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23180 / 23186
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
23180 / 23186
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
RECORD OF REVISIONS
ROR Page 1
ROR Page 2
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
RTR Page 1
RTR Page 2
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
SBL Page 1
SBL Page 2
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COMPONENT MAINTENANCE MANUAL
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
LEP Page 2
TABLE OF CONTENTS
PAGE
INTRODUCTION Intro Page 1
1 – General Intro Page 1
2 – How to Use the Manual Intro Page 1
3 – Measures Intro Page 1
4 – Units of Measure Intro Page 2
5 – Abbreviations Intro Page 3
6 – Definition Intro Page 3
7 – Disposal Intro Page 4
DISASSEMBLY 3001
1 – General 3001
2 – Safety 3001
3 – Risks 3001
4 – Safety Measures 3001
5 – Disassembly 3002
CLEANING 4001
1 – General 4001
2 – Equipment 4001
3 – Materials 4001
4 – Cleaning procedure 4001
5 – Lubrication 4003
CHECK 5001
1 – General 5001
2 – Maintenance in workshop 5001
REPAIR 6001
1 – General 6001
2 – Equipment 6001
3 – Repairs 6001
TOC Page 1
ASSEMBLY 7001
1 – General 7001
2 – Assembly procedures 7001
TOC Page 2
TABLE OF ILLUSTRATIONS
PAGE
Figure 1 23180 / 23186 Battery OP Page 3
Figure 2 Identification plate OP Page 3
Figure 3 Overall dimensions OP Page 4
Figure 1001 Insulation Test 1002
Figure 1002 Insulation Test Parameters 1003
Figure 1003 Electrolyte Adjustment 1006
Figure 1004 Functional Test Flow 1009
Figure 5001 Periodic Check 5003
Figure 5002 Regular Check 5005
Figure 5003 General Overhaul 5008
Figure 7001 Liner spacer kit installation 7002
Figure 7002 Cell Installation 7004
Figure 8001 Torque Specifications 8001
Figure 9001 Polyamide key for vent-valve (T01) 9002
Figure 9002 Syringe with nozzle (T02) 9002
Figure 9003 Equalizing resistor (T03)` 9002
Figure 9004 Cell Extraction Tool (T04) 9003
Figure 9005 Vent-Valve Testing Tool 9003
Figure IPL1 23180 / 23186 Battery (exploded view) 10011
Figure 15001 Charge Retention 15002
Figure 15002 Return to Service Procedure 15003
TOI Page 1
TOI Page 2
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and the AECMA Simplified English
standards. S.I. units of measure are used in this manual, with imperial units in parenthesis.
C. Only approved technicians with the necessary skills should perform maintenance as
described in this manual.
D. Aircraft Maintenance Task Oriented Support System (AMTOSS) is not supported in this
manual.
A. Verify this manual contains information applicable to your model battery. Look for the model
number on the Title Page.
B. If you need to identify a part of find a part number, refer to the IPL, which has an introduction
chapter detailing the procedure.
C. The instructions in this manual must be used for maintenance of all components. Read all
the applicable WARNING and CAUTION notations before you perform work on the
component.
3. Measures
Measures given in this manual are taken from the original manufacturing drawings. Quantities are
given in S.I. units followed by U.S. imperial units in parenthesis.
INTRO Page 1
4. Units of Measure
A. S.I. Units
A Ampere
Ah Ampere hour
C1A Battery rated current
C1Ah Battery rated capacity for one hour
g Gram
N Newton
N·m Newton-Meter
Pa Pascal
VDC Volt direct-current
°C Degree Celsius
% Per cent
W Ohm
mm Millimeter
ft Foot
in Inch
lb Pound
Lb●in Inch pound
Lb●ft Foot pound
InHg Inches of mercury
2
Psi Pounds per in
°F Degree Fahrenheit
C. Multiplying Prefixes
m Micro
m Milli
Da Deca
k Kilo
M Mega
INTRO Page 2
5. Abbreviations
6. Definition
A. WARNINGS call attention to the use of materials, procedures, or limits that must be followed
to avoid personal injury. Warnings will appear directly above the procedure they apply to.
B. CAUTIONS call attention to procedures that must be followed to avoid damage to the
equipment.
C. NOTES call attention to procedures that make the job easier or include special information
that pertains to the procedure.
INTRO Page 3
7. Disposal
Local legislation concerning disposal or recovery must be followed. For more information,
contact your local Saft supplier.
INTRO Page 4
1. Description
A. General
The alkaline battery 23180 has 20 vented nickel-cadmium VO23KH cells with welded
polyamide cases.
