of materials, steps procedures, or limits, which must be fol-
lowed precisely to avoid injury to persons.
(3) Cautions call attention to steps procedures which must be followed to avoid damage to
equipment.
(4) Notes call attention to procedures which make the job easier.
M. Disposal
Ni-Cd batteries contain :
- nickel,
- cadmium,
- potassium hydroxide.
They must therefore be discarded or used again, in agreement with local legislation. For more
information, contact your local SAFT supplier.
Recyclable Product
Figure INTRO-1/GRAPHIC 24-30-00-991-069-A01
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DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium VHP270KH-3 cells with welded polyamide
cases. The battery is connected to the aircraft systems. You can use it:
(1) To start the engine or the APU in reference to the aircraft system.
(2) On the ground, before electrical power is supplied to the aircraft systems.
(3) In flight, if a malfunction or a failure occurs in the power supply system.
NOTE:The 28 VDC electrical system charges the battery in the aircraft
The figure and item numbers are those of the ILLUSTRATED PART LIST.
B. Characteristics
(1) Technical data
Technical data Values

Type of cells VHP270KH-3
Number of cells 20
Nominal voltage 24 V
Rated capacity C1Ah (Ah) see Note below 27 Ah
Electrolyte Solution of KOH
Electrolyte level (mm) 20 mm (0.79 in)
Consumable volume of electrolyte per cell 25 cm3 (1.28 in3)
End of charge voltage / per cell 1.50 V
End of life criteria in % 100%
End of life criteria in hour or minutes 60 min
Maximum dimensions of the battery :
- Length 201 mm (7.9 in)
- Width 268.4 mm (10.6 in)
- Height 300 mm (11.8 in)
Battery maximum weight 28 kg (51.7 lbs)
Battery terminals Connector according to MS 3509
NOTE: 27 Ah at 1 h rate noted as 27 C1Ah or 27 C1Ah.

Current value equivalence: 27 A = 1 C1A and 2.7 A = 0.1 C1A for this 27 C1Ah
battery.
(2) Operational characteristics
Operating temperature : - 40 to + 71 °C (- 40 to + 160 °F)
(3) Electrical characteristics
List of all values used to service the battery
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Item Value Use for

1 C1A 27 A Charge/Discharge
0.5 C1A 13.5 A Charge
0.1 C1A 2.7 A Charge
C. Detailed description
The battery has 20 VHP270KH-3 (130) cells housed in a stainless steel box.
The box (290) is lined with liner spacer kit (200). The cells are kept upright by means of a molded
silicone elastomer part (040) fastened to the cover which presses against the top of the cells.
Cells are interconnected by rigid, nickel-plated copper links (080 thru 120).
The connector (210) connects the battery to the aircraft.
The cover (020), which can be removed, is attached to the box (290) .
Identification plate
Figure 2/GRAPHIC 24-30-00-991-049-A01
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2778-14
Overall dimensions
Figure 3/GRAPHIC 24-30-00-991-050-A01
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TESTING AND FAULT ISOLATION
1. Introduction
A. General
This pageblock gives the tests and inspections required to find the condition of the unit removed
for unscheduled maintenance. The test procedure is given in the TESTING AND FAULT ISO-
LATION TABLE, which for each test refers to a specific procedure specifying all relevant param-
eters.
The figure and item numbers are those of the ILLUSTRATED PARTS LIST.
Do the tests at ambient conditions:
- Ambient temperature: 23 ± 5 °C (73 ± 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.1 InHg).
- Relative humidity: < 85 %.
TASK 24-30-00-700-801-A01
2. Testing
A. reason for the job
Self-explanatory
B. Job set-up information
NOTE:You can use equivalent alternatives for the items in those lists.
NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data
of special tools in this list.
(1) Tools, fixtures and equipment
Code Description
T02 Syringe assembly (with nozzle)
T03 Equalizing resistors (1 Ω / 3 W)
T05 Discharge bench (constant current 0-60 A)
T06 Power supply 0-45 V, 0-60 A
T07 Multimeter range 2 V-50 V accuracy 1%
T08 Megohmeter, range 0-50 MΩ voltage
250 VDC, accuracy 3%
- Standard mechanic’s tools.

- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
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(2) Consumables
Code Reference Description

M01 No special Distilled or deionized water
C. Job set-up
NOTE:You must always do regular maintenance. It is then necessary to obey these pre-
cautions to make sure that you have correct operation of the battery:
Do not install the battery in an aircraft which is too hot.
Carefully obey the instructions given in the aircraft documentation to make sure
that the flow of air is good.
Regularly make sure that the capacity of the battery is correct .
Charge the battery in a battery shop.
You must do maintenance, specially to make sure of level of electrolyte. specially
when ambient temperature is high, time between maintenance must decrease.
You must do maintenance, specially to make sure of tightness of the connection
nuts.
You must do maintenance, specially to make sure of correct charging.
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(1) Preliminary Functional Tests (Ref. Fig. Figure 1001/GRAPHIC 24-30-00-991-067-A01)
NOTE: (*) You must consider average in log book.
1
Discharge at 1 V/cell
Tighten the nuts (060) 1 Ω cell shorting 12 h
charge at 1 C1A (27 A)
box or cells Yes see para. 5.B (6)

damaged note the voltage of each
cell during the charge
No
salt or electrolyte Yes see para. 5.C (1) more than

Yes
usual average added in all see para. 5.B (1)
traces
cells
No No
Topping up at the end
electrolyte in Yes see para. 5.C (2) of charge
the box
No more than
30% versus battery Yes see para. 5.B (2)
cell average added
metallic parts Yes see para. 5.C (3) in 1 cell
corroded No
No 1 or more
cell has a voltage > 0.1 V Yes see para. 5.B (3)
battery Yes see para. 5.A (1) than the others
voltage = 0 V No
No
voltage of 1 cell Yes see para. 5.B (4)
Yes see para. 5.B (7) < 1.50 V
1 or more cell = 0 V
No
No
capacity check Yes see para. 5.B (5)
Yes < 100% C1Ah
1 or more cell < 0 V see para. 5.B (5)
No
No
a link or a Yes
insulation
see para. 5.C (4)
nut is too hot
between cell and box
Yes see para. 5.A (3)
No
< 250 kΩ
No do a General Overhaull
to detect battery fault or
external cause
Preliminary Functional Tests

Figure 1001/GRAPHIC 24-30-00-991-067-A01
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2778-14
D. Procedure
SUBTASK 24-30-00-750-001-A01
(1) Insulation check
- Place the megohmeter (T08) as the figure show (Figure 1002/GRAPHIC 24-30-00-991-
006):
Insulation Check
Figure 1002/GRAPHIC 24-30-00-991-006
- ≥ 250 kΩ under 250 VDC = Min value (Figure 1003/GRAPHIC 24-30-00-991-052-A01).

