Professional Documents
Culture Documents
Component Maintenance Manual With Illustrated Parts List
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 1656-6
RECORD OF REVISIONS
REVISION ISSUE INSERTED REVISION ISSUE INSERTED
No. DATE DATE BY No. DATE DATE BY
original June 1987 June 1987 SAFT
1 May 25/2000 May 25/2000 SAFT
ROR Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
ROR Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
RTR Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
RTR Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SBL Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SBL Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
LOAR Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
LOAR Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
LEP Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
LEP Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
TOC Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
PAGE
REPAIR 6001
1 - General 6001
2 - Equipment 6001
3 - Repairs 6001
ASSEMBLY 7001
1 - General 7001
2 - Assembly procedure 7001
TOC Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TABLE OF ILLUSTRATIONS
PAGE
Figure 1 - 1656-6 Battery 3
Figure 5002 - Level adjustment with a syringe and calibrated nozzle 5004
TOI Page 1
24-31-19 Dec 18/2000
NENT MAINTENANCE MANUAL
1656-6
PAGE
Figure 7002 - Cell installation 7005
TOI Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
INTRO Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
INTRO Page 3
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
INTRO Page 4
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium VP160KH 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 15 Ah (see Note below)
Connector according to ISO 5064/II MS
Battery terminals
3509
Electrolyte Solution of KOH
Consumable volume of electrolyte 20 cm3 (2.44 in3) per cell
Maximum dimensions of the battery
- Length 292 mm (11.49 in)
- Width 167 mm (6.57 in)
- Height 205 mm (8.07 in)
Battery maximum weight 17.8 kg (39.2 lbs)
Page 1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(2) Operational characteristics
1 C1A 15 A Charge/Discharge
C. Detailed description
The battery has 20 VP160KH (130) cells housed in a stainless steel box.
The box (320) is lined with thin sheets of insulation and wedges (200). The cells are kept upright
by means of a molded silicone elastomer part (040) fastened to the cover which presses against
the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (080 thru 120).
The cover (020), which can be removed, is attached to the box (320) by four latches.
Page 2
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
1656-6 Battery
Figure 1//TASK 24-31-19-991-001
Page 3
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Identification plate
Figure 2/TASK 24-31-19-991-002
Amendment plate
Figure 3/TASK 24-31-19-991-003
Page 4
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Overall dimensions
Figure 4/TASK 24-31-19-991-004
Page 5
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 6
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 24-31-19-700-801
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
Page 1001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(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.
Page 1002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (060) 1 Ω cell shorting 12 h
Page 1003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Figure 1001
SUBTASK 24-31-19-720-002
D. Testing procedure
MΩ
Insulation Check
Figure 1002/TASK 24-31-19-991-006
Page 1004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
250 K Ω 2 MΩ 10 M Ω
Insulation Parameters
Figure 1003/TASK 24-31-19-991-007
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 volts, charge the battery.
Page 1005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(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 (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 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).
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 1.5 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 1.5 V.
Page 1006
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TASK 24-31-19-800-801
3. Charge
SUBTASK 24-31-19-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-31-19-820-002
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 > 1.5 V) AND ELECTROLYTE ADJUSTMENTS MUST BE CARRIED OUT
USING A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT : 1.5 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 24-31-19-991-008
Page 1007
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(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.
Page 1008
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TASK 24-31-19-800-802
4. Discharge
TASK 24-31-19-700-802
5. Fault isolation
SUBTASK 24-31-19-760-001
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).
Page 1009
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-770-001
B. Cell faults
(c) Previous maintenance has Note the cell location and and
not been done. check the level of water com-
sumption versus other cells at
the next maintenance.
(3) A cell has an unsually high (a) Dry cell. When the defect occurs, add
voltage at the start of the 5 cm3 (5 ml) of distilled water to
charge. the cell. Do not adjust more
accurately until the end of the
charge.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can
cause temperature to increase very much.
(4) A cell has an unsually low (a) The cell was operated at Replace the cell (refer to DIS-
voltage at the end of the charge temperatures and charge rates ASSEMBLY, ASSEMBLY AND
(Less than 1.5 V at 1.5 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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-750-001
C. Physical faults
Page 1011
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-750-002
D. Vent valve faults
Page 1012
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
1. General
2. Schematic sensor
Schematic sensor
Figure 2001/TASK 24-31-19-991-009
Page 2001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 2002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
Page 3001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 24-31-19-000-801
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.
