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COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

AIRCRAFT BATTERY P/N 26108-6

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Date of issue : June 1996 Title page - Page 1 June 01/96

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COMPONENT MAINTENANCE MANUAL 26108-6

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RECORD OF REVISIONS REVISION No. ISSUE DATE INSERTED DATE BY REVISION No. ISSUE DATE INSERTED DATE BY

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COMPONENT MAINTENANCE MANUAL 26108-6 RECORD OF TEMPORARY REVISIONS TEMPORARY REV. No. PAGE NUMBER ISSUE DATE BY DATE REMOVED BY

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COMPONENT MAINTENANCE MANUAL 26108-6 SERVICE BULLETIN LIST NUMBER BRIEF DESCRIPTION TYPE AFFECTED

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COMPONENT MAINTENANCE MANUAL 26108-6 LIST OF EFFECTIVE PAGES DATE OF LATEST REVISION June 01/96 June 01/96 Blank Disassembly Record of temporary revisions Service bulletin list List of effective pages 1 2 June 01/96 Blank Cleaning 1 2 June 01/96 Blank Check 1 2 June 01/96 June 01/96 501 502 503 504 505 506 507 508 601 602 701 702 703 704 705 706 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 Blank June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 Blank DATE OF LATEST REVISION June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96 June 01/96

CONTENT Title page Record of revisions

PAGE 1 1 2

CONTENT Testing and fault isolation

PAGE 101 102 103 104 301 302 401 402

Table of Contents List of illustrations Introduction

1 2 1 2

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Repair

Assembly and storage

1 2 1 2 3 4 5 6

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Description and operation

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COMPONENT MAINTENANCE MANUAL 26108-6 LIST OF EFFECTIVE PAGES DATE OF CONTENT REVISION DATE OF LATEST REVISION

CONTENT Special tools, fixtures and equipment Illustrated parts list TP 1001

PAGE 901 902 903 904

LATEST June 01/96 June 01/96 June 01/96 June 01/96

PAGE

1 2 1 2 3 4 5 6 1 2 1 2 1001 1001-0 1001-1 1001-2

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INTRO 1001

VCI 1001

NI/NUM 1001 DETAILED PARTS LIST

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COMPONENT MAINTENANCE MANUAL 26108-6 TABLE OF CONTENTS PAGE DESCRIPTION AND OPERATION 1 - Description 2 - Operation TESTING AND FAULT ISOLATION 1 - Testing 2 - Fault isolation DISASSEMBLY 1 - Disassembly CLEANING 1 - Light cleaning 2 - Full cleaning 3 - Lubrication CHECK 1 - Maintenance checks 2 - Maintenance steps in workshop 3 - General overhaul REPAIR 1 - Battery condition 2 - Polarisation test 3 - Added electrical test before repair ASSEMBLY AND STORAGE 1 - Assembly 2 - Storage SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1 - Special tools 2 - Materials and differents products ILLUSTRATED PARTS LIST Introduction Vendor code index Numerical index Detailed parts list 1 2 101 101 301 401 401 402 501 501 506 601 601 602 701 703 901 901 904 INTRO 1001-1 VCI 1001-1 NI/NUM 1001-1 1001

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COMPONENT MAINTENANCE MANUAL 26108-6 LIST OF ILLUSTRATIONS

PAGE Figure 1 - Battery 20 VHP260KH-3 Type 26108-6 Figure 501 - Level adjustment with a syringe and calibrated nozzle Figure 701 - Circuit Figure 901 - Polyamide key for vented filler cap made of polyamide Figure 902 - Syringe with nozzle Figure 903 - Equalizing resistor Figure 904 - Cell removal tool Figure 1 - Battery 20 VHP260KH-3 Type 26108-6 3 502 705 902 902 902 903 1001-0

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INTRODUCTION

1. General This manual supplies the maintenance data and the Illustrated Parts List of the Saft type 26108-6 battery. These instructions agree with specification ATA No. 100 for the manufacturer's technical manuals. They are included in chapters in this sequence :

1-99 101-199 201-299 301-399 401-499 501-599 601-699 701-799 801-899 901-999

Description and operation Testing and fault isolation (Not used) Disassembly Cleaning Check Repair Assembly and storage (Not used) Special tools, fixtures and equipment

1001-1099Illustrated parts lists. Note : The instructions in this manual cannot be used as a specification for an acceptance test; use these instructions for OPERATION and CHECK of an item which is temporarily unserviceable and to REPAIR for overhaul.

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DESCRIPTION AND OPERATION 1. Description A. General The alkaline battery has 20 semi-open nickel-cadmium VHP260KH-3 cells with welded polyamide cases. The battery is connected to the aircraft systems. It can be used: - To start. - On the ground, before electrical power is supplied to the aircraft systems. - In flight, if a malfunction or a failure occurs in the power supply system. The 28 VDC electrical system charges the battery in the aircraft. B. Data (1) Technical data - Nominal voltage : 24 volts. - Rated capacity : 26Ah at a rate of 1h. - Box, cover and connector made in C.E.I. - Electrolyte : Sol. KOH s.g. 1.30. - Consumable volume of electrolyte: 21cm3 (1.28in3) per cell. - Maximum dimensions of the battery base : L=371mm (14.61in), W=176mm (6.93in), H=230mm (9.06in). - Maximum weight : 24.5kg (54lb). a) Temperature sensor complete without connector (270A). . Thermostat closing at 71°C ± 2,8°C (160°F ± 5°F) temperature rise.

