24-30-16 component maintenance manual with illustrated

Transcription

(F6177)
12 rue Sadi Carnot - 93170 Bagnolet - France
Tél. (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
23390
Initial issue: Feb 06/2006
24-30-16
Page 1
Revision n°. 0
Feb 06/2006
COMPONENT MAINTENANCE MANUAL
23390
PAGE INTENTIONALLY LEFT BLANK
24-30-16
BLANK
23390
RECORD OF REVISION
Rev. n°
Issue
date
Inserted
Date
By
Rev. n°
Issue
date
24-30-16
Inserted
Date
By
ROR
Page 1
Feb 06/2006
23390
24-30-16
BLANK
23390
RECORD OF TEMPORARY REVISION
Temp rev.
n°
Issue date
Inserted
Date
Removed
By
Date
24-30-16
By
Page n°
RTR
Page 1
Feb 06/2006
23390
24-30-16
BLANK
23390
SERVICE BULLETIN LIST
Service bulletin
Number
Rev.
Incorporation into
CMM
Date
Title
Rev.
24-30-16
SBL
Page 1
Feb 06/2006
23390
24-30-16
BLANK
23390
LIST OF EFFECTIVE PAGES
TESTING AND FAULT 1001
ISOLATION
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
DISASSEMBLY
1
2
3
4
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
3001
3002
3003
3004
Feb 06/2006
Feb 06/2006
Feb 06/2006
Blank
CLEANING
LIST OF ILLUSTRATIONS
1
2
Feb 06/2006
Feb 06/2006
4001
4002
4003
4004
Feb 06/2006
Feb 06/2006
Feb 06/2006
Blank
INTRODUCTION
1
2
3
4
5
6
7
8
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
DESCRIPTION AND
OPERATION
1
2
3
4
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
INSPECTION/CHECK 5001
5002
5003
5004
5005
5006
5007
5008
5009
5010
5011
5012
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Blank
TITLE PAGE
1
2
Feb 06/2006
Blank
RECORD OF REVISIONS
1
2
Feb 06/2006
Blank
RECORD OF TEMPORARY REVISIONS
1
2
Feb 06/2006
Blank
SERVICE BULLETIN
LIST
1
2
Feb 06/2006
Blank
LIST OF EFFECTIVE
PAGES
1
2
TABLE OF CONTENT
24-30-16
LEP
Page 1
Feb 06/2006
23390
LIST OF EFFECTIVE PAGES
REPAIR
6001
6002
Feb 06/2006
Feb 06/2006
DETAILED
PARTS LIST
10011
10012
Feb 06/2006
Feb 06/2006
ASSEMBLY
7001
7002
7003
7004
7005
7006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Blank
STORAGE (INCLU15001
DING TRANSPORTA- 15002
TION)
15003
15004
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
FITS AND CLEARANCES
8001
8002
Feb 06/2006
Blank
SPECIAL TOOLS,
FIXTURES,
EQUIPMENT
AND CONSUMABLES
9001
9002
9003
9004
9005
9006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Blank
ILLUSTRATED
PARTS LIST
10001
10002
Feb 06/2006
Blank
INTRO IPL
10003
10004
10005
10006
10007
10008
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
Feb 06/2006
ALPHA NUMERICAL
INDEX
10009
10010
Feb 06/2006
Feb 06/2006
24-30-16
LEP
Page 2
Feb 06/2006
23390
TABLE OF CONTENT
RECORD OF REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
B. How to Use the Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
C. Associated Publications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
D. Revision and updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
E. CMM Page Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
F. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
G. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
H. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
I. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
J. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
K. Verifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
L. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
M. Disposal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
B. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
C. Detailed description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4. Discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason of the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5. Fault isolation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
24-30-16
1001
1001
1001
1001
1001
1001
1002
1004
1006
1006
1006
1006
1006
1006
1008
1008
1008
1008
1008
1008
1009
TOC
Page 1
Feb 06/2006
23390
TABLE OF CONTENT
A. Battery electrical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Cell faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Physical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Vent valve faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1009
1009
1011
1012
DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Risks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Safety measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Disassembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
3001
3001
3001
3001
3001
3001
3001
3001
3002
3002
3002
3003
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Cleaning of a unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4001
4001
4001
4001
4001
4001
4001
4001
4003
INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Maintenance steps in workshop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5001
5001
5001
5001
5001
5001
5002
5003
REPAIR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
6001
6001
6001
6001
6001
6001
6001
REPAIR N°1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4. Changing a cover gasket- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Detailed procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
6002
6002
6002
6002
24-30-16
TOC
Page 2
Feb 06/2006
23390
TABLE OF CONTENT
ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Assembly procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
7001
7001
7001
7001
7001
7001
7001
7002
7004
FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
1. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
A. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES - - - - - - - - - - - - - - - 1. Special tools, fixtures and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Special tools table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Consumables material - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. How to Use the illustrated Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Numerical Index (NI) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Detailed Parts List (DPL) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Updating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
9001
9001
9001
9004
10003
10003
10003
10003
10003
10003
10005
VENDOR LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10007
ALPHA NUMERICAL INDEX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10009
DETAILED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011
STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Storage room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Temperature conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Storage procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. Reason for the job - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - B. Job set-up information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - C. Job set up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E. Close up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
24-30-16
15001
15001
15001
15001
15001
15001
15001
15001
15001
15002
15004
15004
15004
TOC
Page 3
Feb 06/2006
23390
24-30-16
Page 4
Feb 06/2006
23390
LIST OF ILLUSTRATIONS
INTRO-1
1
2
3
1001
1002
1003
1004
5001
5002
5003
5004
7001
7002
9001
9002
9003
9004
10001
15001
Recyclable Product - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
23390 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Identification plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Overall dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Preliminary Functional Tests - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003
Insulation Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004
Insulation Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1004
Cell connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1007
Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
Level adjustment with a syringe and calibrated nozzle - - - - - - - - - - - - - - - - - - - - 5005
Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5010
Liner spacer kit installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003
Cell installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7005
Polyamide key for vent valve (T01) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
Syringe with nozzle (T02) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
Equalizing resistor (T03) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
Cell extraction tool (T04) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9003
23390 BATTERY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10011
Short term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
24-30-16
LOI
Page 1
Feb 06/2006
23390
24-30-16
BLANK
23390
INTRODUCTION
TASK 24-30-16-871-801-A01
1. Introduction
A. General
(1) This component maintenance manual (CMM) agrees with the Air Transport Association
(ATA) iSpec 2200, and it is written in AECMA Simplified English (European Association of
Aerospace Industries).
(2) This CMM gives the procedures necessary to do simple checks and replacement of parts
and components. It also gives the procedures for maintenance. The maintenance procedures given in this CMM are only for approved persons with the necessary skills.
