Component Maintenance Manual With Illustrated Parts List: This Document Replaces and Cancels 24-31-40

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

Tél. (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
P/N 4076-10/4076-23
This document replaces

and cancels 24-31-40
Date of issue : Jun 12/2002 Title page - page 1

24-31-41 Jun 12/2002
COMPONENT MAINTENANCE MANUAL
4076-10/4076-23
PAGE INTENTIONALLY LEFT BLANK
Title page - page 2

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RECORD OF REVISIONS
REVISION ISSUE INSERTED REVISION ISSUE INSERTED
No. DATE DATE BY No. DATE DATE BY
ROR Page 1
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ROR Page 2
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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE BY DATE BY
REV. No. NUMBER DATE REMOVED
RTR Page 1
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RTR Page 2
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SERVICE BULLETIN LIST

NUMBER BRIEF DESCRIPTION TYPE AFFECTED
SBL Page 1
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SBL Page 2
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LIST OF APPROVED REPAIRERS

TRADE NAME ADDRESS
LOAR Page 1
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LOAR Page 2
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LIST OF EFFECTIVE PAGES

CONTENT PAGE DATE OF CONTENT PAGE DATE OF
LATEST LATEST
REVISION REVISION
TITLE PAGE 1 Jun 12/2002 TESTING AND FAULT 1001 Jun 12/2002
2 Blank ISOLATION 1002 Jun 12/2002
1003 Jun 12/2002
RECORD OF REVI- 1 Jun 12/2002 1004 Jun 12/2002
SIONS 2 Blank 1005 Jun 12/2002
1006 Jun 12/2002
RECORD OF TEMPO- 1 Jun 12/2002 1007 Jun 12/2002
RARY REVISIONS 2 Blank 1008 Jun 12/2002
1009 Jun 12/2002
SERVICE BULLETIN 1 Jun 12/2002 1010 Jun 12/2002
LIST 2 Blank 1011 Jun 12/2002
1012 Jun 12/2002
LIST OF APPROVED 1 Jun 12/2002
REPAIRERS 2 Blank SCHEMATIC AND 2001 Jun 12/2002
WIRING DIAGRAMS 2002 Jun 12/2002
LIST OF EFFECTIVE 1 Jun 12/2002
PAGES 2 Jun 12/2002 DISASSEMBLY 3001 Jun 12/2002
3002 Jun 12/2002
TABLE OF CON- 1 Jun 12/2002 3003 Jun 12/2002
TENTS 2 Jun 12/2002 3004 Jun 12/2002
TABLE OF ILLUSTRA- 1 Jun 12/2002 CLEANING 4001 Jun 12/2002

TIONS 2 Jun 12/2002 4002 Jun 12/2002
4003 Jun 12/2002
INTRODUCTION 1 Jun 12/2002 4004 Blank
2 Jun 12/2002
3 Jun 12/2002 CHECK 5001 Jun 12/2002
4 Jun 12/2002 5002 Jun 12/2002
5003 Jun 12/2002
DESCRIPTION AND 1 Jun 12/2002 5004 Jun 12/2002
OPERATION 2 Jun 12/2002 5005 Jun 12/2002
3 Jun 12/2002 5006 Jun 12/2002
4 Jun 12/2002 5007 Jun 12/2002
5008 Jun 12/2002
5009 Jun 12/2002
5010 Jun 12/2002
5011 Jun 12/2002
5012 Jun 12/2002
LEP Page 1
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LIST OF EFFECTIVE PAGES

CONTENT PAGE DATE OF CONTENT PAGE DATE OF
LATEST LATEST
REVISION REVISION
REPAIR 6001 Jun 12/2002 DETAILED 10001-0 Jun 12/2002
6002 Jun 12/2002 PARTS LIST 10001-1 Jun 12/2002
10001-2 Jun 12/2002
ASSEMBLY 7001 Jun 12/2002 10001-3 Blank
7002 Jun 12/2002
7003 Jun 12/2002 STORAGE (INCLU- 15001 Jun 12/2002
7004 Jun 12/2002 DING TRANSPORTA- 15002 Jun 12/2002
7005 Jun 12/2002 TION) 15003 Jun 12/2002
7006 Blank 15004 Jun 12/2002
15005 Jun 12/2002
FITS AND CLEA- 8001 Jun 12/2002 15006 Blank
RANCE 8002 Blank
SPECIAL TOOLS, 9001 Jun 12/2002

FIXTURES AND 9002 Jun 12/2002
EQUIPMENT 9003 Jun 12/2002
9004 Jun 12/2002
9005 Jun 12/2002
9006 Blank
ILLUSTRATED 10001 Jun 12/2002

PARTS LIST 10002 Blank
INTRODUCTION 10003 Jun 12/2002

10004 Jun 12/2002
10005 Jun 12/2002
10006 Jun 12/2002
10007 Jun 12/2002
10008 Jun 12/2002
VENDOR CODE 10009 Jun 12/2002

INDEX 10010 Blank
ALPHA NUMERICAL 10011 Jun 12/2002

INDEX 10012 Blank
LEP Page 2
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TABLE OF CONTENTS
PAGE
INTRODUCTION 1
1 - General 1
2 - How to Use the Manual 2
3 - Measurements 2
4 - Units of Measure 2
5 - Abbreviations 3
6 - Definition 3
7 - Disposal 4
DESCRIPTION AND OPERATION 1

1 - Description 1
TESTING AND FAULT ISOLATION 1001

1 - General 1001
2 - Testing 1001
3 - Charge 1008
4 - Discharge 1010
5 - Fault isolation 1010
SCHEMATIC AND WIRING DIAGRAMS 2001

1 - General 2001
2 - Schematic sensor 2001
DISASSEMBLY 3001
1 - General 3001
2 - Safety 3001
3 - Risks 3001
4 - Safety measure 3002
5 - Disassembly 3002
CLEANING 4001
1 - General 4001
2 - Equipment required 4001
3 - Materials 4001
4 - Cleaning procedure 4001
5 - Lubrication 4003
CHECK 5001
1 - General 5001
2 - Maintenance steps in workshop 5001
TOC Page 1
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PAGE
REPAIR 6001
1 - General 6001
2 - Equipment 6001
3 - Repairs 6001
ASSEMBLY 7001
1 - General 7001
2 - Assembly procedure 7001
FITS AND CLEARANCES 8001

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

1 - General 9001
2 - Special tools, fixtures and equipment 9001
3 - Consumables 9005
ILLUSTRATED PARTS LIST 10001

1 - Introduction 10003
2 - Vendor code index 10009
3 - ALPHA Numerical index 10011
4 - Detailed parts list 10001-0
SPECIAL PROCEDURES NOT APPLICABLE
REMOVAL NOT APPLICABLE
INSTALLATION NOT APPLICABLE
SERVICING NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION) 15001