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(2) Operational data - Operating temperature: -40 to +71°C (-40 to +160°F) - Maximum instantaneous power : at +23°C (+77°F): 12V 15s 11.8kW at -18°C (+ 0°F): 12V 15s 7kW. C. Detailed description (Refer to pages 1001-0 and 1001-1) The battery has 20 VHP260KH-3 cells (170) housed in a stainless steel box (050) equipped with a cover made of insulating material. The liner spacer kit (090) delimits two cases in the box. Each one contains ten cells keeped in vertical position by thin sheets of insulation or spacers (110 thru 130). Sixteen links (140), one link (150) and one thermostat link (160) (all of them made of nickel-platted copper) connect the cells one with another. Two supple connections connect the end cells to an electrical connector which connects the battery to the aircraft power system. One thermostat, fixed on the thermostat links (160), are connected by electrical wiring through a grommet at the front face of the box. Four parts of adhesive moss strip (080), attached under the box cover, push down the top of the cells. The box cover is that you can remove and it is attached to the box by two hinges at the front face and one latche at the rear face.

2. Operation A. Charge (1) Flight charge Adjust the charging source to make sure the battery is correctly charged in flight. Do a charging source check as frequently as possible.

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FIGURE 1 26108-6 BATTERY Page 3

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At the usual temperature of +20°C (+68°F), the constant charge voltage must be 28.5 volts. If the climatic or battery operating conditions cause the cell temperature to increase to +40°C (+104°F), adjust the charging source to 27.5 to 28 volts. This is to prevent a fast loss of the electrolyte reserve and a shorter life for the cells. For a given voltage adjustment, the higher the battery temperature, the higher the remaining charge current. The consumption of water from the electrolyte is directly in proportion to the remaining charge current. Thus it is necessary to accurately know the usual operating temperature of the batteries to permit the batteries to be charged in the best conditions.

(2) Ground charge Do all battery maintenance or overhaul steps in a workshop. (ambient temperature: mini +5°C (+41°F), maxi +35°C (+95°F) ). Note: In addition to the constant current and constant voltage methods of charging other methods, such as combination of both or pulse charging, can be used. If the specific instructions are not given in the operating manual, SAFT should first be contacted.

WARNING: REMOVE THE COVER TO CHARGE THE 26108-6 TYPE BATTERIES ON THE GROUND. THIS IS TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX.

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- Constant current charge (Battery fully discharged): To charge a fully discharged battery, do one of these procedures: CONSTANT CURRENT CHARGE Main charge 2.6A (0.1C1A) until 30V as battery voltage Time: mini 10h maxi 12h End of charge

+ 2.6A (0.1C1A) for a 4h time

13A (0.5C1A) until 31V as battery voltage Time: mini 2h maxi 2h 30min

+ 2.6A (0.1C1A) for a 4h time

26A (1C1A) until 31.4V as battery voltage Time: mini 1h maxi 1h 15min

+ 2.6A (0.1C1A) for a 4h time

NOTE: If the battery voltage does not increase sufficiently during the maximum charge time: Refer to "TESTING AND FAULT ISOLATION".. Battery not fully discharged and discharge condition unknow.

Discharge at 26A (1C1A) down to 20V. Charge: refer to A (2) above constant current charge. - Constant voltage charge

Charge at 28.5V at ambient temperature during 4 to 5h Adjusted charge voltage: for a +5°C battery temperature: 29V for a +35°C battery temperature: 28V

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COMPONENT MAINTENANCE MANUAL 26108-6 B. Discharge Rated capacity (C1Ah) Others rates (C1A) one hour discharge at 26A down to 20V 26Ah for a fully charged battery in relation temperature and time : up to 25 C1A

C. Precautions - You must usually supply regular current and do regular maintenance. Thus it is only necessary to use these precautions to get correct operation of the battery: Do not install the battery in an aircraft location which is too hot. Carefully obey the instructions that give the procedure to get a good flow of air. Do a charge level check regularly. Charge the battery on the ground when the discharge is not caused by an incorrect adjustment of the charging source. - Regularly do these checks: Electrolyte level (specially when the weather is hot). Tightness of the connection nuts. Adjustment of the charging source.

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TESTING AND FAULT ISOLATION

1. Testing For the test procedures, refer to "CHECK". 2. Fault isolation

FAILURES Zero volt with the battery set to "charge".

POSSIBLE CAUSES Defective electrical connector (no contact made). Link loose or broken

CORRECTION Examine the electrical contacts and links. Make sure the nuts are tight (CHECK). Charge the battery (DESCRIPTION AND OPERATION).