- > 10 MΩ under 250 VDC = Min value after cleaning and drying (Figure 1003/GRAPHIC
24-30-00-991-052-A01).
250 KΩ 2 MΩ 10 MΩ
Can wait until next

problem to be cleaned maintenance OK
In battery maintenance shop Always required after

cleaning and drying
Cleaning required Cleaning required
Acceptable
Check the cause

(overcharge…)
Insulation Parameters
Figure 1003/GRAPHIC 24-30-00-991-052-A01
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2778-14
SUBTASK 24-30-00-750-003-A01
(2) Polarization test
- Charge the battery at 2.7 A for 1.5 hours.
- Keep the battery in "open circuit" condition for 1 hour.
- Measure the open circuit voltage of every cell.
- If open circuit voltage of any cell is 0 V (or negative), do a supplementary test (24-30-00-
750-010-A01). Then repair.
- If every cell has an open circuit voltage that is more than 0 volts, charge the battery.
SUBTASK 24-30-00-780-003-A01
(3) Vent valve test
NOTE: The Vent Valve Test is not necessary if the full set of used vent valves is re-
placed by a brand new one each year during the General Overhaul or when
there is evidence of electrolyte overflow.
Before you put the vent valve back on the cells, make sure that they operate correctly. Do
these steps:
(a) Install the Vent valve (-190) with its O-ring on the end of a metal tube which has an ap-
plicable end-piece.
(b) Connect this tube to a supply of compressed air through an adjustable reducing valve.
(c) Adjust the pressure to 0.5 bar (7.25 psi) and put the vented filler cap into a container of
water. Air bubbles come out when the valve opens. If there are no bubbles, increase the
pressure until you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi)
and monitor the pressure at which the bubbles stop.
(d) Reject all vent valves that have an opening pressure of more than 0.7 bar (10 psi) or less
than 0.14 bar (2 psi).
(e) Install the vent valve (-190) (24-30-00-420-005-A01).
SUBTASK 24-30-00-750-010-A01
(4) Supplementary test
The first test charge can be unsatisfactory if the electrolyte level is too low in some cells (be-
cause the level is not adjusted until the end of this charge). If you find defects, adjust the
electrolyte level and do the following test:
NOTE: When you charge the battery more than necessary, you decrease the life of
the cells. Thus, do this special test only if a battery malfunction occurred in
the aircraft, or defects are found during shop maintenance.
(a) Charge the battery (24-30-00-800-801-A01). At the end of the total charge time, continue
to charge at 2.7 A for 5 more hours. Regularly record the voltage of the cells. The tem-
perature of cells that have damaged separators increases significantly and continuously.
The voltage of these cells continuously decreases to less than 1.50 V.
(b) Adjust the electrolyte level during the last 30 minutes of charge.
(c) Discharge at 27 A down to 1 V/cell.
(d) After this test, discard the defective cells:
- Cells with a voltage of less than 1.50 V at the end of the charge.
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2778-14
- Cells with a voltage that decreases to less than 1 V before one hour of discharge (dur-
ing the last test discharge).
- Short-circuited cells (zero volt).
E. Close-up
Not applicable.
TASK 24-30-00-800-801-A01
3. Charge
A. Reason of the job
Self explanatory
Code Description
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-00-820-001-A01
(1) Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-30-00-820-002-A01
(2) Ground charge
WARNING:Remove the cover to charge the battery on the ground. this is to make
sure that gas will not collect in the battery box
Do all battery maintenance or overhaul steps in a workshop.
NOTE: 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 > 1.50 V) AND ELECTROLYTE ADJUSTMENTS
MUST BE CARRIED OUT USING A FINAL CHARGE SEQUENCE AT CON-
STANT CURRENT: 2.7 A AT 0.1 C1A. If specific instructions are not given in
the charger operating manual, you must first contact Saft.
Page 1006
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2778-14
Cell connections
Figure 1004/GRAPHIC 24-30-00-991-054-A01
SUBTASK 24-30-00-820-003-A01
(3) Constant current charge (Battery fully discharged)
(a) To charge a fully discharged battery, do one of these procedures If the battery voltage in
main charge is less than the minimum voltage after the minimum time, continue to charge
until the voltage is reached.
Main charge Final charge

Current and duration Minimum voltage Current and duration
2.7 A (0.1 C1A) time mini 10 h 30 V 2.7 A (0.1 C1A) for a 4 h time
maxi 12 h
13.5 A (0.5 C1A) time mini 2 h 31 V 2.7 A (0.1 C1A) for a 4 h time
maxi 2 h 30 min.
27 A (1 C1A) time mini 1 h 31.4 V 2.7 A (0.1 C1A) for a 4 h time
maxi 1 h 15 min.
NOTE: If the battery voltage does not increase sufficiently during the maximum
charge time: Refer to the chapter TESTING AND FAULT ISOLATION.
CAUTION: When you charge the battery more than in the table above, you decrease
the life of the cells.
(b) Battery not fully discharged and discharge condition unknown
Discharge at 27 A (1 C1A) down to 20 V (24-30-00-800-802-A01).
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2778-14
Charge : refer to (24-30-00-820-003-A01) above constant current charge
E. Close-up
Not applicable.
TASK 24-30-00-800-802-A01
4. Discharge
A. Reason of the job
Self explanatory
Code Description
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-00-820+004-A01
(1) Discharge
Rated capacity (C1Ah) 27 A : minimum value obtained for a fully charged battery, when dis-
charged at 27 A, down to 20 V.
Page 1008
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2778-14
TASK 24-30-00-810-801-A01
5. Fault isolation
SUBTASK 24-30-00-810-001-A01
A. Battery electrical faults
Problem Probable cause Correction

(1) Zero battery open-circuit (a) Defective electrical connec- Check electrical contacts, links
voltage tor (no contact made) and tightness of nuts (refer to
INSPECTION/CHECK).
(b) Link loose or broken Make sure the nuts are tight
(refer to INSPECTION/
CHECK).
(2) Zero volt with the battery (a) Battery fully discharged Charge the battery.
set to "discharge" Do an insulation check (refer to
INSPECTION/CHECK)
(b) Battery circuit open or con- Examine the contacts and links.
tacts defective Make sure the terminal nuts are
tight (refer to INSPECTION/
CHECK).
(c) Cell fully dry
Refer to related subsequent
steps.
(3) Low insulation (a) Leakage of electrolyte Disassemble and clean the bat-
tery (refer to DISASSEMBLY
and CLEANING).
Do an electrolyte level check
CHECK).
SUBTASK 24-30-00-810-002-A01
B. Cell faults

