saft-battery-maintenance.pdf

Operating and Maintenance Manualfor Nickel-Cadmium aircraft batteries 24-30-99 OPERATING AND MAINTENANCE MANUAL PAGE INTENTIONALLY LEFT BLANK Page 2 Aug 29/2008 OPERATING AND MAINTENANCE MANUAL TABLE OF CONTENT INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A 1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 2. Website - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 3. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 4. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 4-1. Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 4-2. Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 4-3. Chemical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - a 5. Aircraft Conversions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - b 6. Ground Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - b 7. Placing a new battery in service - initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - b 8. Battery Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - c 8-1. Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - c 9. Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - d 10. End of life cells - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - d 11. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - e 11-1. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - e 11-2. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - e 11-3. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -f 11-4. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -f DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2. Batteries - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3. Cells - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4. Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1. Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3. Ventilation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1. Constant Current Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2. Rapid Partial Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3. Constant Potential Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4. Other method of charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 1 1 2 3 3 3 3 3 3 3 4 5 6 TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - -1001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1. Battery electrical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2. Cell faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3. Physical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001 1001 1002 1003 DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4. Dissassembly procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1. Removing the cover (010) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2. Removing the cells (100) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3. Removing the vent valves (160) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4. Removing the connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5. Removing the sensor (if applicable) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6. Disassembly of the battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001 3001 3001 3001 3001 3001 3001 3001 3001 3001 3001 3001 CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4001 1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001 TOC - Page 1 Aug 29/2008 . All traces of acid and salt should be removed by washing with a neutralizing agent such as sodium bicarbonate (baking soda) in water. 5. Ground Applications Your Saft battery can be used in such ground applications as starting gas turbine generators. electrolyte check. the surface should be painted with an alkaline resistant paint. If it touches the skin. A visual inspection. or in shop testing equipment. make you cough. charge procedure. Once the area has been fully cleaned and prepared. Refer to INSPECTION/CHECK chapter. refer to Servicing after discharged storage. 6. torque check.OPERATING AND MAINTENANCE MANUAL INTRODUCTION . vomiting. Persons having breathed cadmium oxide fumes must get fresh air or get oxygen or must have artificial respiration. cause headaches.Contact with nickel can cause chronic eczema. Check with your local authorities for regulations in effect for your area.Electrolyte is very dangerous for eyes. Ventilation of the battery during ground use can be accomplished through a ventilation system or by simply removing the cover (only in a well-ventilated area). Placing a new battery in service . . Page b Aug 29/2008 .To breathe cadmium oxide can cause a dry throat.Potassium hydroxide in the electrolyte can cause eczema. Do not try to vomit. This preparation should ensure that your new Saft battery will not be harmed by sulfuric acid residue. . If the battery has been stored for longer than 3 months. Aircraft Conversions Saft aircraft batteries come in a wide variety of configurations that are approved for installation on selected aircraft. Get a doctor immediately. vinegar or lemon juice. When replacing a lead-acid battery with a Saft nickel-cadmium aircraft battery. or with boric acid solution at 10% concentration. . flush them with water for 15 minutes at minimum and immediately get a doctor. ground mobile equipment. . and insulation test should be done prior to the battery being placed into the aircraft for service. . use protective goggles. The same principles used in flight operations apply when the battery is used in ground applications. flush the touched part with water and make neutral the solution with acetic solution. 7. it is vitally important to clean all mounting and holding fixtures in the aircraft prior to installation.If the electrolyte touches the eyes. or pain in your chest.Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves and apron.initial commissioning Saft batteries are shipped discharged.Electrolyte ingestion can cause damage to the throat and the respiratory tract. 4°F). A battery rated for 1C1 Ah indicates that the battery is rated at a value based upon a discharge time of 1 hour at 23°C ± 3°C (73. A typical discharge curve for Saft VHP series cells can be found in Figure 1. a battery with a rated capacity of 40 Ah (1C1 Ah) will deliver no less than 40 A for one hour when new.5°F) 1C1A and 10C1A 28 Voltage (V) 26 24 22 20 18 16 Capacity (%C1Ah) 14 0 20 40 60 80 100 120 Discharge Curve for VHP Series Cell Figure 1 Page c Aug 29/2008 . Type VHP-K cells (20 cells) Terminal voltage vs state of discharge for various discharge current at 23°C (73. Capacity Nickel-cadmium batteries are rated in the same manner as any other battery by capacity in ampere-hours (Ah) (rated capacity). In other words.4°F ± 5. American Standard AS8033 defines capacity as "the dischargeable ampere-hours (Ah) available from a fully charged cell/battery at any specified discharge rate/temperature condition".OPERATING AND MAINTENANCE MANUAL INTRODUCTION 8. IEC 60952 and RTCA DO 293. Other definitions for battery ratings can be found in EN2570. Battery Ratings 8-1. In the event of electrolyte leakage.Ensure that the cell is fully discharged (refer to Cell shorting paragraph) . In all cases. Page d Aug 29/2008 . Nickel-cadmium batteries contain nickel. In order to ensure that end of life cells cannot be re-used.Dispose of the cell in accordance with applicable transport. .OPERATING AND MAINTENANCE MANUAL INTRODUCTION 9.saftbatteries. and potassium hydroxide and should be disposed of properly. they are obliged to respect the applicable regulations. the following procedure is recommended: . Universal Recycling Symbols Figure 2 You can find the nearest recycling collection point on our website www. Saft operates recycling facilities in both Europe and North America. End of life cells Saft recommends the same procedure as EASA regulations concerning Maintenance Organisation Approval Part 145 for the disposal of unsalvageable components. .Put one of the terminals from the cell between the two sides of a bench vice and bend until the terminal breaks.com. Recycling All batteries eventually lose their ability to perform and are eligible for scrap and recycling. cadmium. Saft takes environmental matters seriously and advocates proper recycling of nickel-cadmium batteries and their components. To that end. health and safety and recycling regulations (Refer to Recycling paragraph). If the battery workshops are to maintain and retain approval. rely on local and national regulations for proper battery disposal and/or shipping to an appropriate recycling location.Ensure that appropriate protective measures (refer to Safety paragraph) and MSDS are taken. 10. ensure that appropriate clean up measures as described in the MSDS are observed. cause headaches. Once the area has been fully cleaned and prepared. . flush the touched part with water and make neutral the solution with acetic solution. Page b Aug 29/2008 .Contact with nickel can cause chronic eczema. electrolyte check. Persons having breathed cadmium oxide fumes must get fresh air or get oxygen or must have artificial respiration. or pain in your chest. Ground Applications Your Saft battery can be used in such ground applications as starting gas turbine generators. Refer to INSPECTION/CHECK chapter. The same principles used in flight operations apply when the battery is used in ground applications. All traces of acid and salt should be removed by washing with a neutralizing agent such as sodium bicarbonate (baking soda) in water. flush them with water for 15 minutes at minimum and immediately get a doctor. If it touches the skin. and insulation test should be done prior to the battery being placed into the aircraft for service. Aircraft Conversions Saft aircraft batteries come in a wide variety of configurations that are approved for installation on selected aircraft. it is vitally important to clean all mounting and holding fixtures in the aircraft prior to installation. vomiting.Electrolyte is very dangerous for eyes.If the electrolyte touches the eyes. . torque check. If the battery has been stored for longer than 3 months. the surface should be painted with an alkaline resistant paint. Do not try to vomit. charge procedure. Check with your local authorities for regulations in effect for your area. Placing a new battery in service .Potassium hydroxide in the electrolyte can cause eczema. 6. ground mobile equipment. . 7. Get a doctor immediately. When replacing a lead-acid battery with a Saft nickel-cadmium aircraft battery.Electrolyte is very corrosive and can cause dangerous damage to the skin: use gloves and apron.initial commissioning Saft batteries are shipped discharged. or in shop testing equipment. make you cough. use protective goggles. . Ventilation of the battery during ground use can be accomplished through a ventilation system or by simply removing the cover (only in a well-ventilated area). A visual inspection. This preparation should ensure that your new Saft battery will not be harmed by sulfuric acid residue. .Electrolyte ingestion can cause damage to the throat and the respiratory tract. 5. vinegar or lemon juice. refer to Servicing after discharged storage. or with boric acid solution at 10% concentration.OPERATING AND MAINTENANCE MANUAL INTRODUCTION .To breathe cadmium oxide can cause a dry throat. a battery with a rated capacity of 40 Ah (1C1 Ah) will deliver no less than 40 A for one hour when new. A battery rated for 1C1 Ah indicates that the battery is rated at a value based upon a discharge time of 1 hour at 23°C ± 3°C (73. Battery Ratings 8-1.4°F ± 5.OPERATING AND MAINTENANCE MANUAL INTRODUCTION 8. In other words. IEC 60952 and RTCA DO 293. Other definitions for battery ratings can be found in EN2570.4°F). Type VHP-K cells (20 cells) Terminal voltage vs state of discharge for various discharge current at 23°C (73. Capacity Nickel-cadmium batteries are rated in the same manner as any other battery by capacity in ampere-hours (Ah) (rated capacity). A typical discharge curve for Saft VHP series cells can be found in Figure 1. American Standard AS8033 defines capacity as "the dischargeable ampere-hours (Ah) available from a fully charged cell/battery at any specified discharge rate/temperature condition".5°F) 1C1A and 10C1A 28 Voltage (V) 26 24 22 20 18 16 Capacity (%C1Ah) 14 0 20 40 60 80 100 120 Discharge Curve for VHP Series Cell Figure 1 Page c Aug 29/2008 . saftbatteries.Dispose of the cell in accordance with applicable transport. If the battery workshops are to maintain and retain approval.Put one of the terminals from the cell between the two sides of a bench vice and bend until the terminal breaks. Universal Recycling Symbols Figure 2 You can find the nearest recycling collection point on our website www. health and safety and recycling regulations (Refer to Recycling paragraph). To that end. In order to ensure that end of life cells cannot be re-used.com. End of life cells Saft recommends the same procedure as EASA regulations concerning Maintenance Organisation Approval Part 145 for the disposal of unsalvageable components. Recycling All batteries eventually lose their ability to perform and are eligible for scrap and recycling. Nickel-cadmium batteries contain nickel.OPERATING AND MAINTENANCE MANUAL INTRODUCTION 9. . Saft takes environmental matters seriously and advocates proper recycling of nickel-cadmium batteries and their components. they are obliged to respect the applicable regulations.Ensure that appropriate protective measures (refer to Safety paragraph) and MSDS are taken. In all cases.Ensure that the cell is fully discharged (refer to Cell shorting paragraph) . . Saft operates recycling facilities in both Europe and North America. cadmium. and potassium hydroxide and should be disposed of properly. 