(3) This CMM gives the shop maintenance procedures of the component.
(4) This CMM uses the identification of the tasks and subtasks which is defined in the Maintenance Task Oriented Support System (MTOSS). The maintenance tasks and other data
have special MTOSS numbers for the use of Electronic Data Processing (EDP). The user of
the manual can ignore the MTOSS numbers.
(5) This manual contains:
- the technical data for the component,
- the maintenance and repair procedures for the component,
- an Illustrated Parts List (IPL) with the data for the component parts. The parts are identified in all the Page Blocks of the manual, by the IPL Figure and the item number.
(6) A check of the DISASSEMBLY, TESTING and ASSEMBLY procedures in the workshop.
B. How to Use the Manual
(1) Make sure the manual contains the applicable data for your component. Look for the part
number on the Title Page.
(2) To identify a part or to find a part number, refer to the IPL, which has an Introduction to show
the procedure.
(3) You must use the instructions in this manual, for all the maintenance steps of a component.
Read all the applicable WARNINGS and CAUTIONS before you do the work on the component.
(4) When you use consumable materials, these materials are identified by a code number which
is listed in the Consumable Materials Table.
(5) When you use special tools, these tools are identified by a code number which is listed in
the Special Tools Table.
(6) For the tightening torque values of the parts, refer to the Table of Tightening Torques.
C. Associated Publications
Not applicable.
D. Revision and updating
This manual is revised periodically and may be the subject of update which refers to modifications made on the equipment. Detailed instructions relative to the insertion of withdrawal of pages accompany each update.
24-30-16
INTRO
Page 1
Feb 06/2006
23390
E. CMM Page Blocks
(1) The information for each component in the CMM is divided into specific Page Blocks. Each
Page Block has its own specified subject matter and its own specified page numbering.
These Page Blocks have these titles:
PAGEBLOCKS
PAGENUMBER
Description and
Operation
0001 to 0999
Testing and Fault
Isolation
1001 to 1999
Schematics and Wiring Diagrams
2001 to 2999
Disassembly
3001 to 3999
Cleaning
4001 to 4999
Inspection/Check
5001 to 5999
Repair
6001 to 6999
Assembly
7001 to 7999
Fits and Clearances
8001 to 8999
Special Tools, Fixtures, Equipment
and Consumables
9001 to 9999
ACTUAL
VERIFICATIONS
Illustrated Parts List
10001 to 10999
Special Procedure
11001 to 11999
Not applicable
Removal
12001 to 12999
Not applicable
Installation
13001 to 13999
Not applicable
Servicing
14001 to 14999
Not applicable
Storage (including
Transportation)
15001 to 15999
Rework (Service
Bulletin Instructions)
16001 to 16999
DATE
BY
Not applicable
(2) Description and Operation
This Page Block gives general data.
It gives a mechanical description and an electrical description.
It gives a description of the configuration and operation of the component.
(3) Testing and Fault Isolation
(a) It contains special tests and procedures which you must do to find the condition of a component. The general test procedure is given in the FAULT ISOLATION TABLE. For each
test, this table refers to a special procedure which gives all the parameters which you
24-30-16
INTRO
Page 2
Feb 06/2006
23390
must set. It also gives all the parameters for which you must do a check.
(b) The pressure values in the tests are gage-pressure values.
(c) Before you use any of the measuring instruments, make sure that they are in correct operating condition and that they are calibrated.
(d) Do a check for pneumatic system tightness, if this is applicable.
(e) You must do the tests in a room at ambient temperature +23 °C ± 5 °C (73 °F ± 9 °).
(4) Schematic and Wiring Diagrams
This Page Block contains all the schematic diagrams and the wiring and interconnecting diagrams of the cards.
It also contains the diagrams of:
- chassis wiring, modules, and sub-assemblies
- external connector interconnections in the component.
(5) Disassembly
(a) This Page Block gives step-by-step disassembly instructions in a correct sequence, and
it refers to the figure item numbers from the IPL illustration(s), when they are applicable.
Identify the type of fault, to know how much the extent of disassembly is necessary (do
this to prevent disassembly/reassembly work that is not necessary). The procedure given
below is when full disassembly is necessary.
(b) Put the component on a clean workbench, in a dust-free and moisture-free room. Move
all the parts carefully, and prevent corrosion and impact damage to them after disassembly.
NOTE: Always discard all the seals and gaskets during disassembly.
Discard the washers, the nuts and the screws during disassembly if they are
damaged.
(6) Cleaning
(a) This Page Block gives a step-by-step description of the cleaning operations for the component and its parts.
(b) Always use the recommended procedures for the component parts of the unit.
(7) Inspection / Check
(a) This Page Block gives the full check procedures which are necessary during shop maintenance.
(b) Discard all the defective parts if the document does not give a repair procedure.
(c) Do all the inspections/checks on the cleaned parts.
(8) Repair
This Page Block contains the full repair procedures and specifications which are necessary
to repair a worn or damaged part. As specified in the INSPECTION/CHECK section, you
must reject the defective parts if the document does not give a repair procedure. Replace
the defective parts with new parts.
(9) Assembly
(a) This Page Block gives step-by-step assembly instructions in a correct sequence, which
24-30-16
INTRO
Page 3
Feb 06/2006
23390
refer to the figure item numbers from the IPL illustration(s), if applicable.
(b) Put the component on a clean workbench, in a dust-free and moisture-free room. More
all the parts carefully, and prevent corrosion and impact damage to them.
(c) Be sure to remove the storage protection coating from all the new parts before assembly.
Clean the new part if necessary.
(10) Fits and Clearances
(a) This Page Block gives a table and some figures which gives the fits and clearances data
and the torque values for assembly. It also gives the permitted wear for in-service / service, and the manufacturer’s design wear-tolerances.
(b) Fits and Clearances Table
1 The identifiers in column (1) show the location of the clearance or the dimension that
you must measure..
2 The identifiers in column (2) identify the parts in the IPL (Figure + Item number).
3 Column (3) gives the initial manufacturing dimensions and clearances.
4 In-service Wear Limits (Columns 4).
a The maximum limits are the maximum wear limits. If the part is in these limits then
it is serviceable.
b If the parts have more wear than the specified limits, you must repair or replace them.
(c) Torque Values
1 All torque values in this manual are shown in the Table of Tightening Torques. The parts
are identified by the figure number and the item number of the IPL.
(d) Spring Data
1 The technical data for all springs used in the unit are shown in the Table of Spring Data.
The parts are identified by the figure number and the item number of the IPL.
(11) Special Tools, Fixtures, Equipment and Consumables
(a) This Page Block shows all the special tools, the fixtures, the equipment and the consumables which are necessary to do the maintenance actions which are given in the other
page blocks.
(b) All the items shown are identified in this manual by a standard code number: Txx for
Tools, Fixtures and Equipment and Mxx for Consumable Materials.
(12) Illustrated Parts List
This Page Block contains the full list of all the parts of the component (For the detailed description, refer to the IPL INTRO).
(13) Special Procedures
This Page Block contains the tasks which are given in other Page Blocks of the manual, but
which are necessary because of other maintenance tasks. The tasks are self-contained repairs or preventive maintenance.
(14) Removal
This Page Block gives the procedure for the removal of modules/sub-assemblies from complex modular components.
24-30-16
INTRO
Page 4
Feb 06/2006
23390
(15) Installation
This Page Block gives the procedure for the installation of modules/sub-assemblies in complex modular components.
(16) Servicing
This Page Block gives the self-contained tasks which are necessary because of other
maintenance tasks.
(17) Storage
This Page Block gives the requirements for preparation for transportation, for special handling, for packaging, for storage and for preservation: these requirements are for the component after assembly or test.
(18) Rework
This Page Block gives the rework procedures which are necessary for in-service components.
F. Measurements
(1) The measurements which are given in this manual come from the original manufacturing
drawings.