Zero volt with the battery set to "discharge".

Battery fully discharged.

Do an insulation check (CHECK). Battery circuit open or defective contacts. the terminal nuts are tight (CHECK). Cell fully dry Examine the contacts and links. Make sure

Refer to the related subsequent steps. Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK). Examine the aircraft circuit which charges the battery.

Leakage of electrolyte.

Incorrect adjustment of level

Cell polarity incorrect during high-rate discharge (for example, during the engine start).

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FAILURES

POSSIBLE CAUSES

CORRECTION

Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK). Too much charge at high temperature or too much current Examine the aircraft circuit which charges the battery. If necessary, adjust to normal operating temperature (DESCRIPTION AND OPERATION). Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK). Electrolyte found in the battery box. Damaged cell case. Do a leak test of the cells (CHECK). Replace the cell if necessary and refer to the related subsequent steps. Leakage of electrolyte. Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

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COMPONENT MAINTENANCE MANUAL 26108-6 FAILURES Too much water consumption for all the battery cells. POSSIBLE CAUSES Charge much more than the limit or too much charge at high temperature. CORRECTION Examine the aircraft circuit which charges the battery. If necessary, adjust to normal operating temperature AND OPERATION). Cell(s) the water consumption of which is very different from that of the other cells in the battery: more than 30% more than the average 25% (or less) of the average

(DESCRIPTION

Leaks from the cell(s).

Do a leak test of the cells (CHECK). Do the added test (REPAIR). If necessary, replace the cell(s). Make sure the battery test bench and the storage areas have no materials which can give off acid fumes. Replace the damaged links (DISASSEMBLY, ASSEMBLY AND

Cell(s) with damaged separator(s)

Corrosion on the links.

Operation in acid air

Mechanical damage to nickel plating STORAGE). The links are too hot. Loose terminal nuts.

Make sure the nuts are tight (CHECK). When the defect occurs, add 10 ml (10cm3) of distilled water to the cell. Do not adjust more accurately until the end of the charge.

A cell has an unusually high voltage at the start of the charge.

Dry cell .

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COMPONENT MAINTENANCE MANUAL 26108-6 FAILURES POSSIBLE CAUSES CORRECTION NOTE: If you charge a cell with a quantité of electrolyte which is not sufficient, this an cause tempera ture to increase very much. Replace the cell (DISASSEMBLY, AND STORAGE).

A cell has an unusually low voltage at ASSEMBLY the end of the charge (Less than 1.50 V at 2.6A and + 20°C (+68°F) or 1.47V at) +35°C (+95°F). Low capacity cell (The cell shows an opposite ASSEMBLY voltage or a correct polarity voltage of less than1 V after a discharge of 1 hour at 26A).

The cell was operated at temperatures and charge rates that were more than the limits and the separator is damaged.

Usual wear after long operation.

Replace the cell (DISASSEMBLY, AND STORAGE).

Unusual operation (Frequent engine starts with the battery); operation at high temperatures, with low electrolyte level, etc.

Do the applicable procedure (REPAIR).

Cell with a swollen case. ASSEMBLY

Cell operated with low electrolyte level ; deterioration of separators and damaged plates.

Replace the cell (DISASSEMBLY, AND STORAGE)

Cell with zero voltage when the battery circuit is open. Low insulation.

Short-circuited cell.

Replace the cell.

Leakage of electrolyte. the battery (DISASSEMBLY and CLEANING).

Disassemble and clean

Do an electrolyte level check (CHECK). Page 104

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COMPONENT MAINTENANCE MANUAL 26108-6 DISASSEMBLY 1. Disassembly NOTE: REFER TO "TESTING AND FAULT ISOLATION" TO FIND THE CONDITION OF THE COMPONENT OR THE POSSIBLE CAUSE OF ITS MALFUNCTION. THIS WILL GIVE THE NECESSARY LEVEL OF DISASSEMBLY. WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES.

A. Remove a cover .

B. Removal of a vented filler cap (safety cap): - Loosen the vented filler cap (180) with the special tool (Refer to figure 901). - Remove the vented filler cap with its "O" ring (190).

C. Removal of a cell: (refer to figure 1) - Remove the nuts (200) that attach the links (140, 150 and 160) to the cell. Remove the spring washers (210). - Remove the links (140, 150 and 160) from the cell terminals. - Fully engage the end of the special threaded tool (Refer to figure 904) on one of the cell terminals. Then pull up to remove the cell.

D. Removal of the electrical connector: NOTE: In order to avoid a short-circuit, remove a link between two cells. - Remove: - the nuts (200) that attach the positive and negative supple connections from the connector, - the spring washers (210), - the four cells (refer to paragr. C) in front, placed just behind the connector (refer to figure 701).

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- Loosen the four screws which attach the connector and remove them, - Remove the connector.

E. Removal of the temperature sensor complete (270): - Remove: - the nuts (200) that attach the thermostats link (160), - the spring washers (210) and thermostat link(160), - the nuts (280) that attach the thermostat from the thermostat link (160), - the sensor connector. - Pull out the thermostat through the hole at the rear of the box.