The alkaline battery 23186 has 20 vented nickel-cadmium VP230KH cells with welded
polyamide cases.
NOTE: The 28 VDC electrical system charges the battery onboard aircraft
The figure and item numbers in this chapter correspond to those in the ILLUSTRATED
PARTS LIST.
B. Characteristics
Nominal Voltage 24 V
Rated capacity C1Ah 23 Ah (23180)
22 Ah (23186)
(see example below for more info)
Main Power Connector Connector compliant with ISO 5064/II or
MS 3509
3 3
Consumable volume of electrolyte 21 cm (0.915 in ) per cell (23180 & 23186)
Maximum dimensions of the battery 23180 & 23186
case
- Length (base) (max) 196 mm (7.69 in)
- Width (max) 253 mm (9.96 in)
- Height (max) 226 mm (8.90 in)
Battery maximum weight 24.49 Kg (54.0 lb) for 23186 & 23180
OP Page 1
C. Detailed Description
The batteries have 20 cells (150) housed in a stainless steel case (box) (10).
The case (box) (10) is lined with liners and spacers (supplied in a kit (260)). The cells are
kept upright by a molded silicone elastomer pad fastened to the cover that presses against
the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (60 thru 110).
The main power connector (30) connects the battery to the aircraft.
The cover (20) that can be removed is attached to the case (10) by four latches.
OP Page 2
OP Page 3
226 mm 253 mm
8.90 in 9.93 in
196 mm 253 mm
7.69 in 9.96 in
Overall Dimensions
(drawing may not be representative of specific battery)
Figure 3
OP Page 4
1. General
This chapter provides the tests and inspections required to determine the condition of a unit removed
for maintenance (scheduled or unscheduled). The table in section 7 (Fault Isolation) can be used to
assist in isolating and detecting faults noted during the maintenance process.
2. Testing
A. Equipment
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
(3) Instruments
Page 1001
B. Precautions
- Do not install the battery in an aircraft that is too hot (>60°C (140°F)).
- Carefully follow aircraft installation instructions to ensure good airflow.
- Verify the capacity of the battery at specified intervals.
- Charge the battery in a battery shop.
- Maintenance should be performed per instructions found in the CHECK chapter to verify:
ü Level of electrolyte
ü Torque on the connection nuts
ü Correct onboard charging
ü Battery capacity
D. Testing procedures
(a) Place the leads of the megohmeter as indicated below. Check from the outer
case (10) to each cell terminal. See Figure 1002 for information regarding
minimum values.
+
MW
-
Insulation Test
Figure 1001
Page 1002
250 KW 2 MW 10 MW
Can wait until next
Unacceptable To be cleaned OK
maintenance
(a) Charge the battery at 2.3 A (23180) or 2.2 A (23186) for 1.5 hours
(d) If the open circuit voltage of any cell is 0 V (or negative polarity), perform a
Special Test (refer to paragraph (4)) and repair if necessary.
(e) If every cell has an open circuit voltage that is greater than 0 volts, charge
the battery (refer to section 3).
During charge, before putting the vent-valve (240) back onto the cells, verify proper
operation.
(a) Install the vent-valve (240) with its O-ring (250) on the end of a testing
apparatus (Refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT – Fig
9005).
(c) Adjust the pressure to 0.5 bar (7.25 psi) and put the vent-valve into a
container of water. Air bubbles will come out when the valve opens. If there
are no bubbles, increase the pressure until you see bubbles and note the
pressure.
(d) Decrease the pressure slowly to 0.1 bar (1.45 psi) and monitor the pressure
at which the bubbles stop.
Page 1003
(e) Reject all vent-valves that have an opening pressure greater than 0.7 bar (10
psi) and/or remain open at a pressure less than 0.14 bars (2 psi).
(a) If the battery is discharged, charge the battery fully (refer to section 3) then
continue to step (b). If the battery is already charged, continue to step (b).
(b) Continue to charge the battery at 2.3 A (23180) or 2.2 A (23186) for an
additional 5 hours, regularly recording the voltage of each cell.
(c) At the end of the additional 5-hour charge, mark any cell with a voltage less
than 1.50 V for replacement.
(d) With current still flowing, adjust the electrolyte in all cells.
(e) Discharge the battery down to 0 V (Initial and Residual discharges) (Refer to
section 5)
3. Charge
A. Flight Charge
The battery charge is normally maintained onboard by the electrical system or a dedicated
onboard charger.