(2) This CMM uses the “Systeme International” (S.I.) units for quantities and values. It also gives
the imperial units in parentheses.
24-30-16
INTRO
Page 5
Feb 06/2006
23390
G. Units of Measure
(1) I.S. Units
A
Ah
C1A
Ampere
Ampere hours
Rated current
C1Ah
Rated capacity for an hour
g
min
N
N.m
Pa
VDC
Gram
Minute
Newton
Newton meter
Pascal
Volt direct current
°C
%
Ω
Degree Celsius
Per cent
Ohm
(2) U.S. Units
ft
in
inHg
lb
lbf.in
°F
Foot
Inch
Inchs of mercury
Pound
Pound force inch
Degree Fahrenheit
(3) Multiplying Prefixes
μ
m
da
k
M
Micro
Milli
Deca
Kilo
Mega
24-30-16
INTRO
Page 6
Feb 06/2006
23390
H. Measurement Conversion Table
(1) From I.S. Measurement to U.S. Standard System
1 kPa
1 cm
1 cm²
1N
1g
1 kg
1 mm
1 N.m
1 N.m
0.1450 psi
0.3937 in
0.1550 in²
0.2248 lbf
0.0353 oz
2.2046 lb
0.0394 in
8.8507 lbf/in
0.7376 lbf/ft
(2) From U.S. Standard System to I.S. Measurement
1 psi
1 in
1 in
1 in²
1 lbf
1 oz
1 inHg
1 lb
1 gal (U.S.)
1 lbf/in
1 lbf/ft
6,8948 kPa
2,54 cm
25,4 mm
6,4516 cm²
4,4482 N
28,3495 g
3,3864 kPa
0,4536 kg
3,7854 l/min
0,1130 N.m
1,3558 N.m
I. Temperature Conversion Table
(a) SI MEASUREMENT Degrees Celsius (°C)
Celcius = ( Fahrenheit – 32 ) × 0.555 5
(b) U.S. STANDARD SYSTEM Degrees Fahrenheit (°F)
Fahrenheit = ( Celcius × 1.8 ) + 32
J. Abbreviations
The abbreviations given below are used in this manual:
AECMA
ATA
dia.
fig.
ipl
max.
mfr
min.
European Association of Aerospace Industries
Air Transport Association of America
diameter
figure
illustrated parts list
maximum
manufacturer
minimum
24-30-16
INTRO
Page 7
Feb 06/2006
23390
n°
od
p/n
para.
ref.
s/a
TBD
V
number
outside diameter
part number
paragraph
refer to
subassembly
to be defined
Voltage
K. Verifications
(1) The functions (tasks) which are given in this manual were verified by simulation. This component maintenance manual is "shop verified" after all the functions (tasks) are actually
done on the equipment.
(2) We will revise this statement after all verifications are made.
(3) The list of Page Blocks gives the shop verifications which are actually made. We will revise
this statement after all verifications are made.
L. Definition
(1) This paragraph describes the warnings used in this manual.
(2) Warnings call attention to use of materials, steps procedures, or limits, which must be followed precisely to avoid injury to persons.
(3) Cautions call attention to steps procedures which must be followed to avoid damage to
equipment.
(4) Notes call attention to procedures which make the job easier.
M. Disposal
Ni-Cd batteries contain :
- nickel,
- cadmium,
- potassium hydroxide.
They must therefore be discarded or used again, in agreement with local legislation. For more
information, contact your local SAFT supplier.
Recyclable Product
Figure INTRO-1/GRAPHIC 24-30-16-991-069-A01
24-30-16
INTRO
Page 8
Feb 06/2006
23390
DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium VO23KH cells with welded polyamide cases.
The battery is connected to the aircraft systems. You can use it:
(1) To start the engine or the APU in reference to the aircraft system.
(2) On the ground, before electrical power is supplied to the aircraft systems.
(3) In flight, if a malfunction or a failure occurs in the power supply system.
NOTE:The 28 VDC electrical system charges the battery in the aircraft
The figure and item numbers are those of the ILLUSTRATED PART LIST.
B. Characteristics
(1) Technical data
Technical data
Values
Type of cells
VO23KH
Number of cells
20
Nominal voltage
24 V
Rated capacity C1Ah (Ah) see Note below
23 Ah
Electrolyte
Solution of KOH
Electrolyte level (mm)
20 mm (0.79 in)
Consumable volume of electrolyte per cell
21 cm3 (1.28 in3)
End of charge voltage / per cell
1.50 V
End of life criteria in %
80%
End of life criteria in hour or minutes
51 min
Maximum dimensions of the battery :
- Length
- Width
- Height
260 mm (10.2 in)
249.2 mm (9.8 in)
224 mm (8.8 in)
Battery maximum weight
24.4 kg (53.8 lbs)
Battery terminals
Connector according to MS 3509
NOTE: 23 Ah at 1 h rate noted as 23 C1Ah or 23 C1Ah.
Current value equivalence: 23 A = 1 C1A and 2.3 A = 0.1 C1A for this 23 C1Ah
battery.
(2) Operational characteristics
Operating temperature : - 40 to + 71 °C (- 40 to + 160 °F)
(3) Electrical characteristics
List of all values used to service the battery
24-30-16
Page 1
Feb 06/2006
23390
Item
Value
Use for
1 C1A
23 A
Charge/Discharge
0.5 C1A
11.5 A
Charge
0.1 C1A
2.3 A
Charge
C. Detailed description
The battery has 20 VO23KH (130) cells housed in a stainless steel box.
The box (260) is lined with liner spacer kit (200). The cells are kept upright by means of a molded
silicone elastomer part (040) fastened to the cover which presses against the top of the cells.
Cells are interconnected by rigid, nickel-plated copper links (080 thru 120).
The connector (220) connects the battery to the aircraft.
The cover (020), which can be removed, is attached to the box (260) .
Filling instruction plate
Cover
Connector
Box
Indentification plate
23390 Battery
Figure 1/GRAPHIC 24-30-16-991-048-A01
24-30-16
Page 2
Feb 06/2006
23390
Identification plate
Figure 2/GRAPHIC 24-30-16-991-049-A01
24-30-16
Page 3
Feb 06/2006
23390
Overall dimensions
Figure 3/GRAPHIC 24-30-16-991-050-A01
24-30-16
Page 4
Feb 06/2006
23390
TESTING AND FAULT ISOLATION
1. Introduction
A. General
This pageblock gives the tests and inspections required to find the condition of the unit removed
for unscheduled maintenance. The test procedure is given in the TESTING AND FAULT ISOLATION TABLE, which for each test refers to a specific procedure specifying all relevant parameters.
The figure and item numbers are those of the ILLUSTRATED PARTS LIST.
Do the tests at ambient conditions:
- Ambient temperature: 23 ± 5 °C (73 ± 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.1 InHg).
- Relative humidity: < 85 %.
TASK 24-30-16-700-801-A01
2. Testing
A. reason for the job
Self-explanatory
B. Job set-up information
NOTE:You can use equivalent alternatives for the items in those lists.
NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND MATERIALS for full data
of special tools in this list.
(1) Tools, fixtures and equipment
Code
Reference
Qty
Description
T02
016544
1
Syringe assembly (with nozzle)
T03
164829
20
Equalizing resistors (1 Ω / 3 W)
T05
No special
1
Discharge bench (constant current 0-60 A)
T06
No special
1
Power supply 0-45 V, 0-60 A
T07
No special
1
Multimeter range 2 V-50 V accuracy 1%
T08
No special
1
Megohmeter, range 0-50 MΩ voltage
250 VDC, accuracy 3%
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
24-30-16
Page 1001
Feb 06/2006
23390
(2) Consumables
Code
M01
Reference
No special
Description
Distilled or deionized water
C. Job set-up
NOTE:You must always do regular maintenance. It is then necessary to obey these precautions to make sure that you have correct operation of the battery:
Do not install the battery in an aircraft which is too hot.
Carefully obey the instructions given in the aircraft documentation to make sure
that the flow of air is good.
Regularly make sure that the capacity of the battery is correct .
Charge the battery in a battery shop.
You must do maintenance, specially to make sure of level of electrolyte. specially
when ambient temperature is high, time between maintenance must decrease.
You must do maintenance, specially to make sure of tightness of the connection
nuts.
You must do maintenance, specially to make sure of correct charging.
24-30-16
Page 1002
Feb 06/2006
23390
(1) Preliminary Functional Tests (Ref. Fig. Figure 1001/GRAPHIC 24-30-16-991-067-A01)
NOTE: (*) You must consider average in log book.
1
Discharge at 1 V/cell
Tighten the nuts (060)
1 Ω cell shorting 12 h
charge at 1 C1A (23 A)
Yes
see para. 5.B (6)
note the voltage of each
cell during the charge
salt or electrolyte
traces
No
Yes
see para. 5.C (1)
more than
usual average added in all
cells
electrolyte in
the box
Yes
box or cells
damaged
No
Yes
Yes
1 or more cell = 0 V
see para. 5.A (1)
see para. 5.B (7)
No
1 or more cell < 0 V
Yes
see para. 5.B (5)
No
insulation
between cell and box
< 250 kΩ
No
Yes
see para. 5.B (2)
Yes
see para. 5.B (3)
voltage of 1 cell
< 1.50 V
No
Yes
see para. 5.B (4)
capacity check
< 80% C1Ah
Yes
see para. 5.B (5)
Yes
see para. 5.C (4)
see para. 5.C (3)
more than
30% versus battery
cell average added
in 1 cell
No
Yes
Yes
see para. 5.C (2)
No
battery
voltage = 0 V
see para. 5.B (1)
No
Topping up at the end
of charge
No
metallic parts
corroded
Yes
see para. 5.A (3)
No
1 or more
cell has a voltage > 0.1 V
than the others
No
No
a link or a
nut is too hot
No
do a General Overhaull
to detect battery fault or
external cause
Preliminary Functional Tests
Figure 1001/GRAPHIC 24-30-16-991-067-A01
24-30-16
Page 1003
Feb 06/2006
23390
D. Procedure
SUBTASK 24-30-16-750-001-A01
(1) Insulation check
- Place the megohmeter (T08) as the figure show (Figure 1002/GRAPHIC 24-30-16-991006):
Insulation Check
Figure 1002/GRAPHIC 24-30-16-991-006
- ≥ 250 kΩ under 250 VDC = Min value (Figure 1003/GRAPHIC 24-30-16-991-052-A01).