(1) Too much water decrease (a) Charge much more than the Examine the cause of exces-
for all battery cells. limit or too much charge at high sive charge.
temperature. If necessary, adjust to normal
operating temperature (refer to
DESCRIPTION AND OPERA-
TION).
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(2) Water decrease in cell(s) is (a) More than 30% or more Do a leak of the cells (refer to
very different from the other than the average : leaks from INSPECTION/CHECK).
cells in the battery. the cell(s).
(b) 30% (or less) of the Do the added test(refer to

average: cell(s) with damaged INSPECTION/CHECK). If nec-
separator(s). essary, replace the cell(s).
(c) Previous maintenance has Note the cell location and

not been done. and check the level of water
comsumption versus other cells
at the next maintenance.
(3) A cell has an unsually high (a) Dry cell. When the defect occurs, add
voltage at the start of the 5 cm3 (5 ml) of distilled water to
charge. the cell. Do not adjust more
accurately until the end of the
charge.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can
cause temperature to increase very much.
(4) A cell has an unsually low (a) The cell was operated at Replace the cell (refer to DIS-
voltage at the end of the temperatures and charge rates ASSEMBLY, ASSEMBLY AND
charge (Less than 1.50 V at outside the limits, and the sepa- STORAGE (INCLUDING
2.7 A at + 20 °C (+ 68 °F) rator is damaged. TRANSPORTATION)).
(5) Low capacity cell. (a) insufficient balancing Repeat Charge, discharge at 1
C1AH and Cell shorting up to
three times
(b) Usual wear after long opera- Replace the cell (refer to DIS-
tion. ASSEMBLY, ASSEMBLY AND
Storage (including transporta-
tion)).
(c) Unusual operation, opera- Do the applicable procedure

tion at high temperature or (refer to INSPECTION/
operation with low electrolyte. CHECK).
(6) Cell with a swollen case. (a) Cell operated with low elec- Replace the cell (refer to DIS-
trolyte level ; deterioration of ASSEMBLY).
separators and damaged
plates.
(7) Cell with zero voltage (a) Short-circuited cell. Replace the cell (refer to DIS-
when the battery circuit is ASSEMBLY).
open.
Page 1010
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2778-14
SUBTASK 24-30-00-810-003-A01
C. Physical faults

(1) Leakage of electrolyte (a) Incorrect adjustement of Disassemble and clean the bat-
level. tery (refer to DISASSEMBLY
and CLEANING chapters). Do
an electrolyte level check(refer
to INSPECTION/CHECK).
(b) Cell polarity incorrect during Investigate the cause of exces-

high-rate discharge (for exam- sive charge.
ple, during the engine start). Disassemble and clean the bat-
and CLEANING).
CHECK).
(c) Too much charge at high Investigate the cause of exces-

temperature or too much cur- sive charge. If necessary,
rent. adjust to normal operating tem-
perature (refer to DESCRIP-
TION AND OPERATION).
Disassemble and clean the bat-
and CLEANING).
CHECK).
Page 1011
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2778-14

(2) Electrolyte found in the (a) Damaged cell case Do a leak test of the cells (refer
battery box. to INSPECTION/CHECK).
Replace the cell if necessary
and refer to related subsequent
steps.
(b) Leakage of electrolyte Disassemble and clean the bat-

and CLEANING).
CHECK).
(3) Corosion on the links. (a) Operation in acid air Make sure the battery test
bench and the storage areas
have no materials which can
give off acid fumes.
(b) Mechanical damage to Replace the damaged links

nickel plating (refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
(INCLUDING TRANSPORTA-
TION)).
(4) The links are too hot. (a) Loose terminals nuts Make sure the nuts are torqued
CHECK).
TASK 24-30-00-810-004-A01
D. Vent valve faults

Valve open pressure > 0.7 bar Clogged valve. Change the valve.
or stay open.
Valve stays open for a pressure Pierced valve. Change the valve.
< 0.14 bar or not closed.
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SCHEMATIC AND WIRING DIAGRAMS
TASK 24-30-00-871-804-A01
1. General
This page block gives all electrical schematics of battery sensor.
Sensor electrical schematic

Figure 2001/GRAPHIC 24-30-00-991-055-A01
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24-30-00 BLANK
2778-14
DISASSEMBLY
TASK 24-30-00-800-802-A01
1. Introduction
A. General
WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES.
NOTE:Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the
component or the possible cause of its malfunction. This will give the necessary
level of disassembly.
B. Safety
The Safety rules are different from one country to another. Only local rules are applicable.
C. Risks
There are three types of risks.
(1) Physical
- Handling: the battery is heavy. When you lift it, bend your legs and not your back.
- Use protective shoes.
(2) Electrical
- Don’t keep on you rings, watches, chains, belt buckles.
- Use insulated tools.
(3) Chemical
- Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves
- Electrolyte is very dangerous for eyes, use protective goggles.
D. Safety measure
The electrolyte compound is caustic and can cause dangerous burns. If it touches the skin, flush
the touched part with water and make neutral the solution with acetic solution, vinegar or lemon
juice, or with boric acid solution at 10% concentration.
If the electrolyte touches the eyes, flush them with water for 15 minutes at minimum and imme-
diately get a doctor.
Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vom-
it. Mix the solution with water or, if possible, with milk. Get a doctor immediately. Contact with
nickel can cause chronic eczema. To breathe cadmium oxide can cause a dry throat, make you
cough, cause headaches, vomiting, or pain in your chest. Persons having breathed cadmium
oxide fumes must get fresh air or get oxygen or must have artificial respiration.
Potash can cause eczema
TASK .24-30-00-000-801-A01
2. Disassembly
A. Reason for the job
Self explanatory
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2778-14
NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full
data of special tools in this list.
Code Description
T01 Universal vent wrench
T04 Universal cell extraction tool
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-00-020-001
(1) Disassembly procedure
WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES (24-30-00-800-802-
A01).
(a) Remove the the cover (020)
(b) Removal of a cell
NOTE: In order to avoid a short-circuit, remove a link (080) between two cells.
1 Remove the nuts (060) and the spring washers (070) that attach the links from the cell.
2 Remove all links (080 thru 120).
3 Fully engage the end of the special threaded tool (T04) onto one of the cell terminals.
Then pull up to remove the cell.
NOTE: The vent valve cap must stay tight when the cell is removed.
(c) Removal of a vent valve (-190)
1 Unscrew the vent valve (-190) with the special tool (T01).
2 Remove the vent valve (-190) with its O-ring.
(d) Removal of the connector (210)
1 Remove the screws (230) , the washers (- 240), the links (090, 120), and the
washers (060).
2 Remove the connector (210).
3 Remove the protector (220).
(e) Removal of the sensor (250)
1 Remove the screws and the washers (260)
2 Remove the sensor (250).
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(f) Disassembly of the battery
1 Remove
a The cover (020).
b The cells (130).
c The liner spacers kit (200).
d The sensor (250)
e The connector (210).
E. Close up
Not applicable
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24-30-00 BLANK
2778-14
CLEANING
TASK 24-30-00-871-806-A01
1. Introduction
A. General
TASK 24-30-00-100-801-A01
2. Cleaning of a unit
Self explanatory
Code Description
T04 Universal cell extraction tool
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye washing.
- Protective apron.
(2) Consumable