NOTE: The decrease of water from the cells is in direct proportion to the overcharge
the battery receives.
Page 1004
B. Ground Charge
(a) To charge a fully discharged battery, perform one of the Main Charge
procedures listed in the table below followed by the corresponding Final
Charge procedure.
(b) For a battery not fully discharged or when the level of charge is unknown:
Page 1005
(2) Other types of Charging: In addition to the constant current method of charging,
other methods that fully charge the battery can be used. HOWEVER, IN EVERY
CASE, CELL VOLTAGE CHECKS (U > 1.5 V) AND ELECTROLYTE
ADJUSTMENTS MUST BE CARRIED OUT USING A FINAL CHARGE AT
CONSTANT CURRENT: 3.6 A AT 0.1 C1A. If specific instructions are not given in the
charger operating manual, Saft should be contacted before charging.
The easiest tool to use to adjust the level of the electrolyte is a plastic syringe (T02) with a plastic
nozzle on the conical end.
The length of the nozzle that goes into the cell must be 20 mm (0.79 in). This is the distance
necessary between the seat of the vent-valve (240) and the electrolyte (refer to Figure 1003).
3 3
NOTE: The maximum consumable amount of electrolyte for this battery is 21 cm (1.464 in )
per cell (refer to DESCRIPTION AND OPERATION).
20mm
A. Insert the nozzle into the cell until the nozzle rests on the seat of the vent-valve opening. Pull
the syringe plunger up. If the level is not sufficient, the syringe tube stays empty when you
pull the plunger up. If there is too much electrolyte, the electrolyte is removed by the syringe
until the level aligns with the end of the nozzle. Discard any liquid drawn into the syringe
when leveling, do not reuse the liquid in other cells.
B. If in check 4.A there is no liquid removed by the syringe, the level is not sufficient. Perform
the following to adjust the electrolyte:
Page 1006
(1) Add a measured amount (5ml) of distilled or deionized water (M01) into the syringe
and inject it into the cell. Keep record of how much distilled or deionized water (M01)
is being injected into the cell during this procedure.
NOTE: The amount of distilled or deionized water (M01) required to level the
first cell will serve as an approximate guide to the amount required
for the remaining cells in the battery. However, each cell must be
adjusted individually to ensure the correct level is achieved in each
cell.
5. Discharge
The initial discharge can also be used to determine the capacity of the battery. The battery
should be discharged at a rate equal to its rated capacity (noted on the battery label).
(a) Discharge the battery at 1C1A down to 20 V, monitoring the time from the
start of the discharge to the time the battery voltage (at the main terminals)
reaches 20 V.
The time should be greater than 30 minutes. If not, one of the following may
be the cause:
- There was a discharge performed after the last use of the battery onboard
the aircraft
- The aircraft charger may not be functioning properly
- If the battery was left idle for a time, self-discharge occurred
- The battery cells may be imbalanced and need servicing
(a) Discharge the battery at 1C1A, monitoring the time from the start of the
discharge to the time any of the cells voltage falls below 1 V. Mark the time
any cell in the battery reads below 1 V.
Each cell in the battery should maintain a voltage higher or equal to 1 V for a
full 60 minutes of discharge at 1C1A (refer to Discharge Table). If one or
more cells should fall below 1 V in less than 60 minutes, refer to Section 7
(FAULT ISOLATION).
Page 1007
Discharge Table
B. Residual Discharge
The Residual Discharge will clear the battery of all “residual” energy left in the battery after
the Initial Discharge or the Capacity Test. This procedure is to be performed after the battery
has been discharged to 1 V per cell.
These batteries are not equipped with an auxiliary temperature sensor. For temperature monitoring,
consult the Aircraft Maintenance Manual or the aircraft OEM.
Page 1008
7. Fault Isolation
Salt or Yes
electrolyte See para. 7.C (1) More than 25% Yes
average added in See para. 7.B (2)
traces
1 cell
No
No
Electrolyte in Yes
See para. 7.C (2) 1 or more cells Yes
the case See para. 7.B (3)
voltage different
by >0.1V
No
No
No
No
No
No
No
Page 1009
(b) Link loose or broken Verify the nuts have the proper
torque (refer to FITS AND
CLEARANCES).
(2) Zero volts with the battery set (a) Battery fully discharged Perform an Insulation Test and
to “discharge” recharge the battery (refer to
TESTING AND FAULT
ISOLATION).
