156, Avenue de Metz 93230 Romainville France Tel (33-1) 48.43.93.61 Telex 2 3 5 W

SAFT
(F6177)
156,Avenue de Metz - 93230 Romainville - FRANCE

TeL(33-1) 48.43.93.61 - Telex 2 3 5 W
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
TYPE 1606-1
24-39-06
Date of issue : April 01/92 Title page - Page 1
Dec 01/92
The document reference is online, please check the correspondence between the online documentation and the printed version.
SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
RECORD OF REVISIONS
INSERTED INSERTED
REVISION REVISION REVISION REVISION
NO DATE DATE BY NO DATE DATE BY
1 Oct.92 Oct.92 SAFT

2 Dec.92 Dec.92 SAFT
24-39-06 RieFYgEYf:ig
SAFT
1606-l
RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE BY DATE BY

REV. No NUMBER DATE REMOVED
RTR Pages l/2
24-39-06 Apr 01192
SAFT
1606-l
SERVICE BULLETIN LIST
NUMBER BRIEF DESCRIPTION TYPE AFFECTED
SBL Pages l/2
24-39-06 Apr 01/92
SAFT
1606-l
LIST OF EFFECTIVE PAGES
DATE OF DATE OF
CONTENT PAGE LAST CONTENT PAGE LAST
REVISION REVISION
Title page l/2 Dee 01/92 Description 1 Apr 01/92

and 2 Apr 01/92
operation 3 Apr 01/92
Record of l/2 Dee 01/92 4 Apr 01192
revisions
Testing and 101 Apr 01192

Record of l/2 Apr 01192 fault 102 Apr 01/92
temporary isolation 103 Apr 01/92
revisions 104 Apr 01/92
Disassembly 301/302 Dee 01/92

Service l/2 Apr 01/92
bulletin
list Cleaning 401 Apr 01/92
402 Apr 01/92
List of 1 Dee 01/92
effective 2 Apr 01/92 Check 501 Dee 01/92
paw 502 Apr 01/92
503 Apr 01/92
504 Dee 01/92
Table of l/2 Apr 01/92 505 Dee 01/92
contents 506 Apr 01/92
5071508 Dee 01/92
List of l/2 Apr 01/92 Repair 601 Apr 01/92

figures 602 Apr 01/92
Assembly and 701 Dee 01/92

Foreword l/2 Apr 01192 storage 702 Apr 01/92
703 Dee 01/92
704 Apr 01/92
Special 901 Apr 01/92

tools, 902 Apr 01192
fixtures and 9031904 Apr 01192
equipment
24-39-06 ‘~:c’Z:
SAFT
1606-l
LIST OF EFFECTIVE PAGES
DATE OF DATE OF
CONTENT PAGE LAST CONTENT PAGE LAST
REVISION REVISION
Illustrated
parts list
TP 1001-l Apr 01/92
INTRO 1001-l Apr 01/92

1001-2 Apr 01/92
1001-3 Apr 01/92
1001-4 Apr 01/92
1001-5 Apr 01/92
VC1 1001-l Apr 01192
NIINUM 1001-l Apr 01192
Detailed part
list 1001 Apr 01192
1001-O Apr 01/92
1001-l
LEP Page 2
24-39-06 Apr 01192
SAFT
1606-l
TABLE OF CONTENTS
PAGES
DESCRIPTION AND OPERATION
1 - Description 1
2 - Operation 2
TESTING AND FAULT ISOLATION
1 - Testing 101
2 - Fault isolation 101
DISASSEMBLY
1 - Disassembly 301
CLEANING
1 - Light cleaning 401

2 - Full cleaning 401
3 - Lubrication 402
CHECK
1 - Regular checks 501

2 - Maintenance steps in workshop 501
3 - General overhaul 506
REPAIR
1 - Battery condition 601

2 - Polarisation test 601
3 - Added electrical test before repair 602
ASSEMBLY AND STORAGE
1 - Assembly 701
2 - Storage 702
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 - Special tools 901

2 - Materials and different products 903
ILLUSTRATED PARTS LIST
Introduction 1001
Vendor code index VC1 1001-l
Numerical index NI 1001-l
Detailed parts list 1001-l
TC Pages l/2
24-39-06 Apr 01192
SAFT
1606-l
LIST OF FIGURES
PAGES
Figure 501 - Level adjustment with a syringe and a calibrated nozzle 502
Figure 701 - Circuit 704
Figure 901 - Polyamide key for vented filler caps made of polyamide 902
Figure 902 - Syringe with nozzle 902
Figure 903 - Cell removal tool 902
Figure 1 - Battery 20 VP 160KM TYPE 1606-l 1001-O
TF pages l/2
24-39-06 Apr 01192
SAFT
1606-l
FOREWORD
1. General
This manual supplies the maintenance data and the 11 lustrated Parts List
of the type 1606-l alkaline battery.
These instructions agree with specification ATA No. 100 for the
manufacturer's technical manuals. They are included in chapters in this
sequence :
l-100 Description and operation
101-200 Testing and fault isolation
201-300 (Not used)
301-400 Disassembly
401-500 Cleaning
501-600 Check
601-700 Repair
701-800 Assembly and storage
801-900 (Not used)
901-1000 Special tools, fixtures and equipment
1001-1100 Illustrated parts lists.
Note : The instructions in this manual cannot be used as a specification

for an acceptance test ; use these instructions for OPERATION
and CHECK of an item which is temporarily unserviceable and to
REPAIR for overhaul.
F Pages l/2
24-39-06 Apr 01192
SAFT
1606-l
DESCRIPTION AND OPERATION
1. Description
A. General
The SAFT battery has 20 semi-open nickel-cadmium VP 160KM cells with

welded polyamide cases.
The battery is connected to the aircraft systems. It is used:
- To start the APU
- On the ground, before electrical power is supplied to the aircraft

systems
- In flight, if a malfunction or a failure occurs in the power supply

system.
The 28 VDC electrical system charges the battery in the aircraft.
B. Data
(1) Technical data
- Specified voltage: 24 volts
- Specified capacity: 16Ah at a rate of lh
- Connector 3 pins: according to standard VDE OllO/S.65
- Electrolyte: Sol. KOH s.g. 1.30.
- Consumable volume of electrolyte: 20 cm3 for each cell
- Maximum dimensions of the battery base:
L=371.5 mm (14.62 in)