1 - Storage 15001
2 - Storage procedure 15001
3 - Servicing after storage 15005
4 - Transportation 15005
REWORK (service bulletin instructions) 16001
TOC Page 2
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TABLE OF ILLUSTRATIONS
PAGE
Figure 1 - 4076-10/4076-23 Battery 3
Figure 2 - Identification plate 3
Figure 3 - Overall dimensions 4
Figure 1001 - Preliminary Functional Tests 1003
Figure 1002 - Insulation Check 1004
Figure 1003 - Insulation Parameters 1005
Figure 1004 - Cell connections 1008
Figure 2001 - Schematic sensor 4076-10 2001
Figure 2002 - Schematic sensor 4076-23 2002
Figure 5001 - Periodical check 5003
Figure 5002 - Level adjustment with a syringe and calibrated nozzle 5004
Figure 5003 - Regular check 5007
Figure 5004 - General overhaul 5011
Figure 7001 - Liner spacer kit installation 7003
TOI Page 1
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PAGE
Figure 7002 - Cell installation 7004
Figure 9001 - Polyamide key for vent valve (T01) 9002
Figure 9002 - Syringe with nozzle (T02) 9002
Figure 9003 - Equalizing resistor (T03) 9003
Figure 9004 - Cell extraction tool (T04) 9004
Figure 1 - 4076-10/4076-23 BATTERY 10001-0
Figure 15001 - Short term storage 15003
TOI Page 2
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INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and in AECMA Simplified English. IS units of
measure are used in this manual, with imperial units in parentheses.
B. This manual describes maintenance on components in a workshop. It does not describe

maintenance on components when they are installed in aircraft.
C. Only approved persons with the necessary skills can do maintenance tasks described in this
manual.
D. Maintenance Task Oriented Support System (MTOSS) task and subtask identification is used in
this manual. Maintenance tasks and other data have special MTOSS numbers for the use of
Electronic Data Processing (EDP). MTOSS numbers can be ignored by the user of the manual.
E. This manual contains:
- Technical data for components.

- Maintenance and repair procedures for components.
- An Illustrated Parts List (IPL) with data for parts of components. Parts are identified in all sec-
tions of the manual by the IPL figure and item number.
F. Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY procedures

is accomplished by performing the procedure in the manufacturing facility.
2. How to Use this Manual
A. Make sure the manual contains information applicable to your component. Look for the part
number on the Title Page.
B. If you need to identify a part or find a part number, refer to the IPL, which has an Introduction
chapter showing the procedure.
C. The instructions in this manual must be used for all components maintenance. Read all the
applicable WARNINGS and CAUTIONS before you do the work on the component.
INTRO Page 1
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3. Measure
Measure given in this manual are taken from original manufacturing drawings.
Quantities are given in S.I. units followed by U.S. imperial units in parenthesis.
4. Units of Measure
A. I.S. Units
A ampere
Ah ampere hours
C1 A rated current
C1Ah rated capacity for an hour
g gram
min minute
N newton
N.m newton meter
VDC volt direct current
°C degree celsius
% per cent
Ω ohm
B. U.S. Units
ft foot
in inch
lb pound
lbf.in pound force inch
°F degree fahrenheit
C. Multiplying Prefixes
µ Micro
m Milli
da Deca
k Kilo
M Mega
INTRO Page 2
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5. Abbreviations
The abbreviations given below are used in this manual:
ATA AIR TRANSPORT ASSOCIATION OF AMERICA

DIA DIAMETER
FIG. FIGURE
IPL ILLUSTRATED PARTS LIST
MAX. MAXIMUM
MFR MANUFACTURER
MIN. MINIMUM
NO. NUMBER
OD OUTSIDE DIAMETER
P/N PART NUMBER
PARA. PARAGRAPH
REF. REFER TO
S/A SUBASSEMBLY
TBD TO BE DEFINED
6. Definition
This paragraph describes the warnings used in this manual.
Warnings call attention to use of materials, steps procedures, or limits, which must be followed pre-
cisely to avoid injury to persons.
Cautions call attention to steps procedures which must be followed to avoid damage to equipment.
Notes call attention to procedures which make the job easier.
INTRO Page 3
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7. Disposal
Ni-Cd batteries contain:
- nickel,
- cadmium,
- potassium hydroxide.
Local legislation concerning disposal or recovery must therefore be followed. For more information,
contact your local SAFT supplier.
INTRO Page 4
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DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium VP400KH cells with welded polyamide cases.
The battery is connected to the aircraft systems. It can be used:
(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 used in this chapter correspond to those of the ILLUSTRATED
PART LIST.
B. Characteristics
(1) Technical data
Nominal voltage 24 V
Rated capacity C1Ah 36 Ah (see Note below)
Connector compliant with MS 3509 or
Battery terminals
IEC9-3
Electrolyte Solution of potassium hydroxide
Consumable volume of electrolyte 25 cm3 (1.6 in3) per cell
Maximum dimensions of the battery
- Length 300 mm (11.8 in)
- Width 268.4 mm (10.6 in)
- Height 262 mm (10.3 in)
Battery maximum weight 37.4 kg (82.5 lbs)
Note: 36 Ah at 1 h rate noted as 36 C1Ah or 36 C1Ah.

Current value equivalence : 36 A = 1 C1A and 3.6 A = 0.1 C1A for this 36 C1Ah
battery.
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(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:
Item Value Use for
1 C1 A 36 A Charge/Discharge
0.5 C1A 18 A Charge
0.1 C1A 3.6 A Charge
C. Detailed description
The battery has 20 VP400KH (130) cells housed in a stainless steel box.
The box (370A or 380B) is lined with liner spacer kit (200). The cells are kept upright by means of
a molded silicone elastomer part (050) 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 (230) connects the battery to the aircraft.
The cover (030), which can be removed, is attached to the box (370A or 380B) by four latches.
Page 2
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4076-10/4076-23
4076-10 4076-23
4076-10/4076-23 Battery
Figure 1/TASK 24-31-41-991-001
Identification plate
Figure 2/TASK 24-31-41-991-002
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Overall dimensions
Figure 3/TASK 24-31-41-991-003
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TESTING AND FAULT ISOLATION
1. General
This chapter 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 ISOLATION
TABLE, which for each test refers to a specific procedure specifying all parameters to be applied and
those to be inspected.
The figure and item numbers in this chapter correspond to those of the ILLUSTRATED PARTS LIST.
TASK 24-31-41-700-801
2. Testing
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.

- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar (1.4 to 14.5 psi)).
(2) 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.
- charge/discharge bench (constant current 0 - 60 A).

- power supply: 0 - 45 V, range 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V and 50 V, accuracy 1%.

- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
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(4) Check conditions
- Ambient temperature: 23 + 5 °C (73 + 9 °F).

- Pressure: 85 to 106 kPa (25.1 to 31.1 InHg).
- Relative humidity: < 85 %.
B. Precautions
You must always carry out regular maintenance. It is then necessary to observe the following pre-
cautions to ensure correct operation of the battery:
- Do not install the battery in an aircraft which is too hot.
- Carefully follow aircraft installation instructions to ensure a good airflow.
- Verify the capacity of the battery regularly.
- Charge the battery in a battery shop.
- Maintenance must be done (Refer to CHECK chapter), to verify:

- Level of electrolyte. Especially when ambient temperature is high, time between mainte-
nance must be reduced.
- Tightness of the connection nuts.
- Correct charging.
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SUBTASK 24-31-41-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (060) 1 Ω cell shorting 12 h
charge at 1 C1A (36 A)

box or cells Yes see para. 5.B (6) note the voltage of each
damaged
cell during the charge
No
Topping up at the end
salt or electrolyte Yes see para. 5.C (1) of charge
traces
No more than
usual average added in all
Yes see para. 5.B (1)
electrolyte in Yes see para. 5.C (2) cells
the box
No
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 < 1.5 V
1 or more cell = 0 V see para. 5.B (7)
No
No
capacity check < Yes see para. 5.B (5)
Yes 85% C1Ah
1 or more cell < 0 V see para. 5.B (5)
No
No
a link or a Yes see para. 5.C (4)
insulation nut is too hot
between cell and box
Yes see para. 5.A (3)
No
< 250 kΩ
No do a General Overhaul
to detect battery fault or
external cause
Preliminary Functional Tests