B. Cell Faults
Page 1010
(c) Previous maintenance was Note the cell location and check
not performed or performed the level of water consumption
incorrectly versus other cells at the next
maintenance interval
3
(3) A cell has an unusually high (a) Dry cell Add 5 cm of distilled or
voltage at the start of the charge deionized water to the cell. Do
not add more unless voltage
continues to be exceptionally
high. Level electrolyte at final
level at the end of charge (refer
to TESTING AND FAULT
ISOLATION).
NOTE: If a cell is charged with low electrolyte levels, it may cause overheating and permanent
damage to the cell and adjacent cells.
(4) A cell has an unusually low (a) The cell was operated at Replace the cell (refer to
voltage at the end of the Final temperatures and charge rates DISASSEMBLY and
Charge (less than 1.50 V) outside the limits, and the ASSEMBLY)
separator is damaged
Page 1011
C. Physical Faults
(2) Electrolyte found in the (a) Damaged cell case Replace the cell if necessary.
battery case. Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
Page 1012
D. Vent-valve Faults
Page 1013
Page 1014
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
1. General
This chapter gives all electrical schematics of the battery temperature sensor (if applicable).
Page 2001
Page 2002
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
DISASSEMBLY
1. General
Refer to the TESTING AND FAULT ISOLATION chapter to determine the malfunction and necessary
level of disassembly required.
The figures and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2. Safety
The safety regulations are different from one country to another. Check local regulations for those
that apply.
3. Risks
A. Physical
B. Electrical
C. Chemical
- Electrolyte is very corrosive and may cause severe burn to the skin: wear gloves and apron.
- Contact with the eyes is very dangerous; wear protective goggles.
4. Safety Measures
- The electrolyte is caustic and can cause severe burns. If electrolyte comes in contact with the skin,
flush the affected area with water and neutralize the solution with acetic solution, vinegar, lemon
juice, or with boric acid solution at 10% concentration.
- If the electrolyte comes in contact with the eyes, flush with water for at least 15 minutes and contact
a physician.
- Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the
solution with water or milk. Contact a physician immediately.
- Contact with nickel can cause chronic eczema.
- Inhalation of cadmium oxide can cause a dry throat, cough, headaches, vomiting, or pain in the
chest. Persons having inhaled cadmium oxide fumes must get fresh air, take oxygen, or have
artificial respiration. Contact a physician as soon as possible.
- Potash can cause eczema.
Page 3001
5. Disassembly
A. Equipment
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
B. Disassembly procedure
(a) Remove the cover by pulling up the tab on the latches that attach the cover
(20) to the case (10) and lifting the cover upward.
(a) Unscrew the vent-valve (240) with the special tool (T01).
Page 3002
(a) Remove the nuts (130, 160) and spring washers (170, 140) that attach the
links (60 thru 110) to the cells.
(c) Attach the cell extraction tool (T04) to the cell terminal. Pull up to remove the
cell.
Not applicable
(c) Remove the liner-spacer kit (260) by pulling out the liners and spacers,
making sure to mark them to ensure correct placement during assembly.
Page 3003
Page 3004
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
CLEANING
1. General
This chapter provides instructions for the cleaning and preservation of the battery components.
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2. Equipment
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eyewash.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled or deionized water (M01).
- Neutral soap (M02).
- Non-fluffy swab.
- Non-wire brush.
- Rubbing alcohol (isopropyl)
4. Cleaning Procedure
A. Light Cleaning
(2) Blow (with compressed air) across the tops of the cells to remove all dust and light
traces of mineral salts from the battery. Using a clean cloth, wipe off all temperature
sensor components (if installed).
Page 4001
(a) Clean connector pins with rubbing alcohol to clean off any accumulated
grease and/or dirt. Inspect the pins for damage, which includes any pits,
cracks, or scratches, that allow copper to show through the nickel plating.
Replace connectors that are damaged with a Saft factory new unit.
B. Thorough Cleaning
(1) Disassemble the battery (refer to DISASSEMBLY) and then clean all components
except the vent-valve (240) which must be cleaned while cells are in the case.
2 To easily remove all the electrolyte and mineral salts from the
terminals, cover, and sides of the cell cases, clean in warm water
with a soft brush.
1 Clean with light soap (M02) and water, rub with a cloth and let dry.
(c) Nuts (130, 160, 180), flat washers (220), and spring washers (140, 170, 210),
and links (60-110)
1 Clean in warm water with a soft brush and let dry. Inspect for rips,
tears, warping, or heat damage. Replace liners that are damaged.
Not applicable
Page 4002
2 Place a swab or soft cloth over the cell opening to keep out
unwanted material.