M01 Local purchase Distilled or deionized water
M02 Local purchase Soap
C. Job set up
Not applicable
D. Procedure
WARNING:The electrolyte is dangerous. Be careful when handling electrolyte and avoid
splashing. It is a strong caustic agent and can cause severe burns. Always wear
face and eye protection (preferably A transparent face mask, rubber gloves and
Page 4001
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2778-14
long sleeved clothing). In case of contact with skin, flush immediately with much
water. In case of contact with eyes, flush with water at least 15 minutes and, in all
cases, get immediate medical attention.
SUBTASK 24-30-00-160-001-A01
(1) Light cleaning
(a) Remove the cover.
(b) If a clean, filtered supply of compressed air is available, do this procedure to clean the
cells easily and quickly: blow with much force across the tops of the cells to remove all
dust and light traces of mineral salts from the box. To prevent short circuits, use a rubber
tube or an insulating nozzle.
SUBTASK 24-30-00-160-002-A01
(2) Full cleaning
CAUTION: You must clean the vent valve (-190) when the cells are assembled in the
box.
CAUTION: Do not use petrol trichlorethylene or other solvents.
Disassemble the battery (refer to DISASSEMBLY) and then clean all components.
(a) Cells (130)
1 Make sure that the vent valve (-190) is tight.
2 Do not soak the cells in water.
3 To easily remove all the electrolyte and mineral salts from the terminals, the cover and
the sides of the cell cases: clean in warm water with a soft brush.
4 Rub the cell with a cloth and let dry.
(b) Box (290) and handles (050)
1 Clean with lightly soapy water, rub with a cloth and let dry.
(c) Nuts, spring washers and links
1 Clean in warm water with a brush and let dry.
(d) Liner spacer kit (200)
1 Clean in warm water and let dry
(e) Vent valve (-190)
1 Remove the vent valve (-190)
2 Put swab on the cell holes to keep out unwanted material.
3 Soak the vent valve for some period (during the night for example) in a container of dis-
tilled water. Do that to remove all salts from the vent hole.
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E. Close up
SUBTASK 24-30-00-640-001-A01
(1) Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral
petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paint-
brush.
Page 4003
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24-30-00 BLANK
2778-14
INSPECTION/CHECK
TASK 24-30-00-871-805-A01
1. Introduction
A. General
You must do the checks which are necessary to use the Saft batteries in flight and on the
ground. These maintenance steps must be done in a battery shop between 23 °C ± 5 °C
(73 ± 9 °F):
- Periodical check: adjustment of electrolyte levels.
- Regular check: electrical treatment, adjustment of electrolyte levels, and capacity test.
- General overhaul: disassembly, full cleaning, assembly and regular check.
TASK 24-30-00-200-801-A01
2. Maintenance steps in workshop
Self-explanatory
Code Description
T02 Syringe assembly (with nozzle)
T03 Equalizing resistors (1 Ω / 3 W)
T08 Megohmeter, range 0-50 MΩ voltage
250 VDC, accuracy 3%
- Standard mechanic’s tools.

- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
Page 5001
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2778-14
(2) Consumables

M01 No special Distilled or deionized water
C. Job set-up
Do the check at ambient conditions:
- Ambient temperature: 23 ± 5 °C (73 ± 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.3 InHg).
- Relative humidity: < 85 %.
D. Procedure
SUBTASK 24-30-00-210-001-A01
(1) Periodical check
If the electrolyte consumption is more than the usual consumption between 2 regular
checks, do this periodical check:(Ref. Fig. 5001)
NOTE: Time periods are given as a guideline. Modify in accordance with operation-
al experience. Periodic and Regular maintenance checks may be combined
if operating hours permit.
Page 5002
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PERIODICAL CHECK 2.B
Light cleaning
no Insulation check yes
yes > 2 MΩ
dust only?
no
yes U > 21 V no
Salt or electrolyte traces no cell with reversed
polarity
Nut tigthness POLARIZATION TEST

Residual discharge
General overhaul 1 V/cell
figure 5004
Charge
Cell voltage before

end of charge
U > 1.50 V
no Adjustment of elec- yes
FAULT ISOLATION trolyte level before
end of charge
(volume <25 cm3
Supplementary test (1.28 in3))
OK? removal < 30 %
yes
Add 5 h overcharge
U > 1.50 V Vent cleaning
Adjust electrolyte
no
General overhaul Nut tightness
figure 5004
with replacement of
faulty components.
If more than 5 original
cells, then change all Battery accepted after
cells. periodical check
Periodical check
Figure 5001/GRAPHIC 24-30-00-991-056-A01
Page 5003
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2778-14
(a) Charge the battery
1 Discharge the remaining capacity at 27 A down to a voltage of 20 V at the battery ter-
minals.
2 When the battery temperature is at usual temperature range, +23 °C ± 5 °C
(73 °F ± 9 °), charge the battery (TASK 24-30-00-800-801-A01).
3 During the last 1/2 hour of the charge (while the charge current continues to flow), ad-
just the level of electrolyte in the cells (refer to Adjust the electrolyte level). Write down
the quantity of water that is added to each cell. The electrolyte level changes with the
battery charge. The level changes as if the plates absorbed a part of the electrolyte dur-
ing the discharge and released it during the charge. Therefore the level checks are only
satisfactory if they are done almost at the end of the charge (but during the charge).
Leakage can occur during operation if you do not obey these instructions when you add
liquid.
4 Measure the voltage of each cell.
(b) Adjust the electrolyte level
NOTE: For this operation, use plastic syringe with a plastic nozzle (T02) (refer to
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES. The
length of the nozzle is 20 mm (0.79 in). This is the distance necessary be-
tween the seat of the vent valve and the electrolyte (Ref. Fig. Figure 5002/
GRAPHIC 24-30-00-991-011).
WARNING:DO NOT USE ACID OR ACIDULATED WATER TO ADJUST THE ELEC-
TROLYTE LEVELS IN NICKEL-CADMIUM CELLS. A VERY SMALL QUAN-
TITY OF ACID IS SUFFICIENT TO CAUSE PERMANENT DAMAGE.
20 mm (0.79 in)
Level adjustment with a syringe and calibrated nozzle

Figure 5002/GRAPHIC 24-30-00-991-011
1 To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vent
valve and pull the plunger up.
2 If the level is not sufficient, the syringe tube stays empty when you pull the plunger. Add
Page 5004
24-30-00 Mar 03/2009
2778-14
distilled water to these cells. (The syringe is small, it can be necessary to do this step
more than one time for each cell).
3 If there is too much liquid, this liquid is removed by the syringe until the level aligns with
the end of the nozzle.The level is correct when only a small quantity of liquid goes into
the syringe when you pull the plunger.
4 Write down the quantity of distilled water added to each cell.
(c) Vent valve cleaning
1 Clean the vent valve (-190) (Ref. to CLEANING) when you adjust the electrolyte levels.
(d) Nut tightness
1 Make sure that all the nuts that attach the links are torqued (Ref. to FITS AND CLEAR-
ANCES).
(e) Results of the above procedures
1 The battery operates correctly if:
- The voltage of each cell measured during the last hour of charge at 2.7 A is not less
than 1.50 V.
- Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 20 mm (0.79 in).
NOTE: If the average quantity of water added to all the cells is close to 25 cm3
(1.28 in3), do the electrolyte level check more frequently.
2 Do a full overhaul (refer to Subtask 24-30-00-210-003-A01) of the battery if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
- the voltage of each cell measured at the end of a 2.7 A charge is less than 1.50 V (re-
fer to TESTING AND FAULT ISOLATION).
Page 5005
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2778-14
SUBTASK 24-30-00-210-002-A01
(2) Regular check
Light cleaning
REGULAR CHECK 2.C
yes U > 21 V no
no cell with reversed
Cleaning polarity
Nut tigthness POLARIZATION TEST

yes
dust only? Residual discharge
1 V/cell
no
Salt or electrolyte traces 1 Ω cell shorting
overnight
General overhaul Insulation check yes