- > 10 MΩ under 250 VDC = Min value after cleaning and drying (Figure 1003/GRAPHIC
24-30-16-991-052-A01).
250 KΩ
problem
2 MΩ
to be cleaned
In battery maintenance shop
Cleaning required
Cleaning required
10 MΩ
Can wait until next
maintenance
OK
Always required after
cleaning and drying
Acceptable
Check the cause
(overcharge…)
Insulation Parameters
Figure 1003/GRAPHIC 24-30-16-991-052-A01
24-30-16
Page 1004
Feb 06/2006
23390
SUBTASK 24-30-16-750-003-A01
(2) Polarization test
- Charge the battery at 2.3 A for 1.5 hours.
- Keep the battery in "open circuit" condition for 1 hour.
- Measure the open circuit voltage of every cell.
- If open circuit voltage of any cell is 0 V (or negative), do a supplementary test (24-30-16750-010-A01). Then repair.
- If every cell has an open circuit voltage that is more than 0 volts, charge the battery.
SUBTASK 24-30-16-780-003-A01
(3) Vent valve test
NOTE: The Vent Valve Test is not necessary if the full set of used vent valves is replaced by a brand new one each year during the General Overhaul or when
there is evidence of electrolyte overflow.
Before you put the vent valve back on the cells, make sure that they operate correctly. Do
these steps:
(a) Install the Vent valve (190) with its O-ring on the end of a metal tube which has an applicable end-piece.
(b) Connect this tube to a supply of compressed air through an adjustable reducing valve.
(c) Adjust the pressure to 0.5 bar (7.25 psi) and put the vented filler cap into a container of
water. Air bubbles come out when the valve opens. If there are no bubbles, increase the
pressure until you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi)
and monitor the pressure at which the bubbles stop.
(d) Reject all vent valves that have an opening pressure of more than 0.7 bar (10 psi) or less
than 0.14 bar (2 psi).
(e) Install the vent valve (190) (24-30-16-420-005-A01).
SUBTASK 24-30-16-750-010-A01
(4) Supplementary test
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.
(a) Charge the battery (24-30-16-800-801-A01). At the end of the total charge time, continue
to charge at 2.3 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 1.50 V.
(b) Adjust the electrolyte level during the last 30 minutes of charge.
(c) Discharge at 23 A down to 1 V/cell.
(d) After this test, discard the defective cells:
- Cells with a voltage of less than 1.50 V at the end of the charge.
24-30-16
Page 1005
Feb 06/2006
23390
- Cells with a voltage that decreases to less than 1 V before one hour of discharge (during the last test discharge).
- Short-circuited cells (zero volt).
E. Close-up
Not applicable.
TASK 24-30-16-800-801-A01
3. Charge
A. Reason of the job
Self explanatory
Code
Reference
Qty
Description
T05
No special
1
T06
No special
1
T07
No special
1
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-16-820-001-A01
(1) Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-30-16-820-002-A01
(2) Ground charge
WARNING:Remove the cover to charge the battery on the ground. this is to make
sure that gas will not collect in the battery box
Do all battery maintenance or overhaul steps in a workshop.
NOTE: In addition to the constant current method of charging, other methods that
fully charge the battery can be used. HOWEVER, IN EVERY CASE, CELL
VOLTAGE CHECKS (U > 1.50 V) AND ELECTROLYTE ADJUSTMENTS
MUST BE CARRIED OUT USING A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT: 2.3 A AT 0.1 C1A. If specific instructions are not given in
the charger operating manual, you must first contact Saft.
24-30-16
Page 1006
Feb 06/2006
23390
Cell connections
Figure 1004/GRAPHIC 24-30-16-991-054-A01
SUBTASK 24-30-16-820-003-A01
(3) Constant current charge (Battery fully discharged)
(a) To charge a fully discharged battery, do one of these procedures If the battery voltage in
main charge is less than the minimum voltage after the minimum time, continue to charge
until the voltage is reached.
Main charge
Current and duration
Final charge
Minimum voltage
Current and duration
2.3 A (0.1 C1A)
time
mini 10 h
maxi 12 h
30 V
2.3 A (0.1 C1A) for a 4 h time
11.5 A (0.5 C1A)
time
mini 2 h
maxi 2 h 30 min.
31 V
23 A (1 C1A)
time
mini 1 h
maxi 1 h 15 min.
31.4 V
NOTE: If the battery voltage does not increase sufficiently during the maximum
charge time: Refer to the chapter TESTING AND FAULT ISOLATION.
CAUTION: When you charge the battery more than in the table above, you decrease
the life of the cells.
(b) Battery not fully discharged and discharge condition unknown
Discharge at 23 A (1 C1A) down to 20 V (24-30-16-800-802-A01).
24-30-16
Page 1007
Feb 06/2006
23390
Charge : refer to (24-30-16-820-003-A01) above constant current charge
E. Close-up
Not applicable.
TASK 24-30-16-800-802-A01
4. Discharge
A. Reason of the job
Self explanatory
Code
Reference
Qty
Description
T05
No special
1
T06
No special
1
T07
No special
1
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-16-820+004-A01
(1) Discharge
Rated capacity (C1Ah)
23 A : minimum value obtained for a fully charged battery, when discharged at 23 A, down to 20 V.
Other rates (C1A)
Depending on temperature and time: up to 25 C1A.
24-30-16
Page 1008
Feb 06/2006
23390
TASK 24-30-16-810-801-A01
5. Fault isolation
SUBTASK 24-30-16-810-001-A01
A. Battery electrical faults
Problem
(1) Zero battery open-circuit
voltage
(2) Zero volt with the battery
set to "discharge"
Probable cause
Correction
(a) Defective electrical connector (no contact made)
Check electrical contacts, links
and tightness of nuts (refer to
INSPECTION/CHECK).
(b) Link loose or broken
Make sure the nuts are tight
(refer to INSPECTION/
CHECK).
(a) Battery fully discharged
Charge the battery.
Do an insulation check (refer to
INSPECTION/CHECK)
(b) Battery circuit open or contacts defective
Examine the contacts and links.
Make sure the terminal nuts are
tight (refer to INSPECTION/
CHECK).
(c) Cell fully dry
Refer to related subsequent
steps.
(3) Low insulation
(a) Leakage of electrolyte
Disassemble and clean the battery (refer to DISASSEMBLY
and CLEANING).
Do an electrolyte level check
CHECK).
SUBTASK 24-30-16-810-002-A01
B. Cell faults
Problem
Probable cause
Correction
(1) Too much water decrease
for all battery cells.
(a) Charge much more than the
limit or too much charge at high
temperature.
Examine the cause of excessive charge.
If necessary, adjust to normal
operating temperature (refer to
DESCRIPTION AND OPERATION).
24-30-16
Page 1009
Feb 06/2006
23390
Problem
(2) Water decrease in cell(s) is
very different from the other
cells in the battery.
(3) A cell has an unsually high
voltage at the start of the
charge.
Probable cause
Correction
(a) More than 30% or more
than the average : leaks from
the cell(s).
Do a leak of the cells (refer to
INSPECTION/CHECK).
(b) 30% (or less) of the
average: cell(s) with damaged
separator(s).
Do the added test(refer to
INSPECTION/CHECK). If necessary, replace the cell(s).
(c) Previous maintenance has
not been done.
Note the cell location and
and check the level of water
comsumption versus other cells
at the next maintenance.
(a) Dry cell.
When the defect occurs, add
5 cm3 (5 ml) of distilled water to
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
voltage at the end of the
charge (Less than 1.50 V at
2.3 A at + 20 °C (+ 68 °F)
(a) The cell was operated at
temperatures and charge rates
outside the limits, and the separator is damaged.
Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND
STORAGE (INCLUDING
TRANSPORTATION)).
(5) Low capacity cell (The cell
shows a reversed voltage or a
correct polarity voltage of less
than 1 V after a discharge of
51 min at 1 C1A).
(a) Usual wear after long operation.
Replace the cell (refer to DISASSEMBLY, ASSEMBLY AND
STORAGE (INCLUDING
TRANSPORTATION)).
(b) Unusual operation, operation at high temperature or
operation with low electrolyte.
Do the applicable procedure
CHECK).
(6) Cell with a swollen case.
(a) Cell operated with low electrolyte level ; deterioration of
separators and damaged
plates.
Replace the cell (refer to DISASSEMBLY).
(7) Cell with zero voltage
when the battery circuit is
open.
(a) Short-circuited cell.
Replace the cell (refer to DISASSEMBLY).
24-30-16
Page 1010
Feb 06/2006
23390
SUBTASK 24-30-16-810-003-A01
C. Physical faults
Problem
(1) Leakage of electrolyte
Probable cause
Correction
(a) Incorrect adjustement of
level.
and CLEANING chapters). Do
an electrolyte level check(refer
to INSPECTION/CHECK).
(b) Cell polarity incorrect during
high-rate discharge (for example, during the engine start).
Investigate the cause of excessive charge.
and CLEANING).
CHECK).
(c) Too much charge at high
temperature or too much current.
Investigate the cause of excessive charge. If necessary,
adjust to normal operating temperature (refer to DESCRIPTION AND OPERATION).
and CLEANING).
CHECK).
24-30-16
Page 1011
Feb 06/2006
23390
Problem
(2) Electrolyte found in the
battery box.
(3) Corosion on the links.
(4) The links are too hot.
Probable cause
Correction
(a) Damaged cell case