5. Lubrication
When the battery is clean (with the vent-valve installed), put a thin layer of mineral vaseline (M04) or
light oil on the terminals and on the links. Use of a paintbrush will make this procedure easier.
Page 4003
Page 4004
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
CHECK
1. General
The checks in this chapter are necessary to use the batteries in flight and on the ground. The
maintenance procedures in this chapter should be carried out in a battery shop. The three types of
maintenance that will be detailed in this chapter are:
2. Maintenance in workshop
A. Equipment
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
(3) Instruments
B. Conditions
Page 5001
C. Periodic Check
If the electrolyte consumption exceeds the maximum consumable amount between two
Regular Checks, this Period Check may be performed to adjust the electrolyte. Maintenance
should be performed using Fig 5001 as a guide and will include the following steps:
(3) Check the torque on all nuts (130, 160) (refer to FITS AND CLEARANCES).
(5) Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test (refer to TESTING AND FAULT
ISOLATION).
(6) Perform an Initial Discharge at 1C1A down to 20 V at the battery terminals, and allow
the battery to cool (refer to TESTING AND FAULT ISOLATION).
(8) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (240) (refer to CLEANING).
(10) Check the torque on all nuts (130, 160) (refer to FITS AND CLEARANCES).
Page 5002
Periodic Check
Check Torque
Light Cleaning
on all nuts
Yes
Dust Only
Cell to Case
No No
Insulation Test
> 2 Megohms
Electrolyte Traces
Yes
Fault Isolation
No Charge
For standard product
all cells > 1.50V
Special Test
Additional charge with up to Yes
5 hr overcharge Yes
Yes
Check Torque
on all nuts
Battery Accepted
Periodic Check
Figure 5001
Page 5003
D. Regular Check
After six months, or according to aircraft manufacturer’s specifications, perform this check
following the different procedures indicated in Figure 5002.
(3) Check the torque on all nuts (130, 160) (refer to FITS AND CLEARANCES).
(4) Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test.
(9) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (240) (refer to CLEANING).
(12) Re-check the torque on all nuts (130, 160) (refer to FITS AND CLEARANCES).
(13) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Page 5004
Regular Check
Check Torque
on all nuts
Light Cleaning
Yes Total Voltage > 21 V
Dust Only No At main power connector
No No cells with reversed polarity
Electrolyte Traces
Yes
Residual Discharge
1 Ohm - 3W Min Resistor
12-16 hours on all cells
Cell to Case
Insulation Test
No > 2 Megohms Yes
Test Temperature
No Sensor Yes Charge
For standard product
No all cells > 1.50V
Yes
General Overhaul
Charge
For standard product
No all cells > 1.50V
Adjust Electrolyte
at end of charge
Regular Check
Figure 5002
Page 5005
E. General Overhaul
The General Overhaul includes electrical tests contained in the Regular Check. It also
includes disassembly and cleaning of all components. Perform the General Overhaul every
12 months, or according to aircraft manufacturer’s instructions, following the procedures
indicated in Figure 5003.
NOTE: If three cells are replaced during a single maintenance cycle, or five cells
over the life of the battery, Saft recommends that all cells be changed or the
battery be replaced.
(1) Check the torque on all nuts (130, 160) (refer to TESTING AND FAULT ISOLATION).
(2) Measure the voltage of the battery at the main terminals. If the voltage is less than
21 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION).
(3) Perform an Initial Discharge at 1C1A down to 20 V (refer to TESTING AND FAULT
ISOLATION).
(4) Perform a Residual Discharge with resistor clips (T03) down to 0 V (refer to TESTING
AND FAULT ISOLATION).
(6) Thoroughly clean the battery (refer to CLEANING) and inspect components.
(8) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value
measured after a Thorough Cleaning should be at least 10 MW.
Page 5006
(10) During the Final Charge, clean and test the vent-valves (240) (refer to CLEANING
and TESTING AND FAULT ISOLATION).
(13) Check the torque on all nuts (130, 160) (refer to FITS AND CLEARANCES).