W=120.1 mm (4.73 in)
H=207.5 mm (8.17 in)
- Maximum weight: 17.65 kg (39.46 lb).
- 1 thermostat closes at 71"*2.8OC (160"&5"F) on temperature rise
(2) Operational data
- Operating temperature: -30 to +50°C (-22 to +122'F)
Page 1
24-39-06 Apr 01192
SAFT
1606-l
- Maximum instantaneous power:
at +23'C (+73'F): 12 V and 15 s 8.85 kW
at -18'C (+O"F): 12 V and 15 s 4.80 kW.
C. Detailed description (Refer to pages 1001-O and 1001-l)
The battery has 20 VP 160KM (320A) cells in a stainless steel box.
The box (040A) has a lining of thin sheets of insulation and of

spacers (190A)
The cover (060A) has one insulator (070A) and 2 protectors (080A).
The cells are held in place by a hold-down bar (240A).
This hold-down bar is mounted inside box and fixed by 2 screws (1lOA)
and 2 nuts (120A).
The rigid links (290A thru 310A). made of nickel-plated copper,
connect the cells together.
Two insulated holes through the cover (060A) for the battery
terminals (250A).
These terminals (250A) connect the battery to the aircraft.
The battery has a removable cover (060A). It is fixed by 2 screws

(020A) with 2 spring washers (030A).
2. Operation
A. Charge
(1) Flight charge
Adjust the recharger to make sure the battery is correctly

charged in flight. Do a recharger check as frequently as
possible.
At the usual temperature of +20°C (+68"F), the constant charge
voltage must be 28.5 volts. If the climatic or battery operating
conditions cause the cell temperature to increase to +4O"C
(+104"F), adjust the recharger to 27.5 to 28 volts. This is to
prevent a fast loss of the electrolyte reserve and a shorter
life for the cells.
For a given voltage adjustment, the higher the battery
temperature, the higher the remaining charge current.
The consumption of water from the electrolyte is directly in

proportion to the remaining charge current. Thus it is necessary
to accurately know the usual operating temperature of the
batteries to permit the batteries to be charged in the best
conditions.
Page 2
24-39-06 Apr 01192
SAFT
1606-l
(2) Ground charge
Do all battery maintenance or overhaul steps in a workshop.
WARNING: REMOVE THE COVER TO CHARGE THE 1606-l TYPE BATTERIES ON

THE GROUND. THIS IS TO MAKE SURE THAT GAS WILL NOT
COLLECT IN THE BATTERY BOX.
- Constant current charge
- Battery fully discharged:
To charge a fully discharged battery, do one of these

procedures:
- Charge at 0.1 CIA (1.6 amps) until the battery voltage is an

average of 1.5 volt for each cell (30 volts for a 20-cell
battery). Then continue to charge at this same current rate
for 4 more hours. When you do this procedure, the total
charge time must be between 14 hours (minimum) and 16 hours
(maximum).
or
- Charge at 0.5 C A (8A) for not less than 2 hours. It is
possible that t il e battery voltage is not an average of 1.55
volt for each cell (31 volts for a 20-cell battery) after
this time. Then continue to charge at this current rate
until you get the correct voltage. But do not charge at
this rate for more than 2 hours and 30 minutes (refer to
the NOTE). When you get an average of 1.55 volt, charge at
0.1 ClA (1.6 amps) for 4 more hours.
or
- Charge at ClA (16 amps) for not less than 1 hour. It is
possible that the battery voltage is not an average of 1.57
volt for each cell (31.4 volts for a 20-cell battery) after
this time. Then continue to charge at this current rate
until you get the correct voltage. But do not charge at
this rate for more than 1 hour and 15 minutes (refer to the
NOTE). When you get an average of 1.57 volt, charge at 0.1
CIA (1.6 amps) for 4 more hours.
NOTE: If the battery voltage does not increase sufficiently

during the maximum charge time: Refer to "TESTING
AND FAULT ISOLATION"..
Page 3
24-39-06 Apr 01192
SAFT
1606-l
- Battery not fully discharged and discharge condition unknow.
- Discharge the remaining capacity at 1ClA (16 amps) down

to 20 volts. Then charge again as above.
- The battery can also be charged at one of the constant

current values given in section 2 (2). Do this procedure
until you get the correct voltage at the battery
terminals (30, 31, or 31.4 V).
- Constant voltage charge
You can charge the battery with a constant voltage source

(you can use an aircraft generator that has a voltage
regulator).
At the usual temperature of +20°C (+68"F), adjust the

regulator to 28.5 volts (precision 0.5%) and charge the
battery for 4 to 5 hours.
B. Discharge
The specified capacity (ClAh) of the battery gives a discharge time

of 1 hour ; when fully charged, the battery can thus supply a current
of 16 amps for one hour. But the battery can supply currents that are
much higher than the specified discharge, for short times and without
damage. For example, a battery with a specified capacity of 16Ah can
supply peaks of current that can be twenty-five times the usual
capacity.
C. Precautions
- You must usually supply regular current and do regular maintenance.