10. Page d Aug 29/2008 . rely on local and national regulations for proper battery disposal and/or shipping to an appropriate recycling location. the following procedure is recommended: . ensure that appropriate clean up measures as described in the MSDS are observed. In the event of electrolyte leakage. 11-1. Units ft in inHg lb lbf.S.0394 in 8. Units A Ah C1A Ampere Ampere hours Rated current C1Ah Rated capacity for an hour g min N N.S. Standard System 1 kPa 1 cm 1 cm² 1N 1g 1 kg 1 mm 1 N.m Pa VDC Gram Minute Newton Newton meter Pascal Volt direct current °C % Ω Degree Celsius Per cent Ohm 11-1-2.S.) units for quantities and values.54 cm 25. Multiplying Prefixes μ Micro m da k M Milli Deca Kilo Mega 11-2.3937 in 0.m 0.I. Units of Measure 11-1-1.8507 lbf/in 11-2-2. I. It also gives the imperial units in parentheses. Standard System to I.S.2248 lbf 0.2046 lb 0.8948 kPa 2.S. From I.4 mm Page e Aug 29/2008 .0353 oz 2.OPERATING AND MAINTENANCE MANUAL INTRODUCTION 11.1450 psi 0.1550 in² 0. Measurements The measurements which are given in this manual come from the original manufacturing drawings.in °F Foot Inch Inch of mercury Pound Pound force inch Degree Fahrenheit 11-1-3. From U. This OMM uses the “Systeme International” (S.S. U. Measurement 1 psi 1 in 1 in 6. Measurement Conversion Table 11-2-1. Measurement to U. 7854 l/min 0.S.4516 cm² 4.m 1.3558 N. STANDARD SYSTEM Degrees Fahrenheit (°F) · Fahrenheit = ( Celsius × 1.m 11-3. n° p/n para. fig. 8 ) + 32 11-4.4536 kg 3. mfr min. s/a TBD V Page f Aug 29/2008 European Association of Aerospace Industries Air Transport Association of America diameter figure illustrated parts list maximum manufacturer minimum number part number paragraph refer to subassembly to be defined Voltage . ipl max.) 1 lbf.3495 g 3.1130 N. SI MEASUREMENT Degrees Celsius (°C) · Celsius = ( Fahrenheit – 32 ) × 0.3864 kPa 0. U. Temperature Conversion Table 11-3-1. ref.S.4482 N 28.OPERATING AND MAINTENANCE MANUAL INTRODUCTION 1 in² 1 lbf 1 oz 1 inHg 1 lb 1 gal (U.ft 6.in 1 lbf. Abbreviations The abbreviations given below are used in this manual: AECMA ATA dia. 5555 11-3-2. These cells are connected in series to obtain a specified voltage. usually stainless steel. and a cover assembly (010). Each link is held in place by nickelplated copper nuts (110) on the cells’ terminals (or nickel-plated steel screws for internally threaded terminals). General The batteries are connected to the aircraft system . to provide power before electrical power is supplied to the aircraft systems. plastic-coated steel. Individual cells are enclosed in a polyamide container that provides insulation. allowing them to be fitted side-by-side in the battery box.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION 1.On the ground.. painted steel or titanium. individual cells are held in place by partitions. Each battery is designed with appropriate ventilation to allow the escape of gases produced during an overcharge condition and to provide cooling during normal operation. usually 12 or 24 volts nominal. highly conductive.In flight. liners and spacers (200). Inside the battery box. . if a malfunction or a failure occurs in the power supply system. Interconnection of cells is via rigid. containing a number of individual cells. Description 1-1. sensor Identification plate Range plate Nickel-Cadmium Aircraft Battery Figure 1 1-2. . Batteries NOTE:The item numbers are those of the detailed parts list chapter Each Saft nickel-cadmium battery consists of a metallic box (020). nickel-plated copper links(030).According to the aircraft system. Cover assembly Filling instruction plate Box Connector Connector. to start the engine or the APU . Page 1 Aug 29/2008 . Each set of positive and negative plates is connected to a plate tab that employs a continuous welding joint for maximum energy transfer. the design features are on the cutting edge of today’s technology. Saft cells are composed of a cover and body made of polyamide plastic. Each cell is equipped with a vent-valve that can be removed to allow access to the electrolyte (for the addition of distilled or deionized water). Cutaway of a Vented Cell Figure 2 Page 2 Aug 29/2008 .7 bar (10 psi) maximum. Within the cell container. This fabric allows the electrolyte to stay in contact with the plates by “wicking”. a three-part separator separates the plates of opposite polarity. porous. the positive and negative plates are immersed in electrolyte. VP. which is later converted to cadmium-hydroxide during manufacturing. CVK. The active elements of the nickel-cadmium cell are either two groups of thin. CVD)]. These terminals are connected to the respective terminal posts. In the cell. leak proof container. The negative plates are either sintered nickel impregnated with cadmium-hydroxide. The terminal post is what allows external connections to be made.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION 1-3. designed to limit the pressure inside the cell to 0. impregnated with nickel-hydroxide. sintered nickel plates (VO. In all cells. The inner layer is either an organic or a micro-porous synthetic material that acts as a gas barrier to control oxygen recombination during recharge. The outer layers are a felt-like fabric. or cadmium-oxide applied in a non-sintered coating process (PBE). It is here that the electrochemical reaction takes place converting chemical energy into electricity.. In Saft aviation batteries. it will never leak. Cells The cell is the active component of the battery. a solution of potassium hydroxide and water. This ensures that if the battery is maintained and used under normal circumstances. VXP & Delta Plus (VHP) Series) or one group of positive sintered nickel plates and one group of negative Plastic Bonded Electrode (PBE) plates [ULM® Series (CVH. An O-ring seals the terminals. These are thermally welded together to form a single. Many cells have a raised edge surrounding the vent-valve to contain any minor release of electrolyte that may occur during overcharge. This valve also serves as a pressure-checking device. the positive plates are sintered nickel. 2-3. Connectors Figure 3 2. all vent-valves (160). Temperature Although Saft nickel-cadmium batteries are capable of operating in a wide temperature range [-40°C (-40°F) to +71°C (+160°F)]. such as an MS3509 type. should be done specifically in accordance with the instructions contained in this manual or a corresponding Component Maintenance Manual (CMM). but do not remove. including charging. Connectors Each Saft battery is connected to the aircraft by either a standard main power connector. . Charge 3-1. Page 3 Aug 29/2008 . Operation 2-1. 3. optimum performance is obtained between +5°C (+41°F) and +45°C(+113°F). In others. that information will supersede the contents of this manual and this OMM will become supplemental. or a special connector as specified by the aircraft manufacturer. Most Saft batteries are equipped with tubes designed for the connection of a battery venting system. Constant Current Charge Starting with a discharged battery. Maintenance All maintenance.Loosen. Charging is inefficent at temperatures below -30°C (–22°F) and is not recommended above 57°C (135°F). holes in the battery box allow for heat dissipation and ventilation of any hydrogen produced. . Ventilation Battery ventilation and cooling is accomplished through two methods. Refer to "FITS AND CLEARANCES" to determine the connector used on the batteries covered by this manual. Charging must be stopped at temperatures above +71°C (+160°F). If a CMM exists for a battery. discharging. 2-2.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION 1-4.Remove the cover asembly (010). 1 C1A time mini 10 h maxi 12 h 1.5 V/cell for VO/VP/VHP/VXP 1.57 V/cell.55 V/cell for CVH/CVD/CVK Charge Rates Figure 4 3-2.55 V/cell.During the last 15-30 minutes of the overcharge cycle.5 V. Final charge (overcharge) Main charge Current and duration Minimum voltage Current and duration Minimum voltage 0. Adjust electrolyte level.5 C1A time mini 2 h maxi 2 h 30 min.5 V/cell for VO/VP/VHP/VXP 1. Do not use these procedures for charging the battery during normal maintenance. 15 minutes.57 V/cell 0.1 C1A for 4 h 1.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION .1 C1A for 4 h 1.1 C1A for 4 h 1. 1. . but for no longer than 1 hour. add 10 cm3 of distilled or deionized water to that cell.5 V/cell 0.55 V/cell for CVH/CVD/CVK 1 C1A time mini 1 h maxi 1 h 15 min. 1.Charge the battery at 0.5 V/cell for VO/VP/VHP/VXP 1. but for no longer than 2 hours 30 minutes. . If any cell indicates an immediate voltage rise above 1.Charge using one of the methods shown in the table below. Page 4 Aug 29/2008 .5C1A until the battery reaches an average of 1. NOTE: Check cell voltage at the beginning of the charge. .55 V/cell for CVH/CVD/CVK 0. Rapid Partial Charge One of the following two procedures can be used in an emergency situation to charge the battery to approximately 80% of its capacity.55 V/cell 0.Charge the battery at 1C1A until the battery reaches an average voltage of 1. Constant Potential Charge CAUTION: Constant potential charging should not be attempted if the open circuit battery voltage is below 1. Charge for a minimum of 1 hour at 1.6 1. Do not use this procedure for charging the battery during normal maintenance: With the use of a constant potential system. Typical constant potential charge of Ni-Cd cell 80 140 100 60 20 Charging current (A) Charged capacity (%C1Ah) at normal temperature . it is imperative that the charge rate be checked periodically for accuracy. In an emergency.charging voltage. and that the charger be set according to the average ambient operating temperature. a partially discharged battery may be recharged using a constant potential charging system such as exists on the aircraft. 1.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION 3-3. Connect the battery to the constant potential power source.425 V/cell to obtain approximately 90% of the rated capacity of the battery.5 volts for a 20 cells battery to obtain approximately 90% of the rated capacity of the battery. NOTE: A maintenance check of the battery should be done at the earliest opportunity to verify battery performance. Recommanded constant potential cell charge voltage at various temperatures Charge voltage (V) 1..5 1. Charge for a minimum of 1 hour at 28.0 V per cell. Connect the battery to the constant potential power source.425 V Charged capacity (Ah) 60 40 20 0 Charging curent 0 1 2 3 4 5 Charging time (h) Typical Constant Potential Charge Curve Figure 6 NOTE:A maintenance check of the battery should be done at the earliest opportunity to verify battery performance. a partially discharged battery may be recharged using a constant potential charging system such as exists on the aircraft. In an emergency.4 Cell temperature °F -22 °C -30 -10 -20 14 -10 32 0 50 10 68 20 86 30 104 40 122 50 140 60 Recommended Constant Potential Cell Charge Voltage Figure 5 This figure shows the typical charge curves for Saft nickel-cadmium aviation batteries. Page 5 Aug 29/2008 . The figures can be used as a guide to ensure the correct charge rate used for a given ambient temperature. VP. Other method of charging In addition to the constant current method of charging.OPERATING AND MAINTENANCE MANUAL DESCRIPTION AND OPERATION 3-4. Page 6 Aug 29/2008 . in every case.50 V for VO. VXP and U>1. If specific instructions are not given in the charger operating manual.55 V for CVH)) and electrolyte adjustments must be carried out using a final charge sequence at constant current 0.1 C1A. you must first contact Saft. VHP. However. cell voltage checks (U > 1. other methods that fully charge the battery can be used. (b) Link broken .OPERATING AND MAINTENANCE MANUAL TESTING AND FAULT ISOLATION TESTING AND FAULT ISOLATION 1. Page 1001 Aug 29/2008 . The test procedure is given in the tables below. 1-1. Introduction This chapter gives the tests and inspections required to find the cause of a fault condition of the unit either removed for unscheduled maintenance or during scheduled maintenance. Do an electrolyte level check (refer to INSPECTION/CHECK). links and tightness of nuts (refer to INSPECTION/ CHECK). (c) Cell completely dry Refer to related subsequent steps. (a) Leakage of electrolyte Disassemble and clean the battery (refer to DISASSEMBLY and CLEANING). (a) Battery fully discharged Charge the battery. which for each test refer to a specific procedure specifying all relevant parameters. 