(14) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Page 5007
General Overhaul
Disassembly
and Thorough Cleaning
Visual Inspection
Assembly Temperature Sensor Test
Check - Disassembled Battery
Cell to Case
Insulation Test
No > 10 Megohms Yes Charge
For standard product
all cells > 1.50V
No
Yes
Vent Valve Cleaning/Test
Adjust Electrolyte
during last 15 minutes of
Fault Isolation charge with constant
No current flowing
< 25% difference in
Special Test
electrolyte levels
Complete charge with
Additional charge with up to
Yes
5 hr overcharge
Yes No
Capacity Test
For standard product
Yes
All cells > 1.50V
Check Torque
on all nuts
No
Full Discharge
Charge
Replace faulty components For standard product
and return to charge No all cells >1.50V
Adjust Electrolyte
at end of charge
Yes
Battery Accepted
General Overhaul
Figure 5003
Page 5008
REPAIR
1. General
Defective parts for which no repair instructions are given shall be rejected and replaced by Saft
factory new parts only.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2. Equipment
A. Special Tools
When special tools are used in this chapter, a code number that can be found in SPECIAL
TOOLS, FIXTURES AND EQUIPMENT, identifies them.
B. Standard Tools
C. Materials
3. Repairs
A. Cover Gasket
The Cover Gasket (not shown) can only be re-glued one time.
(2) Clean all traces of glue from the metal Cover (20).
(3) Apply the glue (M03) to the flat side of the Cover Gasket (not shown).
(4) Let dry for 2 hours in a dry place (or as specified by manufacturer’s instructions).
(5) Place Cover Gasket (not shown) on the bottom of the Cover (20) and press firmly to
seat.
Page 6001
Page 6002
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COMPONENT MAINTENANCE MANUAL
23180 / 23186
ASSEMBLY
1. General
Battery assembly is to be performed in a clean, dry room where all parts are protected from any
impact from other parts or tools. Any protective layers applied to replacement parts must be removed
prior to assembly.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2. Assembly Procedures
A. Equipment
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
Not applicable
(1) Insert the connector (30) with the gasket (50) into position in the battery case (10)
and attach with screws (40).
(1) Insert the bottom liner into the bottom of the case (10).
(2) Follow the assembly shown in Fig 7001, inserting liners and spacers in each position.
NOTE: Additional liners and spacers may be necessary to keep cells (150) tight in
the case (10).
Page 7001
1 Req’d
3 Max 1 Req’d
Bottom 3 Max
1 Min
8 Max
2 Req’d
1 Min
4 Max
1 Req’d
2 Req’d
1 Req’d
1 Min
8 Max
1 Req’d
1 Req’d
4 Req’d 4 Req’d
9 Max 1 Req’d 1 Req’d 9 Max
4 Max
Page 7002
(1) Cells should be installed in rows. Install all but the center cell in each row according
to their polarity as found in Fig. 7002. Make sure to install any liners and spacers
(refer to Fig 7001) and/or temperature sensor plates (if applicable) that are needed in
between the cells at this time.
(2) Carefully position the last cell (150) in each row, and insert the cell (150) by pressing
on the terminals with a piece of soft wood. This cell should be difficult to insert,
requiring 25-30 lb-ft of pressure to seat. If the cell is too loose, install additional liners
and spacers (260). If the cell is too difficult to insert, remove a liner or spacer (260)
as needed. Never lubricate a cell to facilitate installation.
(3) Lightly lubricate all links (60 thru 110), flat washers (220), spring washers (140, 170,
210), nuts (130, 160, 180), and cell terminals with a mineral vaseline (M04) or light oil
using a paintbrush.
(4) Install the links (60 thru 110), spring washers (140, 170), and nuts (130, 160).
(6) Torque all nuts (130, 160) (refer to FITS AND CLEARANCES).
Page 7003
= Positive
Cell Installation
Figure 7002
Page 7004
1. General
The FITS AND CLEARANCES section provides torque specifications for any components requiring a
specific torque value, or clearance values for moving parts that require specific clearance distance.
2. Torque Specifications
IMPORTANT: The values provided in the torque table (Fig 8001) are “lube torque” values. All
threads should be lightly lubricated with mineral vaseline (M04) or light oil prior to installation and
applying torque.
Torque Specifications
Figure 8001
Page 8001
Page 8002
24-30-05 BLANK
COMPONENT MAINTENANCE MANUAL
23180 / 23186
1 General
This chapter provides pertinent specifications for any special tools that may be needed during battery
maintenance. It also supplies a listing of consumable items that may be useful during normal
servicing, repair, and use.