Do a leak test of the cells (refer
to INSPECTION/CHECK).
Replace the cell if necessary
and refer to related subsequent
steps.
(b) Leakage of electrolyte
and CLEANING).
CHECK).
(a) Operation in acid air
Make sure the battery test
bench and the storage areas
have no materials which can
give off acid fumes.
(b) Mechanical damage to
nickel plating
Replace the damaged links
(refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
(INCLUDING TRANSPORTATION)).
(a) Loose terminals nuts
Make sure the nuts are torqued
CHECK).
TASK 24-30-16-810-004-A01
D. Vent valve faults
Problem
Probable cause
Correction
Valve open pressure > 0.7 bar
or stay open.
Clogged valve.
Change the valve.
Valve stays open for a pressure
< 0.14 bar or not closed.
Pierced valve.
Change the valve.
24-30-16
Page 1012
Feb 06/2006
23390
DISASSEMBLY
TASK 24-30-16-800-802-A01
1. Introduction
A. General
WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES.
NOTE:Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the
component or the possible cause of its malfunction. This will give the necessary
level of disassembly.
B. Safety
The Safety rules are different from one country to another. Only local rules are applicable.
C. Risks
There are three types of risks.
(1) Physical
- Handling: the battery is heavy. When you lift it, bend your legs and not your back.
- Use protective shoes.
(2) Electrical
- Don’t keep on you rings, watches, chains, belt buckles.
- Use insulated tools.
(3) Chemical
- Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves
- Electrolyte is very dangerous for eyes, use protective goggles.
D. Safety measure
The electrolyte compound is caustic and can cause dangerous burns. If it touches the skin, flush
the touched part with water and make neutral the solution with acetic solution, vinegar or lemon
juice, or with boric acid solution at 10% concentration.
If the electrolyte touches the eyes, flush them with water for 15 minutes at minimum and immediately get a doctor.
Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit. Mix the solution with water or, if possible, with milk. Get a doctor immediately. Contact with
nickel can cause chronic eczema. To breathe cadmium oxide can cause a dry throat, make you
cough, cause headaches, vomiting, or pain in your chest. Persons having breathed cadmium
oxide fumes must get fresh air or get oxygen or must have artificial respiration.
Potash can cause eczema
TASK .24-30-16-000-801-A01
2. Disassembly
A. Reason for the job
Self explanatory
24-30-16
Page 3001
Feb 06/2006
23390
NOTE:Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES for full
data of special tools in this list.
Code
Reference
Qty
Description
T01
015528
1
Polyamide key for polyamide vent valve
T04
016544
1
Cell extraction tool
(2) Consumables
None
C. Job set up
Not applicable
D. Procedure
SUBTASK 24-30-16-020-001
(1) Disassembly procedure
WARNING:DO ALL STEPS ON FULLY DISCHARGED BATTERIES (24-30-16-800-802A01).
(a) Remove the the cover (020)
(b) Removal of a cell
NOTE: In order to avoid a short-circuit, remove a link (080) between two cells.
1 Remove the nuts (060) and the spring washers (070) that attach the links from the cell.
2 Remove all links (080 thru 120).
3 Fully engage the end of the special threaded tool (T04) onto one of the cell terminals.
Then pull up to remove the cell.
NOTE: The vent valve cap must stay tight when the cell is removed.
(c) Removal of a vent valve (190)
1 Unscrew the vent valve (190) with the special tool (T01).
2 Remove the vent valve (190) with its O-ring.
(d) Removal of the connector (220)
1 Remove the screws (240) , the washers (- 250), the links (090, 120), and the
washers (060).
2 Remove the connector (220).
3 Remove the protector (230).
(e) Disassembly of the battery
1 Remove
24-30-16
Page 3002
Feb 06/2006
23390
a The cover (020).
b The cells (130).
c The liner spacers kit (200).
d The connector (220).
E. Close up
Not applicable
24-30-16
Page 3003
Feb 06/2006
23390
24-30-16
BLANK
23390
CLEANING
TASK 24-30-16-871-806-A01
1. Introduction
A. General
TASK 24-30-16-100-801-A01
2. Cleaning of a unit
Self explanatory
Code
Reference
Qty
Description
T01
015528
1
T04
016544
1
- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye washing.
- Protective apron.
(2) Consumable
Code
Reference
Description
M01
Local purchase
M02
Local purchase
Soap
C. Job set up
Not applicable
D. Procedure
WARNING:The electrolyte is dangerous. Be careful when handling electrolyte and avoid
splashing. It is a strong caustic agent and can cause severe burns. Always wear
face and eye protection (preferably A transparent face mask, rubber gloves and
24-30-16
Page 4001
Feb 06/2006
23390
long sleeved clothing). In case of contact with skin, flush immediately with much
water. In case of contact with eyes, flush with water at least 15 minutes and, in all
cases, get immediate medical attention.
SUBTASK 24-30-16-160-001-A01
(1) Light cleaning
(a) Remove the cover.
(b) If a clean, filtered supply of compressed air is available, do this procedure to clean the
cells easily and quickly: blow with much force across the tops of the cells to remove all
dust and light traces of mineral salts from the box. To prevent short circuits, use a rubber
tube or an insulating nozzle.
SUBTASK 24-30-16-160-002-A01
(2) Full cleaning
CAUTION: You must clean the vent valve (190) when the cells are assembled in the
box.
CAUTION: Do not use petrol trichlorethylene or other solvents.
Disassemble the battery (refer to DISASSEMBLY) and then clean all components.
(a) Cells (130)
1 Make sure that the vent valve (190) is tight.
2 Do not soak the cells in water.
3 To easily remove all the electrolyte and mineral salts from the terminals, the cover and
the sides of the cell cases: clean in warm water with a soft brush.
4 Rub the cell with a cloth and let dry.
(b) Box (260) and handles (050)
1 Clean with lightly soapy water, rub with a cloth and let dry.
(c) Nuts, spring washers and links
1 Clean in warm water with a brush and let dry.
(d) Liner spacer kit (200)
1 Clean in warm water and let dry
(e) Vent valve (190)
1 Remove the vent valve (190)
2 Put swab on the cell holes to keep out unwanted material.
3 Soak the vent valve for some period (during the night for example) in a container of distilled water. Do that to remove all salts from the vent hole.
24-30-16
Page 4002
Feb 06/2006
23390
E. Close up
SUBTASK 24-30-16-640-001-A01
(1) Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral
petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.
24-30-16
Page 4003
Feb 06/2006
23390
24-30-16
BLANK
23390
INSPECTION/CHECK
TASK 24-30-16-871-805-A01
1. Introduction
A. General
You must do the checks which are necessary to use the SAFT batteries in flight and on the
ground. These maintenance steps must be done in a battery shop between 23 °C ± 5 °C
(73 ± 9 °F):
- Periodical check: adjustment of electrolyte levels.
- Regular check: electrical treatment, adjustment of electrolyte levels, and capacity test.
- General overhaul: disassembly, full cleaning, assembly and regular check.
TASK 24-30-16-200-801-A01
2. Maintenance steps in workshop
Self-explanatory
Code
Reference
Qty
Description
T01
015528
1
T02
016544
1
T03
164829
20
Equalizing resistors (1 Ω / 3 W)
T05
No special
1
T06
No special
1
T07
No special
1
T08
No special
1
Megohmeter, range 0-50 MΩ voltage
250 VDC, accuracy 3%
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
24-30-16
Page 5001
Feb 06/2006
23390
(2) Consumables
Code
M01
Reference
No special
Description
C. Job set-up
Do the check at ambient conditions:
- Ambient temperature: 23 ± 5 °C (73 ± 9 °F).
- Pressure: 85 to 106 kPa (25.1 to 31.3 InHg).
- Relative humidity: < 85 %.
24-30-16
Page 5002
Feb 06/2006
23390
D. Procedure
SUBTASK 24-30-16-210-001-A01
(1) Periodical check
If the electrolyte consumption is more than the usual consumption between 2 regular
checks, do this periodical check:(Ref. Fig. 5001)
24-30-16
Page 5003
Feb 06/2006
23390
PERIODICAL CHECK 2.B
Light cleaning
no
yes
dust only?
no
Insulation check
> 2 MΩ
yes
Salt or electrolyte traces
yes
U > 21 V
no cell with reversed
polarity
Nut tigthness
no
POLARIZATION TEST
Residual discharge
1 V/cell
General overhaul
figure 5004
Charge
no
FAULT ISOLATION
Supplementary test
OK?
Add 5 h overcharge
U > 1.50 V
Adjust electrolyte
yes
Cell voltage before
end of charge
U > 1.50 V
Adjustment of electrolyte level before
end of charge
(volume <21 cm3
(1.28 in3))
removal < 30 %
yes
Vent cleaning
no
General overhaul
figure 5004
with replacement of
faulty components.
If more than 5 original
cells, then change all
cells.
Nut tightness
Battery accepted after
periodical check
Periodical check
Figure 5001/GRAPHIC 24-30-16-991-056-A01
24-30-16
Page 5004
Feb 06/2006
23390
(a) Charge the battery
1 Discharge the remaining capacity at 23 A down to a voltage of 20 V at the battery terminals.
2 When the battery temperature is at usual temperature range, +23 °C ± 5 °C
(73 °F ± 9 °), charge the battery (TASK 24-30-16-800-801-A01).