Thus it is only necessary to use these precautions to get correct
operation of the battery:
- Do not install the battery in an aircraft location which is too hot
- Carefully obey the instructions that give the procedure to get a

good flow of air
- Do a charge level check regularly. Charge the battery on the ground

when the discharge is not caused by an incorrect adjustment of the
recharger.
- Regularly do these checks:
- Electrolyte level (specially when the weather is hot)
- Tightness of the connection nuts
- Adjustment of the recharger.
Page 4
24-39-06 Apr 01192
SAFT
1606-l
TESTING AND FAULT ISOLATION
1. Testinq
For the test procedures, refer to "CHECK".
2. Fault isolation
battery set to connector (no contact cal contacts and

"charge".
Link loose or broken Make sure the nuts
are tight (CHECK).
Zero volt with the Battery fully discharged. Charge the battery
battery set to (DESCRIPTION AND
"discharge". OPERATION).
Do an insulation
check (CHECK).
Battery circuit open or Examine the contacts

defective contacts. and links. Make sure
the terminal nuts
are tight (CHECK).
Refer to the related

subsequent steps.
Leakage of electro- Incorrect adjustment of Disassemble and clean

lyte. the battery (DISAS-
SEMBLY and CLEANING).
Do an electrolyte
level check (CHECK).
Cell polarity inco- Examine the aircraft

rrect during high-rate circuit which charges
discharge (for example,
during the engine start).
Page 101
24-39-06 Apr 01/92
SAFT
1606-l
FAILURES POSSIBLE CAUSES CORRECTION
Disassemble and clean

the battery (DISAS-
Do an electrolyte
Too much charge at high Examine the aircraft

temperature or too much circuit which charges
current the battery.
If necessary, adjust
to normal operating
temperature (DESCRI-
PTION AND OPERATION).
Disassemble and clean

the battery (DISAS-
Do an electrolyte
E:ectrolyte found in Damaged cell case. Do a leak test of the

-t;e battery box. cells (CHECK).
Replace the cell if

necessary and refer
to the related subse-
quent steps.
Leakage of electrolyte. Disassemble and clean

the battery (DISAS-
Do an electrolyte
Page 102
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1606-l
FA1 LURES POSSIBLE CAUSES CORRECTION
Too much water Charge much more than Examine the aircraft
consumption for the limit or too much circuit which charges
all the battery charge at high tempe- the battery.
cells. rature. If necessary, adjust
to normal operating
temperature (DESCRI-
PTION AND OPERATION).
Cell(s) the water

consumption of which
is very different
from that of the other
cells in the battery:
more than 30% Leaks from the cell(s). Do a leak test of

more than the average the cells (CHECK).
25% (or less) of the Cell(s) with damaged Do the added test
average separator(s) (REPAIR).
If necessary, replace
the cell(s).
Corrosion on the Operation in acid air Make sure the battery

links. test bench and the
storage areas have
no materials which
can give off acid
fumes.
Mechanical damage to Replace the damaged

nickel plating links (DISASSEMBLY,
ASSEMBLY AND
STORAGE).
The links are too hot. Loose terminal nuts. Make sure the nuts
are tight (CHECK).
A cell has an unusu- Dry cell When the defect

ally high voltage occurs, add 10 ml of
at the start of the distilled water to
charge. the cell.
Do not adjust more
accurately until the
end of the charge.
Page 103
24-39-06 Apr 01192
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FAILURES I POSSIBLE CAUSES I CORRECTION
NOTE: If you charge

a cell with a quanti-
te of electrolyte
which is not suffi-
cient, this can cause
temperature to
increase very much.
A cell has an unusu- The cell was operated at Replace the cell
ally low voltage at temperatures and charge (DISASSEMBLY, ASSEM-
the end of the charge rates that were more than BLY AND STORAGE).
(Less than 1.5 V at the limits and the sepa-
1.6 amps and + 20°C rator is damaged.
(+68"F)).
Low capacity cell Usual wear after long Replace the cell
(The cell shows an operation. (DISASSEMBLY, ASSEM-
opposite voltage or BLY AND STORAGE).
a correct polarity
voltage of less than
1 V after a discharge
of 1 hour at 16 amps). Unusual operation (Fre- Do the applicable
quent engine starts with procedure (REPAIR).
the battery) ; operation
at high temperatures,
with low electrolyte
level, etc.
Cell with a swollen Cell operated with low Replace the cell
case. electrolyte level ; dete- (DISASSEMBLY, ASSEM-
rioration of separators BLY AND STORAGE)
and damaged plates.
Cell with zero voltage Short-circuited cell, Replace the cell.

when the battery
circuit is open.
Low insulation. Leakage of electrolyte. Disassemble and clean

the battery (DISAS-
Do an electrolyte
Page 104
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1606-l
DISASSEMBLY
1. Disassembly
NOTE: REFER TO "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.
A. Removal of a cover
- Remove the screws (020A) with their spring washers (030A).
- Remove the nut (270A), the nut (280A) and the washers (260A).
- Remove the cover (060A).
B. Removal of a vented filler cap (safety cap):
- Loosen the vented filler cap (330A) with the special tool (Refer to
figure 901).
- Remove the vented filler cap with its O-ring (340A).
C. Removal of a cell:
- Remove the nuts (120A), the screws (110A) and the washers (030A),
then take out hold-down bar (240A).
- Remove the nuts (350A) that attach the links to the cell. Remove
the spring washers (370A).
- Remove the links from the cell terminals.
- Fully engage the end of the special threaded tool (Refer to

figure 903) on one of the cell terminals. Then pull up to remove
the cell.
D. Removal of the temperature sensor.
- Remove the nuts (350A) and spring washers (370A) that hold the link
(310A).Take out link (310A) and the thermostat.
- Remove the nut (430A) and thermostat from link (310A).
- Cut the cable grip (13OA).
- Push right to hole the temperature sensor grommet. Then take out
the thermostat and its connector.
24-39-06 PagDeec?o~~f’~~
SAFT
1606-l
CLEANING
1. Liqht cleaninq
- If a clean filtered supply of compressed air is available, do this