Figure 1001/TASK 24-31-41-991-005
NOTE : average in log book must be considered
Page 1003
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SUBTASK 24-31-41-720-002
D. Testing procedure
(1) Insulation check
- Place the megohmeter as described below:
M:
Insulation Check
Figure 1002/TASK 24-31-41-991-006
- ≥ 250 kΩ under 250 VDC = Min value.
- > 10 MΩ under 250 VDC = value after cleaning and drying.
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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/TASK 24-31-41-991-007
- Measure the insulation resistance between each connector point and every metal housing.
The value must be superior to 30 MΩ at 250 Vdc.
(2) Polarization test
Charge the battery at 3.6 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 (refer to
paragraph 4). Then repair.
If every cell has an open circuit voltage that is more than 0 volts, charge the battery.
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(3) Vent valve test
Before you put the vent valve back on the cells, make sure that they operate correctly.
Do these steps:
1. Install the Vent valve (140) with its O-ring on the end of a metal tube with a suitable
adaptor.
2. Connect this tube to a supply of compressed air through an adjustable reducing valve.
3. 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, in-
crease 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.
4. 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).
5. Install the vent valve (140) (Refer to ASSEMBLY chapter).
(4) Supplementary test before repair
The first test charge can be unsatisfactory if the electrolyte level is too low in some cells
(because 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.
- At the end of normal charge (Refer to one of the procedures given in chapter TESTING
AND FAULT ISOLATION), continue to charge at 3.6 A for 5 more hours. Regularly
record the voltage of the cells. The temperature of cells that have damaged separators
increases significantly and continuously. The voltage of these cells continuously de-
creases to less than 1.5 V.
- Adjust the electrolyte level during the last 30 minutes of charge.
- Discharge at 36 A down to 1 V/cell.
- After this test, discard the defective cells:

- Cells with a voltage of less than 1.5 V at the end of the charge.
- Cells with a voltage that decreases to less than 1 V before one hour of discharge
(during the last test discharge).
- Short-circuited cells (zero volts) overnight.
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TASK 24-31-41-800-801
3. Charge
SUBTASK 24-31-41-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-31-41-820-002
B. Ground charge
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 > 1.5 V) AND ELECTROLYTE ADJUSTMENTS MUST BE CARRIED OUT
USING A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT : 3.6 A (0.1 C1A).
If specific instructions are not given in the charger operating manual, SAFT should
first be contacted.
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.
Cell connections
Figure 1004/TASK 24-31-41-991-008
Page 1007
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(1) Constant current charge
(a) To charge a fully discharged battery, do one of these procedures
CONSTANT CURRENT CHARGE

Main charge Final charge
3.6 A (0.1 C1A) until 30 V as bat-
tery voltage
mini 10 h 3.6 A (0.1 C1A) for a 4 h time
Times :
maxi 12 h
18 A (0.5 C1A) until 31 V as battery
voltage
Times :
maxi 2 h 30 minutes
36 A (1 C1A) until 31.4 V as battery
voltage
Times :
maxi 1 h 15 minutes
Note: If the battery voltage does not increase sufficiently during the maximum charge
time: Refer to the chapter TESTING AND FAULT ISOLATION.
Note: 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 36 A (1 C1A) down to 20 V. Refer to paragraph DISCHARGE.
Charge : refer to B (1) (a) above constant current charge.
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TASK 24-31-41-800-802
4. Discharge
Rated capacity 36 Ah : minimum value obtained for a fully charged

(C1Ah) battery, when discharged at 36 A, down to 20 V.
Other rates
Depending on temperature and time: up to 25 C1A.
(C1A)
TASK 24-31-41-700-802
5. Fault isolation
SUBTASK 24-31-41-760-001
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
CHECK chapter).
(b) Link loose or broken Make sure the nuts are tight
(refer to CHECK chapter).
(2) Zero volts with the battery (a) Battery fully discharged Recharge the battery.
set to "discharge" Do an insulation check (refer to
CHECK chapter).
(b) Battery circuit open or con- Examine the contacts and links.
tacts defective Make sure the terminal nuts are
tight (refer to CHECK chapter).
(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 chapters).
Do an electrolyte level check
Page 1009
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SUBTASK 24-31-41-770-001
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. If necessary,
temperature. adjust the maintenance inter-
val.
(2) The variation of water con- (a) More than 30% or more Do a leak test of the cells (refer
sumption in individual cell than the average: leaks from to CHECK chapter).
exceed ±30% of the average the cell(s).
consumption for all cells.
(b) 30% (or less) of the Do the supplementary test
average: cell(s) with damaged (refer to CHECK chapter
separator(s). para. 2.D.4). If necessary,
replace the cell(s).
(c) Previous maintenance has Note the cell location and check
not been done. 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 overheating.
(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 charge temperatures and charge rates ASSEMBLY, ASSEMBLY AND
(Less than 1.5 V at 3.6 A at outside the limits, and the sepa- STORAGE chapters).
+ 20 °C (+ 68 °F) rator is damaged.
(5) Low capacity cell (The cell (a) Usual wear after long opera- Replace the cell (refer to DIS-
shows a reversed voltage or a tion. ASSEMBLY, ASSEMBLY AND
correct polarity voltage of less STORAGE chapters).
than 1 V after a discharge of
51 min at 1 C1A). (b) Unusual operation, opera- Do the supplementary test
tion at high temperature or (refer to CHECK chapter
operation with low electrolyte. para. 2.D.4). If necessary,
replace the cell(s).
Page 1010
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(6) Cell with a swollen case. (a) Cell operated with low elec- Replace the cell (refer to DIS-
trolyte level ; deterioration of ASSEMBLY chapter).
separators and damaged
plates.
(7) Cell with zero voltage when (a) Short-circuited cell. Replace the cell (refer to DIS-
the battery circuit is open. ASSEMBLY chapter).
SUBTASK 24-31-41-750-001
C. Physical faults

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

high-rate discharge (for exam- sive charge.
ple, during the engine start). Disassemble and clean the bat-
and CLEANING chapters).

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

temperature or too much cur- sive charge.If necessary, adjust
rent. the maintenance interval.
Disassemble and clean the bat-


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(2) Electrolyte found in the bat- (a) Damaged cell case Do a leak test of the cells (refer
tery box. to CHECK chapter).
Replace the cell if necessary

and refer to related subsequent
steps.
(b) Leakage of electrolyte Disassemble and clean the bat-


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

nickel plating (refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
chapters).
(4) The links are too hot. (a) Loose terminals nuts Make sure the nuts are torqued
SUBTASK 24-31-41-750-002
D. Vent valve faults

Valve open pressure > 0.7 bar Clogged valve. Change the valve.
or stay closed.
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
1. General
This chapter gives all electrical schematics of battery sensor.
2. Schematic sensor
Schematic sensor 4076-10

Figure 2001/TASK 24-31-41-991-009
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Schematic sensor 4076-13

Figure 2002/TASK 24-31-41-991-010
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DISASSEMBLY
1. General
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.
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT

ISOLATION CHAPTER).
The figures and items numbers used in this chapter correspond to those of the ILLUSTATED PARTS
LIST.
2. Safety
The Safety rules are different from one country to another. Only local rules are applicable.
3. Risks
There are three types of risks.
A. Physical
- Handling: lift with your legs and not your back.