3 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 Adjust the electrolyte level). Write down
the quantity of water that is added to each cell. The electrolyte level changes with the
battery charge. The level changes as if the plates absorbed a part of the electrolyte 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.
4 Measure the voltage of each cell.
(b) Adjust the electrolyte level
NOTE: For this operation, use plastic syringe with a plastic nozzle (T02) (refer to
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES. The
length of the nozzle is 20 mm (0.79 in). This is the distance necessary between the seat of the vent valve and the electrolyte (Ref. Fig. Figure 5002/
GRAPHIC 24-30-16-991-011).
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.
20 mm (0.79 in)
Level adjustment with a syringe and calibrated nozzle
Figure 5002/GRAPHIC 24-30-16-991-011
1 To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vent
valve and pull the plunger up.
2 If the level is not sufficient, the syringe tube stays empty when you pull the plunger. Add
24-30-16
Page 5005
Feb 06/2006
23390
distilled water to these cells. (The syringe is small, it can be necessary to do this step
more than one time for each cell).
3 If there is too much liquid, this liquid is removed by the syringe until the level aligns with
the end of the nozzle.The level is correct when only a small quantity of liquid goes into
the syringe when you pull the plunger.
4 Write down the quantity of distilled water added to each cell.
(c) Vent valve cleaning
1 Clean the vent valve (190) (Ref. to CLEANING) when you adjust the electrolyte levels.
(d) Nut tightness
1 Make sure that all the nuts that attach the links are torqued (Ref. to FITS AND CLEARANCES).
(e) Results of the above procedures
1 The battery operates correctly if:
- The voltage of each cell measured during the last hour of charge at 2.3 A is not less
than 1.50 V.
- Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 20 mm (0.79 in).
NOTE: If the average quantity of water added to all the cells is close to 21 cm3
(1.28 in3), do the electrolyte level check more frequently.
2 Do a full overhaul (refer to Subtask 24-30-16-210-003-A01) of the battery if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
- the voltage of each cell measured at the end of a 2.3 A charge is less than 1.50 V (refer to TESTING AND FAULT ISOLATION).
24-30-16
Page 5006
Feb 06/2006
23390
SUBTASK 24-30-16-210-002-A01
(2) Regular check
Light cleaning
REGULAR CHECK 2.C
yes
Cleaning
U > 21 V
no cell with reversed
polarity
Nut tigthness
yes
dust only?
POLARIZATION TEST
Residual discharge
1 V/cell
no
1 Ω cell shorting
overnight
Salt or electrolyte traces
General overhaul
figure 5004
no
no
Insulation check
> 2 MΩ
yes
Recharge
no
FAULT ISOLATION
Supplementary test
OK?
yes
Add 5 h overcharge
U > 1.50 V
Adjust electrolyte
Cell voltage before
end of charge
U > 1.50 V
Adjustment of electrolyte level before
end of charge
(volume < 21 cm3
(1.28 in3))
FAULT ISOLATION
no
yes
Capacity check
yes
no
General overhaul
figure 5004
with replacement of
faulty components .
cells, then change all
cells.
Supplementary test
OK?
Completed charge
Add 5 h overcharge
no
U > 1.50 V
Adjust electrolyte
level.
Discharge > 51 min
Vent cleaning
yes
Nut tigthness
Recharge
Battery accepted after
regular check
Regular check
Figure 5003/GRAPHIC 24-30-16-991-058-A01
24-30-16
Page 5007
Feb 06/2006
23390
AFTER A MAXIMUM OF ONE YEAR, do this battery test (follow the different steps indicated
fig 5003):
(a) Measurement of the voltage
1 Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then
do the polarization test.
(b) Residual discharge
1 Discharge the remaining capacity at 23 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.
(c) Cell shorting
1 Connect a resistor (T03) across each cell and continue to discharge. Resistors with
crocodile clips attached to their leads can easily be attached to the cell terminals. Keep
the resistors in position for 12 hours. Remove all resistors
(d) Charge the battery
1 Refer to "Periodical check"
(e) Adjustment of the electrolyte
(f) Capacity check
1 Immediately after the charge and the level adjustment, discharge the battery again at
23 A down to 20 V; measure the terminal voltage of each cell. Write the time necessary
for the second discharge.
(g) Vent valve cleaning
(h) Results of the above tests:
1 The battery operates correctly if:
- The time necessary for the first discharge is more than 30 minutes.
- The time necessary for the second discharge is not less than 1 hour.
- The voltage of each cell measured during the last hour of the charge at 2.3 A is not
less than 1.50 V.
- The variation of water consumption in individual cell does not exceed ±30% of the average consumption for all cells.The maximum limit is 21 cm3 (1.28 in3).
NOTE: If the average quantity of water added to all the cells is close to 21 cm3
(1.28 in3), do the electrolyte level check more frequently.
- If the first discharge time is less than 30 minutes but the second discharge time is 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.
2 Do a full overhaul of the battery if:
- the quantity of water necessary for one or more cell(s) is much higher or smaller than
for the other cells.
24-30-16
Page 5008
Feb 06/2006
23390
- the voltage of each cell measured at the end of a 2.3 A charge is less than 1.50 V
(refer to TESTING AND FAULT ISOLATION).
- The second discharge time is less the correct one or one cell has a voltage of less
than 1 V (or incorrect polarity before 1 hour of discharge).
NOTE: The decrease of water in a SAFT nickel-cadmium cell is in proportion to
the overcharge. Thus, the decrease should be the same for all 20 cells in
the battery.
- If the quantity of water necessary for one or more cell(s) (in the same battery) is much
higher (or smaller) than the other cells. This means that there is a defect (heavy decrease is usually caused by leakage and low decrease is caused by a damaged separator).
SUBTASK 24-30-16-210-003-A01
(3) General overhaul (minimum 1 per year)
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures
to be done systematically for all battery components. Follow the different steps indicated in
Fig. 5004.
24-30-16
Page 5009
Feb 06/2006
23390
GENERAL OVERHAUL 2.D
Scheduled
yes
U > 21 V
no cell with reversed polarity
On fault
no
POLARIZATION TEST
Nut tightness
Residual discharge
1 Ω cell shorting
overnight
Disassembly
Thorough cleaning
Component inspection
Sensor check
Faulty component
replacement
Charge
Assembly
no
Insulation check
> 10 MΩ
yes
no
FAULT ISOLATION
Other test OK?
Add 5 h overno
charge U > 1.50 V
Adjust electrolyte
General overhaul
with replacement of
faulty components .
cells then change all
cells.
Cell voltage before
end of charge
U > 1.50 V
Adjustment of elec- yes
trolyte level before
end of charge
(volume < 21 cm3
(1.28 in3))
dispersion < 30 %
yes
FAULT ISOLATION
no
Capacity check
1 V/cell ≥ 51 min
yes
Other test OK?
Vent cleaning
Completed charge
Add 5 h overNut tightness
charge U > 1.50 V
Recharge
no Adjust electrolyte yes
level. Discharge
Battery accepted af> 51 min.
ter general overhaul
General overhaul
Figure 5004/GRAPHIC 24-30-16-991-059-A01
24-30-16
Page 5010
Feb 06/2006
23390
(a) Dissassembly
1 Refer to "DISASSEMBLY"
(b) Thorought cleaning
1 Refer to "CLEANING" .
(c) Do a battery inspection.
1 Cells
a Verify that cell boxes show no leakage.
2 Box
a Make the sides of the box straight and remove dents (refer to "REPAIR").
3 Nuts, links and spring washers
a Discard the components that show signs of corrosion or damage.
4 Packing parts
a Discard all defective components
5 Connector
a Make sure that the connector is in good condition (inner and outer surfaces). Replace it if contacts are burned.
(d) Insulation check
1 Refer to Subtask 24-30-16-280-001-A01.
(e) Charge the battery
(f) Adjustment of electrolyte
(g) Capacity check
1 Refer to "Regular check"
(h) Vent valve cleaning
NOTE:If more than 5 original cells have been changed or more than 3 cells are faulty in
the same maintenance, then change all cells or replace the battery with a new one.
SUBTASK 24-30-16-280-001-A01
(4) Insulation resistance
Refer to the chapter TESTING AND FAULT ISOLATION.
24-30-16
Page 5011
Feb 06/2006
23390
24-30-16
BLANK
23390
REPAIR
1. General
As indicated in the CHECK chapter, defective parts for which no repair instructions are given shall
be rejected and replaced by new parts.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST.
2. Equipment
A. Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
B. Standard tools
Standard mechanic’s tools.
C. Materials
Neoprene glue [M03]
3. Repairs
The only authorized repair applicable to the unit is:
- Changing a gasket cover (040).
24-30-16
Page 6001
Feb 06/2006
23390
REPAIR N°1
TASK 24-30-16-900-801
4. Changing a cover gasket
A. General
The gasket cover (040) can be changed only one time.
B. Detailed procedure
- Remove the gasket cover (040).
- Clean the joint location.