F. Removal of the battery. - Remove: - the electrical connector (refer to paragr. D), - the cells ( refer to paragr. C), - the temperature sensor complete (refer to paragraph E).

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CLEANING 1. Light cleaning - If a clean filtered supply of compressed air is available, do this procedure to easily and quickly clean the cells: blow with much force across the tops of the cells to remove all dust and mineral salts from the box. - To prevent short-circuits, use a rubber tube or an insulating nozzle. 2. Full cleaning Disassemble the battery (Refer to "DISASSEMBLY") and then clean all the components. A. Cells: - To easily remove all the electrolyte and mineral salts from the terminals, the covers and the sides of the cell cases: clean in warm water with a soft brush. - Make sure that the vented filler cap (safety cap) is tight. - Do not soak the cells in water. - Rub the cell with a cloth and let dry. B. Box: - Clean with water, rub with a cloth and let dry. C. Nuts, spring washers and links: - Clean in warm water with a brush and let dry. D. Packing parts and sealed insulating liner: - Clean in warm water and let dry. E. vented filler caps: - Remove the vented filler caps (Refer to "DISASSEMBLY"). - Put covers on the cell holes to keep out unwanted material.

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- Soak the vented filler caps for some time (during the night, for example) in a container of distilled water (or, if not available, in very clean tap water). Do this to remove all salts from the vent hole.

WARNING: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. - Before you put the vented filler caps back into the cells, make sure that they operate correctly. Do these steps: - Install the vented filler cap (180) with its "O" ring (190) on the end of a metal tube that has a correct end-piece. - Connect this tube to a supply of compressed air through a vented filler cap of the adjustable reducing type. - Adjust the pressure to 0.5 bar (7.25 psi) and put the vented filler cap into a container of water. Air bubbles come out if the vented filler cap is in good condition. If there are no bubbles, increase the pressure until you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi) and monitor the pressure at which the air flow stops. - Reject all vented filler caps that have an operating pressure of more than 0.7 bar (10 psi) (after the check done before to make sure that the related cap operates correctly) or less than 0.14 bar (2 psi). - Install the vented filler caps (Refer to "ASSEMBLY"). 3. Lubrication When the battery is clean (and after installation of the vented filler caps), put a thin layer of neutral petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.

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CHECK 1. Maintenance checks You must do the checks which are necessary to use the SAFT 26108-6 batteries in flight and on the ground. But you must also do these maintenance steps during operation: - Periodical check (in a workshop): adjustment of electrolyte levels - Regular check (in a workshop): electrical treatment, adjustment of electrolyte levels, and capacity test. - General overhaul (in a workshop): disassembly, cleaning, assembly and regular check. 2. Maintenance steps in workshop A. Periodical check Periodically (at flight hour intervals such that the allowable water consumption is not exceeded): - Clean the battery (See "CLEANING") - Adjust the electrolyte level (Refer to (1)). (1) Charge of the battery and adjustment of the electrolyte level: - Discharge the remaining capacity at 26A down to a voltage of 20 volts at the battery terminals. - When the battery temperature is +20°C to +25°C (+68°F to +77°F) (usual temperature range), charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION" for a fully discharged battery). - During the last hour of the charge (while the charge current continues to flow), adjust the level of the electrolyte in the cells. TheN.measure the voltages of each cell. Write the quantity of water that is added to each cell. - The electrolyte level changes with the battery charge. Thus you do not get the maximum level until the battery is fully charged. The level changes as if the plates absorbed a part of the electrolyte during the discharge and released it during the charge. Thus the level checks are only satisfactory if they are done almost at the end of the charge (but during the charge). Page 501

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Leakage can occur during operation if you do not obey these instructions when you add liquid. The level is correct when the distance between the seat of the vented filler cap and the electrolyte is 20mm (0.787in) (distance measured in the conditions given before). - If necessary, add distilled water to adjust the level to this value. WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte levels in nickel-cadmium cells. A very small quantity of acid is sufficient to cause permanent damage. The easiest tool to adjust the level is a plastic syringe tube (equivalent to that used for medical injections, with a plastic nozzle on the conical end). The length of the nozzle which goes into the cell must be 20mm (0.787in) ; this is the distance necessary between the seat of the vented filler cap and the electrolyte (Refer to figure 501). To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vented filler cap and pull the plunger up:

