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Component Maintenance Manual With Illustrated Parts List
Component Maintenance Manual With Illustrated Parts List
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
P/N 441CH1
RECORD OF REVISIONS
REVISION ISSUE INSERTED REVISION ISSUE INSERTED
No. DATE DATE BY No. DATE DATE BY
ROR Page 1
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441CH1
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SBL 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
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
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COMPONENT MAINTENANCE MANUAL
441CH1
PAGE
REPAIR 6001
1 - General 6001
2 - Equipment 6001
3 - Repairs 6001
ASSEMBLY 7001
1 - General 7001
2 - Assembly procedure 7001
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441CH1
TABLE OF ILLUSTRATIONS
PAGE
Figure 1 - 441CH1 Battery 3
Figure 5002 - Level adjustment with a syringe and calibrated nozzle 5004
TOI Page 1
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NENT MAINTENANCE MANUAL
441CH1
PAGE
Figure 9001 - Polyamide key for vent valve (T01) 9002
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COMPONENT MAINTENANCE MANUAL
441CH1
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.
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.
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.
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441CH1
3. Measure
Measure given in this manual are taken from original manufacturing drawings.
4. Units of Measure
A. 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
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
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441CH1
5. Abbreviations
6. Definition
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.
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441CH1
7. Disposal
- nickel,
- cadmium,
- potassium hydroxide.
They must therefore be discarded or used again, in agreement with local legislation. For more infor-
mation, contact your local SAFT supplier.
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COMPONENT MAINTENANCE MANUAL
441CH1
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium CVH441KH cells with welded polyamide
cases.
(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.
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
Nominal voltage 24 V
Rated capacity C1Ah 44 Ah (see Note below)
Connector compliant with ISO 5064/II or
Battery terminals
MS 3509
Electrolyte Solution of KOH
Consumable volume of electrolyte 25 cm3 (1.52 in3) per cell
Maximum dimensions of the battery
- Length 428.6 mm (16.87 in)
- Width 220 mm (8.6 in)
- Height 253.5 mm (9.98 in)
Battery maximum weight 37.1 kg (81.8 lbs)
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(2) Operational characteristics
1 C1A 44 A Charge/Discharge
C. Detailed description
The battery has 20 CVH441KH (120) cells housed in a stainless steel box.
The box (290) is lined with liner spacer kit (230). 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 (100 thru 110).
The cover (020), which can be removed, is attached to the box (290) by four latches.
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441CH1 Battery
Figure 1//TASK 24-30-12-991-001
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441CH1
Identification plate
Figure 2/TASK 24-30-12-991-002
Overall dimensions
Figure 3/TASK 24-30-12-991-003
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441CH1
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 24-30-12-700-801
2. Testing
A. Equipment
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
(3) Instruments
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441CH1
(4) Check conditions
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:
- Carefully obey the instructions that give the aircraft procedure to ensure a good flow of air.
- Maintenance must be done (Refer to CHECK chapter), in particular to make sure of:
- 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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441CH1
SUBTASK 24-30-12-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (070) 1 Ω cell shorting 12 h
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441CH1
Figure 1001
SUBTASK 24-30-12-720-002
D. Testing procedure
MΩ
Insulation Check
Figure 1002/TASK 24-30-12-991-006
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441CH1
250 KΩ 2 MΩ 10 MΩ
Insulation Parameters
Figure 1003/TASK 24-30-12-991-007
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 V, charge the battery.
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441CH1
(3) Vent valve test
NOTE : The Vent Valve Test is not required 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:
1. Install the Vent valve (180) with its O-ring on the end of a metal tube which has an
applicable end-piece.
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 vent valve into a container of wa-
ter. 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.
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).
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.
- Charge the battery (Refer to one of the procedures given in chapter TESTING AND
FAULT ISOLATION). At the end of the total charge time, continue to charge at 4.4 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 decreases to less than 1.55 V.
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441CH1
- Cells with a voltage that decreases to less than 1 V before one hour of discharge
(during the last test discharge).
SUBTASK 24-30-12-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-30-12-820-002
B. Ground charge
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 > 1.55 V) AND ELECTROLYTE ADJUSTMENTS MUST BE CARRIED
OUT USING A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT : 4.4 A AT
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 24-30-12-991-008
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441CH1
(1) Constant current charge (Battery fully discharged)
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.
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TASK 24-30-12-800-802
4. Discharge
Other rates
Depending on temperature and time: up to 25 C1A.
(C1A)
TASK 24-30-12-700-802
5. Fault isolation
SUBTASK 24-30-12-760-001
A. Battery electrical faults
(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).