- Apply paste to the flat side of the gasket
- Let stay dry for 2 hours in a dry place.
- Put gasket on the bottom of the cover (030). Press firmly.
24-30-16
Page 6002
Feb 06/2006
23390
ASSEMBLY
TASK 24-30-16-871-810-A01
1. Introduction
A. General
You must assemble parts on a clean workbench in a clean, dry room. The parts must be protected
from impact damage.
For tightening parts refer to the torque table (Ref. TASK-24-30-16-400-802-A01).
Make sure that the storage protection layer is removed from the new part before assembly.
The figure and item numbers used are those of the ILLUSTRATED PARTS LIST.
To do check points, refer to INSPECTION/CHECK .
TASK 24-30-16-400-801-A01
2. Assembly procedure
Self-explanatory
Code
T01
Reference
Qty
015528
1
Description
(2) Consumables
Code
M04
Reference
No special
Description
Mineral vaseline
C. Job set-up
Not applicable
24-30-16
Page 7001
Feb 06/2006
23390
D. Procedure
SUBTASK 24-30-16-420-001-A01
(1) Installation of the liner spacer kit (200)
CAUTION:You must assemble the C, D and R slotted spacers to keep the ventilating system of the box free.
(a) Put in position the Q insulator.
(b) Put in position the side spacers.
(c) Install the cells.
Item
Description
Dimension (mm)
Unit per
assembly
A
Spacer
1x210x75
3
B
Spacer
1x210x69
1
C
Spacer
1x210x75
1
D
Insulator
0.5x210x75
4
E
Spacer
1x195x45
5
F
Insulator
0.5x195x45
4
G
Insulator
0.5x195x75
5
H
Spacer
1x195x75
1
I
Spacer
1x210x64
1
J
Insulator
0.5x210x75
7
K
Spacer
1x210x75
5
L
Spacer
1x210x190
1
M
Insulator
0.5x210x190
2
N
Spacer
1x195x190
1
O
Insulator
0.5x195x190
1
P
Insulator
0.3x205x188
2
Q
Spacer
1x247x191
1
R
Spacer
1x210x75
4
S
Insulator
0.3x360x145
1
24-30-16
Page 7002
Feb 06/2006
23390
Liner spacer kit installation
Figure 7001/GRAPHIC 24-30-16-991-014
24-30-16
Page 7003
Feb 06/2006
23390
SUBTASK 24-30-16-420-005-A01
(2) Installation of the vent valve (190)
(a) Make sure the vent valves (190) are in good condition. Replace the vent valves (190) if
they are worn.
(b) Install the vent valve (190) with the special tool (T01). Hold the special tool by its upper
ribbed part.
SUBTASK 24-30-16-420-007-A01
(3) Installation of the connector (220)
(a) Put in position the connector (220) with the washer (- 250) and the screw (240).
SUBTASK 24-30-16-460-001-A01
(4) Installation of a cell (Ref. Fig. 7002)
(a) Put five cells (130) in the side compartments.
(b) Move the last cell into position (if it is difficult to put in the last cell, remove one or two
spacers).
(c) Carefully position the cell (130) and push onto terminals with a piece of soft wood.
(d) Install the links (080 thru 120).
(e) Install the spring washers (070).
(f) Install the nuts (060) and torque them.
(g) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush).
(h) Install the cover (020) and attach it .
SUBTASK 24-30-16-970-001-A01
(5) Write the necessary information on:
(a) the identification plate.(- 280) if the box (260) has been changed
(b) the log book.
E. Close up
Not applicable
24-30-16
Page 7004
Feb 06/2006
23390
120
130
: Polarity +
: Polarity -
110
Cell installation
Figure 7002/GRAPHIC 24-30-16-991-015
24-30-16
Page 7005
Feb 06/2006
23390
24-30-16
BLANK
23390
FITS AND CLEARANCES
TASK 24-30-16-400-802-A01
1. Torque table
SUBTASK 24-30-16-820-005-A01
A. Torque table
List of all applicable torque values needed to assemble and do servicing of the battery:
NOTE:The values here are "lube torque" values. The threads should be lightly greased
before to installation and applying torque.
IPL
FIG ITEM
N°
TORQUE VALUE
NAME
060
N.m
lbf.in
Nut
6 to 10
53 to 89
140
Nut
4.5 to 5.5
39.2 to 47.8
240
Nut
6 to 10
53 to 89
24-30-16
Page 8001
Feb 06/2006
23390
24-30-16
BLANK
23390
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMMABLES
TASK 24-30-16-940-801-A01
1. Special tools, fixtures and equipment
A. Special tools table
Tool
code
Part
number
Description
Supplier code or
name and
address
Page block
where
necessary
Qty
T01
015528
Polyamide key for polyamide
vent valve
3000
4000
5000
7000
1
T02
016544
1000
5000
1
T03
164829
Equalizing resistors
(1 Ω / 3 W)
1000
5000
20
T04
014735
3000
1
T05
No special
Discharge bench (constant
current 0-60 A)
Local purchase
1000
5000
1
T06
No special
Local purchase
1000
5000
1
T07
No special
Multimeter
range 2 V-50 V accuracy 1%
Local purchase
1000
5000
1
T08
No special
Megohmeter, range 0-50 MΩ
voltage 250 VDC, accuracy
3%
Local purchase
1000
5000
1
24-30-16
Page 9001
Feb 06/2006
23390
Polyamide key for vent valve (T01)
Figure 9001/GRAPHIC 24-30-16-991-062-A01
Syringe with nozzle (T02)
Figure 9002/GRAPHIC 24-30-16-991-0063-A01
3 W resistance wire
Alligator clips
Equalizing resistor (T03)
Figure 9003/GRAPHIC 24-30-16-991-018
24-30-16
Page 9002
Feb 06/2006
23390
100 mm (4.33 in)
1 mm (0.04 in) x 60°
140 mm (5.5 in)
60 mm (2.4 in)
26 mm (1 in)
Ø 6 mm (0.2 in)
8 mm (0.3 in)
r=2.5 mm (0.1 in)
R = 1.5 mm (0.06 in)
M8x1.25 mm
Ø 16 mm (0.6 in)
Cell extraction tool (T04)
Figure 9004/GRAPHIC 24-30-16-991-065-A01
24-30-16
Page 9003
Feb 06/2006
23390
TASK 24-30-16-13-941-801-A01
2. Consumables material
(1) Consumable materials table
CAUTION: Use only distilled or desionized water
NOTE: Equivalent alternatives can be used for list items.
Material
number
Description
Supplier code or
name and
address
Page block
where
necessary
M01
clear, colourless, oderless while boiling,
resistivity > 30 kΩ/cm
5 < pH < 7
Absence of organic and reducing substances. Reducing agent content
(expressed in weight of oxygen)
< 30 mg/l (test with permanganate).
Total of ions (SO42+, 2Cl-) < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
Local purchase
1000
4000
5000
M02
Soap
Local purchase
4000
M03
Neoprene glue
Local purchase
6000
M04
Mineral vaseline
OTAN: S 743
F: AIR 3565
US: VLP 236
UK: DEF 2333
7000
15000
24-30-16
Page 9004
Feb 06/2006
23390
ILLUSTRATED PARTS LIST
24-30-16
Page 10001
Feb 06/2006
23390
24-30-16
BLANK
23390
INTRODUCTION
TASK 24-30-16-871-802-A01
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed
parts of the unit in disassembly sequence.
It includes the following sections :
- Introduction (INTRO),
- Numerical Index (NI),
- Detailed Parts List (DPL).
B. How to Use the illustrated Parts List
(1) To find the illustration for a part if the part number is known, refer to the Numerical Index and
look for the part number and the corresponding figure and item number. Refer to the 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.
C. Numerical Index (NI)
(1) In this index, part numbers are classified in the following order:
(a) The classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
(b) The sequence in the first left row is :
1 an alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
2 numeral from 0 to 9.
(c) For the subsequent rows, the sequence is:
1 a dash,
2 an alpha letter A to Z (but not the "O" and the "I", because it is possible to read these
letters as a zero and a one),
3 a numeral 0 to 9.
(d) The part number column contains all part numbers included in the Detailed Parts List.
The part numbers that have been deleted or superseded within the Detailed Part List are
listed in the Numerical Index and identified as deleted or superseded.
D. Detailed Parts List (DPL)
(1) Figure and Item Number
(a) Each assembly, sub-assembly and part holding a part number and included in the parts
list is given as an item number.
(b) The figure number linked to the item number is shown on the first line at the top of each
24-30-16
Page 10003
Feb 06/2006
23390
page.
(c) Assemblies, sub-assemblies numbered parts included in the list but not illustrated are
identified by a hyphen (-) preceding the item number.
(d) An index letter shown before the item number refers to the figure showing the modified
portion of the applicable part.
(2) Manufacturer's Part Number
A manufacturer's part number is given to each assembly and detail part, whether illustrated
or not.
(3) Nomemclature
(a) The nomenclature is given with an indenture, to show how the parts and the assemblies
and related to their next higher assemblies. These are the details: :
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
. Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
. . Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
(b) The attaching parts are shown directly after the assembly of the part thereof. They are
listed under the same indent number as the item they are attached to, and are identified
by the words "Attaching Parts" and are followed by three asterisks.
(c) The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme right- hand side of the first line of the parts list column.
(4) Effectivity code
1 An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts
lists in relation to the next higher assembly (ies) or sub-assembly (ies).
2 When the effectivity is fully applicable, the usage code column remains blank.
3 The use code for assemblies and detailed parts refers to the figure/item number of the
next higher assembly (ies) or sub-assembly (ies). Example : Effectivity 1A, 1B, 1C is
written 1ABC.