SUBTASK 24-31-19-020-001
B. Disassembly procedure
NOTE: In order to avoid a short-circuit, remove a link (080) between two cells.
Page 3002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(a) Remove the nuts (050) and the spring washers (060) that attach the links from the cell.
(c) Fully engage the end of the special threaded tool (T03) 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
Page 3003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 3004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 24-31-19-100-801
4. Cleaning procedure
SUBTASK 24-31-19-160-001
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.
Page 4001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
(1) Cells
Make sure that the vent valve (180) (safety cap) is tight.
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. Do that to remove all salts from the vent hole.
Page 4002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TASK 24-31-19-600-801
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. Use a paintbrush.
Page 4003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 4004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
CHECK
1. General
You must do the checks which are necessary to use the SAFT batteries in flight and on the ground.
These maintenance steps must be done in a battery shop between 23 °C ± 5 °C ( 73 ± 9 °F):
TASK 24-31-19-200-801
2. Maintenance steps in workshop
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.
- 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%.
Page 5001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(5) Referenced information
REFERENCE DESIGNATION
Insulation check
Polarisation test
24-31-19-720-002
Vent valve test
Supplementary test
SUBTASK 24-31-19-210-001
B. Periodical check
If the electrolyte consumption exceded the approved used between 2 regular check, apply this
periodical check:
- Follow 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-
larization test.
- Adjust the electrolyte level.
(1) Charging the battery and adjusting the electrolyte level:
(b) Discharge the remaining capacity at 15 A down to a voltage of 20 V at the battery termi-
nals.
(d) 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).
(e) If necessary, add distilled or demineralized water to adjust the level to this value.
Page 5002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Recharge
Page 5003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte
levels in nickel-cadnium 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)
Page 5004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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, add distilled water to these
cells. (The syringe is small; it can thus be necessary to do this step more than one time for
each cell).
The level is correct when only a small quantity of liquid goes into the syringe when you pull
the plunger. To do this check (after water is added to the cell), keep the shoulder of the sy-
ringe nozzle against the seat of the vented filler cap.
(a) The voltage of each cell measured during the last hour of charge at 1.5 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 20 cm3 (2.44 in3).
NOTE : If the average quantity of water added to all the cells is close to 20 cm3/cell
(2.44 in3/cell), do the electrolyte level check more frequently.
- If the quantity of water necessary for one or more cell(s) is much higher or smaller than for
the other cells.
- If the voltage of each cell measured at the end of a 1.5 A charge is less than 1.5 V (refer to
the chapter TESTING AND FAULT ISOLATION).
(3) Clean the vent valve (180) (Refer to "CLEANING" chapter) when you adjust the electrolyte
levels.
(4) Make sure that all the nuts that attach the links are torqued (refer to the chapter FITS AND
CLEARANCES).
Page 5005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(5) Do an insulation check. The insulation resistance mesured 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. If not else refer to CHECK chapter.
SUBTASK 24-31-19-210-002
C. Regular check (Ref Fig. 5003)
At least every 2000 operating hours and AFTER A MAXIMUM OF ONE YEAR, do this battery test:
NOTE : According to aicraft operation, the ratio between operating hours (aircraft
"power on") and flying hours is generally is the 1.2 to 2 range.
(4) Discharge the remaining capacity at 15 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.
Page 5006
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Light cleaning
REGULAR CHECK 2.C
yes U > 21 V no
no cell with reversed
Cleaning polarity
Recharge
Page 5007
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 1.5 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 20 cm3 (2.44 in3).
NOTE : If the average quantity of water added to all the cells is close to 20 cm3/cell
(2.44 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
battery is in good condition but was not fully charged when removed from the aircraft.
- And /or a discharge caused by an unusual operation of the battery after landing.
- 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 1.5 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:
Page 5008
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-210-003
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 these steps:
- Do a battery inspection.
- Do an insulation test.
(a) Cells
1. Make sure that the lower terminal nuts are tight (refer to "FITS AND CLEARANCES"
chapter).
(b) Box
Page 5009
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
SUBTASK 24-31-19-280-001
E. Insulation resistance
SUBTASK 24-31-19-280-002
F. Checking of temperature sensor
Do this test in a climatic chamber with the sensor disassembled from the battery.
Mesure the insulation resistance between each connector point and every metal housing. The val-
ue must be superior to 30 MΩ at 250 Vdc.