20 mm 0.787 in

Level adjustment with a syringe and a calibrated nozzle Figure 501 Page 502

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- If the level is not sufficient, the syringe tube stays empty when you pull the plunger. - If there is too much liquid, this liquid is removed by the syringe until the level aligns with the end of the nozzle. If this check shows that the level is not sufficient in some cells, add distilled water to these cells. (The syringe is small ; it can thus be necessary to do this step more than one time for each cell). The level is correct when only a small quantity of liquid goes into the syringe when you pull the plunger. To do this check (after water is added to the cell), keep the shoulder of the syringe nozzle against the seat of the vented filler cap. - Results of the above procedure: - The battery operates correctly if: - The voltage of each cell measured during the last hour of charge at 2.6A is not less than 1.50 volt (1.47 volt at +35°C (+95°F)). - Approximately the same quantity of distilled3water was added to each 3 cell. This quantity must be less than 21cm (1.28in ). - If the quantity of water added to all cells is more than 21cm (1.28in ): make sure that the voltage adjustment in relation to the temperature during the charge is correct. Also do the electrolyte level check more frequently. - Do a full overhaul of the battery (Refer to paragraph 3 "General overhaul"): - If the quantity of water necessary for one or more cell(s) is much higher or smaller than for the other cells. - If the voltage of each cell measured at the end of a 2.6A charge is less than 1.50 volt (1.47 volt at +35°C (+95°F)) (Refer to "TESTING AND FAULT ISOLATION"). (2) Clean the vented filler caps (Refer to "CLEANING") when you adjust the electrolyte levels.

3 3

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COMPONENT MAINTENANCE MANUAL 26108-6 (3) Make sure the cell terminal nuts are tight. Make sure that all the nuts that attach the links are torqued to 8 ±2N.m (5.90 ±1.47ft.lbf). (4) Do an insulation check (Refer to paragraph 3.D). B. Regular check 1) At the time of a second periodical check OR AFTER A MAXIMUM OF SIX MONTHS, do this battery test (also do the steps given in paragraph 2.A):

- Discharge the remaining capacity at 26A down to a voltage of 20 volts at the battery terminals. - Measure the time from the start of discharge to the time when the voltage is 20 volts. - Connect a resistor of approximately 1ê 3W (refer to fig. 903) across each cell and continue to discharge. Resistors with crocodile clips attached to their leads can be easily attached to the cell terminals. - Let the resistors stay in position for the night. 2) Remove all resistors, charge the battery (Refer to "DESCRIPTION AND OPERATION" for a fully discharged battery). - Adjust the electrolyte level in the cells (Refer to paragraph 2.A (1)). TheN.measure the voltage of each cell during the last hour of the charge. Also write the quantity of distilled water added to each cell. - Immediately after the charge and the level adjustment, discharge the battery again at 26A down to 20 volts ; measure the terminal voltage of each cell. Write the time that is necessary for this second discharge. - Results of the above tests: The battery operates correctly if: - The time necessary for the first discharge (paragraph 2.B (1) is more than 30 minutes, - The time necessary for the second discharge (paragraph 2.B (2)) is not less than one hour,

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- The voltage of each cell measured during the last hour of the charge at 2.6A is not less than 1.50 volt (1.47 volt at +35°C (+95°F)), - The quantity of distilled water added to each cell is approximately equal to or 3 3 less than 21cm (1.28in ). - If the first discharge time is less than 30 minutes but the second discharge time is correct: the battery is in good condition but was not fully charged when removed from the aircraft. This condition can be caused by: - An incorrect charge in the aircraft. - And/or a discharge caused by an unusual operation of the battery after landing. Do a full overhaul of the battery (paragraph 3) if: - The second discharge time is less the correct one or one cell has a voltage of less than 1 volt (or incorrect polarity before 1 hour of discharge). - The voltage of each cell measured during the last hour of charge at 2.6A is less than 1.50 volt (1.47 volt at +35°C (+95°F)). - The quantity of distilled water necessary for one or more cell(s) is much higher or smaller than for the other cells. NOTE: The consumption of water by a SAFT nickel-cadmium cell is in proportion to the unwanted charge. Thus, the consumptioN.must be the same for all the 20 cells in the battery. The quantity of water necessary for one or more cell(s) (in the same battery) can be much higher (or smaller) than the other cells. Then there is a defect: - High consumption is usually caused by a leakage. - Low consumption is caused by a damaged separator. - The consumption is incorrect when it is 25 % more or less than the average.

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3. General overhaul This overhaul includes the electrical tests given in paragraph (2.B). Do an added electrical test before repair (Refer to REPAIR paragr. 3) if the voltage of each cell measured during the last hour of charge at 2.6A is less than 1.50 volt (1.47 volt at +35°C (95°F)). It also includes the disassembly and cleaning procedures to be done systematically for all the battery components. Do an overhaul one time each year or during each most important servicing of the aircraft. Do these steps: - Disassemble the battery - Clean the battery - Do a battery test - Do an insulation test. A. Disassemble the battery (Refer to "DISASSEMBLY"). B. Clean the battery (Refer to "CLEANING"). C. Do a battery test: (1) Cells: - Make sure that the lower terminal nuts are tight: - Tightening torque: 5 ±0.5N.m (3.69 ±0.369ft.lbf). - Verify that cell boxes show no leakage. (2) Box: Make the sides of the box straight and remove the dents. (3) Nuts, links and spring washers: - Discard the components that show signs of corrosion or damage. (4) Packing parts: - Discard all defective components.