procedure to easily and quickly clean the cells: blow with much force
across the tops of the cells to remove all dust and mineral salts from
the box.
- To prevent short-circuits, use a rubber tube or an insulating nozzle.
2. Full cleaninq
Disassemble the battery (Refer to "DISASSEMBLY") and then clean all the
components.
A. Cells:
- To easily remove all the electrolyte and mineral salts from the
terminals, the covers and the sides of the cell cases: clean in warm
water with a soft brush.
- Make sure that the vented filler cap (safety cap) is tight.
- Do not soak the cells in water.
- Rub the cell with a cloth and let dry.
B. Box:
- Clean with water, rub with a cloth and let dry.
C. Nuts, spring washers and links:
- Clean in warm water with a brush and let dry.
D. Packing parts and sealed insulating liner:
- Clean in warm water and let dry.
E. Vented filler caps:
- Remove the vented filler caps (Refer to "DISASSEMBLY").
- Put covers on the cell holes to keep out unwanted material.
- Soak the vented filler caps for some time (during the night, for
example) in a container of distilled water (or, if not available, in
very clean tap water). Do this to remove all salts from the vent
hole.
Page 401
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1606-l
WARNING: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS.
- Before you put the vented filler caps back into the cells, make sure
that they operate correctly. Do these steps:
- Install the vented filler cap with its O-ring (340A) on the end of a
metal tube that has a correct end-piece.
- Connect this tube to a supply of compressed air through a vented

filler cap of the adjustable reducing type.
- 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 if the vented
filler cap is in good condition. 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
air flow stops.
- Reject all vented filler caps that have an operating pressure of more
than 0.7 bar (10 psi) (after the check done before to make sure that
the related cap operates correctly) or less than 0.14 bar (2 psi).
- Install the vented filler caps (Refer to "ASSEMBLY").
3. Lubrication
When the battery is clean (and after installation of the vented filler
caps), put a thin layer of neutral petrolatum (petrolatum that is not
acid) or light oil on the terminals and the links. Use a paintbrush.
Page 402
24-39-06 Apr 01/92
SAFT
1606-l
CHECK
1. Regular checks
You must do the checks which are necessary to use the SAFT 1606-l
batteries in flight and on the ground. But you must also do these
maintenance steps during operation:
- Periodical check (in a workshop): adjustment of electrolyte levels
- Regular check (in a workshop): electrical treatment, adjustment of

electrolyte levels, and capacity test.
2. Maintenance steps in workshop
A. Periodical check
Periodically (at flight hour intervals such that the allowable water
consumption is not exceeded):
- Clean the battery (See "CLEANING")
I - Adjust the electrolyte level (Refer to (1)).
(1) Charge of the battery and adjustment of the electrolyte level:
- Discharge the remaining capacity at 16 amps down to a voltage of

20 volts at the battery terminals.
- When the battery temperature is +2O"C to +25OC (+68OF to +77OF)

(usual temperature range), charge the battery (Refer to one of
the procedures given in "DESCRIPTION AND OPERATION" for a fully
discharged battery).
- During the last hour of the charge (while the charge current
continues to flow), adjust the level of the electrolyte in the
cells. Then measure the voltages of each cell (precision 0.5 %).
Write the quantity of water that is added to each cell.
- The electrolyte level changes with the battery charge. Thus you
do not get the maximum level until the battery is fully charged.
The level changes as if the plates absorbed a part of the
electrolyte during the discharge and released it during the
charge.
Page 501
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SAFT
1606-l
Thus 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 (0.787 in) (distance measured in the
conditions given before).
- If necessary, add distilled water to adjust the level to this

value.
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 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
(0.787 in) ; this is the distance necessary between the seat of
the vented filler cap and the electrolyte (Refer to figure 501).
To adjust the level, keep the shoulder of the syringe nozzle

against the seat of the vented filler cap and pull the
plunger up:
Level adjustment with a syringe and a calibrated nozzle

Figure 501
Page 502
24-39-06 Apr 01/92
SAFT
1606-l
- 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
syringe nozzle against the seat of the vented filler cap.
- Results of the above procedure:
- The battery operates correctly if:
- The voltage of each cell measured during the last hour of

charge at 1.6 amps is not less than 1.50 volt.
- Approximately the same quantity of distilled water as added

to each ell. This quantity must be less than 20 cm5
(1.23 in 5 ).
- If the quantity of water added to all cells is more than 20

cm3 (1.23 in3): make sure that the voltage adjustment in
relation to the temperature during the charge is correct. Also
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 smaller than for the other cells.
- If the voltage of each cell measured at the end of a 1.6-amp

charge is less than 1.5 volt (Refer to "TESTING AND FAULT
ISOLATION").
(2) Clean the vented filler caps (Refer to "CLEANING") when you adjust
the electrolyte levels.
(3) Make sure the cell terminal nuts are tight.
Make sure that all the nuts that attach the links are torqued to
8 + 2 N.m (5.90 + 1.47 ft.lbf).
(4) Do an insulation check (Refer to paragraph 3.D).
Page 503
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1606-l
B. Regular check
1) At the time of a second periodical check OR AFTER A MAXIMUM OF SIX

MONTHS, do this battery test (also do the steps given in paragraph
2.A):
- Discharge the remaining capacity at 16 amps down to a voltage of

20 volts at the battery terminals.
- Measure the time from the start of discharge to the time when the
voltage is 20 volts.
- Connect a resistor of approximately 1 Q across each cell and

continue to discharge. Resistors with crocodile clips attached to
their leads can be easily attached to the cell terminals.
- Let the resistors stay in position for the night.
2) Remove all resistors, charge the battery (Refer to "DESCRIPTION

AND OPERATION" for a fully discharged battery).
- Adjust the electrolyte level in the cells (Refer to paragraph