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). Battery electrical faults Problem (1) Zero battery open-circuit voltage (2) Zero volt with the battery set to "discharge" (3) Low insulation Probable cause Correction (a) Defective electrical connector (no contact made) Check electrical contacts. (a) Short-circuited cell. this can cause temperature to increase very much. (c) Previous maintenance has not been done. ASSEMBLY AND Storage (including transportation). Do a leak check of the cells (refer to INSPECTION/CHECK). (3) A cell has higher voltage at the start of charge than is defined in para. and the separator is damaged. (b) Usual wear after long operation Replace the cell (refer to DISASSEMBLY. Replace the cell (refer to DISASSEMBLY). (b) 30% (or less) of the average: cell(s) with damaged separator(s). discharge at 1 C1AH and Cell shorting up to three times (b) Usual wear after long operation. (5) Low capacity cell (a) insufficient balancing repeat Charge. If necessary. (a) Charge much more than the limit or too much charge at high temperature. ASSEMBLY AND Storage (including transportation). Do not adjust more accurately until the end of the charge. Do the applicable procedure (refer to INSPECTION/CHECK). (4) A cell has lower voltage at the end of charge than is defined in para. Examine the cause of excessive charge. (a) Cell operated with low electrolyte level . (c) Unusual operation. Cell faults Problem Probable cause Correction (1) Too much water decrease for all battery cells. If necessary. (a) Dry cell. add 5 cm3 (5 ml) of distilled water to the cell. Note the cell location and check the level of water comsumption versus other cells at the next maintenance. Charge chapter DESCRIPTION AND OPERATION. Replace the cell (refer to DISASSEMBLY. When the defect occurs. (a) The cell was operated at temperatures and charge rates outside the limits. Charge chapter DESCRIPTION AND OPERATION. Page 1002 Aug 29/2008 .OPERATING AND MAINTENANCE MANUAL TESTING AND FAULT ISOLATION 1-2. Do the Supplementary test (refer to INSPECTION/CHECK). adjust to normal operating temperature (refer to DESCRIPTION AND OPERATION). NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient. (a) More than 30% or more than the average : leaks from the cell(s). (6) Cell with a swollen case. Replace the cell (refer to DISASSEMBLY). (2) Water decrease in cell(s) is very different from the other cells in the battery. (7) Cell with zero voltage when the battery circuit is open. deterioration of separators and damaged plates. operation at high temperature or operation with low electrolyte. replace the cell(s). Do an electrolyte level check (refer to INSPECTION/CHECK).OPERATING AND MAINTENANCE MANUAL TESTING AND FAULT ISOLATION 1-3. Disassemble and clean the battery (refer to INSPECTION/CHECK and CLEANING). Do an electrolyte level check (refer to INSPECTION/CHECK). If necessary. Disassemble and clean the battery (refer to DISASSEMBLY and CLEANING chapters). (a) Operation in acid air (b) Mechanical damage to nickel plating (4) The links are too hot. Do an electrolyte level check (refer to INSPECTION/CHECK). Disassemble and clean the battery (refer to DISASSEMBLY and CLEANING). Disassemble and clean the battery (refer to DISASSEMBLY and CLEANING). Do an electrolyte level check (refer to INSPECTION/CHECK). Investigate the cause of excessive charge. Investigate the cause of excessive charge. ASSEMBLY AND Storage (including transportation)). (c) Too much charge at high temperature or too much current. Correction (a) Loose terminals nuts Do a leak test of the cells (refer to INSPECTION/CHECK). during the engine start). Replace the cell if necessary and refer to related subsequent steps. (a) Damaged cell case (b) Leakage of electrolyte (3) Corrosion on the links. Physical faults Problem (1) Leakage of electrolyte Probable cause (a) Incorrect adjustement of level. Make sure the battery test bench and the storage areas have no materials which can give off acid fumes. Make sure the nuts are torqued (refer to INSPECTION/CHECK). adjust to normal operating temperature (refer to DESCRIPTION AND OPERATION). Page 1003 Aug 29/2008 . Replace the damaged links (refer to DISASSEMBLY. (b) Cell polarity incorrect during highrate discharge (for example. Torque the lower nut (refer to ASSEMBLY chapter) (d) The lower nut is not correctly tightened (2) Electrolyte found in the battery box. OPERATING AND MAINTENANCE MANUAL TESTING AND FAULT ISOLATION PAGE INTENTIONALLY LEFT BLANK Page 1004 Aug 29/2008 . undo the retaining latches or the retaining screws. To facilitate ease of removal. Disassemble only to the extent necessary to effect appropriate repair or replacement. 4-6.OPERATING AND MAINTENANCE MANUAL DISASSEMBLY DISASSEMBLY 1. EQUIPMENT AND CONSUMABLES. The instructions found in this section are designed to allow the maintenance person to completely disassemble the battery for the purpose of General Overhaul. Special tools When special tools are used in this chapter. Remove the vent valve (160) with its O-ring. Remove the cover taking care to avoid contact between the cover and the cell terminals or links. Removing the cells (100) NOTE: Make note of the proper placement of the links (030 to 090) prior to removal. 4-5. Depending on the type of sensor. FIXTURES. Cut cable grip if applicable. Page 3001 Aug 29/2008 . Remove the connector (230). Removing the sensor (if applicable) Unscrew sensors from the links (030 to 090). Removing the cover (010) Depending on the type of cover. 4-1. Removing the connector Remove the screws (210) and the washers (220). Remove the cells (100). 4-2. 3. Push the connector through the hole in the battery box (020). EQUIPMENT AND CONSUMABLES chapter. Safety Refer to Safety paragraph in the INTRODUCTION chapter. Removing the vent valves (160) Unscrew the vent valve with the special tool. 4. remove the center cell in each row first. Remove all links (030 to 090). Equipment 3-1. 3-2. 4-4. 1 item numbers and are using hypertext facility. Introduction NOTE:Refer to TESTING AND FAULT ISOLATION chapter to find the condition of the component or the possible cause of its malfunction. Dissassembly procedures NOTE: All ( ) part identification numbers herein are IPL Fig. FIXTURES. This will give the necessary level of disassembly. However. 4-3. Disassembly of the battery Remove the cover (010). Fully screw the extractor tool onto a cell terminal then pull up to remove the cell (100). Remove the connector and the sensor harness taking care to avoid damaging the cabling. 2. Standard tools Refer to chapter Standard tools in SPECIAL TOOLS. they are identified by a code number listed in SPECIAL TOOLS. undo the retaining nut or the retaining screws. Remove the nuts (110) and the spring (120) washers that attaches links on the cells. some maintenance operations do not require complete disassembly. Remove the connector (230). Page 3002 Aug 29/2008 . Remove the sensor (if applicable).OPERATING AND MAINTENANCE MANUAL DISASSEMBLY Remove the liner spacer kit (200). Note placement prior to removal to ensure proper placement during reassembly. Cells (100) Make sure that the vent valve (160) is tight. . they are identified by a code number listed in SPECIAL TOOLS. 2.OPERATING AND MAINTENANCE MANUAL CLEANING CLEANING 1.Check the battery vent tubes to ensure that they are clean and clear. 5-1-1. Nuts. 1 item numbers. EQUIPMENT AND CONSUMABLES chapter. FIXTURES. 3-2. Consumables When consumables are used in this chapter.Remove potassium carbonates (white deposits) from the top of all cells (100) using a stiff bristle. . Thorough Cleaning On a dissassembled battery. Special tools When special tools are used in this chapter. EQUIPMENT AND CONSUMABLES chapter. Procedure Fully disassemble the battery (refer to DISASSEMBLY chapter). CAUTION: Do not use solvent. 5. Standard tools Refer to chapter Standard tools in SPECIAL TOOLS. . . they are identified by a code number listed in SPECIAL TOOLS.Tighten the vent valves (160) with the Universal vent wrench (T01) . Light Cleaning On an assembled battery. 3. NOTE: All ( ) part identification numbers herein are IPL Fig.Coat all upper nuts (or screws) (110) and links (030 to 090) with M02. CAUTION: Do not soak the cells in water. . dry compressed air. non-metallic brush. The section “Thorough Cleaning” includes the instructions for the cleaning of a disassembled battery for the purpose of General Overhaul. 4-1. rub with a cloth and let dry.Remove the battery cover assembly (010). Safety Refer to Safety paragraph in the INTRODUCTION chapter. 5-1-3. FIXTURES. petroleum spirits. Rub the cell with a cloth and let dry. Procedure WARNING: To prevent injury when using compressed air. Box (010) and handle (if applicable) Clean with lightly soapy water. the cover and the sides of the cell cases: clean in warm water with a soft brush. Introduction The instructions in this chapter are for the general cleaning of your Saft aircraft battery. FIXTURES.Disperse residual salts and dust particles from the battery using blasts of clean. EQUIPMENT AND CONSUMABLES. The use of solvents may degrade the integrity of metal and plastic parts. 5-1-2. and can be accomplished with no disassembly of the battery. Use safety goggles to prevent eye injury from airborne particles. 4. direct air stream away from the body. 3-3. trichlorethylene or other products containing chloride for cleaning the battery. spring washers and links Page 4001 Aug 29/2008 . To easily remove all the electrolyte and mineral salts from the terminals. 5-1. Equipment and consumables 3-1. The instructions under “Light Cleaning” are to be done each time the battery is removed from the aircraft. 5-1-4. rinse well with clean water and let dry. 5-1-5. Liner spacer kit (200) and sensor (if applicable) Clean in warm water and let dry. Remove the vent valve (160) (Refer to DISASSEMBLY chapter). Soak the vent valve for some time (during the night. Do that to remove all salts from the vent hole.OPERATING AND MAINTENANCE MANUAL CLEANING Clean in lightly soapy water with a brush. 6. Lubrication When the battery is clean (and after installation of the vent valve). Cover the cell holes to keep out unwanted material. Coat all upper nuts (or screws) (100) and links (030 to 090) with M02. for example) in a container of distilled water. Vent valve (160) WARNING: The cleaning of the vent valve (160) must be done when the cells are assembled in the box. Page 4002 Aug 29/2008 . they are identified by a code number listed in SPECIAL TOOLS. FIXTURES. Equipment 3-1. Introduction 1-1.Regular check: capacity test and periodical check . These maintenance steps must be done in a battery shop: . 3-2.General overhaul: disassembly. EQUIPMENT AND CONSUMABLES. assembly and regular check. 2. Page 5001 Aug 29/2008 . 3. the maintenance procedures and the functional tests that must be done to use Saft batteries in flight and on the ground. . Safety Refer to Safety paragraph in the INTRODUCTION chapter. full cleaning.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK INSPECTION/CHECK 1. Standard tools Refer to chapter Standard tools in SPECIAL TOOLS. EQUIPMENT AND CONSUMABLES chapter. NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers. General This chapter includes the checks. Special tools When special tools are used in this chapter.Periodical check: adjustment of electrolyte levels. FIXTURES. Visual Inspection Visual inspection should be done each time the battery is removed for maintenance.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK 4.05 V/cell no cell with reversed polarity no no Polarization test OK yes yes Residual discharge Vent valve cleaning (refer to CLEANING) Charge and Adjust electrolyte level no TESTING AND FAULT ISOLATION no Supplementary test OK? Charge OK yes yes no General overhaul with Replacement of faulty components. Periodic and Regular maintenance checks may be combined if operating hours permit. or every 3 months. Periodical check PERIODICAL CHECK Visual Inspection OK? Light Cleaning yes no Insulation check yes no General overhaul Nut tightness U > 1. 4-1. Battery accepted after Periodical check Periodical check Figure 1 At specific intervals according to aircraft use. NOTE: Time periods are given as a guideline. Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Modify in accordance with operational experience. test the battery according to the above figure. Page 5002 Aug 29/2008 . . corrosion. cracks. The hardware should be free of bends. Ensure the cover gasket (011). corrosion. Because leakage current can affect battery performance. the temperature sensor and/or heater blanket harness assembly should be inspected for obvious damage. 4-2. it is necessary that it be kept to a minimum. On a completely assembled battery. Defective hardware should be replaced. or cross-threaded terminals. Insulation check A breakdown in electrical insulation between the cells (100) and the battery box (020) will result in a “leakage” current. and/or thermocouple assemblies (as applicable) for any damaged or loose wire connections.