figure 5004 no
> 2 MΩ
Recharge
Cell voltage before

end of charge
U > 1.50 V
FAULT ISOLATION no Adjustment of elec- yes
trolyte level before
end of charge
(volume < 25 cm3
Supplementary test (1.28 in3))
OK? yes
Add 5 h overcharge
U > 1.50 V
Adjust electrolyte FAULT ISOLATION no Capacity check yes
no
Supplementary test
OK?
General overhaul
Completed charge Vent cleaning
figure 5004
Add 5 h overcharge
with replacement of no Nut tigthness
U > 1.50 V
faulty components . yes
Adjust electrolyte
If more than 5 original Recharge
level.
cells, then change all
Discharge > 60 min
cells. Battery accepted after
regular check
Regular check
Figure 5003/GRAPHIC 24-30-00-991-058-A01
Page 5006
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2778-14
AFTER A MAXIMUM OF ONE YEAR, do this battery test (follow the different steps indicated
fig 5003):
(a) Measurement of the voltage
1 Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then
do the polarization test.
(b) Residual discharge
1 Discharge the remaining capacity at 27 A down to a voltage of 20 V at the battery ter-
minals. Measure the time from the start of discharge to the time when the voltage
reaches 20 V.
(c) Cell shorting
1 Connect a resistor (T03) across each cell and continue to discharge. Resistors with
crocodile clips attached to their leads can easily be attached to the cell terminals. Keep
the resistors in position for 12 hours. Remove all resistors
(d) Charge the battery
1 Refer to "Periodical check"
(e) Adjustment of the electrolyte
(f) Capacity check
1 Immediately after the charge and the level adjustment, discharge the battery again at
27 A down to 20 V; measure the terminal voltage of each cell. Write the time necessary
for the second discharge.
(g) Vent valve cleaning
(h) Results of the above tests:
1 The battery operates correctly if:
- The time necessary for the first discharge is more than 30 minutes.
- The time necessary for the second discharge is not less than 1 hour.
- The voltage of each cell measured during the last hour of the charge at 2.7 A is not
less than 1.50 V.
- The variation of water consumption in individual cell does not exceed ±30% of the av-
erage consumption for all cells.The maximum limit is 25 cm3 (1.28 in3).
NOTE: If the average quantity of water added to all the cells is close to 25 cm3
(1.28 in3), do the electrolyte level check more frequently.
- If the first discharge time is less than 30 minutes but the second discharge time is cor-
rect: the battery is in good condition but was not fully charged when removed from
the aircraft. This condition can be caused by an incorrect charge in the aircraft and /
or a discharge caused by an unusual operation of the battery after landing.
2 Do a full overhaul of the battery if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
Page 5007
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2778-14
- the voltage of each cell measured at the end of a 2.7 A charge is less than 1.50 V
(refer to TESTING AND FAULT ISOLATION).
- The second discharge time is less the correct one or one cell has a voltage of less
than 1 V (or incorrect polarity before 1 hour of discharge).
NOTE: The decrease of water in a SAFT nickel-cadmium cell is in proportion to
the overcharge. Thus, the decrease should be the same for all 20 cells in
the battery.
- If the quantity of water necessary for one or more cell(s) (in the same battery) is much
higher (or smaller) than the other cells. This means that there is a defect (heavy de-
crease is usually caused by leakage and low decrease is caused by a damaged sep-
arator).
SUBTASK 24-30-00-210-003-A01
(3) General overhaul (minimum 1 per year)
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures
to be done systematically for all battery components. Follow the different steps indicated in
Fig. 5004.
Page 5008
24-30-00 Mar 03/2009
2778-14
GENERAL OVERHAUL 2.D
Scheduled On fault
yes U > 21 V no
no cell with rever- POLARIZATION TEST
sed polarity
Nut tightness
Residual discharge
1 Ω cell shorting
overnight
Disassembly
Thorough cleaning
Component inspection Sensor check
Faulty component
replacement Charge
Assembly Cell voltage before
end of charge
Insulation check U > 1.50 V
no > 10 MΩ yes no Adjustment of elec- yes
trolyte level before
end of charge
FAULT ISOLATION (volume < 25 cm3
(1.28 in3))
Other test OK? dispersion < 30 %
Add 5 h over- yes
no
charge U > 1.50 V
Adjust electrolyte no Capacity check
FAULT ISOLATION yes
1 V/cell ≥ 60 min
Other test OK?

General overhaul Completed charge Vent cleaning
with replacement of Add 5 h over-
faulty components . Nut tightness
charge U > 1.50 V
If more than 5 original Recharge
no Adjust electrolyte yes
cells then change all
level. Discharge
cells. Battery accepted af-
> 60 min.
ter general overhaul
General overhaul
Figure 5004/GRAPHIC 24-30-00-991-059-A01
Page 5009
24-30-00 Mar 03/2009
2778-14
(a) Dissassembly
1 Refer to "DISASSEMBLY"
(b) Thorought cleaning
1 Refer to "CLEANING" .
(c) Do a battery inspection.
1 Cells
a Verify that cell boxes show no leakage.
2 Box
a Make the sides of the box straight and remove dents (refer to "REPAIR").
3 Nuts, links and spring washers
a Discard the components that show signs of corrosion or damage.
4 Packing parts
a Discard all defective components
5 Connector
a Make sure that the connector is in good condition (inner and outer surfaces). Re-
place it if contacts are burned.
(d) Insulation check
1 Refer to Subtask 24-30-00-280-001-A01.
(e) Charge the battery
(f) Adjustment of electrolyte
(g) Capacity check
1 Refer to "Regular check"
(h) Vent valve cleaning
NOTE:If more than 5 original cells have been changed or more than 3 cells are faulty in
the same maintenance, then change all cells or replace the battery with a new one.
SUBTASK 24-30-00-280-001-A01
(4) Insulation resistance
Refer to the chapter TESTING AND FAULT ISOLATION.
Page 5010
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2778-14
SUBTASK 24-36-01-280-002
E. Checking of temperature sensor
Refer to SCHEMATIC DIAGRAM chapter.
Do this test in a climatic chamber with the sensor disassembled from the battery.
CHECK OF BETWEEN VALUE

Thermistor A-B R = 300 kΩ ± 0.3 kΩ at 25 °C (77 °F)
Closes at 60 °C ± 2.8 °C (140 °F ± 5 °F)
Thermostat T1 C-E
when temperature increases
Closes at 71 °C ± 2.8 °C (160 °F ± 5 °F)
Thermostat T2 D-F
when temperature increases
Measure the insulation resistance between each connector point and every metal housing. The
value must be superior to 30 MΩ at 250 Vdc..
Page 5011
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2778-14
24-30-00 BLANK
2778-14
REPAIR
1. General
As indicated in the CHECK chapter, defective parts for which no repair instructions are given shall
be rejected and replaced by new parts.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST.
2. Equipment
A. Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
B. Standard tools
Standard mechanic’s tools.
C. Materials
Neoprene glue [M03]
3. Repairs
The only authorized repair applicable to the unit is:
- Changing a gasket cover (040).
Page 6001
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2778-14
REPAIR N°1
TASK 24-30-00-900-801
4. Changing a cover gasket
A. General
The gasket cover (040) can be changed only one time.
B. Detailed procedure
- Remove the gasket cover (040).
- Clean the joint location.
- Apply paste to the flat side of the gasket
- Let stay dry for 2 hours in a dry place.
- Put gasket on the bottom of the cover (030). Press firmly.
Page 6002
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ASSEMBLY
TASK 24-30-00-871-810-A01
1. Introduction
A. General
You must assemble parts on a clean workbench in a clean, dry room. The parts must be protected
from impact damage.
For tightening parts refer to the torque table (Ref. TASK-24-30-00-400-802-A01).
Make sure that the storage protection layer is removed from the new part before assembly.
The figure and item numbers used are those of the ILLUSTRATED PARTS LIST.
To do check points, refer to INSPECTION/CHECK .
TASK 24-30-00-400-801-A01
2. Assembly procedure
Self-explanatory
Code Description
(2) Consumables