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COMPONENT MAINTENANCE MANUAL 26108-6 (5) Connector: - Make sure that the connector is in good condition (inner and outer surfaces); replace it if the contacts are burned. D. Do a temperature sensors test (refer to fig. 701) : Checking of temperature sensor can only be carried out when the battery is dismantled . - Check the continuité between C and D. control connector A and B

Check of

Temperature

+71°C Th

Ambient temperature On temperature rise between +65°C and +77°C (150°F and 170°F)

Circuit opened Circuit closes

+71°C Th On 4°C to 10°C (7°F to 18°F) temperature decrease than precedent closing temperature circuit opens

(This range includes a ±3°C (±5°F) temperature and ±3°C (±5°F) thermostat precision. - The insulation of thermostat poles in relation to their metal housing must be greater or equal to 30Mê under 250V continuous. If the measures are not corrects, replace the temperature sensor complete (refer to "DISASSEMBLY", paragr. 1.E and "ASSEMBLY", paragr. 1.D).

E. Insulation resistance : - Fully assemble the battery. TheN.measure the insulation resistance between the block of cells and the metal box. The resistance must not be less than 10Mê at 250V continuous.

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REPAIR

1. Battery condition Do a polarisation test (Refer to paragraph 2) if you find these defects on the battery (after a removal that was not scheduled or before regular maintenance): - The polarity of the cells is incorrect - The battery open voltage is less than 21 V. Do an added test (Refer to paragraph 3) if you find these defects on the battery (during regular maintenance or general overhaul): - The voltages at the end of the charge are too low - The voltage during the charge is too high - The capacity is not sufficient - The water consumption is incorrect.

2. Polarisation test - Charge the battery at 2.6A for 1.5 hour. - Keep the battery in the "open circuit" condition for 1 hour. - Measure the open voltage of every cell. If the cell open voltage is 0 volt (or opposite), do an added test (refer to paragraph 3). Then repair. If each cell has an open voltage that is more than 0 volt, charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery).

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3. Added electrical test before repair The first test charge can be unsatisfactory if the electrolyte level is too low in some cells (the level is not adjusted until the end of this charge). If you find defects, do a second test: - Charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery). At the end of the total charge time, continue to charge at 2.6A for 5 more hours. Regularly write the voltage and temperature of the cells. The temperature of the cells that have damaged separators increases very much and continuously. The voltage of these cells continuously decreases to less than 1.50 volt (1.47 volt at +35°C (+95°F)).

NOTE: When you charge the battery more than necessary, you decrease the life of the cells. Thus, do this special test only if: - A battery malfunction occurred in the aircraft - Defects were found during shop maintenance. - Adjust the electrolyte level during the last one of the 5 last hours of charge. - Discharge at 26A down to 20 volts. After this test, discard the defective cells: - Cells with a voltage of less than 1.50 volt at the end of the charge. - Cells with a voltage that decreases to less than 1 volt before one hour of discharge (during the last test discharge). - Short-circuited cells (zero volt).

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ASSEMBLY AND STORAGE 1. Assembly NOTE : Tooling and equipment are identified in the list of "SPECIAL TOOLS AND EQUIPMENT". A. Installation of the vented filler caps: - Make sure the "O" ring (190) is in good condition; replace the "O" ring if it is worn. - Install the safety vented filler cap (180) with the special tool (Refer to figure 901); hold the special tool by its upper ribbed part. B. Installation of à cell: - Install the discharged cell (170) and make sure its polarity is correct (refer to figure 701). - Carefully position the cell and push on the terminals with a piece of soft wood. - Install: - the links (140, 150 and 160) (Refer to figure 1 for their locations), - the spring washers (210), - the nuts (200) and torque them to 8 ±2N.m (5.90 ±1.47ft.lbf).

C. Installation of the electrical connector: - Install the connector in the box, - install the four screws with their four lock washers and their four flat washers, - install the cells (refer to paragr. B), - attach the two supple connections from the connector and the links (140) to the cells, - put the spring washers (210) on the cells, - install the nuts (200) and torque them to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). Page 701

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D. Installation of the temperature sensor complete (270) (Refer to figure 1) - Pull on the thermostat through the hole at the rear of the box. - Install: - the grommet, the sensor connector on the box, - the thermostat on the thermostat link (160). then the nuts (280) and torque them, - the thermostat link on the cell terminal (refer to fig. 701), - Attach the thermostat link with the spring washers (210) and the nuts (200) then torque the nuts to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). E. Assembly of the battery Install these components in the box: - the spacers below (100 thru 130) (refer. to fig. 1 for their location).

Item

Designation

Units per assy 1 38 2 2

Dimensions

100 *110 120 130

Bottom spacer Spacer Slotted insulator Insulator

292x160x1 195x 77x1 280x210x0.5 280x175x0.5

* Caution, put only that number is necessary to wedge each cell row. Install: - Twenty VHP260KH-3 cells (170) (refer to paragr. B), and make sure their polarities are correct as shown in figure 701. - The electrical connector (Refer. to paragr. C) - All links (140, 150 and 160) on the cell terminals with the spring washers (210) and the nuts (200). Torque the nuts to 8 ± 2N.m (5.90 ± 1.47ft.lbf). - The temperature sensor complete (270) (Refer to paragr.D). Page 702

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Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush). - Install the cover and affix it with the latcher of the box.