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK . thermostat.Inspect the thermistor. to measure the insulation resistance between the positive terminal of each cell (100) and the battery box (020). Any evidence of damage to the temperature sensor and/or heater blanket harness assembly indicates a need for Saft factory new replacement of the device. cracks. which over time will discharge the battery. cracks.Visually check each cell (100) for any evidence of electrolyte leakage. Replace any defective connectors. or any loss of nickel plating.Inspect the links (030 to 090) and all upper nuts or screws (110). Minor tarnish can be polished off with a fine wire brush. . Page 5003 Aug 29/2008 . if applicable. . set to for 250 V DC.Check the main power connector (230) for evidence of arcing. . A defective main power connector (230) can cause battery self-discharge as well as low voltage in service.Inspect the battery box (020) and cover (010) for any damage. Minor dents may be repaired with a small rubber mallet. burns. If there is salt or electrolyte traces do a General overhaul Excessive salts around a terminal post indicates possible leakage from the terminal O-ring. faulty wire connections.Visually check all wiring insulation to ensure there is no evidence of cracks. use a megohmeter. . and washers (120 and 150). tarnish.If applicable.Inspect the electrical connector for bent or loose pins. Verify the torque of the lower nut (refer to chapter ASSEMBLY). . dents. or bubbling. or other physical damage. The most common cause for the loss of insulation is the leakage of electrolyte from the cells (100) that acts as a conductor between the cells and the battery box (020). CAUTION: Worn aircraft connectors and/or loose connections can greatly affect the performance of the battery.Remove the cover assembly (010). is undamaged and fully secured to the metal cover (010). . corrosion. cuts. . or cracked or loose potting material. This in no way replaces the full testing procedures found hereafter that ensure full operation of the sensor assembly. evidence of arcing. Battery accepted after general overhaul General overhaul Figure 4 At specific intervals according to aircraft use. test the battery according to the above figure. Page 5008 Aug 29/2008 .OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK 6.05 V/cell no cell with reversed polarity On fault GENERAL OVERHAUL no Polarization test Polarization test Nut tightness Residual discharge Charge and Adjust electrolyte level Cell shorting no yes Charge OK DISASSEMBLY TESTING AND FAULT ISOLATION Thorough Cleaning no Component inspection Supplementary test OK? yes no TESTING AND FAULT ISOLATION Capacity check OK yes Sensor check Replacement of faulty components no Supplementary test OK? ASSEMBLY no yes yes Vent valve cleaning (refer to CLEANING) Vent valve test Insulation check Charge and Adjust electrolyte level General overhaul with Replacement of faulty components. or AFTER A MAXIMUM OF ONE YEAR. General overhaul Scheduled yes U > 1. Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. must be .4.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK .55 V for CVH/CVD/CVK . Any excess liquid in the cell will be drawn into the syringe until the electrolyte is level with the end of the nozzle. Insert the syringe (T02) into the cell opening until the shoulder of the nozzle rests on the ventvalve seat . Refer to FITS AND CLEARANCES for proper distance between electrolyte and vent-valve seat. At the point in step 6 when some excess liquid is drawn into the syringe. Draw 5 cm3 of the distilled water (M01) into the syringe and inject it into the cell. In this case. . Record the amount of water added to each cell on the maintenance record. . Check with local authorities for proper disposal of hazardous waste. Withdraw the plunger and check for any liquid in the syringe.8. the syringe will remain empty. Page 5005 Aug 29/2008 .must not decrease by 0. Measure the voltage of the individual cell voltages every 30 min. slowly withdraw the plunger in the syringe.1 C1A. counting the number of 5 cm3 injections required to achieve the correct level. If the liquid level is too low.6.U > 1. Position of Syringe in Cell Vent Seat Figure 2 . Supplementary test At the end of complete charge. repeat steps 5 and 6.7.5 V for VO/VP/VHP/VXP .U > 1. Expel the excess liquid into a separate container for disposal. This is the correct level for the electrolyte. If the syringe remains empty. . continue to charge for 5 h at 0. . The individual cell voltages: .Adjust the electrolyte level (refer to Adjust electrolyte level). Do not reuse the liquid removed from cells.5.03 V during the test . replenish low electrolyte:. indicating that the end of the syringe nozzle did not reach the liquid in the cell. 4-7.3. With the syringe nozzle remaining on the vent-valve (100) seat. the correct level for that cell has been reached. Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed.05 V/cell no cell with reversed polarity yes yes Polarization test OK Residual discharge Charge and Adjust electrolyte level no Charge OK yes Cell shorting yes TESTING AND FAULT ISOLATION no Supplementary test OK? Capacity check OK yes yes no Vent valve cleaning (refer to CLEANING) Charge and Adjust electrolyte level General overhaul with Replacement of faulty components. Page 5006 Aug 29/2008 .OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK 5. test the battery according to the above figure. or AFTER A MAXIMUM OF ONE YEAR. Regular check Light Cleaning REGULAR CHECK Visual Inspection OK? yes no yes Insulation check no General overhaul Nut tightness no no U > 1. Battery accepted after Regular check Regular check Figure 3 At specific intervals according to aircraft use. 5-2. Leave the resistors in place for 12 to 16 hours to allow each cell to completely discharge and the battery to cool. Capacity check Discharge the battery at 1C1A. Page 5007 Aug 29/2008 . CVD and CVK cells. Periodic and Regular maintenance checks may be combined if operating hours permits.0 volt. VXP.0 V. Record the time that the first cell reaches 1. NOTE: As an alternative to the resistor a shorting clip can be applied when the voltage has dropped to 0. 5-1. Modify in accordance with operational experience.5 V/cell. This time must be equal or greater to 51 min for VO and VP and 1 h for VHP. Cell shorting As each cell’s voltage drops below 1. CVH.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK NOTE:Time periods are given as a guideline. connect an equalizing resistor (T03) across each cell’s terminals. test the battery according to the above figure.05 V/cell no cell with reversed polarity On fault GENERAL OVERHAUL no Polarization test Polarization test Nut tightness Residual discharge Charge and Adjust electrolyte level Cell shorting no yes Charge OK DISASSEMBLY TESTING AND FAULT ISOLATION Thorough Cleaning no Component inspection Supplementary test OK? yes no TESTING AND FAULT ISOLATION Capacity check OK yes Sensor check Replacement of faulty components no Supplementary test OK? ASSEMBLY no yes yes Vent valve cleaning (refer to CLEANING) Vent valve test Insulation check Charge and Adjust electrolyte level General overhaul with Replacement of faulty components. General overhaul Scheduled yes U > 1. Battery accepted after general overhaul General overhaul Figure 4 At specific intervals according to aircraft use. Page 5008 Aug 29/2008 . Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK 6. or AFTER A MAXIMUM OF ONE YEAR. Component inspection 6-1-1. Cells Make sure that the lower terminal nuts are tight (refer to FITS AND CLEARANCES chapter). corrosion. cracks.99 KΩ 1% resistor D-E: close on rise @ 71°C (160°F) A-B: open on rise @ 71°C (160°F) C-D: close after open 60°C (145°F) C-D: close on rise @ 71°C (160°F) 407CH13 413861 019504-000 442CH2 114722 017125-000 4-6: short circuit 8-9: open on rise @ 67°C (154°F) 11-12: 2. Any cells that are to be changed must be replaced by a new Saft original cell.9°C (75°F) A-B: 200 Ω @ 60°C (140°F) C-D: 174 Ω @ 23. then change all cells. 6-2-2.46 KΩ ± 25 Ω @ 23°C (73°F) A-B: 174 Ω @ 23. Connector Check the main power connector (230) for evidence of arcing. 6-2. 6-1-4. Packing parts Discard all defective components 6-1-5. Verify that cell boxes show no leakage. Replacement of faulty components 6-2-1. Nuts. Box Make the sides of the box straight and remove dents. according to the table below Battery description 276CH7 F6177 P/N Sensor 413032 277CH1 161297 310VX-2 411980 407CH-2 407CH5 V09052 P/N Sensor 023697-000 114722 407CH-11 017125-000 019422-000 Check A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21-27°C (70-80°F) B-E: close on rise @ 57°C (135°F) D-L1: short circuit A-B: 3 KΩ @ 25°C (73°F) C: middle point with 4. 6-1-2. Sensor check Check the sensor. if applicable. 6-1-3.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK 6-1. links and spring washers Discard the components that show signs of corrosion or damage.9°C (75°F) C-D: 200 Ω @ 60°C (140°F) C-D: close on rise @ 71°C (160°F) 447CH1 414976 616 411157 1277-1 114722 017125-000 A-B: close on rise @ 71°C (160°F) A-C: close on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) B-C: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) 1277-2 1277-3 019656-000 414139 A-B: 30 KΩ @ 25°C (77°F) C-D: close on rise @ 71°C (160°F) Page 5009 Aug 29/2008 . 6-3. Other components Any other components that are to be changed must be replaced by a new Saft original component. Cells NOTE: If more than 5 original cells have been changed or more than 3 cells are faulty in the same maintenance. Replace any defective connectors. or cross-threaded terminals. OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description 1608-1 F6177 P/N Sensor 412757 V09052 P/N Sensor 023258-000 1656-1 114722 017125-000 1656-2 162901 1656-5 117497 1658-2 162901 1666-1 116051 019220-000 A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 57°C (135°F) 018652-000 A-B: close on rise @ 71°C (160°F) B-C: short circuit A-B: close on rise @ 63°C (146°F) C-D: close on rise @ 63°C (146°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) 019230-000 1756-2 023808-500 114722 017125-000 2371-1 114722 017125-000 2371-2 162901 2371-4 166900 018802-000 2371-5 162366 019437-000 2371-6 410156 2371-7 411345 2376-2 117497 2376-3 413032 2376-8 413469 019220-000 2376-9 018932-000 2376-10 019498-000 2386-1 117497 019220-000 2506-1 116051 018652-000 2506-2 116051 018652-000 2708-1 411758 2778-5 166578 2778-10 413032 Page 5010 Aug 29/2008 C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 57°C (135°F) 018484-000 2376-7 1-2: close on rise @ 71°C (160°F) 1-3: close on rise @ 71°C (160°F) 2-3: short circuit C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 57°C (135°F) 1756 2353-1 Check A-B: 49.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) AF-BC: close on rise @ 71°C (160°F) AF-DE: close on rise @ 57°C (135°F) A-B: close on rise @ 57°C (135°F) B-E: close on rise @ 57°C (135°F) C-D: close on rise @ 65°C (145°F) C-E: close on rise @ 65°C (145°F) A-C: 100 Ω @ 23°C (73°F) B-C: 30 KΩ @ 23°C (73°F) D-E: 100 Ω @ 23°C (73°F) E-F: 30 KΩ @ 23°C (73°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) 1-2: close on rise @ 57°C (135°F) 3-4: close on rise @ 57°C (135°F) A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21-27°C (70-80°F) AB: close on rise 71°C (160°F) A-B:174 Ω @ 24°C (75°F) A-B: 200 Ω @ 60°C (140°F) C-D: 174 Ω @ 24°C (75°F) C-D: 200 Ω @ 60°C (140°F) A-B: close on rise @ 63°C (146°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-B: close on rise @ 71°C (160°F) B-C: short circuit A-B: close on rise @ 71°C (160°F) B-C: short circuit C-D: close on rise @ 71°C (160°F) A-B: 40 KΩ @ 23°C (73°F) E-F: 40 KΩ @ 23°C (73°F) D-G: short circuit A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21-27°C (70-80°F) . OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description 2778-15 F6177 P/N Sensor 413330 V09052 P/N Sensor 2778-18 413032 4000A1-1 116051 018652-000 4006A-1 116051 018652-000 4008-1 116051 018652-000 Check 4017CH-1 116109 016420-000 4017CH-3 116109 016420-000 4050A1-1 114722 017125-000 A-B: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) E-F: open on rise @ 71°C (160°F) A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21-27°C (70-80°F) A-B: close on rise @ 71°C (160°F) B-C: short circuit A-B: close on rise @ 71°C (160°F) B-C: short circuit A-B: close on rise @ 71°C (160°F) B-C: short circuit 4-6: short circuit 8-9: open on rise @ 67°C (154°F) 11-12: 2.46 KΩ ± 25 Ω @ 23°C (73°F) 1-2: close on rise @ 57°C (135°F) 3-4: close on fall @ 8°C (46°F) 1-2: close on rise @ 57°C (135°F) 3-4: close on fall @ 8°C (46°F) C-D: close on rise @ 71°C (160°F) 4071-1 114722 017125-000 C-D: close on rise @ 71°C (160°F) 4071-2 117497 019220-000 A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-B: close on rise @ 63°C (146°F) C-D: close on rise @ 63°C (146°F) A-B: 49.9 KΩ @ 25°C (77°F) B-C: 300 KΩ @ 25°C (77°F) C-D: close on rise @ 57°C (135°F) 4015CH11 019422-000 4071-3 023046-000 4071-10 166900 4076-2 161057 018802-000 4076-8 019757-000 4076-11 019422-000 4076-12 019498-000 4076-13 413861 4076-15 412812 4076-16 412160 4076-17 413033 4076-19 019504-000 023627-000 4076-21 412299 4078-1 114722 017125-000 4078-5 117497 019220-000 4078-6 4078-9 019422-000 410669 021564-000 A-L1: short circuit B-C: 3 KΩ @ 25°C (77°F 4-6: short circuit 8-9: open on rise @ 67°C (154°F) 11-12: 2.46 KΩ ± 25 Ω @ 23°C (73°F) A-B: close on rise @ 63°C (146°F) A-B: 174 Ω @ 23.9°C (75°F) A-B: 200 Ω @ 60°C (140°F) C-D: 174 Ω @ 23.9°C (75°F) C-D: 200 Ω @ 60°C (140°F) B-C: close on rise @ 57°C (135°F) E-F: close on rise @ 57°C (135°F) A-B: close on rise @ 71°C (160°F) A-C: 200 Ω @ 60°C (140°F) A-C: 174 Ω @ 21/27°C (70/80°F) A-L1: short circuit B-C: 3 KΩ @ 25°C (77°F) A-B: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) D-E: short circuit C-D: close on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) 4-6: 0 Ω @ 23°C (73°F) 8-9: open on rise @ 67°C (154°F) 11-12: 2.46 KΩ ± 25 Ω @ 