Page 5010
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
G E N E R A L O V E R H A U L 2.D
S che du le d O n fau lt
yes U > 21 V no
no cell with rever- P O L A R IZ A T IO N T E S T
sed polarity
N u t tig htn ess
Residual discharge
1 Ω cell shorting
overnight
D isassem b ly
T h oro ug h clea ning
C o m p on en t insp ection S en sor ch eck
Faulty component
replacement C ha rge
A sse m b ly
Cell voltage be-
Insulation check fore end of charge
no > 10 MΩ yes U > 1.5 V
no yes
Adjustment of
electrolyte level
F A U L T IS O L A T IO N before end of
charge
Other test OK?
Add 5 h over- yes
no
charge U > 1.5 V
Adjust electrolyte no Capacity check
F A U LT IS O LA TIO N yes
1 V/cell ≥ 51 min
G e neral overhaul
w ith replace m en t of Other test OK?
faulty com ponents . Completed charge V e nt cle a nin g
If more than 5* original Add 5 h over-
N u t tigh tn e ss
cells then change all charge U > 1.5 V
cells. no Adjust electrolyte ye s R e cha rg e
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 24-31-19-991-013
Page 5011
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
Page 6001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
REPAIR N°1
TASK 24-31-19-900-801
1. Changing a cover gasket
A. General
B. Detailed procedure
Page 6002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 24-31-19-400-801
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.
Page 7001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-420-001
B. Installation of the liner spacer kit (190) (Ref. Fig. 7001)
A Insulator 0.5x268x160
B Insulator 0.5x169x65 1
C Insulator 0.3x170x65 4
D Insulator 0.5x170x53 3
E Insulator 0.3x157x65 4
F Insulator 0.5x157x53 4
G Insulator 0.5x157x65 1
H Insulator 0.5x169x44 3
I Insulator 0.3x220x55 3
J Insulator 0.3x170x55 2
K Spacer 1x153x55 6
L Insulator 0.5x169x103 1
M Insulator 0.5x157x103 1
N Insulator 0.5x157x45 1
O Spacer 1x169x55 1
P Insulator 0.5x169x115 1
Q Insulator 0.3x400x90 1
R Insulator 0.3x157x115 1
S Spacer 1x169x115 2
T Insulator 0.3x110x96 2
U Insulator 0.3x170x96 1
V Insulator 0.3x157x96 1
Page 7002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 7003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
SUBTASK 24-31-19-420-002
C. 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 24-31-19-420-003
D. 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 (130) and push onto terminals with a piece of soft wood.
(8) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
brush).
SUBTASK 24-31-19-970-001
E. Inform
(1) Identification plate (310) if the box (290) has been changed
Page 7004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Cell installation
Figure 7002/TASK 24-31-19-991-015
Page 7005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 7006
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TASK 24-31-19-400-802
1. Torque table
SUBTASK 24-31-19-420-001
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.
050 Nut 6 to 10 52 to 87
140 Nut 4.5 to 5.5 39 to 47
Page 8001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 8002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
Page 9001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 9002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 9003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 9004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
Page 9005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 9006
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TP Page 10001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
TP Page 10002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
Page 10003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
Page 10004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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).
Page 10005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
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
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 10009
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 10010
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
1656-6 -001 PM
412802 -010 1
412803 020 1
412792 030 1
412800 040 1
412488 050 2
062007 060 42
100094 070 42
012374 080 11
015539 090 2
015266 100 1
411691 110 3
114767 120 4
165949 130 20
062007 140 2
100694 150 1
100693 160 1
100094 170 2
100078 180 2
415218 190 1
412806 200 1
100431 210 4
100430 220 4
163038 230 2
102392 240 1
100713 250 1
166925 260 1
412804 270 1
105405 280 3
161061 290 1
116056 300 5
412801 -310 1
412791 320 1
117026 330 1
411108 340 1
166309 350 2
413609 360 2
413611 370 2
166314 380 1
280068 390 1
Page 10011
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 10012
24-31-19
COMPONENT MAINTENANCE MANUAL
1656-6
1656-6 BATTERY
Figure 1/TASK 24-31-19-991-020
Page 10001-0
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 10001-1
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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-
ommendto put the batteries in a welded plastic container. In this type of container, with the recom-
manded 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).
Page 15001
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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).
Page 15002
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
100
90
AVAILABLE CAPACITY (%C1Ah)
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
60
0 10 20 30 40 50 60 70 80 90
Page 15003
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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.
Page 15004
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
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 15005
24-31-19 Dec 18/2000
COMPONENT MAINTENANCE MANUAL
1656-6
Page 15006
24-31-19 Dec 18/2000