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441CH1
SUBTASK 24-30-12-770-001
B. Cell faults
(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 a rapid temperature increase.
(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 1.55 V at 4.4 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
1 hour 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).
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441CH1
SUBTASK 24-30-12-750-001
C. Physical faults
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441CH1
SUBTASK 24-30-12-750-002
D. Vent valve faults
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COMPONENT MAINTENANCE MANUAL
441CH1
1. General
2. Schematic sensor
Schematic sensor
Figure 2001/TASK 24-30-12-991-009
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441CH1
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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.
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
A. Physical
B. Electrical
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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441CH1
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 make an unconscious
person 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 respiration.
- Potash can cause eczema.
TASK 24-30-12-000-801
5. Disassembly
A. Equipment
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
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441CH1
SUBTASK 24-30-12-020-001
B. Disassembly procedure
NOTE: In order to avoid a short-circuit, remove a link (100) between two cells.
(a) Remove the nuts (070) and the spring washers (080) that attach the links from the cell.
(c) 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 must stay tight when the cell is removed.
(a) Unscrew the vent valve (180) with the special tool (T01).
(a) Remove
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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.
- Protectives goggles.
- Safety shoes.
- Eye washing.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled water.[MO1]
- Neutral soap.[MO2]
- Non-fluffy swab.
- Non-wire brush.
TASK 24-30-12-100-801
4. Cleaning procedure
SUBTASK 24-30-12-160-001
A. Light cleaning
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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441CH1
SUBTASK 24-30-12-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
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.
Clean with lightly soapy water, rub with a cloth and let dry.
CAUTION: THE CLEANING OF THE VENT VALVE (180) MUST BE DONE WHEN THE
CELLS ARE ASSEMBLED IN THE BOX.
(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 to remove all salts from the vent hole.
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TASK 24-30-12-600-801
5. Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral petrola-
tum (petrolatum that is not acid) or light oil on the terminals and the links with a paintbrush.
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CHECK
1. General
You must do the checks which are necessary to use the Saft batteries in flight and on the ground:
TASK 24-30-12-200-801
2. Maintenance steps in workshop
A. Equipment
- 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%.
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441CH1
(5) Referenced information
REFERENCE DESIGNATION
Insulation check
Polarisation test
24-30-12-720-002
Vent valve test
Supplementary test
SUBTASK 24-30-12-210-001
B. Periodical check
If the electrolyte consumption exceeded the approved used between 2 regular check, apply this
periodical check according to Fig 5001.
(1) Charging the battery
(a) Discharge the remaining capacity at 44 A down to a voltage of 20 V at the battery termi-
nals.
(b) When the battery temperature is at usual temperature range, 23 °C ± 5 °C (73 ± 9 °F) ,
charge the battery (refer to one of the procedures given in the chapter TESTING AND
FAULT ISOLATION for a fully discharged battery).
(c) During the last 1/2 hour of the charge (while the charge current continues to flow), adjust
the level of electrolyte in the cells (refer to PARA B (2)). Write down the quantity of water
that is added to each cell. The electrolyte level changes with the battery charge. The lev-
el changes as if the plates absorbed a part of the electrolyte during 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.
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441CH1
yes U > 21 V no
yes no cell with reversed
dust only? polarity
no
Nut tightness POLARIZATION TEST
Salt or electrolyte traces
Residual discharge
1 V/cell
Charge
General overhaul
figure 5004
Cell voltage before
end of charge
no U > 1.55 V yes
FAULT ISOLATION Adjustment of elec-
trolyte level before
end of charge
(volume < 25 cm3)
Supplementary test dispersion < 30 %
OK?
yes
Add 5 h overcharge
U > 1.55 V Vent valve cleaning
Adjust electrolyte
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 24-30-12-991-010
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441CH1
(2) Adjustment of electrolyte level
For this operation, use plastic syringe with a plastic nozzle (T02) (refer to SPECIAL TOOLS,
FIXTURES AND EQUIPMENT). The length of the nozzle is 20 mm (0.79 in). This is the dis-
tance necessary between the seat of the vent valve and the electrolyte (Refer to figure 5002).
20 mm (0.79 in)
If the level is not sufficient, the syringe tube stays empty when you pull the plunger. Add dis-
tilled water to these cells. (The syringe is small, it may be necessary to do this step more than
one time for each cell).
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.
Also, write down the quantity of distilled water added to each cell
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441CH1
(3) Vent valve cleaning
Clean the vent valve (180) (Refer to "CLEANING" chapter) when you adjust the electro-
lyte levels.