- Wear protective shoes.
B. Electrical
- Don’t wear rings, watches, chains, belt buckles.

- Use insulated tools.
C. Chemical
- Electrolyte is very corrosive and may cause severe damage to the skin: wear gloves
- Contact with eyes is very dangerous, wear protective goggles.
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4. Safety measure
- The electrolyte compound is caustic and can cause severe burns. If it comes in contact with the skin,
flush the touched part with water and neutralize 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 at least 15 minutes and call a doctor.
- Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the
solution with water or, if possible, with milk. Call a doctor immediately. Do not try to make somebody
unconscious drink . Contact with nickel can cause chronic eczema. Inhalation of cadmium oxide can
cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest. Persons
having inhaled cadmium oxide fumes must get fresh air or take oxygen or must have artificial respi-
ration.
- Potash can cause eczema.
TASK 24-31-41-000-801
5. Disassembly
A. Equipment
(1) Standard tools

- Safety gloves and apron.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
SUBTASK 24-31-41-020-001
B. Disassembly procedure
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT

ISOLATION CHAPTER).
(1) Remove the cover (030)
(2) Removal of a vent valve (140)
NOTE: The vent valve must stay tight when the cell is removed. Remove the valve
only when the cells are placed in the battery.
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(a) Unscrew the vent valve (140) with the special tool (T01).
(b) Remove the vent valve with its O-ring.
(3) Removal of a cell (130)
NOTE: In order to avoid a short-circuit, remove a link (080) between two cells.
(a) Remove the nuts (060) and the spring washers (070) that attach the links to the cell.
(b) Remove all links (080 thru 120).
(c) Fully engage the end of the special threaded tool (T03) onto one of the cell terminals.
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Then pull up to remove the cell.
(4) Removal of the connector (230)
(a) Remove the screws (210) and the washers (220)
(b) Remove the connector (230) with the O-ring (240)
(5) Removal of the sensor (280)
(a) Remove the nut (300) and the washer (270)
(b) Remove the protector (260)
(c) Remove the sensor (280)
(6) Removal of the sensor (330B)
(a) Remove the nut (350B)
(b) Remove the nut (340B)
(c) Remove the protector (310B)
(d) Remove the sensor (280)
(7) Disassembly of the battery
(a) Remove
1. The cover (030).
2. The cells (130).
3. The liner spacers kit (200).
4. The connector (230).
5. The sensor (280)
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CLEANING
1. General
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST.
2. Equipment required
- Safety gloves.
- Safety shoes.
- Eye washing.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled water.[MO1]
- Neutral soap.[MO2]
- Non-fluffy swab.
- Non-wire brush.
TASK 24-31-41-100-801
4. Cleaning 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 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 24-31-41-160-001
A. Light cleaning
Remove the cover.
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.
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SUBTASK 24-31-41-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
(1) Cells
Make sure that the vent valve (140) is tight.
NOTE: Do not soak the cells in water.
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.
Rub the cell with a cloth and let dry.
(2) Box and handle
Clean with lightly soapy water, rub with a cloth and let dry.
(3) Nuts, spring washers and links
Clean in warm water with a brush and let dry.
(4) Liner spacer kit and sensor
Clean in warm water and let dry.
(5) Vent valve
CAUTION: THE CLEANING OF THE VENT VALVE (140) MUST BE DONE WHEN THE
CELLS ARE ASSEMBLED IN THE BOX.
(a) Remove the vent valve (140) (Refer to "DISASSEMBLY chapter).
(b) Put swab on the cell holes to keep out unwanted material.
(c) Soak the vent valve for some time (during the night, for example) in a container of dis-
tilled water. Do that to remove all salts from the vent hole.
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS.
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TASK 24-31-41-600-801
5. Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of mineral vaseline
or light oil on the terminals and the links. Use a paintbrush.
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CHECK
1. General
You must perform 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:
- 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 24-31-41-200-801
2. Maintenance steps in workshop
A. Equipment
(1) Standard tools

- Safety gloves.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
- Power supply 0 - 45 V, 0 - 60 A.
- Discharge bench, constant current 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V and 50 V, accuracy 1%.
- A megohmeter, range 0 - 50 MΩ (voltage 250 VDC), accuracy 3%.
(4) Check conditions

- Ambient temperature: 23 + 5 °C (73 + 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.1 InHg).
- Relative humidity: < 85 %.
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(5) Referenced information
REFERENCE DESIGNATION
Insulation check
Polarisation test
24-31-41-720-002
Vent valve test
Supplementary test
SUBTASK 24-31-41-210-001
B. Periodical check
If the electrolyte consumption exceded the approved used between 2 regular check, apply this
periodical check following the differents steps indicated in Fig 5001:
- Clean the battery (see "CLEANING" chapter).
- Measure the voltage Ubat (in open circuit) at the terminal of the battery. If Ubat < 21 V do a po-
larisation test (see "TESTING AND FAULT ISOLATION" para. 2.D.2).
- Check the nut tightness (see "FITS AND CLEARANCES" chapter).
- Discharge and charge according to the procedure below (1).
- Clean the vent valves (see "CLEANING" chapter).
(1) Discharging and charging the battery, and adjusting the electrolyte level:
(a) Remove the cover.
(b) Discharge the remaining capacity at 36 A down to a voltage of 20 V at the battery termi-
nals.
(c) Check the insulation (see "TESTING AND FAULT ISOLATION" para. 2.D.1)
(d) When the battery temperature is + 20 °C to + 25 °C (+ 68°F to + 77 °F) (usual tempera-

ture range), charge the battery (refer to one of the procedures given in the chapter TEST-
ING AND FAULT ISOLATION for a fully discharged battery).
(e) During the last 1/2 hour of the charge (while the charge current continues to flow), adjust
the level of electrolyte in the cells. Then measure the voltage of each cell. 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. The level is correct when the distance between the seat of the vented filler cap
and the electrolyte is 20 mm (0.79 in) (distance measured in the condition given above)
(Fig. 5002). If the cell voltage before end of charge was less than 1.5 V proceed a Fault
Isolation (see TESTING AND FAULT ISOLATION chapter).
(f) If necessary, add distilled or deionized water to adjust the level to this value.
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PERIODICAL CHECK 2.B

Light cleaning
Cleaning yes U >21 V and no

no cell with reversed
polarity
yes
dust only?
Nut tigthness POLARISATION TEST
no
Residual discharge
Salt or electrolyte traces 1 V/cell
no Insulation check yes

General overhaul
figure 5004 > 2 MΩ
Recharge
Cell voltage before

end of charge
no U > 1.5 V yes
FAULT ISOLATION Adjustment of elec-
trolyte level before
end of charge
(volume < 25 cm3)
Supplementary test removal < 30 %
Add 5 h overcharge
yes
U > 1.5 V
Adjust electrolyte Vent cleaning
level. OK?
no
General overhaul Nut tightness
figure 5004
with replacement of
faulty components.
If more than 5* original * If 3 or more cells changed du-
cells, then change all Battery accepted after
ring the same check, change all periodical check
cells.
cells.
Periodical check
Figure 5001/TASK 24-31-41-991-011
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WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte
levels in nickel-cadmium cells. A very small quantity of acid is sufficient to
cause permanent damage.
The easiest tool to use to adjust the level is a plastic syringe tube (equivalent to that used for
medical injections, with a plastic nozzle on the conical end).
The length of the nozzle which goes into the cell must be 20 mm (0.79 in); this is the distance
necessary between the seat of the vented filler cap and the electrolyte (Refer to figure 5002).
To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vented
filler cap and pull the plunger up.
20 mm (0.79 in)
Level adjustment with a syringe and calibrated nozzle