M04 No special Mineral vaseline
C. Job set-up
Not applicable
Page 7001
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2778-14
D. Procedure
SUBTASK 24-36-01-420-001
(1) Installation of the sensor
(a) Put in position the sensor (250) with the washer (260) and fix it with the nut.
SUBTASK 24-30-00-420-001-A01
(2) Installation of the liner spacer kit (200)
CAUTION:You must assemble the E and F slotted spacers to keep the ventilating system
of the box free.
(a) Put in position the bottom spacers and insulators.
(b) Put in position the side spacers and insulators.
(c) Install the cells.
Unit per
Item Description Dimension (mm)
assembly
A Insulator 0.3x248x80 3
B Insulator 0.5x167x75 3
C Spacer 2x167x78 5
D Spacer 1x102x75 1
E Spacer 1x245x167 4
F Insulator 0.5x245x167 3
G Insulator 0.5x245x162 2
H Spacer 1x210x162 2
I Insulator 0.5x210x162 2
SUBTASK 24-30-00-420-005-A01
(3) Installation of the vent valve (-190)
(a) Make sure the vent valves (-190) are in good condition. Replace the vent valves (-190)
if they are worn.
(b) Install the vent valve (-190) with the special tool (T01). Hold the special tool by its upper
Page 7002
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2778-14
ribbed part.
SUBTASK 24-30-00-420-007-A01
(4) Installation of the connector (210)
(a) Put in position the connector (210) with the washer (- 240) and the screw (230).
SUBTASK 24-30-00-460-001-A01
(5) Installation of a cell (Ref. Fig. 7002)
(a) Put five cells (130) in the side compartments.
(b) Move the last cell into position (if it is difficult to put in the last cell, remove one or two
spacers).
(c) Carefully position the cell (130) and push onto terminals with a piece of soft wood.
(d) Install the links (080 thru 120).
(e) Install the spring washers (070).
(f) Install the nuts (060) and torque them.
(g) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
brush).
(h) Install the cover (020) and attach it .
SUBTASK 24-30-00-970-001-A01
(6) Write the necessary information on:
(a) the identification plate.(310) if the box (290) has been changed
(b) the log book.
E. Close up
Not applicable
Page 7003
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2778-14
24-30-00 BLANK
2778-14
FITS AND CLEARANCES
TASK 24-30-00-400-802-A01
1. Torque table
SUBTASK 24-30-00-820-005-A01
A. Torque table
List of all applicable torque values needed to assemble and do servicing of the battery:
NOTE:The values here are "lube torque" values. The threads should be lightly greased
before to installation and applying torque.
IPL TORQUE VALUE

FIG ITEM NAME
N° N.m lbf.in
060 Nut 12 to 14 106 to 123

-140 Nut 4.5 to 5.5 39.2 to 47.8
230 Nut 12 to 14 106 to 123
Page 8001
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24-30-00 BLANK
2778-14
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES
TASK 24-30-00-940-801-A01
1. Special tools, fixtures and equipment
A. Special tools table
Supplier code or Page block

Tool Part
Description name and where Qty
code number
address necessary
T01 413876 Universal vent wrench 3000 1
4000
5000
7000
T02 016544 Syringe assembly (with noz- 1000 1
zle) 5000
T03 164829 Equalizing resistors 1000 20
(1 Ω / 3 W) 5000
T04 416159 Universal cell extraction tool 3000 1
T05 No special Discharge bench (constant Local purchase 1000 1
current 0-60 A) 5000
T06 No special Power supply 0-45 V, 0-60 A Local purchase 1000 1
5000
T07 No special Multimeter Local purchase 1000 1
range 2 V-50 V accuracy 1% 5000
T08 No special Megohmeter, range 0-50 MΩ Local purchase 1000 1
voltage 250 VDC, accuracy 5000
3%
Page 9001
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2778-14
Polyamide key for vent valve (T01)

Figure 9001/GRAPHIC 24-30-00-991-062-A01
Syringe with nozzle (T02)

Figure 9002/GRAPHIC 24-30-00-991-0063-A01
24-30-00 BLANK
2778-14
3 W resistance wire
Alligator clips
Equalizing resistor (T03)
Figure 9003/GRAPHIC 24-30-00-991-018
24-30-00 BLANK
2778-14
M8
M10 x 1.25
Cell extraction tool (T04)

Figure 9004/GRAPHIC 24-30-00-991-065-A01
24-30-00 BLANK
2778-14
TASK 24-30-00-13-941-801-A01
2. Consumables material
(1) Consumable materials table
CAUTION: Use only distilled or desionized water
NOTE: Equivalent alternatives can be used for list items.
Supplier code or Page block