2. Storage A. Preparation of the battery before storage - Adjust the electrolyte levels (Refer to "CHECK", paragraph 2.A. Then discharge at a constant current of 26A down to a terminal voltage of 20 volts. - Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the connector contacts and all the components that can be damaged by atmospheric corrosion. - Put the battery in its usual vertical position. B. Storage room: Keep the SAFT 26108-6 batteries in a dry and clean room. C. Temperature conditions: Keep the batteries at a temperature of -60°C to +60°C (-76°F to +140°F). But the best temperature range is between 0 and +30°C (+32°F and +86°F). D. Packing The SAFT 26108-6 batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommend that you put the batteries in a welded plastic container. In this type of container, the batteries can be kept for 10 years in the best storage conditions. E. Transportation It is important that you move the nickel-cadmium SAFT 26108-6 batteries in the vertical position. Thus, the containers must be identified with "TOP" and "BOTTOM" marks that can be read easily.

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F. Servicing after storage Storage time Less than 3 months

3 months to 1 year More than 1 year

Servicing procedure Charge the battery (Do one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2)) for a fully discharged battery) Do the periodical check (Refer to "CHECK" 2.A). Do the Regular check (Refer to "CHECK" 2.B).

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Figure 701 Page 705/706

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COMPONENT MAINTENANCE MANUAL 26108-6 SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1. Special tools. USE Manufact. P/N DESIGNATION T E S T / F A U L T D I S A S S E M B L Y C L E A N I N G C H E C K R E P A I R

015528

Polyamide key for vented filler caps made of polyamide (Refer to figure 901) Syringe nozzle (Refer to figure 501 and 902) Syringe: 20 cm (1.22in ) (Refer to figure 902) Cell removal tool (Refer to figure. 904) Equalizing resistors (1ê 3W) (Refer to figure 903)

3 3

X X X

X

X

X X X

X X X X

016544 105112 014735 164829

X X X

NOTE: Equivalent tools can be used as alternatives to the ones above.

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Polyamide key for vented filler caps made of polyamide Figure 901

Syringe with nozzle Figure 902

Equalizing resistor Figure 903

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Cell removal tool Figure 904

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COMPONENT MAINTENANCE MANUAL 26108-6 2. Materials and different products. SPECIFICATION 1-NATO 2-F 3-US 4-UK 1- S.743 2- AIR 3565 3- VLP 2336 4- DEF 2333

DESIGNATION Mineral petrolatum

SUPPLIER REFERENCE ESSO Industrial n.2 ELF Aviation vaseline DOW CORNING Molykote 55M

Grease

1- G.392 3- MIL-G4343 4- DTD 5610

Glue

3 M FRANCE EC1236

Distilled water

Local supply

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COMPONENT MAINTENANCE MANUAL 26108-6 INTRODUCTION

1. General The Illustrated Part List (IPL) agrees with the ATA 100 specification. It is used to identify all the components of the unit. The Illustrated Parts List includes these sections:

- Introduction - Vendors Code Index - List of Circuit Symbols (if applicable) - Alphanumeric Index of Manufacturer's Part Numbers - Detailed Parts List.

2. How to use the Detailed Parts List The Detailed Parts List includes the list and the figures of the unit components. It has these columns: - 1st column: Fig. Item - (Figure and item numbers) - 2nd column: Part Number - (Manufacturer's part number) - 3rd column: Airline Part Number - 4th column: Nomenclature - (List of components) - 5th column: Usage Code - (Applicability) - 6th column: Units per Assy - (Quantity for each immediately higher assembly). A. Figure and item numbers (Fig. Item) The figure number for the items given in the list is shown on the first line of each page.

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Each assembly, sub-assembly or item with a part number that is given in the parts list has an item number. A letter follows the item number to identify the variant. Letter A is for the basic variant. The assemblies, sub-assemblies and parts that are not shown in the figure have a dash (-) before their item numbers. A letter before the item number is a reference to the figure of the variant (this variant is shown on the main figure). B. Manufacturer's part number (Part Number) Each assembly, sub-assembly and detail part (that is shown on the figure or not) has a manufacturer's part number. When the manufacturer's part number has more than 15 characters, an equivalent part number is given in the "Part Number" column. This note comes before the part number: ORDER OVERLGTH ...MADE BY V... The two part numbers are given in the Alphanumeric Index in the logical sequence ; the part number that is too long is referenced to the equivalent part number. This note comes before the equivalent part number: "SEE..". C. List of components (Nomenclature) The list of components is moved to the right to show the relation between the parts: 1234567 Assembly . Detail parts for assembly . Sub-assembly . Attaching parts and/or storage for sub-assembly *** .. Detail parts for sub-assembly .. Sub-sub-assembly .. Attaching parts and/or storage parts for sub-assembly *** ... Detail parts for sub-sub-assembly, etc.