23°C (73°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) E-F: 98 Ω @ 20°C (68°F) Page 5011 Aug 29/2008 OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description 4078-10 F6177 P/N Sensor 410929 V09052 P/N Sensor 019756-000 4078-13 166900 018802-000 4078-14 413861 019504-000 4078-15 413011 4078-16 413339 4078-18 412812 4078-19 024849-000 4078-21 413033 4078-25 415137 4079-1 161057 4079-2 117497 4079-4 019757-000 4079-6 114722 4079-9 413084 4079-10 4410CH1 017753-000 017125-000 024976-500 415378 12277-1 018910-000 12277-2 019787-000 16106-1 412759 16108-1 412759 16156-1 411103 16256-3 16258 Page 5012 Aug 29/2008 023510-000 410922 Check A-C/D-F: 100 Ω @ 25°C (77°F) B-C/E-F: 30 KΩ @ 25°C (77°F) A-B: 49.9 KΩ @ 25°C (77°F) B-C: 300 KΩ @ 25°C (77°F) A-B: 174 Ω @ 23.9°C (75°F) A-B: 200 Ω @ 60°C (140°F) C-D: 174 Ω @ 23.9°C (75°F) C-D: 200 Ω @ 60°C (140°F) A-B: open on rise @ -12°C (-10.4°F) B-C: R=13 Ω open on rise @ -12°C (-10.4°F) D-E: close on rise @ 71°C (160°F) A-B: close on rise @ 65°C (150°F) C-D: close on rise @ 65°C (150°F) B-C: close on rise @ 57°C (135°F) E-F: close on rise @ 57°C (135°F) A-B: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) E-F: open on rise @ 71°C (160°F) A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21/27°C (70/80°F) A: middle point C-D: open on rise @ 71°C (160°F) E-F: 2.25 KΩ @ 25°C (73°F) C-D: close on rise @ 57°C (135°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-L1: short circuit B-C: 3 KΩ @ 25°C (77°F C-D: close on rise @ 71°C (160°F) A: + B: C-D: 15 kΩ @ 25°C (77°F) E-F: 15 kΩ @ 25°C (77°F) G-H: 15 kΩ @ 25°C (77°F) A-B: 300 KΩ ± 2.9 KΩ @ 25°C (73°F) C-E: close on rise @ 60°C (140°F) D-F: close on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) A-B: 30.1 KΩ @ 25°C (77°F) A-C: 100 Ω @ 25°C (77°F) B-C: 30 KΩ @ 25°C (77°F) D-E: 30.1 KΩ @ 25°C (77°F) D-F: 100 Ω @ 25°C (77°F) E-F: 30 KΩ @ 25°C (77°F) A-B: close on rise @ 71°C (160°F) B-C: 0 Ω @ 23°C (73°F) A-B: close on rise @ 71°C (160°F) B-C: 0 Ω @ 23°C (73°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) B-C: close on rise @ 71°C (160°F) C-D: close on rise @ 60°C (140°F) A: middle point B-C: 3 KΩ ± 1% @ 25°C (77°F) E-F: close on rise @ 71°C (160°F) OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description 20126-2 F6177 P/N Sensor V09052 P/N Sensor 018582-000 Check 23171-4 166900 23376 161297 23476 161057 A-B:174 Ω @ 24°C (75°F) A-B: 200 Ω @ 60°C (140°F) A-B:174 Ω @ 24°C (75°F) A-B: 200 Ω @ 60°C (140°F) C-D: 174 Ω @ 24°C (75°F) C-D: 200 Ω @ 60°C (140°F) A-B: 49.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) B-E: close on rise @ 57°C (135°F) D-L1: short circuit C-D: close on rise @ 57°C (135°F) 23478 161057 C-D: close on rise @ 57°C (135°F) 23491-4 414890 A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) E-F: 143 Ω @ 25°C (73°F) G-H: opens on rise @ 8°C (46°F) 20126-3 018581-000 018802-000 23576-2 019493-000 23576-1 019747-000 L1: open on rise @ 65°C (150°F) 018802-000 A-B: 49.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) L1: open on rise @ 65°C (150°F) 23676-1 166900 23676-2 019747-000 23678-1 162901 C-D: close on rise @ 57°C (135°F) 23678-2 411345 23678-3 413031 25106-2 165226 26108-3 414093 A-C: 100 Ω @ 23°C (73°F) B-C: 30 KΩ @ 23°C (73°F) D-E: 100 Ω @ 23°C (73°F) E-F: 30 KΩ @ 23°C (73°F) A-B: close on rise @ 57°C (135°F) C-D: open on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) F: box A-B: close on rise @ 71°C (160°F) 26108-4 414137 26108-5 414182 26108-7 415280 26308-1 114722 017125-000 26308-5 166900 018802-000 26408-1 114722 017125-000 26508-1 116051 27168-1 411345 27278-2 117497 27578-2 A-B: close on rise @ 71°C (160°F) C-D: close on rise @ 57°C (135°F) A-B: close on rise @ 71°C (160°F) 017753-000 024470-000 40100-1 114722 017125-000 40108-2 166900 018802-000 A-B: close on rise @ 71°C (160°F) C-D: 300 KΩ @ 25°C (77°F) C-D: close on rise @ 71°C (160°F) A-B: 49.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) C-D: close on rise @ 71°C (160°F) A-B: close on rise @ 71°C (160°F) C-D: short circuit A-C: 100 Ω @ 25°C (77°F) B-C: 30 KΩ @ 25°C (77°F) D-F: 100 Ω @ 25°C (77°F) E-F: 30 KΩ @ 25°C (77°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) A-B: 49.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) Page 5013 Aug 29/2008 46 kΩ ± 0.75 KΩ @ 25°C (73°F) B-C: 300 KΩ @ 25°C (73°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-B: open on rise @ 60°C (140°F) D-G: open on rise @ 65°C (150°F) E-F: 2.75 KΩ @ 25°C (77°F) B-C: 300 KΩ @ 25°C (77°F) A-CONN: close on rise @ 60°C (140°F) C-CONN: close on rise @ 71°C (160°F) E-F: 1 KΩ ± 70 Ω @ 25°C (77°F) A-B: close on rise 57°C (135°F) C-D: close on rise 71°C (160°F) E-F: 140 Ω @ 25°C (77°F) A-B: 49.25 Ω @ 25°C (77°F) A-C/D-F: 100 Ω @ 25°C (77°F) B-C/E-F: 30 KΩ @ 25°C (77°F) BC: 3 KΩ @ 25°C (77°F) A-B: 49.3 Ω A-B: 33 kΩ 1% @ 25°C (77°F) C: middle point E-F: close on rise @ 71°C (160°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) A-B: 49.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description 40176-10 F6177 P/N Sensor V09052 P/N Sensor 023172-000 40178-7 410669 40178-21 413033 40179-7 116109 40200-1 413455 40206-2 115807 40208-1 166854 40208-2 114722 40208-4 410718 40208-5 411124 40208-6 411980 40208-7 413455 40209-2 166900 018802-000 40278-2 117497 019220-000 40478-1 40508-1 021564-000 016420-000 017125-000 021173-500 410929 019756-000 40576-3 017694-000 40576-14 017446-000 40678-1 107446-000 40678-4 023451-000 40778-11 413351 40876-10 401176-9 017446-000 410929 401176-10 A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) E-F: 91 Ω @ 0°C (32°F) A-B: 200 Ω @ 60°C (140°F) A-B: 174 Ω @ 21/27°C (70/80°F) 1-2: close on rise @ 57°C (135°F) 3-4: close on fall @ 8°C (46°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) C-D: close on rise @ 71°C (160°F) A-B: 111 Ω ± 4 Ω @ 20°C (68°F) B-C: 111 Ω ± 4 Ω @ 20°C (68°F) C-D: close on rise @ 71°C (160°F) A-B: T1 OPEN @ -12°C (-56°F) A-B: R1 23 Ω @ 23°C (73°F) A-B: 111 Ω ± 4 Ω @ 20°C (68°F) D-E: open on rise @ -5°C (23°F) E-F: open on rise @ -15°C (5°F) with R = 23 Ω ± 2.75 KΩ @ 25°C (77°F) B-C: 300 KΩ @ 25°C (77°F) A-C/D-F: 100 Ω @ 25°C (77°F) B-C/E-F: 30 KΩ @ 25°C (77°F) 023172-000 A2609-1 416275 A26908 415537 A40209-1 413175 Page 5014 Aug 29/2008 019756-000 Check A-B: close on rise @ 71°C (160°F) C-D: close on rise @ 57°C (135°F) E-F: 174 Ω ± 5 Ω @ 21-27°C (70-80°F) A-B: close on rise @ 57°C (135°F) C-D: close on rise @ 71°C (160°F) B-C: close on rise @ 71°C (160°F) B-D: short circuit . 99 KΩ 1% resistor D-E: open on rise @ 8°C (46°F) D-F: open on rise @ 8°C (46°F) with 13 Ω resistor A-B: open on rise @ 71°C (160°F) C: middle point with 4.14 bar (2 psi) Vent valve is closed 0. This test should be done while the battery is on charge.Test according to the table.14 (2 psi) < air pressure < 0. Return to Service After Storage When a battery is to be returned to service after storage.Place the vent valve (160) with its O-ring into the vent valve adapter (T05) of the pressure test fixture. just following the electrolyte leveling procedure. procedures should be followed as given in chapter Storage (including transportation).99 KΩ 1% resistor D-E: open on rise @ 8°C (46°F) D-F: open on rise @ 8°C (46°F) with 13 Ω resistor 6-4.OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Battery description B153CH1 F6177 P/N Sensor 415445 B1513CH1 415445 V09052 P/N Sensor Check A-B: open on rise @ 71°C (160°F) C: middle point with 4.7 bar (10 psi) Vent valve opens 7. and change all vent valve if they do not pass th test. . Check the operation of the vent-valve assembly as follows: .split or cracks air pressure < 0. Page 5015 Aug 29/2008 .Immerse the vent-valve in water and slowly raise the air pressure. test Check O-ring no distortion. . 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. OPERATING AND MAINTENANCE MANUAL INSPECTION/CHECK Page 5016 Aug 29/2008 . when reassembling a battery. 4-1. Fill in Identification plate if the box (010) has been changed Log book. Torque the lower nuts (110) to desired torque (refer to FITS AND CLEARANCES chapter) Put the links (030 to 090). Put the sensor.OPERATING AND MAINTENANCE MANUAL ASSEMBLY ASSEMBLY 1. Ensure these items are installed properly prior to the first cell in each row being installed. NOTE: Some temperature sensors and/or heater blankets include components that require installation between cells and/or within the battery box. 4. 4-2. Page 7001 Aug 29/2008 . 2. they are identified by a code number listed in SPECIAL TOOLS. For easier installation. Standard tools Refer to chapter Standard tools in SPECIAL TOOLS. Assembly of the battery Lightly lubricate the terminals. all components should be clean and dry. 1 item numbers. Introduction This section covers basic battery assembly procedures. 4-3. 3. Installation of the vent valve (160) Install the vent valve (160) with the special tool (T01). Battery Assembly NOTE:All ( ) part identification numbers herein are IPL Fig. Equipment 3-1. Make sure the ventilating system of the box is unobstructed. Place the sensor in the box (if applicable) CAUTION: Some liners or spacer are slotted. the nuts (110) and the links (030 to 090) with M02 using a paintbrush. FIXTURES. the washers (120) and the nuts (110) on the terminals. EQUIPMENT AND CONSUMABLES chapter. In all cases. liners and spacers (200) in the box Insert the cells in the battery box making sure to maintain proper polarity. Special tools When special tools are used in this chapter. 3-2. Torque the nuts (110) to desired torque (refer to FITS AND CLEARANCES chapter) Do an isulation test (refer to Insulation check chapter) Put the cover on the battery and attach it. FIXTURES. the washers (120). Press firmly on the last cell in each row with a block of soft wood to seat it firmly in place. EQUIPMENT AND CONSUMABLES chapter. Safety Refer to Safety paragraph in the INTRODUCTION chapter. the center cell in each row should be the last one installed. OPERATING AND MAINTENANCE MANUAL ASSEMBLY PAGE INTENTIONALLY LEFT BLANK Page 7002 Aug 29/2008 . 5 (39.0x200.195 to 2.8) 9.2 to 47. petroleum jelly prior to assembly and applying torque.1 11 117.0 (12.25 D EN2570 fig.95 to 3.1 25 HVO1.9 (8.7) - - 181CH 20 CVH180KH 18 310.64x3.87) 18.8) 9.82) 25.1 (9) G 1.5 G 4.0x224.6 (83.5) 20 12 276CH 20 CVH271KH 27 254. 2 F ISO 5064-2 or MS 3509 style G Non-Standard H MIL C 5015 J Non-Standard K Special.5) 20 12 187CH 20 CVH180KH 18 223.95 to 2.6) G 1.6 (5. the type of cells.5 (39.0 25.2) 3.05 (170 to 178) 2.OPERATING AND MAINTENANCE MANUAL FITS AND CLEARANCES FITS AND CLEARANCES 1.3x4.0 (10.4) 1 (8.m (lbf.0x167.2 to 47.3 (4.2) G 0.in) ARINC 404 Number of cells A Page 8001 Aug 29/2008 . Specification table Type of connector Characteristic Female threaded M8 x 1.83x7.3102.2 to 47.F80 Upper Nut torque value N.3x4.in) B Lower Nut torque value N.95 to 3.m (lbf.0x249.5) G 4.61x6.0x198.95 to 2.0x171.5 G 4.8) K 0.2) 4.73) 18.5 to 5.6x84. Contact Factory 72-19-4 L Russian Standard 3 254x109x106 (10x4.05 (22 to 30) 22 5 20VO23KHB 20 VO3KHB 3 254x109x106 (10x4.2x226.8) 7 to 9 (62 to 80) 20 21 276CH7 20 CVH271KH 27 276. A legend is provided below that contains the connector codes.00x7.24.6 (83.3x4.95 to 3.5 (39.5 to 5.78x9. NOTE:The torque values in these tables are “lube torque” values.5 (4.05 (170 to 178) 2. The tables include the capacity rating necessary for charge and discharge procedures. 2.9S.005 (170 to 178) 2.8) 7 to 9 (62 to 80) 20 25 Type of Connector VO3KHB Weight kg (lbs) 19 Dimension mm (in) 19VO23KHB Cells Rated Capacity C1A Battery Electrolyte water volume ml C Electrolyte Level mm Cannon CA.32 2. non-acid. 2 & 3 E MIL B 83769 fig.9x86.2 (55.41x3. The thread of the terminals and attaching nuts (or screws) should be lightly greased with a white.2 to 47.R.20x6.0x244.0 (8. the torque values for each cell type and important electrolyte volume and consumable volume information.05 (22 to 30) 22 5 20VO3KHB 20 VO3KHB 3 254x109x106 (10x4. Introduction The Specification Tables in this section are designed to provide basic information about each battery.05 (22 to 30) 22 5 25HV01.5 to 5.5 (39.5 (56) G 4.80x8.5 to 5. 