Figure 5002/TASK 24-31-41-991-011
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If the level is not sufficient, the syringe tube stays empty when you pull the plunger. If there
is too much liquid, this liquid is removed by the syringe until the level aligns with the end of
the nozzle.
If this check shows that the level is not sufficient in some cells, do these steps :
a - add a measured amount of distilled water, such as 5 ml, into the syringe and inject
it into the cell.
b - with the syringe nozzle resting on the valve seat, fully withdraw the plunger on the
syringe
c - if the syringe remains empty, repeat a and b, counting the number of 5 ml injec-
tions required to achieve the correct level
d - at the point in step b when some excess liquid is drawn into the syringe, the correct
level for that cell has been reached. Expel the excess liquid into a container for later
disposal
e - the number of milliliters of distilled water required to fill the first cell to the correct
level will serve as an approximate guide to the amount required for the remaining
cells. However, the water in each cell must be adjusted individually to the correct
level.
(2) Results of the above procedure
The battery operates correctly if:
(a) The voltage of each cell measured during the last hour of charge at 3.6 A is not less than
1.5 V.
(b) Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 25 cm3 (1.6 in3).
NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell
(1.6 in3/cell), do the electrolyte level check more frequently.
Do a full overhaul of the battery (refer to paragraph 3 "General overhaul"):

- If the quantity of water necessary for one or more cell(s) is much higher or lower than for the
other cells.
- If the voltage of each cell measured at the end of a 3.6 A charge is less than 1.5 V (refer to
the chapter TESTING AND FAULT ISOLATION).
(3) Clean the vent valve (140) (Refer to "CLEANING" chapter) when you adjust the electrolyte
levels.
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(4) Make sure that all the nuts that attach the links are torqued (refer to "FITS AND CLEARANC-
ES" chapter).
(5) Do an insulation check. The insulation resistance measured between the block of cells and
the metal box must be at least 2 MΩ under 250 VDC if the battery has not gone through a
general overhaul. Otherwise refer to CHECK chapter.
SUBTASK 24-31-41-210-002
C. Regular check (Ref Fig. 5003)
AFTER A MAXIMUM OF ONE YEAR, do this battery test following the different steps indicated in
Fig 5003:
- Clean the battery (See "CLEANING" chapter).

- Measure the voltage Ubat (in open circuit) at the terminal of the battery. If Ubat < 20 V do a po-
larisation test (refer to TESTING AND FAULT ISOLATION para. 2.D.2).
- Discharge the battery (refer to para. (4))
- 1 ohm cell shorting overnight (refer to para. (6))
- Do an insulation test (refer to TESTING AND FAULT ISOLATION para. 2.D.1)
- Charge the battery (refer to TESTING AND FAULT ISOLATION chapter)
- Adjust the electrolyte level (refer to para. (8)).
- Do a capacity check (refer to para. (9))
- Clean the vent valves (see "CLEANING" chapter).
- Recharge the battery (refer to TESTING AND FAULT ISOLATION chapter)
NOTE : The ratio between operating hours (aircraft "power on") and flying hours is
generally in the 1.2 to 2 range.
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Light cleaning
REGULAR CHECK 2.C
yes U > 21 V and no
no cell with reversed
Cleaning polarity
Nut tigthness POLARISATION 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 > 1.5 V
FAULT ISOLATION no Adjustment of elec- yes
trolyte level before
end of charge
(volume < 25 cm3)
Supplementary test removal < 30 %
OK? yes
Add 5 h overcharge
U > 1.5 V
Adjust electrolyte FAULT ISOLATION no Capacity check yes
1 V/cell ≥ 51 min
no
Supplementary test
OK?
General overhaul
Completed charge Vent cleaning
figure 5004
Add 5 h overcharge
with replacement of no Nut tigthness
U > 1.5 V
faulty components . yes
Adjust electrolyte
If more than 5* original Recharge
level.
cells, then change all
Discharge > 51 min
cells. Battery accepted after
regular check
* If 3 or more cells changed during the same check, change all cells.
Regular check
Figure 5003/TASK 24-31-41-991-012
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(1) Remove the cover.
(2) Clean the battery.
(3) Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then do the
polarisation test.
(4) Discharge the remaining capacity at 36 A down to a voltage of 20 V at the battery terminals.
Measure the time from the start of discharge to the time when the voltage reaches 20 V.
(5) Do an insulation test.
(6) Connect a resistor approximately 1 Ω 3 W (T03) across each cell and continue to discharge.
Resistors with crocodile clips attached to their leads can easily be attached to the cell termi-
nals. Keep the resistors in position for 12 hours.
(7) Remove all resistors, charge the battery (refer to the chapter TESTING AND FAULT ISOLA-
TION for a fully discharged battery).
(8) Adjust the electrolyte level in the cells.Then measure the voltage of each cell during the last
hour of charge.If the cell voltage before end of charge was less than 1.5 V proceed a Fault
Isolation (see TESTING AND FAULT ISOLATION chapter). Also, write down the quantity of
distilled water added to each cell.
(9) Immediately after the charge and the level adjustment, discharge the battery again at 36 A.
at 1 hour of discharge, measure voltage of each cell. This voltage must be over 1 V. Continue
to discharge the battery down to 20 V. Write the time necessary for the second discharge.
(10) Clean the vent valve (140) (Refer to CLEANING chapter) when you adjust the electrolyte
levels.
Results of the above tests:
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 3.6 A is not less than
1.5 V.
- The variation of water consumption in individual cell does not exceed ±30% of the average con-
sumption for all cells.The maximum limit is 25 cm3 (1.6 in3).
NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell
(1.6 in3/cell), do the electrolyte level check more frequently.
- If the first discharge time is less than 30 minutes but the second discharge time is correct: the
Page 5008
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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.
Do a full overhaul of the battery if:
- 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).
- The voltage of each cell measured during the last hour of charge at 3.6 A is less than 1.5 V.
- The quantity of water necessary for one or more cell(s) is much higher or smaller than for the
other cells.
NOTE : The decrease of water in a SAFT nickel-cadmium cell is in proportion to the over-
charge. 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:
- Leakage usually causes heavy decrease.
- A damaged separator causes low decrease.
SUBTASK 24-31-41-210-003
D. General overhaul (minimum 1 per year)
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures to
do systematically for all battery components. Do this battery test following the differents steps in-
dicated in Fig 5004:
- Measure the voltage Ubat (in open circuit) at the terminal of the battery. If Ubat<21V do a Po-
larization Test (refer to TESTING AND FAULT ISOLATION para. 2.D.2).
- Disassemble the battery (refer to "DISASSEMBLY" chapter).
- Clean the battery (refer to "CLEANING" chapter).
- Do a battery inspection.
- Test the sensor (refer to para. F)
- Assemble the battery (refer to "ASSEMBLY" chapter).
- Do an insulation test (refer to TESTING AND FAULT ISOLATION para. 2.D.1)
- Charge the battery (refer to TESTING AND FAULT ISOLATION chapter)
- Adjust the electrolyte level (refer to para. (8)).
- Do a capacity check (refer to para. (9))
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- Test the vent valves (refer to "TESTING AND FAULT ISOLATION" chapter).
- Clean the vent valve (refer to "CLEANING" chapter).
- Check the nut tightness (refer to "FITS AND CLEARANCES" chapter).
- Recharge the battery (refer to TESTING AND FAULT ISOLATION chapter)
(1) Disassemble the battery (Refer to "DISASSEMBLY" chapter).
(2) Clean the battery (Refer to "CLEANING" chapter).
(3) Do a battery inspection.
(a) Cells
1. Make sure that the lower terminal nuts are tight (refer to "FITS AND CLEARANCES"
chapter).
2. Verify that cell boxes show no leakage.
(b) Box
Make the sides of the box straight and remove dents.
(c) Nuts, links and spring washers
Discard the components that show signs of corrosion or damage.
(d) Packing parts
Discard all defective components.
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
SUBTASK 24-31-41-280-001
E. Insulation resistance
Refer to the chapter TESTING AND FAULT ISOLATION .
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GENERAL OVERHAUL 2.D
Scheduled On fault
yes U > 21 V and no
no cell with rever- POLARISATION 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 be-
Insulation check fore end of charge
no > 10 MΩ yes no
U > 1.5 V
yes
Adjustment of
electrolyte level
FAULT ISOLATION before end of
charge
Other test OK?
Add 5 h over- yes
no
charge U > 1.5 V
Adjust electrolyte no Capacity check
FAULT ISOLATION yes
1 V/cell ≥ 51 min
General overhaul
with replacement of Other test OK?
faulty components . Completed charge Vent cleaning and test
If more than 5* original Add 5 h over-
Nut tightness
cells then change all charge U > 1.5 V
cells. no Adjust electrolyte yes Recharge
level. Discharge
* If 3 or more cells changed during > 51 min. Battery accepted af-
the same check, change all cells. ter general overhaul
General overhaul
Figure 5004/TASK 24-31-41-991-013
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SUBTASK 24-31-41-280-002
F. Checking of temperature sensor
Refer to SCHEMATIC DIAGRAM chapter.
Do this test in a climatic chamber with the sensor disassembled from the battery
(1) For battery 4076-10.
CHECK OF BETWEEN VALUE