Material
Description name and where
number
address necessary
M01 Distilled or deionized water Local purchase 1000
clear, colourless, oderless while boiling, 4000
resistivity > 30 kΩ/cm 5000
5 < pH < 7
Absence of organic and reducing sub-
stances. Reducing agent content
(expressed in weight of oxygen)
< 30 mg/l (test with permanganate).
Total of ions (SO42+, 2Cl-) < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
M02 Soap Local purchase 4000
M03 Neoprene glue Local purchase 6000
M04 Mineral vaseline OTAN: S 743 7000
F: AIR 3565 15000
US: VLP 236
UK: DEF 2333
Page 9005
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24-30-00 BLANK
2778-14
ILLUSTRATED PARTS LIST
Page 10001
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24-30-00 BLANK
2778-14
INTRODUCTION
TASK 24-30-00-871-802-A01
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed
parts of the unit in disassembly sequence.
It includes the following sections :
- Introduction (INTRO),
- Numerical Index (NI),
- Detailed Parts List (DPL).
B. How to Use the illustrated Parts List
(1) To find the illustration for a part if the part number is known, refer to the Numerical Index and
look for the part number and the corresponding figure and item number. Refer to the De-
tailed Parts List and look for the first figure and item number found in the Numerical Index
for that part. If this figure shows the part in a section or system of the equipment other than
the one necessary, refer to the other figure numbers listed in the Numerical Index.
(2) To determine the part number of a given part, refer to the illustration showing the assembly
including this part. Note the item number of the illustrated part and refer to the Detailed Parts
List which indicates its part number and identification.
C. Numerical Index (NI)
(1) In this index, part numbers are classified in the following order:
(a) The classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
(b) The sequence in the first left row is :
1 an alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
2 numeral from 0 to 9.
(c) For the subsequent rows, the sequence is:
1 a dash,
2 an alpha letter A to Z (but not the "O" and the "I", because it is possible to read these
letters as a zero and a one),
3 a numeral 0 to 9.
(d) The part number column contains all part numbers included in the Detailed Parts List.
The part numbers that have been deleted or superseded within the Detailed Part List are
listed in the Numerical Index and identified as deleted or superseded.
D. Detailed Parts List (DPL)
(1) Figure and Item Number
(a) Each assembly, sub-assembly and part holding a part number and included in the parts
list is given as an item number.
(b) The figure number linked to the item number is shown on the first line at the top of each
Page 10003
24-30-00 Mar 03/2009
2778-14
page.
(c) Assemblies, sub-assemblies numbered parts included in the list but not illustrated are
identified by a hyphen (-) preceding the item number.
(d) An index letter shown before the item number refers to the figure showing the modified
portion of the applicable part.
(2) Manufacturer's Part Number
A manufacturer's part number is given to each assembly and detail part, whether illustrated
or not.
(3) Nomemclature
(a) The nomenclature is given with an indenture, to show how the parts and the assemblies
and related to their next higher assemblies. These are the details: :
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
. Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
. . Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
(b) The attaching parts are shown directly after the assembly of the part thereof. They are
listed under the same indent number as the item they are attached to, and are identified
by the words "Attaching Parts" and are followed by three asterisks.
(c) The manufacturer's code or the abbreviation NP (not procurable) are placed at the ex-
treme right- hand side of the first line of the parts list column.
(4) Effectivity code
1 An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts
lists in relation to the next higher assembly (ies) or sub-assembly (ies).
2 When the effectivity is fully applicable, the usage code column remains blank.
3 The use code for assemblies and detailed parts refers to the figure/item number of the
next higher assembly (ies) or sub-assembly (ies). Example : Effectivity 1A, 1B, 1C is
written 1ABC.
(5) Units per Assembly
(a) The units per assembly column showns the quantity of units required for one next higher
assembly.
(b) In some cases, the information is replaced by the abbreviation RF (for reference) or AR
Page 10004
24-30-00 Mar 03/2009
2778-14
(as required).
(6) Abbreviation used
ALT FROM PNR XXX Part that is functionally and physically interchangeable with original
part after reworking.
AMDT Amendment
AR As required
DELETED Deleted part
DET Detail
DPL Detailed Parts List
EDI Equipment Designator Index
IPL Illustrated Parts List
LH Left hand
MFR Manufacturer or Optional Manufacturer in the IPL
MODIFIED FROM A part got after a different part is modified
NHA Next higher assembly
NP Not procurable
OLD PNR Optional part number. Optional part number that is fully interchange-
able with the part in the part number column.
OPT SEE TABLE Refer to the optional table
ORDER OVRLGTH PNR A part number with more than fifteen chararacters
OVERSIZE A part with a size which is larger than its nominal dimension
PNR Part number.
POST SB After a modification given up by a Service Bulletin.
PRE SB Before modification given up by a Service Bulletin.
R Revised
RF For reference.
RH Right hand.
SEE CMM Refer to the Component Maintenance Manual.
SEE FIG FOR DET Refer to figure for details.
SEE FIG FOR NHA Refer to figure for next higher assembly.
SEL FROM Selected from. A part that you must select from a collection of parts,
as necessary
SUPSD BY Superseded by XXX.
SUPSDS Supersedes XXX.
UNDERSIZE A part with a size wich is smaller than its nominal voltage
VL Vendors List.
E. Updating
(1) General
(a) When an item is revised, added or deleted, the letter " R " is shown in the right-hand mar-
gin (the date of issue changes).
(2) Added items
(a) 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
Page 10005
24-30-00 Mar 03/2009
2778-14
more than nine new items, a new number is to be added at the end of the IPL.
(3) Deleted items
(a) Should a part number definitively deleted, the information given in the parts list zone is
deleted. The old part number always remains in the numerical index.
(4) New Figure Number Added
(a) When new illustrations are necessary the alternative figures are inserted. They refer to
the same nomenclature. The alternative figure is given with the basic figure number and
letter. This letter precedes the item number in the parts list.
Page 10006
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2778-14
VENDOR LIST
Code Name Address
F6177 Saft 12 rue Sadi Carnot
93170 Bagnolet
France
Phone: +33 (0) 1 49 93 19 18
Fax: +33 (0c) 1 49 93 19 56
V09052 Saft America Inc. 711, Industrial Blvd
Valdosta
Georgia, 31601
USA
Phone: +1 (229) 247 2331
Fax: +1 (229) 247 8486
Page 10007
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2778-14
24-30-00 BLANK
2778-14
ALPHA NUMERICAL INDEX
AIRLINE FIG INDEX TOTAL
PART NUMBER
STOCK NUMBER NUMBER NUMBER REQUIRED
012374 080 14
015539 100 2
015575-000 080 14
015576-000 090 3
015577-000 100 2
015579-000 060 42
015579-000 140 2
015599-000 020 1
015926-000 120 1
015990-000 190 1
016423-000 110 1
018124-000 180 2
018346-000 220 1
021103-000 130 20
021740-000 210 1
022228-000 070 42
022228-000 170 2
023786-000 001 RF
023935-001 150 1
023935-002 160 1
023947-000 290 1
024081-000 250 1
062007 060 42
062007 140 2
093616-000 230 4
100078 180 2
100094 070 42
100094 170 2
100430 240 4
100431 230 4
100693 160 1
100694 150 1
102295 030 1
102392 210 1
105405 270 1
113605 040 1
114724 260 1
114767 120 1
116056 280 4
Page 10009
24-30-00 Mar 03/2009
2778-14
AIRLINE FIG INDEX TOTAL
PART NUMBER
STOCK NUMBER NUMBER NUMBER REQUIRED
116112 110 1
117026 300 1
165949 130 20
166309 320 2
166314 350 1
166925 220 1
280068 340 1
411108 310 1
411691 090 3
412488 050 1
413172 001 RF
413508 250 1
413512 290 1
413514 200 1
413515 020 1
413516 010 1
413609 330 2
413611 360 2
415218 190 1
Page 10010
24-30-00 Mar 03/2009
2778-14
DETAILED PARTS LIST
2778-14 BATTERY
Figure 10001/GRAPHIC 24-30-00-991-020
Page 10011
24-30-00 Mar 03/2009
2778-14
PART NOMENCLATURE UNITS