PART PART
NUMBER NUMBER
CODE FIGURE QTY (where (where DESCRIPTION USE
applicable) applicable)
F6177 V09052
-DISASSEMBLY
-CLEANING
T01 9001 1 N/A 093365-000 Vent-Valve Wrench
-CHECK
-ASSEMBLY
105112
Syringe w/20 mm -TESTING AND
Syringe
T02 9002 1 020915-004 Nozzle FAULT ISOLATION
016544 -CHECK
(for M8 Valves)
Nozzle
Page 9001
Page 9003
3. Consumables
A
D
I
I A
R C
S S S
L L R
A C S T
I T E E
DESIGNATION PART S H E O
MANUFACTURER N E A P
CODE NUMBER AND S E M R
OR SUPPLIER E S N A
SPECIFICATION E C B A
T I I
M K L G
C N R
B Y E
O G
L
D
Y
E
Distilled or deionized water;
clear, colorless, odorless
while boiling, resistivity
>30 KW/cm
5 < pH > 7
Absence of organic and
reducing substances.
M01 X X
Reducing agent content Local Vendor
(expressed in weight of
oxygen) < 30 mg/l (test with
permanganate). Total of
2+ -
ions: SO4 Cl < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
NATO: S 743
M04 Mineral Vaseline F: AIR 3565 X X
US: SLP 236
UK: DEF 2333
Page 9004
Page 10001
Page 10002
24-30-05 BLANK
COMPONENT MAINTENANCE MANUAL
23180 / 23186
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed
parts of the unit.
- Introduction
- Equipment Designator Index (EDI)
- Numerical Index
- Detailed Parts List (DPL)
- Vendor Code Index
(1) To find the illustration for a part if the part number is known, refer to the Numerical
Index and look for the part number and the corresponding figure and item number.
Refer to the Detailed Parts List and look for the figure and item number found in the
Numerical Index for that part to verify it is the part specified.
(2) To determine the part number of a given part, refer to the Illustrated Parts List figures.
Note the item number of the illustrated part and refer to the Detailed Parts List that
indicates the part number and identification.
The Equipment Designator Index provides all circuit symbols given to the electrical and
electronic components of the items listed. If applicable, they are listed in alphanumeric order.
Classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
- Hyphen
- Alpha from A to Z (except for “O” and “I” which will be considered zero and one)
- Numbers from 0-9
The part number column contains all part numbers included in the Detailed Parts List. Part
numbers that have been deleted or superceded from the Detailed Parts List are listed in the
Numerical Index and identified as deleted or superceded.
Page 10003
The figure number linked to the item number is shown on the first line at the top of
each page.
Assemblies, sub-assemblies, and numbered parts included in the list but not
illustrated are identified by a hyphen (-) preceding the item number.
The letter “R” shown in the index before the item number refers to a modified item of
the Detailed Parts List.
(3) Indenture
The parts list is represented with indenting showing the relationship of parts and
assemblies to their next higher assemblies as follows:
1234567
Assembly
. Sub-assembly
The attaching parts are shown directly after the assembly of the part they attach.
They are listed under the same indenture number as the item they are attached to,
and are identified by the words “Attaching Parts”, followed by three asterisks (*).
Page 10004
When the part is applicable to all effective products, the usage column remains blank.
The usage code for assemblies and detailed parts refer to the figure/item number of
the next higher assembly(ies) or subassembly(ies).
The units per assembly column show the quantity of units required for one next
higher assembly.
F. Abbreviations
Page 10005
G. Updating
(1) General
When an item is revised, added or deleted, the letter “R” is shown in the right-hand
margin (the date of issue in the footer also changes).
The basic sequence of the items given from 10 to 10 makes it possible to add new
items between the old ones in the appropriate order of the breakdown. With the
addition of more than nine new items, a new number would be added at the end of
the IPL.
Should a part number be deleted, the information given in the Detailed Parts List is
deleted. The old part number will always remain in the Numerical Index.
Whenever new illustrations are necessary, they are inserted in the appropriate place
within the manual. The new illustration will refer to the same parts list.
The new figure number is given with the basic figure number and a letter designation.
This letter precedes the item number in the parts list.
Page 10006
F6177 Saft
12 avenue Sadi Carnot
93170 Bagnolet
France
Phone: (33) 1 49 93 19 18
Fax: (33) 1 49 93 19 56
V09052 Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Phone: (1) 229-247-2331
Fax: (1) 229-247-8486
Page 10007
Page 10008
24-30-05 BLANK
COMPONENT MAINTENANCE MANUAL
23180 / 23186
ALPHANUMERIC INDEX
PART PART
AIRLINE FIGURE INDEX TOTAL
NUMBER NUMBER
STOCK NUMBER NUMBER NUMBER REQUIRED
V09052 F6177
Page 10009
Page 10010
24-30-05 BLANK
COMPONENT MAINTENANCE MANUAL
23180 / 23186
250 240
160
170
180
200,190
210
20
220
230
150
120
260
130
140
10
40
100
30 90
50
70
110
80
60
23180 / 23186 BATTERY
IPL FIGURE 1
Page 10011
Page 10012
A nickel-cadmium battery storage location should be free of acid, dust, or dampness. No corrosive
liquids or gases should be stored in the same room. Temperatures may range from -60°C (-76°F) to
+60°C (+140°F) without harming the battery. The most desirable range for storage is between 0°C
(32°F) to +30°C (+86°F).