Resistor R1 A-B R = 49.9 kΩ ± 0.5 KΩ at 25 °C (77 °F)
Thermistor T1 B-C R = 300 KΩ ± 35 KΩ at 25 °C (77 °F)
(2) For battery 4076-23.
CHECK OF BETWEEN VALUE

closes on temperature rise between
Thermostat T C-D
+65 °C and 77 °C (150 °F and 170 °F)
Resistor R A-B R = 49.9 kΩ ± 0.5 KΩ at 25 °C (77 °F)
Thermistor S B-C R = 300 KΩ ± 35 KΩ at 25 °C (77 °F)
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.
Page 5012
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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
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 (050).
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REPAIR N°1
TASK 24-31-41-900-801
1. Changing a cover gasket
A. General
The cover gasket (050) can be changed only one time.
B. Detailed procedure
- Remove the cover gasket (050).
- 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.
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ASSEMBLY
1. General
Parts assembly shall be done on a clean workbench in a clean, dry room. They will be protected from
hit damage.
For tightening parts refer to the torque table in the chapter FITS AND CLEARANCES .
Check that the storage protection layer is removed from the new part before assembly.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST.
To do check points, refer to CHECK chapter.
TASK 24-31-41-400-801
2. Assembly procedure
A. Equipment
(1) Special tools
When special tools are used in this chapter they are identified by a code number listed in the
(2) Standard tools

- Safety gloves.
- Safety shoes.
- Eye wash.
- Protective apron.
B. Procedure
- Installation of the sensor

- installation of the connector
- installation of the liner spacer kit
- installation of a cell
- installation of vent valve
- recording
Page 7001
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SUBTASK 24-31-41-420-001
C. Installation of the sensor (280)
(1) Put in position the sensor (280) with the washer (270), the protector (260) and the nut (300)
SUBTASK 24-31-41-420-002
D. Installation of the sensor (330B)
(1) Put in position the sensor (340B) on the link (120B) with the screw (360B)
(2) Put in position the sensor (340B) with the washer (350B), the protector (310B) and the
nut (350B)
SUBTASK 24-31-41-420-003
E. Installation of the connector
(1) Put in position the connector (230) and the O-ring (240) with the washer (220) and the
screw (210)
SUBTASK 24-31-41-420-004
F. Installation of the liner spacer kit (200) (Ref. Fig. 7001)
(1) Put in position the E insulators.
(2) Put in position the A, B, C, D, F, G and H side spacers.
(3) Install the cells..
UNIT
DIMENSION
ITEM DESCRIPTION PER
(mm)
ASSY
A Spacer 2x238x75 5
B Spacer 1x238x75 6
C Insulator 0.5x245x235 2
D Spacer 1x235x210 2
E Insulator 0.3x236x58 3
F Insulator 0.5x245x238 3
G Spacer 1x220x75 1
H Spacer 1x245x238 4
NOTE : The F and H slotted spacer will be assembled so as to keep the ventilating system
of the box free.
Page 7002
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Liner spacer kit installation

Figure 7001/TASK 24-31-41-991-014
Page 7003
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4076-10/4076-23
SUBTASK 24-31-41-420-005
G. Installation of a cell (Ref. Fig. 7002)
(1) Put the cells (130) in the compartments.
(2) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spac-
ers).
(3) Carefully position the cell (130) and push onto terminals with a piece of soft wood.
(4) Install the links (080 thru 120).
(5) Install the spring washers (070).
(6) Install the nuts (060) and torque them.
(7) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
brush).
(8) Install the cover (030) and attach it.
Cell installation
Figure 7002/TASK 24-31-41-991-015
Page 7004
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4076-10/4076-23
SUBTASK 24-31-41-420-006
H. Installation of the vent valve (140)
NOTE : The vent valve must stay tight when the cell is removed. Remove the valve only when
the cells are placed in the batterie.
(1) Make sure the vent valves (140) are in good condition. Replace the vent valves (140), with
its O-ring, if they are worn.
(2) Install the vent valve (140) with the special tool (T01). Hold the special tool by its upper ribbed
part.
SUBTASK 24-31-41-970-001
I. Recording
(1) Identification plate (400) if the box (380B or 370A) has been changed
(2) Log book.
Page 7005
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Page 7006
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4076-10/4076-23
FITS AND CLEARANCES
TASK 24-31-41-400-802
1. Torque table
SUBTASK 24-31-41-420-001
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 be-
fore to installation and applying torque.
IPL TORQUE VALUE

FIG ITEM NAME
N° N.m lbf.in
060 (upper) Nut 12 to 14 106 to 124

150 (lower) Nut 4.5 to 5.5 39 to 47
Page 8001
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Page 8002
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General
This chapter is divided into two parts:
- The first part provides the list of SPECIAL TOOLS, AND FIXTURES AND EQUIPMENT needed to
perform the steps listed in the order chapters.
- The second part provides the listing of Consumable Materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for TOOLS, FIXTURES AND EQUIPMENT,

- Mxx for Consumable Materials.
2. Special tools, fixtures and equipment
PART
CODE QTY NUMBER DESCRIPTION USE
F6177
Polyamide key for polyamide DISASSEMBLY - CLEANING -