(5) Units per Assembly
(a) The units per assembly column showns the quantity of units required for one next higher
assembly.
(b) In some cases, the information is replaced by the abbreviation RF (for reference) or AR
24-30-16
Page 10004
Feb 06/2006
23390
(as required).
(6) Abbreviation used
ALT FROM PNR XXX
AMDT
AR
DELETED
DET
DPL
EDI
IPL
LH
MFR
MODIFIED FROM
NHA
NP
OLD PNR
OPT SEE TABLE
ORDER OVRLGTH PNR
OVERSIZE
PNR
POST SB
PRE SB
R
RF
RH
SEE CMM
SEE FIG FOR DET
SEE FIG FOR NHA
SEL FROM
SUPSD BY
SUPSDS
UNDERSIZE
VL
Part that is functionally and physically interchangeable with original
part after reworking.
Amendment
As required
Deleted part
Detail
Detailed Parts List
Equipment Designator Index
Illustrated Parts List
Left hand
Manufacturer or Optional Manufacturer in the IPL
A part got after a different part is modified
Next higher assembly
Not procurable
Optional part number. Optional part number that is fully interchangeable with the part in the part number column.
Refer to the optional table
A part number with more than fifteen chararacters
A part with a size which is larger than its nominal dimension
Part number.
After a modification given up by a Service Bulletin.
Before modification given up by a Service Bulletin.
Revised
For reference.
Right hand.
Refer to the Component Maintenance Manual.
Refer to figure for details.
Refer to figure for next higher assembly.
Selected from. A part that you must select from a collection of parts,
as necessary
Superseded by XXX.
Supersedes XXX.
A part with a size wich is smaller than its nominal voltage
Vendors List.
E. Updating
(1) General
(a) When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the date of issue changes).
(2) Added items
(a) The basic sequence of the items given from 10 to 10 makes it possible to add new items
between the old ones in the appropriate order of the breakdown. With the addition of
24-30-16
Page 10005
Feb 06/2006
23390
more than nine new items, a new number is to be added at the end of the IPL.
(3) Deleted items
(a) Should a part number definitively deleted, the information given in the parts list zone is
deleted. The old part number always remains in the numerical index.
(4) New Figure Number Added
(a) When new illustrations are necessary the alternative figures are inserted. They refer to
the same nomenclature. The alternative figure is given with the basic figure number and
letter. This letter precedes the item number in the parts list.
24-30-16
Page 10006
Feb 06/2006
23390
VENDOR LIST
Code
Name
Address
F6177
Saft
12 rue Sadi Carnot
93170 Bagnolet
France
Phone: +33 (0) 1 49 93 19 18
Fax: +33 (0c) 1 49 93 19 56
V09052
Saft America Inc.
711, Industrial Blvd
Valdosta
Georgia, 31601
USA
Phone: +1 (229) 247 2331
Fax: +1 (229) 247 8486
24-30-16
Page 10007
Feb 06/2006
23390
24-30-16
BLANK
23390
ALPHA NUMERICAL INDEX
PART NUMBER
AIRLINE
STOCK NUMBER
FIG
NUMBER
INDEX
NUMBER
TOTAL
REQUIRED
015078
210
1
015255
050
1
057012
100
3
062000
060
42
062000
140
2
063410
130
20
100111
070
42
100111
170
2
100430
-250
4
100431
240
4
100479
180
2
100695
150
1
100696
160
1
101228
120
8
101229
080
7
101230
090
2
102226
220
1
105620
040
1
105623
110
1
105664
020
1
105665
030
1
117026
270
1
166309
290
2
166925
230
1
280068
- 310
1
411108
280
1
412645
000
1
413609
300
2
415220
190
1
415598
260
1
415611
- 010
1
24-30-16
Page 10009
Feb 06/2006
23390
- Item not illustrated.
24-30-16
Page 10010
Feb 06/2006
23390
DETAILED PARTS LIST
23390 BATTERY
Figure 10001/GRAPHIC 24-30-16-991-020
24-30-16
Page 10011
Feb 06/2006
23390
FIG. ITEM
01 - 001
- 010
020
030
040
050
060
070
080
090
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
- 250
260
- 270
- 280
- 290
- 300
- 310
PART
NUMBER
23390
415611
105664
105665
105620
015255
062000
100111
101229
101230
057012
105623
101228
063410
062000
100695
100696
100111
100479
415220
412645
015078
102226
166925
100431
100430
415598
117026
411108
166309
413609
280068
AIRLINE
STOCK
NUMBER
NOMENCLATURE
1234567
Battery, VO23KH
. Box and cover complete
. Cover complete
. . Cover, assembly
. . Gasket, cover
. Handle, strap
. Nut M8X1.25
. Washer, spring
. Link, intercell, E27
. Link, intercell, E28.5
. Link, intercell
. Link, intercell
. Link, intercell, E33,
. Cell, VO23KH, assembly
. . Nut M8X1.25
. . Washer, positive polarity
. . Washer, negative polarity
. . Washer, spring
. . Washer, flat
. . Vent valve
. Liner-spacer kit
. Spacer
. Connector, complete
. Protector
. . Screw, F/90 M4-10
. . Washer
. Box assembly
. Film, protector
. Plate, identification
. Plate, filling instruction
. Plate, SAFT label
. Plate, recycling
EFF.
CODE
UNITS
PER
ASSY
RF
1
1
1
1
1
42
42
7
2
3
1
8
20
2
1
1
2
2
1
1
1
1
1
4
4
1
1
1
2
2
1
- Item not illustrated.
24-30-16
Page 10012
Feb 06/2006
23390
STORAGE (INCLUDING TRANSPORTATION)
TASK 24-30-16-871-809-A01
1. Introduction
A. General
Storage inhibition and packaging guarantee the equipment against any attack by atmospheric
agents.
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommended temperature range is + 20 °C ±15 °C (68 °F ±27 °F). However, occasional
excursion into the range of -60 °C to +60 °C (-76 °F to +140 °F) is permitted.
TASK 24-30-16-871-809-A01.
2. Storage procedure
Self explanatory
None
(2) Consumables
Code
M04
Reference
No special
Description
Mineral vaseline
C. Job set up
SUBTASK 24-30-16-550-001-A01
(1) Preparation of the battery before storage
(a) Visual inspection: if dust or salt do a General Overhaul according to procedure (Ref. PGBLK-24-30-16-5000-2).
(b) Then light cleaning (Ref. PGBLK-24-30-16-4000-2), then service as scheduled (periodical check, regular check or general overhaul check) (Ref. PGBLK-24-30-16-5000-2).
(c) Adjust the electrolyte levels (Ref. PGBLK-24-30-16-5000-2), then discharge at a constant current of 23 A down to 20 V.
(d) Lightly lubricate these components with mineral vaseline (M04): the nuts, the links, and
24-30-16
Page 15001
Feb 06/2006
23390
all the components that can be damaged by atmospheric corrosion.
(e) Put the battery in its usual vertical position.
D. Procedure
SUBTASK 24-30-16-530-001-A01
(1) Packaging
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we
recommend to put the batteries in a welded plastic container. In this type of container, with
the recommanded temperature range, the batteries can be kept for 10 years.
SUBTASK 24-30-16-550-002-A01
(2) Short term storage (Ref. Fig. 15001)
(a) Place the charged battery (serviced according to CMM procedure) in a cool room or discharge to 1 V/cell (refer TESTING AND FAULT ISOLATION).
(b) Light greasing of cells terminals.
(c) Place in a storage room.
24-30-16
Page 15002
Feb 06/2006
23390
AVAILABLE CAPACITY (%C1Ah)
100
90
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) Disch. (0%C1Ah)
60
0
10
20
30
40
50
60
70
REST TIME (days)
Short term storage
Figure 15001/GRAPHIC 24-30-16-991-021
80
90
TASK 24-30-16-550-003-A01
(3) Long term storage
CAUTION:Saft Ni-Cd batteries may be stored in temperatures ranging from - 60 °C (67 °F)
to + 60 °C (+ 140 °F) for short periods of time without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years
of storage under the above conditions.
No maintenance operation needs to be performed during the storage period.
Lead batteries must be stored in a different room.
NOTE:Lead batteries must be stored in a different room
(a) Operations
1 Discharge to 20 V.
2 Light greasing of cells terminals.
3 Place in a storage room.
24-30-16
Page 15003
Feb 06/2006
23390
(b) Conditions
1 The battery should be stored filled and discharged.
2 The storage life is 10 years, if using the following conditions :
- Sealed packaging.
- Temperature: + 20 °C ± 15 °C (68 °F ± 27 °F).
- Humidity: < 70 %.
- Normal vertical position.
- Isolated from detrimental agents : dirt, dust, clampness, vibration, corrosive atmosphere.
SUBTASK 24-30-16-540-001-A01
(4) Servicing after storage
Storage time
Servicing procedure
Less than 3 months
Charge the battery (Do one of the procedures given in "TESTING
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year
Do the Periodical check (Ref. PGBLK-24-30-16-5000-1).
More 1 year
Do the Regular check (Ref. PGBLK-24-30-16-5000-1).
E. Close up
Not applicable
TASK 24-30-16-500-801-A01
3. Transportation procedure
A. General
The battery must be discharged before packing.
The battery should then be packed vertically in its original container. If the original container is
not available, the international and/or local packaging regulations applicable to the mode of
transport and destination must be followed.
24-30-16
Page 15004
Feb 06/2006

24-30-16 component maintenance manual with illustrated

Transcription

Similar documents

MADTOWN BLOODBATH PT. 1 FEB. 10-12,

Eagle Happenings Newsletter 01/05/16

Ghost Ships Picky Eaters Phantom Islands

January Newsletter 2016

read more

DOS SD-STD-02.01 K12 L3 ASTM F2656 M50 P1

File - Adrian Christian Church

THE KICK-LINE - McNeil Majestics

February 2015 - Berea Christian Church

crusader chronicle - Our Lady of Perpetual Help