A. In-service batteries to be stored for less than 90 days should undergo completion of the
Regular Check or General Overhaul and be left in an airworthy status. See Section 5
(CHECK).
B. In-service batteries to be stored longer than 90 days should be discharged and placed in a
container suitable to the duration of storage.
C. Factory new batteries may be stored as received for a period of up to 24 months. Longer
storage duration requires placement in sealed packaging prior to storage.
Active stand-by storage is to be used when the battery must be charged and ready for service
onboard an aircraft in a short period of time. The length of time that a battery will retain a minimum
capacity (80%) will vary dependent upon the ambient temperature of the storage environment (refer
to Figure 15001). For storage longer than 90 days, see procedures for Inactive Storage.
NOTE: Saft vented-cell aircraft batteries may be stored charged, ready for service in the
normal, upright or vertical position.
Page 15001
100
90
AVAILABLE CAPACITY (%C1Ah)
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) (41°F) Disch. (0%C1Ah)
Temp. (15°C) (59°F) Disch. (0%C1Ah)
Temp. (25°C) (77°F) Disch. (0%C1Ah)
Temp. (35°C) (95°F) Disch. (0%C1Ah)
60
0 10 20 30 40 50 60 70 80 90
Days
Charge Retention
Figure 15001
(1) Place fully-serviced, airworthy battery into proper storage for a period not to exceed
90 days.
st
(2) After 90 days (on the 91 day), the battery must receive an electrolyte level
verification. See Section 1 (TESTING AND FAULT ISOLATION).
(3) After electrolyte leveling, the battery can be returned to storage for another period not
to exceed 90 days.
(4) It is possible to repeat Steps 2 and 3 a maximum of two times (three 90 day
intervals).
(5) If the battery has not been installed into an aircraft after three 90 day intervals, it must
undergo completion of the Regular Check or General Overhaul as required. See
Section 5 (CHECK).
Page 15002
(2) Refer to Figure 15001 to determine the maximum number of days a battery can be
stored before maintenance is required.
(3) Place a fully-serviced, airworthy battery into proper storage for a period not to exceed
the maximum number of days determined in step 2.
(4) One day past the maximum number of storage days, the battery must receive an
electrolyte level verification. See Section 1 (TESTING AND FAULT ISOLATION).
(5) The battery can then be returned to storage for a period not to exceed the maximum
duration for the ambient storage temperature.
(6) It is possible to repeat steps 4 and 5 a maximum of two times (three storage
intervals).
(7) If the battery has not been installed into an aircraft after three storage intervals, it
must undergo completion of the Regular Check or General Overhaul as required.
See Section 5 (CHECK).
4. Trickle Charging
The principle of trickle charging is to keep a battery in active stand-by condition by continuously
charging the battery in an over-charge condition. Saft does not recommend this method, however
some operators take responsibility for its use.
WARNING: USE OF A TRICKLE CHARGER WILL CONSUME WATER OVER TIME. FAILURE
TO VERIFY ELECTROLYTE LEVEL PRIOR TO INSTALLATION MAY RESULT IN
PREMATURE BATTERY FAILURE.
Example: If a 40 Ah battery remains on a continuous trickle charge of 3 mA/Ah for one month, the
3
total consumption of water is 35 cm /cell.
The operator must adjust the electrolyte level before placing the battery onboard the aircraft.
Otherwise, the risk of a battery incident exists; cells dry out before the normal end of the
maintenance interval.
Page 15003
Saft nickel-cadmium aviation batteries can be stored in the original cardboard packaging for a period
of two years, and up to 10 years in sealed packaging under the following conditions:
6. Preparation for Use After Storage (other than Active Stand-by Storage)
The normal packing for shipment of Saft nickel-cadmium batteries is with fiberboard or injected foam
packing enclosed in fiberboard or wooden outer containers. For overseas shipments, wrapping in
sealed plastic is recommended. Precautions must be taken to keep batteries upright while in transit.
All markings and documentation should conform to current IATA regulations (UN2795 or UN2800 as
applicable) governing the shipment of vented nickel-cadmium batteries.
Page 15004