T01 1 015528
vented filler cap CHECK - ASSEMBLY
Syringe assembly (with noz- TESTING AND FAULT ISOLA-
T02 1 016544
zle) TION - CHECK
Equalizing resistors
T03 1 164829 TESTING - CHECK
(1 Ω / 3 W)
T04 1 013169 Cell extraction tool DISASSEMBLY
Page 9001
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4076-10/4076-23
Polyamide key for vent valve (T01)

Figure 9001/TASK 24-31-41-991-016
Syringe with nozzle (T02)

Figure 9002TASK 24-31-41-991-017
Page 9002
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4076-10/4076-23
Equalizing resistor (T03)

Figure 9003/TASK 24-31-41-991-016
Page 9003
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4076-10/4076-23
Cell extraction tool (T04)

Figure 9004/TASK 24-31-41-991-019
Page 9004
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4076-10/4076-23
3. Consumables
NOTE: Equivalent alternatives can be used for list items.
A
I D
R I
C A
L S S
MANUFACTU L R S
I A C T
DESIGNATION RER T E E S
N S H O
PARTNUMBER OR SUPPLIER E A P E
CODE E S E R
AND (NAME, S N A M
S E C A
SPECIFICATION ADDRESS, T I I B
M K G
CODE) N R L
C B E
G Y
O L
D Y
E
Distilled or deionized
water
clear, colorless, oderless
while boiling, resistivity
> 30 kΩ/cm
5 < pH < 7
Absence of organic and
reducing substances.
M01 Reducing agent content Local vendor X X
(expressed in weight of
oxygen) < 30 mg/l (test
with permanganate).
Total of ions
SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
M02 Soap Local vendor X

M03 Neoprene glue Local vendor X
NATO: S 743
F: AIR 3565
M04 Mineral vaseline X X
US: SLP 236
UK: DEF 2333
Page 9005
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Page 9006
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ILLUSTRATED PARTS LIST
TP Page 10001
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TP Page 10002
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INTRODUCTION
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 Detailed
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.
2. Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and electronic
components of the items listed in alphanumeric order for the letters, numerical order for the figures.
Page 10003
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4076-10/4076-23
3. Numerical Index (NI)
In this index, part numbers are classified in the following order:
Classification is made from left to right, each character (letter, number, hyphen) being considered
separately.
The first left row ordering is :
- hyphen
- alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
- numbers from 0 to 9.
The part number column contains all part numbers included in the Detailed Parts List. 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.
4. Detailed Parts List (DPL)
A. Figure and Item Number
Each assembly, sub-assembly and part holding a part number and included in the parts list is giv-
en a time number.
The figure number linked to the item number is shown on the first line at the top of each page.
Assemblies, sub-assemblies and numbered parts included in the list but not illustrated are identi-
fied by a hyphen (-) preceding the item number.
An index letter shown before the item number refers to the figure showing the modified portion of
the applicable part.
B. Manufacturer’s Part Number
A manufacturer’s part number is given to each assembly and detail part, whether illustrated or not.
Page 10004
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C. Parts List
The parts list is represented with indenting showing the relationship of parts and assemblies to
their next higher assemblies as follows :
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.
The attaching parts are shown directly after the assembly of the part there of. They are listed un-
der the same indent number as the item they are attached to, and are identified by the words "At-
taching Parts" and are followed by three asterisks.
The manufacturer’s code or the abbreviation NP (not procurable) are placed at the extreme right-
hand side of the first line of the parts list column.
D. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in re-
lation to the next higher assembly (ies) or sub-assembly (ies).
When the effectivity is fully applicable, the usage code column remains blank.
The usage 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.
Page 10005
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4076-10/4076-23
E. Units per Assembly
The units per assembly column showns the quantity of units required for one next higher assem-
bly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR (as re-
quired).
Page 10006
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4076-10/4076-23
5. Abbreviation used
ALT FROM PN 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 Part obtained by modifying another part
NHA Next higher assembly
NP Not procurable
OLD PN Old part number. This item has never been installed.
OPT PN Optional part number that is fully interchangeable with the part in the
part number column.
OPT SEE TABLE See optional table
ORDER OVRLGTH MPN Part number over fifteen characters
OVERSIZE Part with size exceeding its nominal dimension.
PN Part number.
POST SB After modification brought up by a Service Bulletin.
PRE SB Before modification brought up by a Service Bulletin.
R Modified
RF For reference.
RH Right hand.
SEE CMM See component Maintenance Manual.
SEE FIG FOR DET See figure for details.
SEE FIG FOR NHA See figure for next higher assembly.
SEL FROM Selected from. Part which is to be selected as necessary from collec-
tion of parts.
SUPSD BY Superseded by XXX.
SUPSDS Supersedes XXX.
UNDERSIZE Part with size smaller than its nominal dimension.
VL Vendors List.
Page 10007
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4076-10/4076-23
6. Updating
A. General
When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the
date of issue changes).
B. Added items
The basic sequence of the items given from 10 to 10 makes it possible to add new items between
the old ones in the appropriate order of the breakdown. With the addition of more than nine new
items, a new number is to be added at the end of the IPL.
C. Deleted items
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.
D. New Figure Number Added
Whenever new illustrations are necessary the alternative figures are inserted. They refer to the
same parts list.
The alternative figure is given with the basic figure number and letter. This letter precedes the item
number in the parts list.
Page 10008
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VENDOR CODE INDEX
VENDOR CODE NAME-ADDRESS

SAFT
12 avenue Sadi Carnot
F6177 93170 Bagnolet
Phone: (33) 1 49 93 19 18
Fax: (33) 1 93 93 19 56
SAFT AMERICA INC.
711 Industrial Boulevard
Valdosta, GA 31601
V09052
USA
Phone: (1) 229 247 8486
Fax: (1) 229 245 2827
Page 10009
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Page 10010
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ALPHA NUMERICAL INDEX
AIRLINE FIG INDEX TOTAL

PART NUMBER
STOCK NUMBER NUMBER NUMBER REQUIRED
007788 270 1
012374 080A 15
012374 080B 14
015266 100 1
015539 090 2
031282 400 2
034031 410 1
057014 110 3
062007 060 42
062007 150 2
063412 130 20
100078 190 2
100094 070 42
100094 160 2
100430 220 4
100431 210 4
100693 180 1
100694 170 1
100713 240 1
102295 040 1
102392 230 1
105405 350B 1
113605 050 1
114300 030 1
114722 330B 1
114724 320B 1
114767 120A 1
117026 380 1
166900 280 1
166925 250 1
280068 430 1
410764 360A 1
410778 010A 1
411108 390 1
411424 200 1
412488 020B 2
413609 420 2
415020 370B 1
415021 310B 1
415022 260 1
415154 010B 1
415213 140 1
- Item not illustrated
Page 10011
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4076-10/4076-23
Page 10012
24-31-41
4076-10/4076-23
DETAILED PARTS LIST
Page 10001-0
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4076-10/4076-23
FIGURE AIRLINE NOMENCLATURE UNITS