Make sure that all the nuts that attach the links are torqued (refer to the chapter FITS
AND CLEARANCES).
- The voltage of each cell measured during the last hour of charge at 4.4 A is not less
than 1.55 V.
- Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 25 cm3 (1.52 in3).
NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell
(1.52 in3/cell), do the electrolyte level check more frequently.
(b) Do a full overhaul of the battery (refer to PARA D "General overhaul") 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 4.4 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
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SUBTASK 24-30-12-210-002
C. Regular check (Ref Fig. 5003)
According to aircraft manufacturer instruction AFTER A MAXIMUM OF ONE YEAR, do this bat-
tery test according to Fig 5003.
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441CH1
General overhaul
figure 5004 Charge
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441CH1
(8) Results of the above tests:
- 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 4.4 A is not less
than 1.55 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 (1.52 in3).
NOTE : If the average quantity of water added to all the cells is close to 25 cm3/cell
(1.52 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 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 dis-
charge caused by an unusual operation of the battery after landing.
- the quantity of water necessary for one or more cell(s) is much higher or lower than for
the other cells.
- the voltage of each cell measured at the end of a 4.4 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
- The second discharge time is less than 1 hour 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 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:
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441CH1
SUBTASK 24-30-12-210-003
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 according to Fig 5004
(1) Disassembly
Refer to "DISASSEMBLY" chapter.
Make the sides of the box straight and remove dents (Refer to "REPAIR" chapter).
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
(4) Sensor
Refer to PARA F. (Checking of temperature sensor)
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441CH1
(7) Adjustment of electrolyte
Refer to PARA B (2) "Periodical Check"
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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 > 1.55 V
no > 10 MΩ yes no
Adjustment of electro-
yes
lyte level before end of
charge
FAULT ISOLATION (volume < 25 cm3)
Dispersion < 30 %
Supplementary
test OK? yes
no
Add 5 h over-
charge U > 1.55 V no Capacity check
FAULT ISOLATION yes
1 V/cell ≥ 1 hour
General overhaul
Supplementary test
with replacement of
OK? Vent valve cleaning
faulty components .
Completed charge
If more than 5* original Nut tightness
Add 5 h overcharge
cells then change all
U > 1.55 V Charge
cells. no yes
Adjust electrolyte
* If 3 or more cells changed during level. Discharge Battery accepted af-
> 1 hour. ter general overhaul
the same check, change all cells.
General overhaul
Figure 5004/TASK 24-30-12-991-013
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NOTE: If more than 5 of the original cells in the battery have previously been changed, or more
than 3 cells are found to be faulty during the same maintenance, then change all the
cells or replace the battery with a new one.
SUBTASK 24-30-12-280-001
E. Insulation check
Mesure the insulation resistance between each connector point and every metal housing. The val-
ue must be superior to 30 MΩ at 250 Vdc.
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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
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
C. Materials
3. Repairs
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REPAIR N°1
TASK 24-30-12-900-801
1. Changing a cover gasket
A. General
B. Detailed procedure
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441CH1
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.
TASK 24-30-12-400-801
2. Assembly procedure
A. Equipment
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. Procedure
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SUBTASK 24-30-12-420-001
C. Installation of the liner spacer kit (240) (Ref. Fig. 7001)
A Spacer 1x230x78 4
B Insulator 0.5x350x230 4
C Spacer 1x350x230 4
D Insulator 0.5x230x79 3
E Spacer 0.5x230x69 1
F Insulator 0.5x198x78 1
G Spacer 1x200x69 1
H Insulator 0.3x348x340 1
I Insulator 0.5x358x78 2
J Spacer 1x350x78 1
K Spacer 1x350x69 1
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SUBTASK 24-30-12-420-001
D. Installation of the sensor
(1) Put in position the sensor (220) and the gasket with the washer 210 and the screw.
SUBTASK 24-30-12-420-002
E. Installation of the connector
(1) Put in position the connector (260) and the O-ring (270) with the washer (250) and the screw
(240)
SUBTASK 24-30-12-420-002
F. Installation of the vent valve (180)
(1) Make sure the vent valves (180) are in good condition. Replace the vent valves (180) if they
are worn.
(2) Install the vent valve (180) with the special tool (T01). Hold the special tool by its upper ribbed
part.
SUBTASK 24-30-12-420-003
G. Installation of a cell (Ref. Fig. 7002)
(3) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spac-
ers).
(4) Carefully position the cell (120) and push on terminals with a piece of soft wood.
(8) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
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COMPONENT MAINTENANCE MANUAL
441CH1
brush).