2.A (1)). Then measure the voltage of each cell during the last
hour of the charge. Also write the quantity of distilled water
added to each cell.
- Immediately after the charge and the level adjustment, discharge

the battery again at 16 amps down to 20 volts ; measure the
terminal voltage of each cell. Write the time that is necessary
for this second discharge.
- Results of the above tests:
The battery operates correctly if:
- The time necessary for the first discharge (paragraph 2.8 (1) is
more than 30 minutes
- The time necessary for the second discharge (paragraph 2.B (2)) is
not less than 51 minutes
- The voltage of each cell measured during the last hou r of the
charge at 1.6 amps is not less than 1.50 volt (Precis ion 0.5%)
- The quantity of distilled water added to each cell 's

approximately equal to or less than 20 cm3 (1.23 in 4 1
24-39-06
Page 504
Dee 01/92
SAFT
1606-l
- 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.
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 (paragraph 3) if:
- The second discharge time is less the correct one or one cell has
a voltage of less than 1 volt (or incorrect polarity before 1 hour
of discharge)
- The voltage of each cell measured during the last hour of charge
at 1.6 amps is less than 1.50 volt
- The quantity of distilled water necessary for one or more cell(s)

is much higher or smaller than for the other cells.
NOTE: The consumption of water by a SAFT nickel-cadmium cell is in

proportion to the unwanted charge.
Thus, the consumption must be the same for all the 20 cells in the
battery.
The quantity of water necessary for one or more cell(s) (in the same
battery) can be much higher (or smaller) than the other cells. Then
there is a defect:
- High consumption is usually caused by a leakage.
- Low consumption is caused by a damaged separator.
- The consumption is incorrect when it is 25 % more or less than the

average.
24-39-06
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SAFT
COMPONENTMAINTENANCE MANUAL
1606-l
3. General overhaul
This overhaul includes the electrical tests given in paragraph 2.8. It

also includes the disassembly and cleaning procedures to be done
systematically for all the battery components. Do an overhaul one time
each year or during each most important servicing of the aircraft.
Do these steps:
- Disassemble the battery
- Clean the battery
- Do a battery test
- Do an insulation test.
A. Disassemble the battery (Refer to "DISASSEMBLY").
B. Clean the battery (Refer to "CLEANING").
C. Do a battery test:
(1) Cells:
- Make sure that the lower terminal nuts are tight:
- Tightening torque: 5 rt 0.5 N.m (3.69 f 0.369 ft.lbf).
- Do a leak test of the cells:
- Install a metal or plastic adaptor with an O-ring as an

alternative to the vented filler cap.
- Put the cell between two metal flanges of correct dimension to

prevent too much distortion. The terminals must be parallel to
the flanges.
Attach the adaptor to a compressed air supply with an adjustable

reducing vented filler cap of the adjustable reducing type ;
fully put the cell and flange assembly into clean water ;
increase the pressure in the cell to 0.7 bar (10 psi).
- Make sure there are no air bubbles.
Page 506
24-39-06 Apt- 01/92
SAFT
1606-l
(2) Box:
Make the sides of the box straight and remove the dents.
(3) Nuts, links and spring washers:
- Discard the components that show signs of corrosion or damage.
(4) Packing parts:
- Discard all defective components.
(5) Connector:
- Make sure that the connector is in good condition (inner and

outer surfaces) ; replace it if the contacts are burned.
D. Do a temperature sensor test:
Checking of complete sensor can only be carried out when the battery is
dismantled
- Check at ambient temperature that the thermostat circuit between the

pins 1 and 2 then 1 and 3 of the control connector is open.
- Check between the pins 1 and 2 then 1 and 3 of the control connector
that the thermostat circuit closes on temperature rise between +65'C
and +77'C.
(This range includes a +3OC temperature precision and +3OC

thermostat precision
- Check between the pins 1 and 2 then 1 and 3 of the control connector
that the thermostat circuit opens on temperature decrease 4'C to
10°C lower than the precedent closing temperature.
- The insulation of thermostat poles in relation to their metal housing

must be greater or equal to 30Mn under 250V continuous.
E. Insulation resistance :
- Fully assemble the battery. Then measure the insulation resistance

between the block of cells and the metal box. The resistance must
not be less than 10 MQ at 250 V continuous*.
24-39-06 PagieZoL:FE
SAFT
1606-l
REPAIR
1. Battery condition
Do a polarisation test (Refer to paragraph 2) if you find these defects

on the battery (after a removal that was not scheduled or before regular
maintenance):
- The polarity of the cells is incorrect
- The battery open voltage is less than 21 V.
Do an added test (Refer to paragraph 3) if you find these defects on the

battery (during regular maintenance or general overhaul):
- The voltages at the end of the charge are too low
- The voltage during the charge is too high
- The capacity is not sufficient
- The water consumption is incorrect.
2. Polarisation test
- Charge the battery at 1.6 A for 1.5 hour.
- Keep the battery in the "open circuit" condition for 1 hour.
- Measure the open voltage of every cell.
If the cell open voltage is 0 V (or opposite). do an added test (refer

to paragraph 3). Then repair.
If each cell has an open voltage that is more than 0 V, charge the
battery (Refer to one of the procedures given in "DESCRIPTION AND
OPERATION", paragraph 2.A (21, for a fully discharged battery).
Page 601
24-39-06 Apr 01/92
SAFT
1606-l
3. Added electrical test before repair
The first test charge can be unsatisfactory if the electrolyte level is

too low in some cells (the level is not adjusted until the end of this
charge). If you find defects, do a second test:
- Charge the battery (Refer to one of the procedures given in

"DESCRIPTION AND OPERATION", paragraph 2.A (21, for a fully discharged
battery). At the end of the total charge time, continue to charge at
1.6 amps for 5 more hours. Regularly write the voltage and temperature
of the cells.
The temperature of the cells that have damaged separators increases

very much and continuously. The voltage of these cells continuously
decreases to less than 1.50 volt.
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
- Defects were found during shop maintenance.
- Adjust the electrolyte level during the last one of the 5 last hours
of charge.
- Discharge at 16 amps down to 20 volts.
After this test, discard the defective cells:
- Cells with a voltage of less than 1.50 volt at the end of the charge
(precision 0.5%).
- Cells with a voltage that decreases to less than 1 volt before one
hour of discharge (during the last test discharge).
- Short-circuited cells (zero volt).
Page 602
24-39-06 Apr 01/92
SAFT
1606-l
ASSEMBLY AND STORAGE
1. Assemb1.y
NOTE : Tooling and equipment are identified in the list of "SPECIAL TOOLS
I AND EQUIPMENT".
A. Installation of the vented filler caps:
- Make sure the O-ring (340A) is in good condition: replace the