6x205.5 (39.2 to 47.5 (39.81) 15.76x10.0x262.5 to 5.5 (39.0x118.74x8.5x197.5 to 5.0) G 4.5 (39.00x9.OPERATING AND MAINTENANCE MANUAL Lower Nut torque value N.8) 12 to 14 (106 to 124) 20 60 407CH11 20 CVH400KA 40 248.0x198.8) 7 to 9 (62 to 80) 12 8 616 20 VP65K 6 267.5 (39.4 (7.0x198.75x7.1 (20.0 8.6) G 4.6 (71.5x197.31) 24.6) G 4.8) 7 to 9 (62 to 80) 20 20 1656 20 VP160KH 15 271.1) C 4.3 (38.8) 7 to 9 (62 to 80) 20 20 Page 8002 Aug 29/2008 Type of Connector 20 Weight kg (lbs) 277CH1 Dimension mm (in) Cells Battery Rated Capacity C1A Number of cells FITS AND CLEARANCES .m (lbf.2 to 47.8) 12 to 14 (106 to 124) 20 60 407CH19 20 CVH400KA 40 254.2 (55.5 (22 to 31) 24 15 1277-2 19 VP120KHB 14 193.0x169.1 (53.5 17.9) G 4.5x211.8) 7 to 9 (62 to 80) 12 8 615 19 VP65K 6 267.0x216.8 (39.8) 7 to 9 (62 to 80) 20 20 407CH2 20 CVH400KA 40 254.00x254.2 to 47.0x167.80x8.5x197.5 (39.5 to 5.0x198.5 to 5.0) 34.1) G 4.5x120.6) I 4.7 G - 2.8) 12 to 14 (106 to 124) 20 60 407CH13 20 CVH400KA 40 248.3x3 3.2 to 47.0 8.0x224.0 (10.5 (39.5 (39.75x7.0 7.5 to 5.8) 7 to 9 (62 to 80) 20 20 1606 20 VP160KM 16 370.5 (39.00x254.0) G 4.5 to 5.00x9.65x10.0x262.9 (19.5 to 5.62x7.5 (39.75x7.2 to 47.5 (39.2 to 47.78x10.8) 7 to 9 (62 to 80) 20 25 340CD 20 CVD34KH 32 407.31) 24.8) 7 to 9 (62 to 80) 12 8 1277 19 VP120KHMS 14 193.5 to 5.0x198.5x197.0x168.8) 12 to 14 (106 to 124) 20 60 442CH2 20 CVH441KH 44 363.31) 34.0x254.0 17.0 (9.in) Upper Nut torque value N.5 to 3.2) B 4.8 (79.6) I 4.in) Electrolyte Level mm Electrolyte water volume ml CVH271KH 27 254.3x3 3.4 (38.6x204.5 (39.2 to 47.0x248.1) I 4.2 to 47.5x155.1) G 4.0x250.5 (39.5 9.04x4.5 (22 to 31) 24 15 1277-1 19 VP120KHB 14 193.62x7.5 (39.5 to 5.2 to 47.2) C 4.2 to 47.0x254.5 17.5 (39.8) 12 to 14 (106 to 124) 20 25 606 20 VP65K 6 366x125.4 (7.8) 7 to 9 (62 to 80) 20 20 340CD-2 20 CVD34KH 32 407.3x3 3.5x121.2 to 47.2 to 47.5 to 5.5 to 3.2 (17.4 (7.5 to 5.0x120.04x4.8) 7 to 9 (62 to 80) 20 20 1656-1 20 VP160KH 15 292.4 (38.7 G - 2.0x182.3) G 4.0 18.2 to 47.0 32.5 (39.5 to 5.75x7.1x207.4x254.8) 7 to 9 (62 to 80) 12 8 653 21 VP65K 6 204.0x158.0 (16.0x205.0x262.0x142.00x7.81) 15.7x117.2 to 47.78x10.0 37.2 to 47.0x198.0x270.0) G 4.0 17.31) 35.5 (39.7 G - 2.0x174.0x118.5 17.7 G - 2.5 to 5.0 (6.4x300.8) 7 to 9 (62 to 80) 20 20 1608-1 20 VHP170KH-3 17 370.1) I 4.8 (17.5x120.76x10.5x211.7 I 4.74x8.0 (16.5 to 5.0 (17.5 (22 to 31) 24 15 1600 20 VO16KH 16 337.0 (75.7x117.5 to 5.2 to 47.6x163.0 (81.81) 15.0 (10.0x248.3x3 3.8) I 4.8) 12 to 14 (106 to 124) 20 25 447CH1 20 CVH441KH 44 268.2 to 47.2 to 47.0x129.5 (39.5 (39.5 to 5.5 to 3.2 (82) G 4.2 to 47.6 (76.m (lbf.1 (53.0 (9.82) 25.7 (41.63x81.5 to 3.5 to 5.0 8.6) 37.0 (10.0) G 4.2 to 47.5 (39.8 (79.5 to 5.5 to 5.8) 7 to 9 (62 to 80) 20 20 1608 20 VHP170KH-3 17 370.6x207.81) 15.4x254.0) 35.2 to 47.8) 7 to 9 (62 to 80) 12 8 666 20 VP65K 6 177.4 (7.5 (22 to 31) 24 15 1277-3 19 VP120KHB 14 193.5x121.62x7.5) G 4.62x7.8) 7 to 9 (62 to 80) 20 21 310VX2 20 VXP310KH 31 420.5 (39.5 to 5.5 to 5. m (lbf.2x276.2 to 47.5 to 5.5 to 5.5 to 5.0x187.2 to 47.2 to 47.6x163.0x224.2 to 47.5) G 4.6x205.1 G 4.2 to 47.6) G 4.8) 7 to 9 (62 to 80) 20 20 1718 10 VHP170KH-3 17 206.0 23.5 (54) G 4.5 to 5.2 to 47.5 (39.2) G 4.5 (39.5 to 5.6x228.2 to 47.8) 7 to 9 (62 to 80) 20 21 2353-1 19 VO23KH 23 252.2x6.8) 7 to 9 (62 to 80) 20 20 1756-2 20 VP170KH 17 322.6x163.2 to 47.5 (39.2x276.5 to 5.0 17.5 to 5.2 to 47.5 to 5.8) 7 to 9 (62 to 80) 20 20 1656-5 20 VP160KH-SQ 15 271.0 17.1 G 4.8) 7 to 9 (62 to 80) 20 21 2371-2 20 VO23KH 23 249.2x276.1x199.2 to 47.8) 7 to 9 (62 to 80) 20 21 2376-7 20 VP230KH 22 249.4 (54) G 4.2x276.8) 7 to 9 (62 to 80) 20 21 Type of Connector 20 Cells Weight kg (lbs) Dimension mm (in) 1656-2 Battery Number of cells Rated Capacity C1A FITS AND CLEARANCES Page 8003 Aug 29/2008 .6x228.8) 7 to 9 (62 to 80) 20 21 2371-6 20 VO23KH 23 249.2 to 47.5 (39.5x181.6x163.2 to 47.3x163.5 to 5.5 (39.4 (38.2x276.0 25.8) 7 to 9 (62 to 80) 20 21 2371 20 VO23KH 23 249.5 (39.0 25.0 10.5 (39.4x224.0x224.5 to 5.2x276.9 18.8) 7 to 9 (62 to 80) 20 21 2371-5 20 VO23KH 23 249.1 (11.5 to 5.8) 7 to 9 (62 to 80) 20 20 1756 20 VP170KH 17 322.2 to 47.0 17.5 (54) G 4.8) 7 to 9 (62 to 80) 20 21 2371-1 20 VO23KH 23 249.2x276.5 (39.0x224.8) 7 to 9 (62 to 80) 20 20 1811CH 20 CVH180SK 18 310.0x195.0x154.5 (39.2 to 47.5 to 5.2x276.2 to 47.5 to 5.7) 18.0x200.8) 7 to 9 (62 to 80) 20 21 2371-7 20 VO23KH 23 249.5 (39.50) 23.2 to 47.5 to 5.5 to 5.0 25.2 to 47.0x195.8) 7 to 9 (62 to 80) 20 12 2026 20 VP200KHB 22 298.0x224.0 25.5x181.2 to 47.0 24.0 C 4.75x9.9 23.6x205.1x199.0x224.0x224.8) 7 to 9 (62 to 80) 20 20 1658 20 VHP170KH-3 17 271.1x165.0 24.8 C 4.6x194.5 (39.6x163.0x224.5 to 5.in) Upper Nut torque value N.5x245.0x214.2 to 47.5 (54) G 4.5 (39.0 17.5 to 5.8) 7 to 9 (62 to 80) 20 20 1658-2 20 VHP170KH-3 17 271.9 18.5 (39.6x163.2 to 47.9 18.0x126.0x224.8) 7 to 9 (62 to 80) 20 20 1666-1 20 VP160KM 16 233.3 (40.83x6.5 (39.OPERATING AND MAINTENANCE MANUAL Lower Nut torque value N.2) G 4.7 (52.5 (39.5 to 5.6x165.0 24.8 (39.8) 7 to 9 (62 to 80) 20 60 2353 19 VO23KH 23 252.5 (39.2 to 47.5 G 4.5 to 5.5 to 5.6) G 4.4 I 4.0 17.5) G - 4 (40.5 (39.5 (39.8 (39.5 to 5.0x167.2x268.5 (39.5 to 5.6x208.0 17.1 G 4.8) 7 to 9 (62 to 80) 20 21 2376-2 20 VP230KH 22 249.5 G 4.5 G 4.1x199.5 (39.8) 7 to 9 (62 to 80) 20 20 1666 20 VP160KM 16 233.5 to 5.6x194.2 to 47.8) 7 to 9 (62 to 80) 20 21 2371-4 20 VO23KH 23 249.0x224.2x276.2 to 47.5 (54) G 4.1x208.8) 7 to 9 (62 to 80) 20 20 1758 20 VHP170KH-3 17 308.7 (23.2 E 4.5 (39.2 to 47.0 24.5 (39.9 G 4.4 (54) G 4.in) Electrolyte Level mm Electrolyte water volume ml VP160KH 15 271.8) 7 to 9 (62 to 80) 20 21 2376-3 20 VP230KH 22 249.65x6.0 C 4.5 (39.0 23.m (lbf.9 (39.5 to 5.0) 24 33 2318 20 VHP230KA3 23 427.0 25.0 (12.0 24.2 E 4.5 (39. 9 D 4.5 to 5.0x224.5 to 5.0x172.8) 12 to 14 (106 to 124) 20 25 2778-18 20 VHP270KH-3 27 268.2 to 47.2 to 47.0x224.3 G 4.0x270.5 G 4.8) 12 to 14 (106 to 124) 20 25 2778-10 20 VHP270KH-3 27 268.5 (39.6) D 4.2 to 47.2 to 47.2 to 47.0 36.5 (39.5 (39.2 to 47.29x6.0x222.0 28.6 D 4.5 to 5.0x224.8) 12 to 14 (106 to 124) 20 60 Page 8004 Aug 29/2008 .0x172.0x182.5 to 5.8) 7 to 9 (62 to 80) 20 21 2378 20 VHP260KH-3 26 249.1x165.0 28.0x201.0 25.2x276.5 to 5.6) D 4.5 (39.0x212.5 (39.5 to 5.0 D 4.5 (39.5 to 5.0x201.4x300.8) 12 to 14 (106 to 124) 20 25 4010CH 20 CVH400KA 40 363.5 (39.5 (39.0x275.2 to 47.0 25.5 to 5.5 (39.2 to 47.2 to 47.5 to 5.0 G 4.1 (11.8) 12 to 14 (106 to 124) 20 25 4002 20 VO40KH-C 40 420.4x300.0x224.5 (39.5 to 5.8) 12 to 14 (106 to 124) 20 25 2778-15 20 VHP270KH-3 27 268.5 to 5.OPERATING AND MAINTENANCE MANUAL FITS AND CLEARANCES 2376-8 20 VP230KH 22 249.8) 7 to 9 (62 to 80) 20 21 2522 20 VO25KA-C 25 549.0 29.5 (39.0 25.5 to 5.5) G - 4 (40.0x201.5 (39.8) 7 to 9 (62 to 80) 20 60 2506-1 20 VP250KH 23 363.5 (80.0 G 4.0 36.5 to 5.2 G 4.3 D 4.0 28.2 to 47.8) 12 to 14 (106 to 124) 20 25 2778-20 20 VHP270KH-3 27 268.0x129.65x10.8 (52.2 H 4.2 to 47.2 G 4.50) 23.5 to 5.3 D 4.0 28.3 G 4.5 (39.63) 34.8) 12 to 14 (106 to 124) 20 25 4008-1 20 VHP430KH-3 43 363.0x216.0 37.4x300.0x198.0 25.5 (39.6 D 4.5 (39.5 to 5.2 to 47.0x113.0x169.8) 12 to 14 (106 to 124) 20 25 2778-5 20 VHP270KH-3 27 268.2 to 47.5 to 5.0x270.0x223.0x201.5 to 5.2x276.8) 7 to 9 (62 to 80) 20 21 2376-9 20 VP230KH 22 249.0x270.8) 12 to 14 (106 to 124) 20 25 4006A1-1 20 VP400KH 36 363.0 28.0) 24 33 2500 20 VO25KA 25 497.2 to 47.2 to 47.8) 12 to 14 (106 to 124) 20 25 2708-1 20 VHP270KH-3 27 363.6 (80.75x9.2 to 47.0 D 4.8) 7 to 9 (62 to 80) 20 21 2376-10 20 VP230KH 22 249.0 28.2 to 47.0 27.6 G 4.0x216.0 28.8) 12 to 14 (106 to 124) 20 25 4000A1 20 VO40KH 40 420.65x6.0x169.0 36.0x169.0x222.0x216.8) 7 to 9 (62 to 80) 20 21 2506-2 20 VP250KH 23 363.5 (39.0x212.4 G 4.5 to 5.0 (14.4x300.2 to 47.2x276.8) 7 to 9 (62 to 80) 20 21 2708 20 VHP270KH-3 27 363.5 (39.0x201.8) 12 to 14 (106 to 124) 20 25 4000A-1 20 VO40KH 40 420.5 (39.5 G 4.7 (76.0 26.0x198.5 (39.0x221.2 to 47.8) 12 to 14 (106 to 124) 20 25 2778 20 VHP270KH-3 27 268.0x275.8) 7 to 9 (62 to 80) 20 21 2386-1 20 VP200KHB 22 298.5 31.0 29.5 (39.5 G 4.0x275.2 to 47.5 to 5.5 to 5.4x300.0 28.5 (39.5 G 4.5 to 5.5 to 5.2 to 47.8) 7 to 9 (62 to 80) 20 60 2608 20 VHP260KH-3 26 418.2 to 47.0x129.2x276.0 37.5 (39.4x300.5 to 5.5x245.2 to 47.5 (39.3) G 4.0x201. 4) 18.m (lbf.6 (9.5 to 5.63x4.3x117.63) 7.8) 7 to 9 (62 to 80) 33 8 A40209 20 VHP370KH-3SQ 37 363.15) 17 8 Type of Connector 18 Weight kg (lbs) CVH180KH-SQ Dimension mm (in) 20 Cells Rated Capacity C1A A185CH Battery Number of cells Lower Nut torque value N.m (lbf.8) 12 to 14 (106 to 124) 38 25 A447CH-12 20 CVH441KH-SQ 44 254.5 (39.5 to 5.0x169.5 (39.in) Electrolyte Level mm Electrolyte water volume ml 253.8) 12 to 14 (106 to 124) 38 10 A2609-1 20 VHP260KH-3SQ 26 - 21.7) J 4.5 (39.5x196.2 to 47.6x246.4 (12.9 D 4.5 to 5.0x270.0 15.2 to 47.0 37.76x10.1 (77.94x9.5 to 5.8 J 1.0 15.3 (40.5 (39.7 (61.5 to 5.8) 7 to 9 (62 to 80) 26 9 A408CH 20 CVH400KH-SQ 40 252.5 to 5.in) FITS AND CLEARANCES Page 8011 Aug 29/2008 .5 (47.0x169.5 (39.6x266.0x262.3 (33.7) G 4.0x197.3 (33.5x196.0 (9.5 to 5.0x138.8x6.5 (9.2 to 47.0x162.0 (10.8) 7 to 9 (62 to 80) 33 8 A26908 20 VHP260KH-3SQ 26 - 27.0 37.5 (39.OPERATING AND MAINTENANCE MANUAL Upper Nut torque value N.15) 1.4) G 4.6x16 .0x248.0x270.8) 7 to 9 (62 to 80) 20 15 B1513CH1 20 CVH150KH 15 364.5 (39.9 D 4.8) 12 to 14 (106 to 124) 38 25 A40209-1 20 VHP370KH-3SQ 37 363.2 to 47.00x9.31) 36.5 (39.9x7.6 (80.2 to 47.50) 35.4) D 4.5 to 5.91x4.8) 7 to 9 (62 to 80) 20 15 GB170 19 KO7.1) G 4.6x117.5KH 7 251.8) 12 to 14 (106 to 124) 38 25 B153CH1 20 CVH150KH 15 364.5 (39.5 to 5.2 to 47.71x10.0x138.2 to 47.4) I 4.7) J 4.2 to 47.2 to 47.4 (12. OPERATING AND MAINTENANCE MANUAL FITS AND CLEARANCES PAGE INTENTIONALLY LEFT BLANK Page 8012 Aug 29/2008 . 8) 7 to 9 (62 to 80) 20 20 17 273.2 to 47.8) 7 to 9 (62 to 80) 20 20 18.5 to 5.0x198.3 25.5 (39.75x9.75x9.5 to 5.5 (39.5 (39.0) 24 33 20126-3 20 VP200KHB 22 298.8) 7 to 9 (62 to 80) 20 20 273.0 23.2 to 47.5 G 4.2 to 47.65x6.65x6.5 to 5.2 to 47.5 17.5 G 4.0 18.5 G 4.1x187.2 to 47.5 to 5.5 to 5.2 18.2 18.5 to 5.0 26.5 (39.50 23.8x165.0x198.5 (39.5 (39.2 to 47.in) Electrolyte Level mm FITS AND CLEARANCES Cells Page 8007 Aug 29/2008 .75x9.8) Weight kg (lbs) 7 to 9 (62 to 80) Dimension mm (in) 4.0x257.1x165.5 (39.0x198.1 11.5 (39.5 to 5.6x187.2x114.5 to 5.5 (39.5x183.8 G - 4 (40.8 G 4.5 18.8) 7 to 9 (62 to 80) 20 20 20126 20 VP200KHB 22 298.0x129.8) 7 to 9 (62 to 80) 20 21 23576-1 20 VP230KH 24 252.50 23.2 to 47.1 G 4.0x198.0x224.5 (39.1 G 4.5 to 5.5 (39.2 to 47.2 to 47.5 to 5.5 16156 20 VP160KH 15 16156-1 20 VP160KH 16158 20 16256 Battery Number of cells Type of Connector 4.5x195.6 G 4.2 to 47.0x204.8) 7 to 9 (62 to 80) 20 21 23476 20 VP230KH 22 254.m (lbf.0 25.8) 7 to 9 (62 to 80) 33 8 G 4.5 to 5.8) 7 to 9 (62 to 80) 20 21 23491-4 20 VO23KH 23 254.0 G 4.5 (39.0 25.0x224.7 I 4.OPERATING AND MAINTENANCE MANUAL Electrolyte water volume ml 20 7 to 9 (62 to 80) 33 8 4.5 to 5.3 I 4.0x198.8) 7 to 9 (62 to 80) 20 20 20 VHP170KH-3 17 271.1 11.6x187.2 to 47.8) Rated Capacity C1A Upper Nut torque value N.2 to 47.5 to 5.0 G 4.8) 7 to 9 (62 to 80) 20 20 16556 20 VP160KM 16 267.4 G 4.0x179.1 15 271.2 to 47.0 J 4.5 to 5.7 16108-1 20 VHP170KH-3SQ 17 356.5 to 5.1x165.5 (39.0x224.0x204.5 (39.8) 7 to 9 (62 to 80) 20 21 23576-2 20 VP230KH 24 252.2 to 47.0 25.5 to 5.1x165.0x182.5 G - 4 (40.3 25.0 18.2 to 47.6x163.3x222.0 18.8) 7 to 9 (62 to 80) 20 21 23676 20 VP230KH 24 457.5 (39.8) 7 to 9 (62 to 80) 20 21 7 to 9 (62 to 80) I 4.5 (39.5x245.0x181.1 11.8) 7 to 9 (62 to 80) 20 20 16356 20 VP160KH 15 273.0x204.5 23.5 (39.6x187.5 (39.0) 24 33 23171-4 20 VO23KH-SQ 23 254.5 G 4.8) 17.1 (37.7 I 271.0x198.0x164.0x164.6x163.2 to 47.5 (39.9 G 4.0x164.0x198.5 to 5.m (lbf.6x224.1x185.0x224.8) 7 to 9 (62 to 80) 20 21 23378 20 VHP260KH-3 26 254.2 to 47.0 25.5x195.8) 7 to 9 (62 to 80) 20 21 23376 20 VP230KH 22 254.2 to 47.5 17.8) 7 to 9 (62 to 80) 20 20 VP160KH 17 273.0 G 4.5x245.8) 7 to 9 (62 to 80) 20 21 23478 20 VHP260KH-3 26 254.0x125.0 24.5 19.5x245.5 G - 4 (40.2 to 47.5 to 5.5x132.5 (39.0x224.in) 20 Lower Nut torque value N.7) 16108-1 20 VHP170KH-3SQ 17 356.2 to 47.0 25.5 to 5.2 to 47.2 18.8) 7 to 9 (62 to 80) 20 21 23576 20 VP230KH 24 254.7 B 16106-1 20 VP160KM-SQ 16 356.2 to 47.1x185.5 (39.0) 24 33 20126-2 20 VP200KHB 22 298.65x6.5 to 5.3x222.0x125.5 to 5.5 VHP170KH-3 17 20 VP160KH 16256-3 20 16258 16100 20 VO16KH 16 337.0x224.5 (39.5 to 5.6x215.0 J 4. 5 G 4.5 to 5.5 to 5.5 to 5.8 J 4.0x248.2 to 47.0x230.8) 7 to 9 (62 to 80) 33 8 23678-3 20 VHP260KH-3SQ 26 254.0x248.OPERATING AND MAINTENANCE MANUAL Dimension mm (in) Weight kg (lbs) Type of Connector Lower Nut torque value N.0 28.0 25.0x222.5 to 5.2 to 47.5 to 5.2 to 47.8) 7 to 9 (62 to 80) 20 21 23678-1 20 VHP260KH-3SQ 26 254.0x230.0 28.2 to 47.8 J 4.0 G 4.0x172.8) 7 to 9 (62 to 80) 20 21 26508 20 VHP260KH-3 26 466.0x224.5 G 4.5 to 5.8) 12 to 14 (106 to 124) 20 25 Page 8008 Aug 29/2008 .5 to 5.0x172.0x170.2 to 47.0x198.9 (59.5 (54) G 4.8) 7 to 9 (62 to 80) 20 21 26108-7 20 VHP260KH-3 26 301.0x170.2x114.2 to 47.in) Electrolyte Level mm Electrolyte water volume ml 23676-1 20 VP230KH 24 457.2 to 47.0x248.0x198.3) J 4.0x230.5 (39.0x201.5 to 5.0x201.8) 12 to 14 (106 to 124) 20 25 40042 10 VOEC40KH 40 223.8) 7 to 9 (62 to 80) 20 21 26108-5 20 VHP260KH-3 26 301.0 28.0 25.3 G 4.5 (39.8) 7 to 9 (62 to 80) 20 21 26308-1 20 VHP260KH-3 26 281.5 to 5.5 (39.0 24.8) 7 to 9 (62 to 80) 20 21 26408-1 20 VHP260KH-3 26 281.8) 12 to 14 (106 to 124) 38 10 27278 20 VHP270KH-3 27 254.2 to 47.3 G 4.5 to 5.2 to 47.0x222.5 (39.2 26.0x224.0 G 4.8) 12 to 14 (106 to 124) 20 25 27278-2 20 VHP270KH-3SQKH-3 27 254.5 (39.2 to 47.5 G 4.8) 7 to 9 (62 to 80) 20 21 26508 20 VHP260KH-3 26 466.5 to 5.8) 7 to 9 (62 to 80) 20 21 26708 20 VHP260KH-3 26 464.5 to 5.0 25.2 to 47.8) 7 to 9 (62 to 80) 20 21 VHP260KH-3 26 482.5 to 5.5 to 5.0 21.0x245.0 26.0x201.5 (39.0x169.0 25.5x174.2 to 47.5 (39.5 (39.4) J 4.7 G 4.9 G 4.0 24.5x174.5 (39.1 G 4.0 26.5 (39.8) 7 to 9 (62 to 80) 20 21 25106-2 20 VP250KH 23 363.5 G 4.5 to 5.0x224.2 to 47.0 28.5 to 5.0 28.5 to 5.5 (39.8 26.m (lbf.0x166.0x202.0 24.0x229.8) 12 to 14 (106 to 124) 20 25 40100A 20 VO40KH 40 363.8) 7 to 9 (62 to 80) 20 21 26108-4 20 VHP260KH-3 26 301.5 (39.6x188x245.0 24.2 to 47.0x236.5 (39.in) Upper Nut torque value N.8) 7 to 9 (62 to 80) 20 21 Battery Number of cells Rated Capacity C1A FITS AND CLEARANCES 26808 Cells 27168-1 20 VHP270KH-3SQ 27 360.0 28.0x275.0 25.8) 7 to 9 (62 to 80) 20 21 26108-3 20 VHP260KH-3 26 301.5 (39.5 to 5.0x245.5 (39.8) 12 to 14 (106 to 124) 38 10 27578-2 20 VHP270KH-3 27 254.2 to 47.5 (39.4 G 4.0 35.5 (39.5 (39.0x170.5 to 5.0x198.5 (39.5x170.2 to 47.5 to 5.8) 7 to 9 (62 to 80) 33 8 25106 20 VP250KH 23 363.2 to 47.0x229.8) 7 to 9 (62 to 80) 20 21 26308-5 20 VHP260KH-3 26 281.9 J 4.5 (39.2 to 47.3 G 4.5 G 4.5 (39.4 G 4.2 to 47.2 26.5 (39.0x170.5 to 5.2 to 47.5x174.0x230.2 to 47.0x166.5x174.2 to 47.5 (39.8) 7 to 9 (62 to 80) 33 8 23678-2 20 VHP260KH-3SQ 26 254.0x166.0 25.5 to 5.0x248.0x229.5 G 4.4 G 4.2x114.2 26.5 (39.6x224.9 (58.2 to 47.2 26.5 to 5.9 G 4.0x245.8) 7 to 9 (62 to 80) 20 21 26608-1 20 VHP260KH-3 26 476.8) 7 to 9 (62 to 80) 20 21 23676-2 20 VP230KH 24 457.2 to 47.3 G 4.2 to 47.5 (39.m (lbf.6x224.0x184.5 to 5.5 to 5. 