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A vendor code is given for all items or articles that are not made by the prime manufacturer of the assembly. This vendor code (or the abbreviation "NP": non procurable) is shown to the right of the 1st line of the nomenclature.

D. Applicability (Usage Code) An alphanumeric usage code shows the applicability of the sub-assemblies and detail parts to the immediately higher assembly(ies) or sub-assembly(ies). When the applicability is general, the "Usage Code" column is blank. The usage code is applicable to the figure/item number of the immediately higher assembly(ies) or sub-assembly(ies) (for example, the applicability 1A, 1B, 1C is written 1ABC). E. Quantity for each immediately higher assembly (Units per Assy) The "Units per Assy" column shows the number of units that are necessary for the immediately higher assembly. This number can be replaced by the letters REF (Reference) or AR (As Required). 3. Terms and abbreviations used - AR: As required - ATTACHING PARTS - DELETED - DET: Detail - LH and RH: Left and Right - MADE BY - MADE FROM - MATCHED PARTS - MODIFIED FROM - NHA: Next higher assembly

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- NP: Non procurable - OPT TO: Optional parts - ORDER OVERLGHT MPN: Part number longer than 15 characters - OVERSIZE: Oversize repair parts - POST SB: After the Service Bulletin is included - R - Changed - REF: For reference - SEE - SEL FROM: Select from parts - STORAGE PARTS - SUPSDS by: Superseded by - SUPSDS: Supersedes - UNDERSIZE: Undersize repair parts - T: tera 10E12 G: giga 10E9 M: mega 10E6 K: kilo 10E3 4. Changes When an item is changed, added or removed, the letter "R" is shown in the right margin (the date of issue of the page changes). The letter "R" is shown opposite the page number (in the right margin) when all the item numbers are changed. m: milli 10E-3 µ: micro 10E-6 n: nano 10E-9 p: pico 10E-12

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5. Page numbers The Detailed Parts List is divided into sections. The page numbers are given independently for each section.

Introduction Vendor Code Index Numerical Index Numerical Detailed Parts List Figure, Main Parts List (1st page of text)

INTRO 1001 VCI 1001

Page 1 to 6 Page 1

NI/NUM 1001 (figure xx)

Page 1 Page 10xx Page 10xx-O Page 10xx-1

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VENDOR CODE INDEX VENDOR CODE

NAME-ADDRESS

F6177

SAFT DPT ACCUMULATEURS INDUSTRIELS 156, Avenue de Metz FRANCE Telex - 235566 F Phone: (1) 49-15-36-00 Fax : (1) 49-15-34-00 93230 ROMAINVILLE

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NUMERICAL INDEX

PART NUMBER 062000 062023 100111 100479 100593 100695 100696 101228 101230 102939 105405 163366 166300 166595 26108-2 411996 412704 412705 413360 413361 413470 413471 413472 413609 413611 413892 413893 413894 414259 414260

AIRLINE PART NUMBER

FIG.

ITEM

TTL QTY 40 40 80 40 20 20 20 1 17 2 1 1 20 20 40 38 2 2 1 1 1 2 1 1 1 1 2 1 1

1

200 260 210 220 190 240 250 150 140 040 290 010 170 180 -001 230 110 120 130 080 100 090 070 030 020 050 060 160 280 270

-ITEM NOT ILLUSTRATED

NI/NUM 1001 Page 1

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DETAILED PARTS LIST

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FIGURE 1 26108-6 BATTERY Page 1001-0

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FIG.

ITEM

PART NUMBER

NOMENCLATURE 1234567 I I I I I I I Battery, 20VHP 260KH-3 . Plate, identification . Plate, range label . Plate, SAFT label . Plug, stepped . Box and cover complete . . Box and cover, assembly . . Plate, filling instruction . . Moss strip, adhesive . Liner spacer kit . . Spacer, bottom . . Spacer . . Insulator, slotted . . Insulator . Link, intercell E28.5 . Link, intercell E33 . Link, intercell E33 . Cell, VHP 260 KH-3, Assembly . . Cap, vented filler . . "O" Ring . . Nut, M 8 X 1.25 . . Washer, spring . . Washer, flat . . "O" Ring . . Washer, positive polarity . . Washer, negative polarity . . Nut, M 8 X 1.25 . Temperature sensor complete . . Temperature, assembly . . Nut, self locking

UNITS PER ASSY

1

-001 010 020 030 040 050 060 070 080 090 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290

26108-2 163366 413611 413609 102939 413892 413893 413472 413361 413471 413470 412704 412705 413360 101230 101228 413894 166300 166595 100593 062000 100111 100479 411996 100695 100696 062023 414260 414259 105405

1 1 1 2 1 1 2 1 1 1 38 2 2 17 1 2 20 1 1 2 4 2 2 1 1 2 1 1 1

- ITEM NOT ILLUSTRATED Page 1001-1/2

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