O-ring if it is worn.
- Install the safety vented fil ler cap (330A) using the special tool
(Refer to fig. 901); hold the special tool by its upper ribbed part.
B. Installation of the cells:
- Install the discharged cell and make sure its polarity is correct.
- Carefully position the cell by pushing on the terminals with a

piece of soft wood.
- Install the links in this sequence:
- Links (Refer to figure 1 for their locations)
- Spring washers (370A)
- Nuts (350A) and torque them to 8 + 2 N.m (5.90 + 1.47 ft.lbf).
C. Installation of the temperature sensor:
- Install:
- The temperature sensor (420A) in the box (040A).
- The grommet of the temperature sensor
- The thermostat on its link (310A) with the nut (430A) and torque
it to 0.2 Nm (0.15 ft.lbf.1.
- The link (310A) on cell terminals (refer to figure 701).
- Spring washers (370A).
- Nuts (350A) and torque them to 8 + 2 N.m (5.90 f 1.47 ft.lbf).
D. Assembly of the battery
Install these components in the box (040A):
- The liner-spacer kit (190A) (except hold-down bar). Refer to

figure 1 for the location of spacers.
24-39-06
Page 701
Dee 01/92
SAFT
1606-l
The liner-spacer kit includes these spacers and insulators:
Units
Item Designation per Dimensions
assy
200A Spacer 2 156x112x0.5

210A Spacer 1 323x174x0.3
220A Spacer 1 323x156x0.3
230A Insulator, bottom 1 323x112~1
240A Hold-down bar 1 315x18~3
- Twenty VP 160KM cells (32OA) (make sure their polarities are

correct as shown in figure 701)
- The temperature sensor (Refer to paragr. C)
- All links on the cells with the spring washers (370A) and the nuts
(350A). Torque the nuts to 8 f 2 N.m (5.90 + 1.47 ft.lbf).
- The hold-down bar (240A) and fix it with the screws (llOA), the
nuts (120A) and the washers (030A).
- One nut (250A) on the positive terminal of one end cell and one nut
(250A) on the negative terminal of the other end cell (Refer to
figure 701).
Lightly lubricate the terminals and the links with neutral petrolatum
or light oil (use a paintbrush).
- Install:
- The cover (050A) and affix it with the screws (020A) and spring
washers (030A).
- The spring washers (260A).
- The nut (270A) on the positive terminal.
- The nut (280A) on the negative terminal.
2. Storaqe
A. Preparation of the battery before storage
- Adjust the electrolyte levels (Refer to "CHECK", paragraph 2.A (1).

Then discharge at a constant current of 16 amps down to a terminal
voltage of 20 volts.
Page 702
24-39-06 Apr 01/92
SAFT
1606-l
- 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 SAFT 1606-l batteries in a dry and clean room.
C. Temperature conditions:
Keep the batteries at a temperature of -60°C to +6O"C (-76°F to

+140°F). But the best temperature range is between 0 and +30°C (+32'F
and +86"F).
D. Packing
The SAFT 1606-l batteries are usually put in cardboard boxes. For
long storage or sea transportation, we recommend that you put the
batteries in a welded plastic container. In this type of container,
the batteries can be kept for 10 years in the best storage
conditions.
E. Transportation
It is important that you move the nickel-cadmium SAFT 1606-l

batteries in the vertical position. Thus, the containers must be
identified with "TOP" and "BOTTOM" marks that can be read easily.
F. Servicing after storage
Storage
time Servicing procedure
Less than 3 Charge the battery (Do one of

months the procedures given in
"DESCRIPTION AND OPERATION",
paragraph 2.A (2)) for a
fully discharged battery)
3 months to Do the Periodical check

1 year (Refer to "CHECK" 2.A).
Do the Regular check

(Refer to "CHECK" 2.B).
24-39-06
Page 703
Dee 01/92
SAFT
COMPONENTMAINTENANCE MANUAL
1606-l
Thermostat
----_.
-----==z=-\
310 \\
II
II
II
II
II
II
I,
iI
II
/130
-Thermostat grommet
Circuit
Figure 701
Page 704
24-39-06 Apr 01192
SAFT
1606-l
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. Special tool;.
USE
Manufact. DESIGNATION T D C C R
P/N E I L H E
S S E E P
T A A C A
IS N K I
F S I R
A E N
U M G
L B
T L
Y
015528 Polyamide key for

vented filler caps
made of polyamide
(Refer to figure 901) x x x x x
016544 Syringe nozzle

(Refer to figure 902) X x x
105112 Syringe. 20 cm3

(1.22in3)
(Refer to figure 902) X x x
014735 Cell removal tool

(Refer to figure. 903) X X
164829 Equalizing resistors

cm 3W) X X
NOTE: Equivalent tools can be used as alternatives to the ones above.
Page 901
24-39-06 Apr 01192
SAFT
1606-l
Polyamide key for vented filler caps made of polyamide
Figure 901
Syringe with nozzle
Figure 902
R= 7 5mm (0 06in)
D=l6mm (0.269in)
- I-
Cell removal tool
Fiqure 903
Page 902
24-39-06 Apr 01192
SAFT
1606-l
2. Materials and different products.
SPECIFICATION
DESIGNATION l-OTAN 2-F SUPPLIER
3-us 4-UK REFERENCE
Mineral l- s.743 ESSO

petrolatum 2- AIR 3565 Industrial
3- VLP 2336 n.2
4- DEF 2333 ELF
Aviation vase line
Grease l- G.392 DOW CORNING