0x270.5 G 4.2 to 47.4 G 4.5 (39.0 38.5 to 5.8) 12 to 14 (106 to 124) 20 40208-4 20 VHP430KH-3 43 420.8) 12 to 14 (106 to 124) 20 55 40278-2 20 VHP430KH-3SQ 43 254.8 G 4.0 G 4.0x270.5 to 5.0x248.5 (46.1) D 4.0x275.in) Electrolyte Level mm Electrolyte water volume ml 40100-1 20 VO40KH 40 363.5 to 5.0x270.2 to 47.5 (39.2 to 47.2 to 47.3 D 4.2 to 47.0x270.0x181.2 (84.m (lbf.0x248.5 to 5.5 to 5.5 (39.1) D 4.1) D 4.8) 12 to 14 (106 to 124) 20 25 40208-7 20 VHP430KH-3 43 420.0x262.5 to 5.0 35.0x248.2 to 47.OPERATING AND MAINTENANCE MANUAL Dimension mm (in) Weight kg (lbs) Type of Connector Lower Nut torque value N.0 21.0 38.4x304.0x270.5 (39.8) 12 to 14 (106 to 124) 20 25 40178-24 20 VHP430KH-3 43 254.0x169.5 to 5.2 to 47.2 to 47.0x230.0x209.0 37.0x216.6x254.0x216.2 to 47.2 (84.0 38.5 to 5.5 (39.0x262.3 D 4.2 to 47.5 to 5.2 to 47.2 to 47.5 (39.0x216.8) 12 to 14 (106 to 124) 20 25 40152 11 VO40KH 40 233.5 to 5.5 (39.0x169.5 (39.0x181.7x231.0 38.2 (84.8) 12 to 14 (106 to 124) 20 25 40208-5 20 VHP430KH-3 43 420.5 (39.8) 12 to 14 (106 to 124) 20 25 40142 11 VOEC40KH 40 223.5 (39.8) 12 to 14 (106 to 124) 20 25 40176-10 20 VP400KH 36 254.1) D 4.9) G 4.0x270.0 33.5 G 4.2 to 47.5 (39.8) 12 to 14 (106 to 124) 20 25 40209-2 20 VHP370KA3 37 412.5 (39.5 (39.0x248.5 (39.5 to 5.2 to 47.5 (39.5 to 5.5 21.0x262.5 (39.5 (39.0 J 4.2 to 47.2 to 47.0x169.8) 12 to 14 (106 to 124) 20 25 40206-2 20 VP400KH 36 420.0x216.8) 12 to 14 (106 to 124) 20 25 40178 20 VHP430KH-3 43 340.8) 12 to 14 (106 to 124) 20 25 40178-7 20 VHP430KH-3 43 340.9 D 4.5 (39.0x270.4) G 4.2 to 47.0x216.5 (39.6 21.0x169.5 (39.0 38.8) 12 to 14 (106 to 124) 20 25 40200-1 20 VO40KH 40 420.0 41.5 to 5.0 37.0 37.4 G 4.0 G 4.8) 12 to 14 (106 to 124) 20 25 40153 11 VP400KH 36 224.0 38.2 to 47.8) 12 to 14 (106 to 124) 20 25 40208 20 VHP430KH-3 43 420.5 (39.0 38.5 to 5.0 35.0 36.0x184.0 41.5 G 4.8) 12 to 14 (106 to 124) 20 25 40208-6 20 VHP430KH-3 43 420.6 D 4.8) 12 to 14 (106 to 124) 20 25 Battery Number of cells Rated Capacity C1A FITS AND CLEARANCES Cells Page 8009 Aug 29/2008 .5 to 5.5 to 5.2x290.6x253.9 G 4.8) 12 to 14 (106 to 124) 20 25 40208-1 20 VHP430KH-3 43 420.8) 12 to 14 (106 to 124) 20 60 40253 11 VP340KA 34 224.8) 12 to 14 (106 to 124) 20 60 40200 20 VO40KH 40 420.in) Upper Nut torque value N.5 to 5.0x169.5 (84.3 D 4.0x248.5 (39.0x248.0x270.5 (39.5 to 5.0 38.0 G 4.0x216.0x262.2 (84.0x262.5 to 5.0x262.2 to 47.0 37.2 to 47.2 to 47.0 38.0x270.0x270.2 to 47.0x169.5 to 5.5 to 5.m (lbf.0 38.5 (39.0x270.8) 12 to 14 (106 to 124) 20 25 40179-7 20 VHP370KA-3 37 268.2 to 47.2 to 47.0x270.0 D 4.8) 12 to 14 (106 to 124) 20 25 40178-21 20 VHP430KH-3 43 254.5 to 5.8) 12 to 14 (106 to 124) 20 25 40208-2 20 VHP430KH-3 43 420.4 G 4.0x248.5 (39.8) 12 to 14 (106 to 124) 20 25 40108-2 20 VHP430KH-3 43 363.0 D 4.2 to 47.5 to 5.0 38.8x264.6 21.8) 12 to 14 (106 to 124) 38 10 40300 20 VO40KH-3 40 363.0x216.5 to 5.5 to 5. 2 to 47.2 to 47.8) 12 to 14 (106 to 124) 20 25 40678-1 20 VHP430KH-3 45 254.0x248.6 G 4.5 to 5.0x181.5 (39.5 to 5.3 G 4.5 (39.5x260.3 G 4.2 to 47.0 G 4.0 37.9x256.8) 12 to 14 (106 to 124) 38 10 40576 20 VP400KH-AC 36 254.5 to 5.in) Electrolyte Level mm Electrolyte water volume ml 40306 20 VP400KH-SQ 36 363.5 (39.0x246.8) 12 to 14 (106 to 124) 20 25 40508-1 20 VHP430KH-3SQ 43 398.0 36.8 G 4.0 36.5x249.5 to 5.5 (39.3x249.5 to 5.0 37.7 36.0 38.5 (39.8 G 4.5 to 5.8) 12 to 14 (106 to 124) 20 25 40676 20 VP400KH-AC 36 254.5 (39.0x270.0x262.0x247.0 (10.4 G 4.2 to 47.6x254.8) 12 to 14 (106 to 124) 20 25 40678-4 20 VHP450KH-3 45 254.2 to 47.5 (39.5 to 5.8) 12 to 14 (106 to 124) 20 25 40876 20 VP400KH 36 252.5 (39.5 to 5.0x262.2 to 47.5 to 5.8) 12 to 14 (106 to 124) 20 10 40342 10 VOEC40KH 40 219.5 to 5.2 to 47.5 (39.0x262.5 (39.0x248.8) 12 to 14 (106 to 124) 20 25 40876-10 20 VP400KH 36 252.5 (39.0x260.0x248.2 to 47.8) 12 to 14 (106 to 124) 20 25 40379 20 VHP370KH-3SQ 37 254.0x262.2 to 47.8) 12 to 14 (106 to 124) 24 25 40576-14 20 VP400KH-AC 36 254.5x169.2 to 47.0x247.6 G 4.m (lbf.2 to 47.2 to 47.2 to 47.2 to 47.5 to 5.8) 12 to 14 (106 to 124) 20 25 40378 20 VHP430KH-3 43 277.0x262.7x266.0x247.0x248.0x247.5 (39.0x248.0x262.2 to 47.5 to 5.6 G 4.5 (39.0x250.0x247.6 G 4.6x213.0 G 4.31) 38.5 to 5.2 to 47.5 to 5.76x10.5 21.3 G 4.5 to 5.5 (39.0x262.5 to 5.8) 12 to 14 (106 to 124) 20 25 40776 20 VP400KH-AC 40 254.00x9.2 to 47.0 38.2 to 47.8) 12 to 14 (106 to 124) 38 25 40408 20 VHP430KH-3 43 363.8 37.2 to 47.4 G 4.5 (39.in) Upper Nut torque value N.2 to 47.8) 12 to 14 (106 to 124) 20 25 401176-10 20 VP400KH 40 254.5 (39.0 18.8) 12 to 14 (106 to 124) 24 25 40576-3 20 VP400KH-AC 36 254.8 36.0 G 4.3 G 4.0 36.5 to 5.4 G 4.6 G 4.8) 12 to 14 (106 to 124) 24 25 401176-9 20 VP400KH 40 254.5 to 5.0x247.0x248.8) 12 to 14 (106 to 124) 20 25 40376 20 VP400KH 36 303.8) 12 to 14 (106 to 124) 20 25 40371 20 VOEC40KH 40 253.8) 12 to 14 (106 to 124) 20 25 Battery Page 8010 Aug 29/2008 Number of cells Rated Capacity C1A FITS AND CLEARANCES Cells .5 to 5.5 (39.0x248.5 (39.0 G 4.0x248.0 37.5 to 5.0x169.5 (39.2 to 47.0 G 4.0 37.0 D 4.0 37.2 to 47.5x264.8) 12 to 14 (106 to 124) 20 25 40478-1 20 VHP430KH-3 43 254.0x270.8) 12 to 14 (106 to 124) 20 25 401076 20 VP400KH-AC 40 254.5 to 5.2 to 47.0x248.8) 12 to 14 (106 to 124) 20 25 40353 11 VP380KH 42 224.0 38.0 36.0x248.0 36.0 37.5 G 4.5x260.0x260.5 (39.0 37.0x169.4x262.5 (39.0x248.2 to 47.0x248.5 (39.0x265.m (lbf.0 37.5 to 5.5 (39.8 G 4.9 D 4.5 (39.5 to 5.5 (39.0x262.4x262.2 to 47.0x166.8) 12 to 14 (106 to 124) 24 25 40578-1 20 VHP430KH-3 43 254.7 G 4.0 38.5 to 5.0x246.0 38.OPERATING AND MAINTENANCE MANUAL Dimension mm (in) Weight kg (lbs) Type of Connector Lower Nut torque value N.0 G 4.0 36.8) 12 to 14 (106 to 124) 24 25 40678 20 VHP430KH-3 43 254.5 to 5.8) 12 to 14 (106 to 124) 24 25 40778-11 20 VHP430KH-3 43 254. OPERATING AND MAINTENANCE MANUAL Upper Nut torque value N.5 (39.2 to 47.0 15.7) J 4.2 to 47.5KH 7 251.76x10.5 to 5.6x117.91x4.4) G 4.6 (9.5 (39.8) 7 to 9 (62 to 80) 26 9 A408CH 20 CVH400KH-SQ 40 252.3 (33.5 (39.8) 7 to 9 (62 to 80) 20 15 B1513CH1 20 CVH150KH 15 364.9x7.6x266.2 to 47.m (lbf.0x162.2 to 47.8 J 1.0x138.4) I 4.4 (12.8) 12 to 14 (106 to 124) 38 25 B153CH1 20 CVH150KH 15 364.2 to 47.5 (39.6x16 .8) 7 to 9 (62 to 80) 33 8 A40209 20 VHP370KH-3SQ 37 363.in) Electrolyte Level mm Electrolyte water volume ml 253.5 to 5.5 to 5.5 to 5.3x117.31) 36.0 15.63x4.4) 18.5 (39.3 (33.9 D 4.2 to 47.0x197.5 to 5.5 (39.0x138.5 (39.0x262.50) 35.00x9.9 D 4.7 (61.5 (39.3 (40.0 (10.8) 7 to 9 (62 to 80) 33 8 A26908 20 VHP260KH-3SQ 26 - 27.4 (12.0x248.6 (80.5x196.2 to 47.0 37.0 37.5 (9.8) 12 to 14 (106 to 124) 38 25 A447CH-12 20 CVH441KH-SQ 44 254.in) FITS AND CLEARANCES Page 8011 Aug 29/2008 .5 to 5.8) 7 to 9 (62 to 80) 20 15 GB170 19 KO7.5 to 5.2 to 47.0x270.94x9.71x10.8) 12 to 14 (106 to 124) 38 10 A2609-1 20 VHP260KH-3SQ 26 - 21.7) J 4.m (lbf.1 (77.15) 1.8x6.63) 7.6x246.0x270.5 to 5.0x169.4) D 4.5 to 5.1) G 4.5 (47.2 to 47.5x196.5 (39.15) 17 8 Type of Connector 18 Weight kg (lbs) CVH180KH-SQ Dimension mm (in) 20 Cells Rated Capacity C1A A185CH Battery Number of cells Lower Nut torque value N.0 (9.8) 12 to 14 (106 to 124) 38 25 A40209-1 20 VHP370KH-3SQ 37 363.7) G 4.0x169. OPERATING AND MAINTENANCE MANUAL FITS AND CLEARANCES PAGE INTENTIONALLY LEFT BLANK Page 8012 Aug 29/2008 . Constant Current Power Unit (0-60 A) . All listed items are identified in this manual by a standard code number: . EQUIPMENT AND CONSUMABLES 1.Constant Current Load Bank (0-60 A) . EQUIPMENT AND CONSUMABLES SPECIAL TOOLS. 2.Eye wash.4 bar (20 psi)] . equivalent substitutes may be used. FIXTURES. .Soft.Safety shoes.Megohmeter (0-50 MΩ @ 250 V continuous) . . compressed air source [less than 1. .in) .The second part provides the listing of consumable materials used in this manual. mA) .Dry. Standard tools The following items are recommended to do the procedures descibed in this manual.Precision Multimeter (Volt.Protectives goggles.OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS.Small paintbrush (non-metallic) . . .m (0-133 lbf. Ω.Txx for tools. .Stiff bristle brush (non-metallic) . fixtures and equipment needed to do the steps listed in the other chapters. FIXTURES.The first part provides the list of special tools. clean cloth (at least two required) Page 9001 Aug 29/2008 .Safety gloves.Standard mechanic’s tools. . Introduction This chapter is divided into two parts: .Mxx for consumable materials. fixtures and equipment.Torque Wrench (Fully insulated) 0-15 N. . When necessary. .Protective apron. EQUIPMENT AND CONSUMABLES 3. Special tools NOTE:Equivalent tools can be used CODE F6177 P/N DESCRIPTION T01 Universal vent wrench T02 Syringe assembly (with nozzle) V09052 P/N 413876 093365-000 416228 020915-002 Nozzle Length in millimeters 12 416229 15 416231 020915-004 416232 020916-001 416233 020916-002 20 for M8 valves 20 for MS valves 24 416235 33 416236 38 Page 9002 Aug 29/2008 . FIXTURES.OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS. OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS. FIXTURES. EQUIPMENT AND CONSUMABLES CODE T03 F6177 P/N DESCRIPTION 1 Ω 3 W equalizing resistors V09052 P/N 164829 3 W resistance wire Alligator clips Shorting clip T04 - Universal cell extration tool 022069-000 416159 M8 M10 x 1.25 Page 9003 Aug 29/2008 . OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS. Tool kit A special toolkit is availaible from Saft with the P/N 416161 containing all special tools T01. FIXTURES. A special version for CEI60952 type A connector is available with P/N 416160 . EQUIPMENT AND CONSUMABLES CODE T05 F6177 P/N DESCRIPTION V09052 P/N Vent valve adapter for M8 valve - 025098-000 Vent valve adapter for MS valve - 024398-000 3-1. T03. and T04. T02. Tool Kit Figure 1 Page 9004 Aug 29/2008 . EQUIPMENT AND CONSUMABLES 4. Reducing agent content (expressed in weight of oxygen) < 30 mg/l (test with permanganate). FIXTURES.< 10 mg/l Dry abstract < 15 mg/l Silicium in SiO2 < 15 mg/l Local vendor M02 Neutral petroleum jelly Density @ 60°C (140°F) Range = 0. .866 Kg/L Melting Point Range = 46°C . ADDRESS. CODE) M01 Distilled or deionized water clear.0.OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS. resistivity > 30 kΩ/cm 5 < pH < 7 Absence of organic and reducing substances. colourless. oderless while boiling. Total of ions SO42+ Cl. Consumables NOTE:Equivalent alternatives can be used for list items This paragraph describes the consummables used in the OMM.52°C (115°F .126°F) Acidity/Alkalinity = Neutral to Litmus Mineral vaseline OTAN: S 743 F: AIR 3565 US: VV-P-236/A UK: DEF 2333 M03 Soap Local vendor Page 9005 Aug 29/2008 . DESIGNATION PARTNUMBER AND SPECIFICATION CODE MANUFACTURER OR SUPPLIER (NAME.840 . EQUIPMENT AND CONSUMABLES PAGE INTENTIONALLY LEFT BLANK Page 9006 Aug 29/2008 . FIXTURES.OPERATING AND MAINTENANCE MANUAL SPECIAL TOOLS. OPERATING AND MAINTENANCE MANUAL Illustrated part list ILLUSTRATED PART LIST 1. Detailled part list 110 120 030 to 090 110 130 120 150 160 100 010 011 140 210 and 220 230 020 Nickel-Cadmium Aircraft Battery Figure 1 Page 10001 Aug 29/2008 . . Link 050 . O-ring This example of an Illustrated Parts List (IPL) is for general reference only. Screw 220 . . spring 130 . Vent valve assembly 180 . . Link 040 . Link 100 . Page 10002 Aug 29/2008 . flat 160 . Refer to specific battery IPL’s for relevant parts and part numbers. Link 080 .OPERATING AND MAINTENANCE MANUAL Illustrated part list Figure Number Item Number 1 Airline Stock Number Nomenclature 1234567 Quantity per Battery BATTERY 010 . . Nut 190 . Gasket cover 1 020 . . Washer. complete -240 . Link 090 . Washer. positive polarity 140 . Link 060 . . Washer. Nut 120 . Washer 230 . negative polarity 150 . Box 1 030 . Washer 200 . Connector. Cell 110 . Cover 1 011 . . Washer. Liner-spacer kit 210 . Link 070 . OPERATING AND MAINTENANCE MANUAL Illustrated part list 2. Battery part list Battery P/N cell 010 +020 010 020 200 210 220 230 240 19VO3KHB 414547 VO3KHB 415550 414558 414551 414562 412213 - 414570 - 20VO3KHB 414548 VO3KHB 415550 414558 414551 414562 412213 - 414570 - 407CH5 415007 CVH400KA 415786 413791 415784 413714 100431 100430 102392 100713 606 410689 VP65K 165701 165699 120148 411684 120170 100166 163292 - 615 410766 VP65K 167738 167726 167722 - - 167520 167727 - 616 411146 VP65K 411147 411306 411151 411343 108045 410456 411303 - 653 167327 VP65K 410181 - - 412656 108045 107644 160809 - 666 410705 VP65K 415705 410707 410706 415659 - - - - 1277 100504 VP120KHMS 114453 100514 100505 411707 102129 78011 160510 100713 1277-1 115944 VP120KHB 118105 100514 118101 411707 100523 100430 160510 100713 1277-3 414140 VP120KHB 118105 100514 118101 411707 100523 100430 160510 100713 1600 103275 VO16KH 161093 103281 103276 412635 102037 102036 43120 - 1606 161185 VP160KM 410825 410823 410822 