NUMBER EFF.
FIG. ITEM PER
CODE
F6177 V09052 1234567 ASSY
01 - 001 413172 023786-000 Battery, 2778-14 RF
010 413516 . Box and cover complete 1
020 413515 015599-000 . Cover complete 1
030 102295 . . Cover, assembly 1
040 113605 . . Gasket, cover 1
050 412488 . Handle, strap 1
060 062007 015579-000 . Nut M10X1.25 42
070 100094 022228-000 . Washer, spring 42
080 012374 015575-000 . Link, intercell, E34 14
090 411691 015576-000 . Link, intercell 3
100 015539 015577-000 . Link, intercell, E37 2
110 116112 016423-000 . Link, intercell 1
120 114767 015926-000 . Link, intercell 1
130 165949 021103-000 . Cell, VHP270KH-3, assembly 20
-140 062007 015579-000 . . Nut M8X1.25 2
-150 100694 023935-001 . . Washer, positive polarity 1
-160 100693 023935-002 . . Washer, negative polarity 1
-170 100094 022228-000 . . Washer, spring 2
-180 100078 018124-000 . . Washer, flat 2
-190 415218 015990-000 . . Vent valve 1
200 413514 . Liner-spacer kit 1
210 102392 021740-000 . Connector, complete 1
220 166925 018346-000 . Protector 1
230 100431 093616-000 . Screw 4
- 240 100430 . Washer 4
250 413508 024081-000 . Sensor 1
-260 114724 . . Washer, 18.5x32 1
-270 105405 . . Screw, 6/32" 1
-280 116056 . Stirrup 4
290 413512 023947-000 . Box assembly 1
- 300 117026 . Film, protector 1
310 411108 . Plate, identification 1
320 166309 . Plate, filling instruction 2
330 413609 . Plate, SAFT label 2
-340 280068 . Plate, recycling 1
-350 166314 . Plate, amendment 1
360 413611 . Plate, range 2
- Item not illustrated.
Page 10012
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2778-14
STORAGE (INCLUDING TRANSPORTATION)
TASK 24-30-00-871-809-A01
1. Introduction
A. General
Storage inhibition and packaging guarantee the equipment against any attack by atmospheric
agents.
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommended temperature range is + 20 °C ±15 °C (68 °F ±27 °F). However, occasional
excursion into the range of -60 °C to +60 °C (-76 °F to +140 °F) is permitted.
TASK 24-30-00-871-809-A01.
2. Storage procedure
Self explanatory
None
(2) Consumables

M04 No special Mineral vaseline
C. Job set up
SUBTASK 24-30-00-550-001-A01
(1) Preparation of the battery before storage
(a) Visual inspection: if dust or salt do a General Overhaul according to procedure (Ref. PG-
BLK-24-30-00-5000-2).
(b) Then light cleaning (Ref. PGBLK-24-30-00-4000-2), then service as scheduled (periodi-
cal check, regular check or general overhaul check) (Ref. PGBLK-24-30-00-5000-2).
(c) Adjust the electrolyte levels (Ref. PGBLK-24-30-00-5000-2), then discharge at a con-
stant current of 27 A down to 20 V.
(d) Lightly lubricate these components with mineral vaseline (M04): the nuts, the links, and
Page 15001
24-30-00 Mar 03/2009
2778-14
all the components that can be damaged by atmospheric corrosion.
(e) Put the battery in its usual vertical position.
D. Procedure
SUBTASK 24-30-00-530-001-A01
(1) Packaging
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we
recommend to put the batteries in a welded plastic container. In this type of container, with
the recommanded temperature range, the batteries can be kept for 10 years.
SUBTASK 24-30-00-550-002-A01
(2) Short term storage (Ref. Fig. 15001)
(a) Place the charged battery (serviced according to CMM procedure) in a cool room or dis-
charge to 1 V/cell (refer TESTING AND FAULT ISOLATION).
(b) Light greasing of cells terminals.
(c) Place in a storage room.
Page 15002
24-30-00 Mar 03/2009
2778-14
100
CHARGE RETENTION
Aircraft Ni-Cd battery
90
AVAILABLE CAPACITY (%C1Ah)
5 °C
20 °C
80
25 °C
30 °C
70 35 °C
40 °C
60
0 10 20 30 40 50 60 70 80 90
REST TIME (days)
Short term storage
Figure 15001/GRAPHIC 24-30-00-991-021
TASK 24-30-00-550-003-A01
(3) Long term storage
CAUTION:Saft Ni-Cd batteries may be stored in temperatures ranging from - 60 °C (67 °F)
to + 60 °C (+ 140 °F) for short periods of time without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years
of storage under the above conditions.
No maintenance operation needs to be performed during the storage period.
Lead batteries must be stored in a different room.
NOTE:Lead batteries must be stored in a different room
(a) Operations
1 Discharge to 20 V.
2 Light greasing of cells terminals.
3 Place in a storage room.
Page 15003
24-30-00 Mar 03/2009
2778-14
(b) Conditions
1 The battery should be stored filled and discharged.
2 The storage life is 10 years, if using the following conditions :
- Sealed packaging.
- Temperature: + 20 °C ± 15 °C (68 °F ± 27 °F).
- Humidity: < 70 %.
- Normal vertical position.
- Isolated from detrimental agents : dirt, dust, clampness, vibration, corrosive atmo-
sphere.
SUBTASK 24-30-00-540-001-A01
(4) Servicing after storage
Storage time Servicing procedure

Less than 3 months Charge the battery (Do one of the procedures given in "TESTING
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year Do the Periodical check (Ref. PGBLK-24-30-00-5000-1).
More 1 year Do the Regular check (Ref. PGBLK-24-30-00-5000-1).
E. Close up
Not applicable
TASK 24-30-00-500-801-A01
3. Transportation procedure
A. General
The battery must be discharged before packing.
The battery should then be packed vertically in its original container. If the original container is
not available, the international and/or local packaging regulations applicable to the mode of
transport and destination must be followed.
Page 15004
24-30-00 Mar 03/2009

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(F6177)

12 rue Sadi Carnot - 93170 Bagnolet - France

Rev. Inserted Issue Inserted

PAGE INTENTIONALLY LEFT BLANK

Temp rev. Inserted Removed

PAGE INTENTIONALLY LEFT BLANK

PAGE INTENTIONALLY LEFT BLANK

SPECIAL TOOLS, 9001 Mar 03/2009

ILLUSTRATED 10001 Mar 03/2009

INTRO IPL 10003 Mar 03/2009

ALPHA NUMERICAL 10009 Mar 03/2009

RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001

REPAIR N°1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6002

FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES - - - - - - - - - - - - - - - - 9001

VENDOR LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10007

ALPHA NUMERICAL INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10009

DETAILED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011

STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001

PAGE INTENTIONALLY LEFT BLANK

PAGE INTENTIONALLY LEFT BLANK

(2) Description and Operation

(2) U.S. Units

(3) Multiplying Prefixes

1 kPa 0.1450 psi

(2) From U.S. Standard System to I.S. Measurement

1 psi 6,8948 kPa

I. Temperature Conversion Table

AECMA European Association of Aerospace Industries

Technical data Values

NOTE: 27 Ah at 1 h rate noted as 27 C1Ah or 27 C1Ah.

Item Value Use for

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- Standard mechanic’s tools.

Code Reference Description

box or cells Yes see para. 5.B (6)

salt or electrolyte Yes see para. 5.C (1) more than

Preliminary Functional Tests

- ≥ 250 kΩ under 250 VDC = Min value (Figure 1003/GRAPHIC 24-30-00-991-052-A01).

Can wait until next

In battery maintenance shop Always required after

Check the cause

Main charge Final charge

Problem Probable cause Correction

Problem Probable cause Correction

(b) 30% (or less) of the Do the added test(refer to

(c) Previous maintenance has Note the cell location and

(c) Unusual operation, opera- Do the applicable procedure

Problem Probable cause Correction

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

(c) Too much charge at high Investigate the cause of exces-

Problem Probable cause Correction

(b) Leakage of electrolyte Disassemble and clean the bat-

(b) Mechanical damage to Replace the damaged links

Problem Probable cause Correction

Sensor electrical schematic

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Code Reference Description

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