3- MIL-G4343 Molykote 55M
4- DTD 5610
Glue 3 M FRANCE
EC1236
Distilled Local supply

water
Page 903/904
24-39-06 Apr 01192
SAFT
1606-l
ILLUSTRATED PA
TP 1001 Page 1
24-39-06 Apr 01/92
SAFT
1606-l
INTRODUCTION
1. General
The Illustrated Part List (IPL) agrees with the ATA 100 specification.
It is used to identify all the components of the unit.
The Illustrated Parts List includes these sections:
- Introduction
- Vendors Code Index
- List of Circuit Symbols (if applicable)
- Alphanumeric Index of Manufacturer's Part Numbers
- Detailed Parts List.
2. How to use the Detailed Parts List
The Detailed Parts List includes the list and the figures of the unit
components.
It has these columns:
- 1st column: Fig. Item - (Figure and item numbers)
- 2nd column: Part Number - (Manufacturer's part number)
- 3rd column: Airline Part Number
- 4th column: Nomenclature - (List of components)
- 5th column: Usage Code - (Applicability)
- 6th column: Units per Assy - (Quantity for each immediately higher
assembly).
A. Figure and item numbers (Fig. Item)
The figure number for the items given in the list is shown on the
first line of each page.
INTRO 1001 Page 1
24-39-06 Apr 01/92
SAFT
1606-l
Each assembly, sub-assembly or item with a part number that is given

in the parts list has an item number. A letter follows the item
number to identify the variant. Letter A is for the basic variant.
The assemblies, sub-assemblies and parts that are not shown in the
figure have a dash (-1 before their item numbers.
A letter before the item number is a reference to the figure of the

variant (this variant is shown on the main figure).
B. Manufacturer's part number (Part Number)
Each assembly, sub-assembly and detail part (that is shown on the

figure or not) has a manufacturer's part number.
When the manufacturer's part number has more than 15 characters, an

equivalent part number is given in the "Part Number" column. This
note comes before the part number:
ORDER OVERLGTH . ..MADE BY V...
The two part numbers are given in the Alphanumeric Index in the
logical sequence ; the part number that is too long is referenced to
the equivalent part number. This note comes before the equivalent
part number: "SEE..".
C. List of components (Nomenclature)
The list of components is moved to the right to show the relation

between the parts:
I234567
Assembly
. Detail parts for assembly
. Sub-assembly
, Attaching parts and/or storage for sub-assembly
***
. . Detail parts for sub-assembly
. . Sub-sub-assembly
. . Attaching parts and/or storage parts for sub-assembly
***
. . . Detail parts for sub-sub-assembly, etc.
INTRO 1001 Page 2
24-39-06 Apr 01/92
SAFT
1606-l
A vendor code is given for all items or articles that are not made by
the prime manufacturer of the assembly.
This vendor code (or the abbreviation "NP": non procurable) is shown
to the right of the 1st line of the nomenclature.
D. Applicability (Usage Code)
An alphanumeric usage code shows the applicability of the sub-

assemblies and detail parts to the immediately higher assembly(ies)
or sub-assembly(ies).
When the applicability is general, the "Usage Code" column is blank.
The usage code is applicable to the figure/item number of the

immediately higher assembly(ies) or sub-assembly(ies) (for example,
the applicability lA, lB, 1C is written 1ABC).
E. Quantity for each immediately higher assembly (Units per Assy)
The "Units per Assy" column shows the number of units that are
necessary for the immediately higher assembly.
This number can be replaced by the letters REF (Reference) or AR (As
Required).
3. Terms and abbreviations used
- AR: As required
- ATTACHING PARTS
- DELETED
- DET: Detail
- LH and RH: Left and Right
- MADE BY
- MADE FROM
- MATCHED PARTS
- MODIFIED FROM
- NHA: Next higher assembly
INTRO 1001 Page 3
24-39-06 Apr 01/92
SAFT
1606-l
- NP: Non procurable
- OPT TO: Optional parts
- ORDER OVERLGHT MPN: Part number longer than 15 characters
- OVERSIZE: Oversize repair parts
- POST SB: After the Service Bulletin is included
- R - Changed
- REF: For reference
- SEE
- SEL FROM: Select from parts
- STORAGE PARTS
- SUPSDS by: Superseded by
- SUPSDS: Supersedes
- UNDERSIZE: Undersize repair parts
- T: tera lOE12 m: milli lOE-3
G: giga lOE9 p: micro lOE-6
M: mega lOE6 n: nano lOE-9
K: kilo lOE3 p: pica lOE-12
4. Chanqes
When an item is changed, added or removed, the letter "R" is shown in

the right margin (the date of issue of the page changes).
The letter "R" is shown opposite the page number (in the right margin)
when all the item numbers are changed.
INTRO 1001 Page 4

24-39-06 Apr 01192
SAFT
1606-l
5. Paqe numbers
The Detailed Parts List is divided into sections. The page numbers are
given independently for each section.
Introduction INTRO 1001 Page 1 to 4
Vendor Code Index VC1 1001 Page 1
Numerical Index,
Alphabetical NI/ALPHA 1001 Page 1
Numerical Index
Numerical NI/NUM 1001 Page 1
Detailed Parts List (figure xx)
Figure, Main Page lOxx-0
Figure, Variant A Page lOxx-OA
Figure, Variant B Page lOxx-OB
Parts List (1st page of text) Page lOxx-1
Parts List (2nd page of text) Page lOxx-2
INTRO 1001 Page 5
24-39-06 Apr 01/92
SAFT
1606-l
VENDOR CODE INDEX
VENDOR
CODE NAME-ADDRESS
F6177 SAFT
DPT ACCUMULATEURS INDUSTRIELS
156, Avenue de Metz 93230 ROMAINVILLE

FRANCE
Telex - 235566 F
Phone: (1) 48-43-93-61
Fax : (1) 49-42-34-00
VC1
1001 Page 1
24-39-06 Apr 01192
SAFT
1606-l
NUMERICAL INDEX
PART NUMBER AIRLINE PART FIG. ITEM TTL