412230 - - - - 1656-2 164747 VP160KH 167601 100316 115737 410996 100523 100430 160510 - 1656-5 410378 VP160KH-SQ 167601 100316 115737 410996 100523 100430 160510 - 1658 410385 020770000 VHP170KH-3 114607 106337 106314 410996 100523 100430 102226 - 1658-2 410231 VHP170KH-3 167601 106335 115737 412637 100523 100430 160510 - 1666-1 167598 VP160KM 166893 166892 166815 411226 - - - - 2378 166851 VHP260KH-3 166863 166892 166864 411225 100431 100430 102226 100713 2500 103261 VO25KA 161010 102001 103262 412651 102013 100433 43124 - 2522 412920 VO25KAC 114363 103388 103377 412458 100431 100430 160510 - 2778 166130 VHP270KH-3 166259 166260 166312 411428 100431 100430 102392 100713 4017CH-1 023789000 CVH400KA 015924 024050 -000 015579 -000 015577 -000 022078 -000 4072 412931 VO40KHC 114278 114300 102391 411424 100431 100430 102392 100713 4077 102289 VP400KH-MS 114268 102295 102290 412658 100523 100430 160510 100713 4078 166133 018718000 VHP430KH-3 166262 411020 411022 021714 -000 100431 100430 102392 100713 4078-10 022019000 VHP430KH-3 015599 -000 022023 -000 015579 -000 022228 -000 021740 -000 4078-19 023694000 VHP430KH-3 015599 -000 023695 -000 015579 -000 022228 -000 021740 -000 4079 166131 VHP370KA3 166262 166324 166232 411424 100431 100430 102392 100713 4080 100162 VO40KH 018301 412660 contact saft contact saft contact saft - 4410CH1 416017 CVH441KH 112804 411344 100431 100430 116426 - 16158 411105 VHP170KH-3 411024 411301 100523 100430 411075 - Page 10003 Aug 29/2008 . OPERATING AND MAINTENANCE MANUAL Illustrated part list Battery P/N cell 40206-2 167468 VP400KH 40208-1 166409 VHP430KH-3 40208-2 410089 40208-5 010 +020 010 020 200 210 220 230 240 165877 167543 410995 - - 100708 - 165763 165888 167522 410995 - - 100708 - VHP430KH 167523 165888 167543 410995 - - - - 410687 VHP430KH-3 167523 165888 167522 411314 - - 100708 - 40253 019654000 VP340KA 021424 -000 022041 -000 40576 023311000 VP400KH 023313 -000 021442 -000 093616 -000 - 022077 -000 009384 -000 40576-14 023311000 VP400KH 023664 -000 021442 -000 093616 -000 - 022077 -000 009384 -000 40776 023673000 VP400KH-AC 023674 -000 020581 -000 093616 -000 - 022077 -000 009384 -000 A2609-1 416266 VHP260KH-3SQ - - - - - - - - A26908 415509 VHP260KH-3SQ - - - 415665 - - - - B153CH1 415223 CVH150KH 415262 415268 415264 415346 108045 104960 415251 - B1513CH1 415444 CVH150KH 415557 415268 415554 415564 108045 104960 415251 - Page 10004 Aug 29/2008 022078 -000 . Links part list 3-1. List Battery Cell connections 030 040 050 060 070 080 090 19VO3KHB 011949 - - - - - - 20VO3KHB 011949 414573 - - - - - 407CH5 A2 012374 015539 015266 411691 114767 - - 1277 C1 100516 100517 100518 100519 100520 102256 - 1277-1 C1 100516 100517 100518 118096 100520 102256 - 1277-3 C1 414142 414141 100518 414143 414144 414242 - 1600 G1 012943 014704 014702 - - - - 1606 G2 013678 012943 - - - - - 1608 G2 013678 012943 - - - - - 1608-1 G3 013678 012943 114735 - - - - 1656 D1 013678 012944 013633 012943 014703 - - 1656-2 D2 012943 012944 013633 013678 014703 - - 1656-5 D2 012943 012944 013633 013678 014703 - - 1658 D1 012943 012944 013633 013678 014703 - - 1658-2 D2 012943 012944 013633 013678 014703 - - 1666-1 E 012943 014702 166878 114735 - - - 1756 D1 015734000 015735000 015736000 015737000 019728000 - - 2371-1 C2 101228 101229 101230 101231 057012 100880 114735 2371-2 C2 101228 101229 101230 101231 057012 100880 114735 2371-5 C2 101228 101229 101230 101231 057012 100880 114735 2371-6 C2 101228 101229 101230 101231 057012 100880 114735 2371-7 C3 101228 101229 101230 101231 057012 100880 - 2376-2 C2 101228 101229 101230 101231 057012 100880 114735 2376-7 C3 101228 101229 101230 101231 057012 100880 - 2376-8 C2 101228 101229 101230 101231 057012 100880 114735 2378 C3 101228 101229 101230 101231 057012 100880 - 2500 G1 014709 103267 014702 - - - - 2506-1 I1 013678 013955 115601 115598 - - - 2506-2 I2 013678 013955 115601 115598 116060 - - 2522 J1 013955 103459 014702 014404 - - - 2708-1 B1 012374 165881 165882 - - - - 2778 A1 012374 015539 015266 057014 - - - 2778-5 A2 012374 015539 166686 057014 166687 - - 2778-10 A2 012374 015539 015266 057014 114767 - - 2778-15 A2 012374 015539 116112 057014 114767 114767 - 2778-18 A1 012374 015539 015266 411691 - - - 4002 B1 012374 100079 100080 - - - - Page 10005 Aug 29/2008 .OPERATING AND MAINTENANCE MANUAL Illustrated part list 3. OPERATING AND MAINTENANCE MANUAL Illustrated part list Cell connections 030 040 050 060 070 080 090 4006A-1 B1 012374 100079 100080 - - - - 4008-1 B2 012374 100079 100080 114767 - - - 4017CH-1 K 015575000 015577000 015576000 - - - - 4050A1-1 A2 012374 100098 012521 057014 - - - 4071-2 A2 012374 015539 116112 057014 114767 - - 4072 A1 012374 015539 015266 057014 - - - 4076-2 A2 012374 015539 015266 057014 114767 - - 4076-3 A2 012374 015539 015266 057014 114767 - - 4076-16 A2 012374 015539 015266 057014 114767 - - 4076-17 A1 012374 015539 015266 411691 - - - 102298 102299 102300 102301 - - - Battery 4077 4078 A1 012374 015539 015266 057014 - - - 4078-1 A2 012374 015539 015266 057014 114767 - - 4078-5 A2 012374 015539 116112 057014 114767 - - 4078-10 A2 015575000 015577000 015578000 015576000 015926000 - - 4078-13 A1 012374 015539 015266 057014 - - - 4078-14 A1 012374 015539 015266 411691 - - - 4078-16 A2 012374 015539 116112 411691 114767 - - 4079-19 A2 015575000 015577000 01642300 015576000 015926000 - - 4078-21 A1 012374 015539 015266 411691 - - - 4079 A1 012374 015536 015266 057014 - - - 4079-1 A2 012374 015539 015266 057214 102393 - - 4079-6 A2 012374 015539 015266 411691 114767 - - 4079-9 A1 012374 015539 015266 411691 - - - 4080 A1 014184 015539 012521 057014 012374 - - 4410CH1 H2 012374 114767 - - - - - 16106-1 G3 013678 012943 114735 - - - - 16108-1 G3 013678 012943 114735 - - - - 119084 114881 119083 412240 100431 100430 40179-7 40206-2 B2 012374 165881 165882 114767 - - - 40208-1 H1 012374 165881 165882 - - - - 40208-2 B2 012374 165881 165882 114767 - - - 015576000 015575000 015579000 - - - - 40253 40576 A1 015575000 015577000 015578000 015576000 - - - 40576-14 A1 015575000 015577000 015578000 015576000 - - - Page 10006 Aug 29/2008 . OPERATING AND MAINTENANCE MANUAL Illustrated part list Battery Cell connections 030 040 050 060 070 080 090 40776 A2 0155575 -000 015577000 015578000 015576000 015926000 - - A2609-1 G3 012943 014403 413983 - - - - A26908 G4 415569 415568 014403 012943 414917 - - Page 10007 Aug 29/2008 . OPERATING AND MAINTENANCE MANUAL Illustrated part list 3-2. Drawings polarity + A1 Page 10008 Aug 29/2008 polarity - . OPERATING AND MAINTENANCE MANUAL Illustrated part list C1 50 Page 10009 Aug 29/2008 . OPERATING AND MAINTENANCE MANUAL Illustrated part list 30 G3 G4 40 H1 40 50 60 50 30 50 50 40 30 I1 60 50 40 30 Page 10010 Aug 29/2008 60 40 70 . Cell part list Cell 100 110 120 130 140 150 160 CVD34KH 413481 413445 100111 100695 100696 100479 415219 CVH150KH 414400 411810 100111 100695 100696 100479 415215 CVH180KH 414244 411810 100111 100695 100696 100479 415215 CVH180KH-SQ 413105 411810 100111 100695 100696 100479 415221 CVH271KH 415227 062000 100111 100695 100696 100479 415215 CVH400KA 413597 062007 100094 100694 100693 100078 413600 CVH400KH-SQ 413598 062007 100094 100694 100693 100078 413618 CVH441KH 414470 062007 100094 100694 100693 100078 415213 CVH441KH-SQ 414491 062007 100094 100694 100693 100078 415217 KO7.OPERATING AND MAINTENANCE MANUAL Illustrated part list 4.1 062023 415213 093625000 Page 10011 Aug 29/2008 .5KH 019872000 090312000 091179014 VHP170KH-3 166129 062000 100111 100695 100696 100479 415219 VHP170KH-3-SQ 412827 062023 100110 100695 100696 100479 415220 VHP230KA3 410406 062007 100094 100694 - 100078 415218 VHP260KH-3 166300 062000 100111 100695 100696 100479 415219 VHP260KH-3-SQ 410232 VHP270KH-3 165949 062007 100094 100694 100693 100078 415218 VHP270KH-3-SQ 410155 062007 100094 100694 100693 100078 415217 VHP370KA-3 165823 062007 100094 100694 100693 100078 415218 VHP370KH-3-SQ 166127 062007 100094 100694 100693 100078 415217 VHP430KH-3 165797 062007 100094 100694 100693 100078 415218 VHP430KH-3-SQ 411288 062007 100094 100694 100693 100078 415217 VHP450KA-3 411480 062007 100094 100694 100693 100078 415213 VO3KHB 102875 062005 100132 102158 102159 - 102880 + 100656 VO16KH 063409 062000 100111 100973 013998 013999 415215 VO23KH 063410 062000 100111 100695 100696 100479 415215 VO23KH-SQ 410537 062000 100111 100695 100696 100479 415220 VO25KA 103247 062000 100111 100695 100696 100479 415215 VO25KA-C 412948 062000 100111 100695 - 100479 415215 VO40KH 063428 062007 100094 100694 100693 100078 415213 VO40KH-3 412462 062023 100111 100695 100696 100479 VO40KH-C 412933 062007 100094 100694 100693 100078 VO80KH 102555 062013 011649 100325 100326 412269 VOEC40KH 411366 411362 100094 100694 - 100078 VP120KHB 018910000 009772000 091179035 - - - VP120KH-MS 063424 102883 - - - VP160KH 063417 100111 100695 100696 100479 HVO1. OPERATING AND MAINTENANCE MANUAL Illustrated part list Cell 100 110 120 VP160KH-SQ 410379 062000 100111 VP160KM 161144 062003 100111 100695 100696 100479 415215 VP160KM-SQ 167590 062003 100111 100695 100696 100479 415220 VP170KH 163937 062002 100111 100695 100696 100479 415215 VP200KHB 459842 062000 100111 100695 100696 100479 415220 VP230KH 063415 62000 100111 - - 100479 415215 VP250KH 063413 062023 100111 100695 100696 100479 415215 VP340KA 021684000 015579000 022228000 - - - 015957000 VP380KH 021685000 015579000 022228000 - - - 015957000 VP400KH 063412 062007 100094 100694 100693 100078 415813 VP400KH-AC 410863 062007 100094 100694 100693 100078 414089 VP400KH-MS 410583 083003 078011 - - - VP400KH-SQ 166927 062007 100111 100694 100693 100094 415217 VP65K 100742 100736 100111 - - 100735 415214 VXP310KH 412960 062007 100094 100694 - 100094 415218 Page 10012 Aug 29/2008 130 140 150 160 415220 . we recommend to put them in a heavy gauge plastic bag that is subsequently heat sealed. Put the battery in its usual vertical position. Short term storage Place the charged battery (serviced according to OMM procedure) in a cool room or discharge to 1 V/cell (refer Residual discharge). and all the components that can be damaged by atmospheric corrosion with M02. the links. 2-2. 90 5 °C 20 °C 80 25 °C 30 °C 70 35 °C 40 °C 60 0 10 20 30 40 50 60 REST TIME (days) 70 80 90 Short term storage Figure 1 2-4. The standard cardboard packaging is considered unsealed and allows 2 years of storage Page 15001 Aug 29/2008 . In this type of container. with the recommended temperature range.OPERATING AND MAINTENANCE MANUAL Storage (including transportation) STORAGE (INCLUDING TRANSPORTATION) 1. 1-3. Packaging The batteries and cells are usually put in cardboard boxes. the batteries can be kept for 10 years. Temperature conditions The recommended temperature range is + 20 °C ±15 °C (68 °F ±27 °F). 100 CHARGE RETENTION Aircraft Ni-Cd battery Place in a storage room. However. Introduction 1-1. Lightly lubricate the nuts. 1-2. Storage procedure 2-1. For long storage or sea transportation. Storage room Keep the batteries and spares in a dry and clean room. The figure and item numbers are those of the Illustrated part list chapter. 2-3.60 °C (67 °F) to + 60 °C (+ 140 °F) for short periods of time without harming the battery. General Storage preparation and packaging makes sure that the equipment is protected against any attack by atmospheric agents. Preparation of the battery before storage Service the battery as scheduled (periodical check. occasional excursion into the range of -60 °C to +60 °C (-76 °F to +140 °F) is permitted. AVAILABLE CAPACITY (%C1Ah) Light greasing of cells terminals. regular check or general overhaul check). Long term storage CAUTION: Saft Ni-Cd batteries may be stored in temperatures ranging from . 2. . . 3 months to 1 year Do the Periodical check More 1 year Do the Regular check .Normal vertical position. Light greasing of cells terminals.Humidity: < 70 %. 2-5. filled with alkali) according to packing instruction 800 Page 15002 Aug 29/2008 . Servicing after discharged storage Storage time Servicing procedure Less than 3 months Charge the battery (Do one of the procedures given in INSPECTION/CHECK chapter) for a fully discharged battery. According to the IATA / IMDG dangerous goods regulations. if using the following conditions : . No maintenance operation needs to be done during the storage period. . 2-4-1. The storage life is 10 years. 2-4-2.OPERATING AND MAINTENANCE MANUAL Storage (including transportation) under the above conditions. vibration. . If the original container is not available. Place in a storage room. The battery should then be packed vertically in its original container. 3. Operations Discharge to 20 V. the international and/or local packaging regulations applicable to the mode of transport and destination must be followed. If it is necessary to transport a charged battery.Temperature: + 20 °C ± 15 °C (68 °F ± 27 °F).Sealed packaging. corrosive atmosphere. make sure that the output terminals are protected against short circuit. humidity. Conditions The battery should be stored filled and discharged. Transportation procedure The battery is normally discharged before packing.Isolated from detrimental agents : dirt. Saft ships all existing nickel-cadmium batteries or cells for aircraft under the classification UN2795 (wet. dust. Lead batteries must be stored in a different room.