SUBTASK 24-30-12-970-001
H. Inform
(1) Identification plate (310) if the box (290) has been changed
Cell installation
Figure 7002/TASK 24-30-12-991-015
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COMPONENT MAINTENANCE MANUAL
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COMPONENT MAINTENANCE MANUAL
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TASK 24-30-12-400-802
1. Torque table
SUBTASK 24-30-12-420-001
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.
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COMPONENT MAINTENANCE MANUAL
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1. General
- 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:
PART
CODE QTY DESCRIPTION USE
NUMBER
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3. Consumables
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, colourless, 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
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TP Page 10001
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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.
- Introduction (INTRO),
(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.
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.
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441CH1
3. Numerical Index (NI)
Classification is made from left to right, each character (letter, number, hyphen) being considered
separately.
- 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.
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.
A manufacturer's part number is given to each assembly and detail part, whether illustrated or not.
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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
. Sub-assembly
***
. . Sub-sub-assembly,
***
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 "Attach-
ing 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).
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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).
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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.
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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 in steps of 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.
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.
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441CH1 -001 PM
012374 100 19
015539 110 2
062007 070 42
062007 130 2
100078 170 2
100094 080 42
100094 160 2
100430 250 4
100431 240 4
100693 150 1
100694 140 1
100713 270 1
102392 260 1
114724 210 1
116056 090 4
117026 300 1
166309 320 2
166925 280 1
280068 350 1
411108 310 1
412488 060 2
412662 200 2
413607 340 2
413609 330 2
413980 050 1
414470 120 20
415140 290 1
415145 030 1
415147 040 1
415149 020 1
415205 190 1
415213 180 1
415250 -010 1
415278 230 1
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Page 10012
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COMPONENT MAINTENANCE MANUAL
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441CH1 BATTERY
Figure 1/TASK 24-30-12-991-020
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COMPONENT MAINTENANCE MANUAL
441CH1
01
-001 441CH1 Battery 441CH1, CVH441KH PM
-010 415250 . Box and cover complete 1
020 415149 . Cover complete 1
030 415145 . . Cover, assembly 1
040 415147 . . Gasket, cover 1
050 413980 . Handle, strap 1
060 412488 . Handle, strap 2
070 062007 . Nut M10X1.25 42
080 100094 . Washer, spring 42
090 116056 . Strirrup 4
100 012374 . Link, intercell, E34 19
110 015539 . Link, intercell, E37 2
120 414470 . Cell, CVH441KH, assembly 20
130 062007 . . Nut M10X1.25 2
140 100694 . . Washer, positive polarity 1
150 100693 . . Washer, negative polarity 1
160 100094 . . Washer, spring 2
170 100078 . . Washer, flat 2
180 415213 . . vent valve, complete 1
190 415205 . Sensor, complete 1
200 412662 . . Stand, sensor 2
210 114724 . . Washer 1
220 NP . . sensor 1
230 415278 . Liner-spacer kit 1
240 100431 . Screw M4X10 4
250 100430 . Washer, lock 4
260 102392 . Connector complete 1
270 100713 . O-ring, 56.75 1
280 166925 . Protector 1
290 415140 . 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 413607 . Plate, range label 2
350 280068 . Plate, recycling 1
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COMPONENT MAINTENANCE MANUAL
441CH1
TASK 24-38-52-600-802
1. Storage
- Adjust the electrolyte levels (Refer to "CHECK"), then discharge at a constant current of 40 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.
B. Storage room
C. Temperature conditions
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
- 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).
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441CH1
SUBTASK 24-38-52-610-001
(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).
90
AVAILABLE CAPACITY (%C1Ah)
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
60
0 10 20 30 40 50 60 70 80 90
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441CH1
SUBTASK 24-38-52-610-002
(1) Operations
- Discharge to 1 V/cell.
(2) Conditions
- Sealed packaging.
- Humidity: < 70 %.
- Isolated from detrimental agents : Le. dirt, dust, clampness, vibration, corrosive atmo-
sphere.
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.
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441CH1
TASK 24-38-52-600-804
3. Servicing after storage
TASK 24-38-52-500-801
4. Transportation
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
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P/N 441CH1
N°ATA 24-30-12
Creation date Dec 19/2000
Revision date 1 Nov 19/2003
Type of cell CVH441KH
Number of cells 20
rated capacity 44 Ah
rated capacity without unit 44
1 C1A 44 A
0.5 C1A 22 A
0.1 C1A 4.4 A
Nominal voltage 24 V
End of life criteria in % 100%
End of life criteria in hour or minutes 1 hour
Electrolyte level in mm 20 mm
Electrolyte level in inch 0.79 in