NUMBER QTY
-- 1 -0OlA 1
012943 1 300A 8
013678 1 290A 10
031282 1 160A 2
034031 1 170A 1
062002 1 360A 40
062003 1 350A 40
080010 1 330A 20
100111 1 260A 2
100111 1 370A 80
100479 1 400A 40
100593 1 340A 20
100695 1 380A 20
100696 1 390A 20
102077 1 120A 2
105405 1 430A 1
112013 1 020A 2
114735 1 310A 1
116056 1 130A 1
116172 1 200A 2
116173 1 210A 1
116174 1 220A 1
116175 1 250A 2
116182 1 230A 1
116386 1 110A 2
116711 1 030A 4
117026 1 -150A 1
117704 1 180A 1
160840 1 240A 1
161144 1 320A 20
164581 1 090A 1
164583 1 080A 1
164584 1 270A 1
164585 1 280A 1
164841 1 100A 2
167542 1 070A 1
410822 1 040A 1
410823 1 060A 1
410824 1 -050A 1
410825 1 -0lOA 1
411108 1 140A 1
411996 1 410A 40
412230 1 -190A 1
412757 1 420A 1
-Item not illustrated
SA FT
MANUEL D'ENTRETIEN EQUIPEMENT
1606-1
NOMENCLATURE DETAILLEE
Page 1001
Oct 01/92
SAFT
MANUEL D'ENTRETIEN EQUIPEMENT
1606-1
&- 280
290
FIGURE 1
1606-1 BATTERIE
Page 1001-0
24-39-06 O c t 01/92
SA FT
MANUEL D ' E N T R E T I E N EQUIPEMENT
1606-1
Fig. DESIGNAT1ON
1234567
Repere
1 -001A Batterie, 20 VP 160KM, 1606- 1 type

1 -010A . Coffre et couvercle complet
1 020A .
. Vis, CL M 4-10
1 030A .
. Rondelle, Blastique
1 040A .
. Coffre, complet
1 -050A .. Couvercle, complet
1 060A . . , CouvercIe, Bquipbe
1 070A .
. . Isolant, couvercle
1 080A .
. . Protecteur, couvercle
t 090A .
. . Isolant, Borne positive
1 lOOA .. . Passe-fils
1 t1OA . Vis, CL TF 4- 10
1 120A . Ecrou, HM4
I 130A . Serre cables
l 140A . Plaque, identification
1 -150A . Film, protecteur
1 160A . Plaque, instruction de remplissage
1 170A . Plaque, amendement
1 180A . Plaque, code
1 -190A . Kit de calage
1 200A .
. Cale
1 210A .. Cale
1 220A . . Cde
1 230A . .Isolant de fond
1 240A . . Cde lat6rale
1 250A . Borne, batterie
1 260A . Rondelle, Blastique
1 270A . Ecrou, Borne positive
1 280A . Ecrou, Borne negative
1 290A . Connexion, interval E24
1 300A . Connexion, interval E33
1 310A . Connexion, thermostat
1 320A . Accurnulateur, VP 160 KM, &quip6
1 330A . . Soupape de s&curiti!
1 340A .. Joint torique
1 350A . . Ecrou, M 8X1',25
1 360A . . Ecrou, M 8X1,25
1 370A . . Rondelle, hlastique
1 380A . . Rondelle, polarite positive
1 390A . . Rondelle, polarite negative
1 400A . . Rondelle, plate
1 410A . . Joint torique
1 420A . Sonde temperature, complete
1 430A . . Ecrou, auto-freini
-Repere non illustr6 Page 1001-1

O c t 01/92

156, Avenue de Metz 93230 Romainville France Tel (33-1) 48.43.93.61 Telex 2 3 5 W

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SAFT

156,Avenue de Metz - 93230 Romainville - FRANCE

1 Oct.92 Oct.92 SAFT

RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE BY DATE BY

RTR Pages l/2

24-39-06 Apr 01192

SERVICE BULLETIN LIST

NUMBER BRIEF DESCRIPTION TYPE AFFECTED

SBL Pages l/2

24-39-06 Apr 01/92

LIST OF EFFECTIVE PAGES

Title page l/2 Dee 01/92 Description 1 Apr 01/92

Testing and 101 Apr 01192

Disassembly 301/302 Dee 01/92

List of l/2 Apr 01/92 Repair 601 Apr 01/92

Assembly and 701 Dee 01/92

Special 901 Apr 01/92

LIST OF EFFECTIVE PAGES

TP 1001-l Apr 01/92

INTRO 1001-l Apr 01/92

VC1 1001-l Apr 01192

NIINUM 1001-l Apr 01192

24-39-06 Apr 01192

TESTING AND FAULT ISOLATION

1 - Light cleaning 401

1 - Regular checks 501

1 - Battery condition 601

ASSEMBLY AND STORAGE

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1 - Special tools 901

ILLUSTRATED PARTS LIST

24-39-06 Apr 01192

Figure 701 - Circuit 704

Figure 902 - Syringe with nozzle 902

Figure 903 - Cell removal tool 902

Figure 1 - Battery 20 VP 160KM TYPE 1606-l 1001-O

24-39-06 Apr 01192

l-100 Description and operation

101-200 Testing and fault isolation

201-300 (Not used)

701-800 Assembly and storage

801-900 (Not used)

901-1000 Special tools, fixtures and equipment

1001-1100 Illustrated parts lists.

Note : The instructions in this manual cannot be used as a specification

24-39-06 Apr 01192

DESCRIPTION AND OPERATION

The SAFT battery has 20 semi-open nickel-cadmium VP 160KM cells with

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

- To start the APU

- On the ground, before electrical power is supplied to the aircraft

- In flight, if a malfunction or a failure occurs in the power supply

The 28 VDC electrical system charges the battery in the aircraft.

(1) Technical data

- Specified voltage: 24 volts

- Specified capacity: 16Ah at a rate of lh

- Connector 3 pins: according to standard VDE OllO/S.65

- Electrolyte: Sol. KOH s.g. 1.30.

- Consumable volume of electrolyte: 20 cm3 for each cell

- Maximum dimensions of the battery base:

L=371.5 mm (14.62 in)

- Maximum weight: 17.65 kg (39.46 lb).