PART EFF.
AND STOCK PER
NUMBER CODE
ITEM NUMBER 1234567 ASSY
01
- 001A 4076-10 Battery 4076-10, VP400KH PM
- 001B 4076-23 Battery 4076-23, VP400KH PM
010A 410778 . Box and cover complete 1
010B 415154 . Box and cover complete 1
020B 412488 . Handle 2
030 114300 . . Cover complete 1
040 102295 . . . Cover, assembly 1
050 113605 . . . Gasket, cover 1
060 062007 . Nut, M10x1.25 42
070 100094 . Washer, spring 42
080A 012374 . Link, intercell, E34 15
080B 012374 . Link, intercell, E34 14
090 015539 . Link, intercell, E37 2
100 015266 . Link, intercell, E49 1
110 057014 . Link, curved 3
120B 114767 . Link, curved 1
130 063412 . Cell, VP400KH, assembly 20
140 415213 . . vent valve, complete 1
150 062007 . . Nut, M10x1.25. 2
160 100094 . . Washer, spring 2
170 100694 . . Washer, positive polarity 1
180 100693 . . Washer, negative polarity 1
190 100078 . . Washer, flat 2
200 411424 . Liner-spacer kit 1
210 100431 . Screw, F/90x1.25 4
220 100430 . Washer, locking 4
230 102392 . Connector complete 1
240 100713 . O-ring, 56.75 1
250 166925 . Protector 1
260 415022 . Protector 1
270 007788 . Washer, 14.5/24 1
280 166900 . Sensor, complete 1
290 NP . . Sensor, assembly NP
300 NP . . Nut, sensor NP
310B 415021 . Protector 1
320B 114724 . Washer, 18.5/32 1
330B 114722 . Sensor, complete 1
340B NP . . Sensor, assembly NP
350B NP . . Nut, sensor NP
360B 105405 . . Nut, 6/32" 1
Page 10001-1
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4076-10/4076-23
FIGURE AIRLINE NOMENCLATURE UNITS

PART EFF.
AND STOCK PER
NUMBER CODE
ITEM NUMBER 1234567 ASSY
370A 410764 . . Box complete 1
380B 415020 . . Box complete 1
390 117026 . Film, protector 1
400 411108 . Plate, identification 1
410 031282 . Plate, filling instruction 2
420 034031 . Plate, amendment 1
430 413609 . Plate, SAFT label 2
440 280068 . Plate, recycling 1
- Item not illustrated.
Page 10001-2
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Page 10001-3
24-31-41 Jun 12/2002
4076-10/4076-23
STORAGE (INCLUDING TRANSPORTATION)
TASK 24-38-52-600-802
1. Storage
A. Preparation of the battery before storage
- Adjust the electrolyte levels (Refer to "CHECK"), then discharge at a constant current of 36 A
down to 20 V.
- Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the
connector contacts and all the components that can be damaged by atmospheric corrosion.
- Put the battery in its usual vertical position.
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommanded temperature range is + 20 °C ± 15 °C (68 °F ± 27 °F). However, occasional

excursions into the range of - 60 °C to + 60 °C (- 76 °F to + 140 °F) is permitted.
D. Packing
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we rec-
ommend to put the batteries in a welded plastic container. In this type of container, with the re-
commanded temperature range, the batteries can be kept for 10 years.
TASK 24-38-52-600-803
2. Storage procedure
A. General
When the battery arrives in the battery shop for servicing:
- Visual inspection: if dust or salt do a General Overhaul according procedure (refer to CHECK
chapter).
- Then light cleaning (refer to CLEANING chapter), then service as scheduled (periodical check,
regular check or general check) (refer to CHECK chapter).
Page 15001
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4076-10/4076-23
SUBTASK 24-38-52-610-001
B. Short term storage (Ref. Fig. 15001)
(1) Operations
- 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 chapter).
- Light greasing of cells terminals.
- Place in a storage room.
Page 15002
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4076-10/4076-23
100
90
AVAILABLE CAPACITY (%C1Ah)
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) Disch. (0%C1Ah)

60
0 10 20 30 40 50 60 70 80 90
REST TIME (days)
Short term storage

Figure 15001/TASK 24-31-41-991-021
Page 15003
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4076-10/4076-23
SUBTASK 24-38-52-610-002
C. Long term storage
(1) Operations
- Discharge to 1 V/cell.
- Light greasing of cells terminals.
- Place in a storage room.
(2) Conditions
The battery should be stored filled and discharged.
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 : ie. dirt, dust, clampness, vibration, corrosive atmosphere.
NOTE : Lead batteries must be stored in a different room.
CAUTION : Saft Ni-Cd batteries may be stored in temperatures ranging from - 60 °C (- 76 °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.
Page 15004
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4076-10/4076-23
TASK 24-38-52-600-804
3. Servicing after storage
Storage time Servicing procedure

Charge the battery (Do one of the procedures given in "TESTING
Less than 3 months
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year Do the Periodical check (refer to "CHECK" chapter).
More 1 year Do the Regular check (refer to "CHECK" chapter).
TASK 24-38-52-500-801
4. Transportation
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 15005
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4076-10/4076-23
Page 15006
24-31-41 Jun 12/2002

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(F6177)

12 rue Sadi Carnot - 93170 Bagnolet - France

This document replaces

Date of issue : Jun 12/2002 Title page - page 1

PAGE INTENTIONALLY LEFT BLANK

Title page - page 2

PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISIONS

PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST

PAGE INTENTIONALLY LEFT BLANK

LIST OF APPROVED REPAIRERS

PAGE INTENTIONALLY LEFT BLANK

LIST OF EFFECTIVE PAGES

TABLE OF ILLUSTRA- 1 Jun 12/2002 CLEANING 4001 Jun 12/2002

LIST OF EFFECTIVE PAGES

SPECIAL TOOLS, 9001 Jun 12/2002

ILLUSTRATED 10001 Jun 12/2002

INTRODUCTION 10003 Jun 12/2002

VENDOR CODE 10009 Jun 12/2002

ALPHA NUMERICAL 10011 Jun 12/2002

DESCRIPTION AND OPERATION 1

TESTING AND FAULT ISOLATION 1001

SCHEMATIC AND WIRING DIAGRAMS 2001

FITS AND CLEARANCES 8001

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

ILLUSTRATED PARTS LIST 10001

SPECIAL PROCEDURES NOT APPLICABLE

REMOVAL NOT APPLICABLE

INSTALLATION NOT APPLICABLE

SERVICING NOT APPLICABLE

STORAGE (INCLUDING TRANSPORTATION) 15001

REWORK (service bulletin instructions) 16001

Figure 2 - Identification plate 3

Figure 3 - Overall dimensions 4

Figure 1001 - Preliminary Functional Tests 1003

Figure 1002 - Insulation Check 1004

Figure 1003 - Insulation Parameters 1005

Figure 1004 - Cell connections 1008

Figure 2001 - Schematic sensor 4076-10 2001

Figure 2002 - Schematic sensor 4076-23 2002

Figure 5001 - Periodical check 5003

Figure 5003 - Regular check 5007

Figure 5004 - General overhaul 5011

Figure 7001 - Liner spacer kit installation 7003

Figure 9001 - Polyamide key for vent valve (T01) 9002

Figure 9002 - Syringe with nozzle (T02) 9002

Figure 9003 - Equalizing resistor (T03) 9003

Figure 9004 - Cell extraction tool (T04) 9004

Figure 1 - 4076-10/4076-23 BATTERY 10001-0

Figure 15001 - Short term storage 15003

B. This manual describes maintenance on components in a workshop. It does not describe

E. This manual contains:

- Technical data for components.

F. Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY procedures

2. How to Use this Manual

The abbreviations given below are used in this manual:

ATA AIR TRANSPORT ASSOCIATION OF AMERICA

This paragraph describes the warnings used in this manual.

Notes call attention to procedures which make the job easier.

Ni-Cd batteries contain:

DESCRIPTION AND OPERATION

The battery is connected to the aircraft systems. It can be used: