151 CH 1

(F6177)
12, Rue Sadi Carnot - 93170 Bagnolet - France

Tl. (33) (0)1 49 93 19 18 - Fax (33) (0)1 49 93 19 56
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
P/N 151CH1
P/N 151CH2
Date of initial issue: sep 15/1998 Title page - page 1

Revision n 1 24-33-96 Feb 15/2001
COMPONENT MAINTENANCE MANUAL
151CH1
PAGE INTENTIONALLY LEFT BLANK
Title page - page 2

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RECORD OF REVISIONS
REVISION ISSUE INSERTED REVISION ISSUE INSERTED
No. DATE DATE BY No. DATE DATE BY
1 Feb 15/2001 Feb 15/2001 SAFT
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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE BY DATE BY
REV. No. NUMBER DATE REMOVED
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RTR Page 2
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SERVICE BULLETIN LIST

NUMBER BRIEF DESCRIPTION TYPE AFFECTED
SBL Page 1
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SBL Page 2
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151CH1/151CH2
LIST OF APPROVED REPAIRERS

TRADE NAME ADDRESS
12, Rue Sadi Carnot
93170 BAGNOLET
SAFT Telex - 235566 F
Phone: (33) (0)1 49 93 19 18
Fax: (33) (0)1 49 93 19 50
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LOAR Page 2
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LIST OF EFFECTIVE PAGES

CONTENT PAGE DATE OF CONTENT PAGE DATE OF
LATEST LATEST
REVISION REVISION
TITLE PAGE 1 Feb 15/2001 1006 Feb 15/2001
2 Blank 1007 Feb 15/2001
1008 Feb 15/2001
RECORD OF REVI- 1 Feb 15/2001 1009 Feb 15/2001
SIONS 2 Blank 1010 Feb 15/2001
1011 Feb 15/2001
RECORD OF TEMPO- 1 Feb 15/2001 1012 Feb 15/2001
RARY REVISIONS 2 Blank 1013 Feb 15/2001
1014 Blank
SERVICE BULLETIN 1 Feb 15/2001
LIST 2 Blank SCHEMATIC AND 2001 Feb 15/2001
WIRING DIAGRAMS 2002 Blank
LIST OF APPROVED 1 Feb 15/2001
REPAIRERS 2 Blank DISASSEMBLY 3001 Feb 15/2001
3002 Feb 15/2001
LIST OF EFFECTIVE 1 Feb 15/2001 3003 Feb 15/2001
PAGES 2 Feb 15/2001 3004 Blank
TABLE OF CON- 1 Feb 15/2001 CLEANING 4001 Feb 15/2001

TENTS 2 Feb 15/2001 4002 Feb 15/2001
4003 Feb 15/2001
TABLE OF ILLUSTRA- 1 Feb 15/2001 4004 Blank
TIONS 2 Feb 15/2001
CHECK 5001 Feb 15/2001
INTRODUCTION 1 Feb 15/2001 5002 Feb 15/2001
2 Feb 15/2001 5003 Feb 15/2001
3 Feb 15/2001 5004 Feb 15/2001
4 Feb 15/2001 5005 Feb 15/2001
5006 Feb 15/2001
DESCRIPTION AND 1 Feb 15/2001 5007 Feb 15/2001
OPERATION 2 Feb 15/2001 5008 Feb 15/2001
3 Feb 15/2001 5009 Feb 15/2001
4 Feb 15/2001 5010 Feb 15/2001
5 Feb 15/2001 5011 Feb 15/2001
6 Blank 5012 Feb 15/2001
TESTING AND FAUL- 1001 Feb 15/2001 REPAIR 6001 Feb 15/2001
TISOLATION 1002 Feb 15/2001 6002 Feb 15/2001
1003 Feb 15/2001
1004 Feb 15/2001 ASSEMBLY 7001 Feb 15/2001
1005 Feb 15/2001 7002 Feb 15/2001
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LIST OF EFFECTIVE PAGES

CONTENT PAGE DATE OF CONTENT PAGE DATE OF
LATEST LATEST
REVISION REVISION
7003 Feb 15/2001
7004 Feb 15/2001 STORAGE (INCLU- 15001 Feb 15/2001
7005 Feb 15/2001 DING TRANSPORTA- 15002 Feb 15/2001
7006 Feb 15/2001 TION) 15003 Feb 15/2001
7007 Feb 15/2001 15004 Feb 15/2001
7008 Feb 15/2001 15005 Feb 15/2001
7009 Feb 15/2001 15006 Blank
7010 Blank
FITS AND CLEA- 8001 Feb 15/2001

RANCE 8002 Blank
SPECIAL TOOLS, 9001 Feb 15/2001

FIXTURES AND 9002 Feb 15/2001
EQUIPMENT 9003 Feb 15/2001
9004 Feb 15/2001
9005 Feb 15/2001
9006 Blank
ILLUSTRATED 10001 Feb 15/2001

PARTS LIST 10002 Blank
INTRODUCTION 10003 Feb 15/2001

10004 Feb 15/2001
10005 Feb 15/2001
10006 Feb 15/2001
10007 Feb 15/2001
10008 Feb 15/2001
VENDOR CODE 10009 Feb 15/2001

INDEX 10010 Blank
ALPHA NUMERICAL 10011 Feb 15/2001

INDEX 10012 Feb 15/2001
10013 Feb 15/2001
DETAILED 10014 Feb 15/2001

PARTS LIST 10015 Feb 15/2001
10016 Feb 15/2001
10017 Feb 15/2001
10018 Blank
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151CH1/151CH2
TABLE OF CONTENTS
PAGE
INTRODUCTION 1
1 - General 1
2 - How to Use this Manual 1
3 - Measure 2
4 - Units of Measure 2
5 - Abbreviations 3
6 - Definition 3
7 - Disposal 4
DESCRIPTION AND OPERATION 1

1 - Description 1
TESTING AND FAULT ISOLATION 1001

1 - General 1001
2 - Testing 1001
3 - Charge 1007
4 - Discharge 1010
5 - Fault isolation 1010
SCHEMATIC AND WIRING DIAGRAMS 2001

1 - General 2001
2 - Schematic sensor 2001
DISASSEMBLY 3001
1 - General 3001
2 - Safety 3001
3 - Risks 3001
4 - Safety measure 3002
5 - Disassembly 3002
CLEANING 4001
1 - General 4001
2 - Necessary equipment 4001
3 - Materials 4001
4 - Cleaning procedure 4001
5 - Lubrication 4003
CHECK 5001
1 - General 5001
2 - Maintenance steps in workshop 5001
TOC Page 1
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151CH1/151CH2
PAGE
REPAIR 6001
1 - General 6001
2 - Equipment 6001
3 - Repairs 6001
ASSEMBLY 7001
1 - General 7001
2 - Assembly procedure 7001
FITS AND CLEARANCES 8001

1 - Torque table 8001
SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

1 - General 9001
2 - Special tools, fixtures and equipment 9001
3 - Consumables 9005
ILLUSTRATED PARTS LIST 10001

1 - Introduction - 10003
2 - Vendor code index - 10009
3 - ALPHA Numerical index - 10011
4 - Detailed parts list - 10014
STORAGE (WITH TRANSPORTATION) 15001

- Storage 15001
- Storage procedure 15001
- Servicing after storage 15005
- Transportation 15005
TOC Page 2
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151CH1/151CH2
TABLE OF ILLUSTRATIONS
PAGE
Figure 1 - 151CH2 Battery 3
Figure 2 - Identification plate 4
Figure 3 - Amendment plate 4
Figure 4 - Overall dimensions 5
Figure 1001 - Preliminary Functional Tests 1003
Figure 1002 - Insulation Check 1004
Figure 1003 - Insulation Parameters 1005
Figure 1004 - Cell connections battery 151CH1 1007
Figure 1005 - Cell connections battery 151CH2 1008
Figure 2001 - Schematic sensor Battery 151CH1 2001
Figure 2002 - Schematic sensor Battery 151CH2 2002
Figure 5001 - Periodical check 5003
Figure 5002 - Level adjustment with a syringe and calibrated nozzle 5004
Figure 5003 - Regular check 5007
TOI Page 1
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151CH1/151CH2
PAGE
Figure 5004 - General overhaul 5011
Figure 7001 - Battery 151CH1 liner spacer kit installation 7003
Figure 7002 - Battery 151CH2 liner spacer kit installation 7004
Figure 7003 - Battery 151CH1 cells assembly 7005
Figure 7004 - Battery 151CH1 assembly 7007
Figure 7005 - Battery 151CH2 cells assembly 7008
Figure 9001 - Polyamide key for vent valve (T01) 9002
Figure 9002 - Syringe with nozzle (T02) 9002
Figure 9003 - Equalizing resistor (T03) 9003
Figure 9004 - Cell extraction tool (T04) 9004
Figure 1 - 151CH1 BATTERY 10014
Figure 2 - 151CH2 BATTERY 10016
Figure 15001- Short term storage 15003
TOI Page 2
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151CH1/151CH2
INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and in AECMA Simplified English. This manual
uses IS units of measure, with imperial units in parentheses.
B. This manual gives the procedures of maintenance on components in a workshop. It does not give
the procedures of maintenance on components when they are installed in aircraft.
C. Only approved persons with the necessary skills can do maintenance tasks given in this manual.
D. This manual uses Maintenance Task Oriented Support System (MTOSS) task and subtask
identification. Maintenance tasks and other data have special MTOSS numbers for the use of
Electronic Data Processing (EDP). MTOSS numbers can be ignored by the user of the manual.
E. This manual contains:
- Technical data for components.

- Maintenance and repair procedures for components.
- An Illustrated Parts List (IPL) with data for parts of components. Parts are identified in all sec-
tions of the manual by the IPL figure and item number.
F. We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY

procedures by doing them.
NOTE: This manual gives the description and the maintenance procedures of two batteries
(P/N 151CH1 and P/N 151CH2). The description of operations is written for both bat-
teries. If a special operation or description is necessary, the P/N of the applicable
battery is written in the title of the paragragrph or figure.
2. How to Use this Manual
A. Make sure the manual contains information applicable to your component. Look for the part
number on the Title Page.
B. If you need to identify a part or find a part number, refer to the IPL, which has an Introduction
chapter showing the procedure.
C. You must use the instructions in this manual for all components maintenance. Read all the
applicable WARNINGS and CAUTIONS before you do the work on the component.
INTRO Page 1
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151CH1/151CH2
3. Measure
Measure given in this manual are taken from original manufacturing drawings.
Quantities are given in I.S. Units followed by U.S. Units in parentheses.
4. Units of Measure
A. I.S. Units
A Ampere
Ah Ampere hours
C1A Rated current
C1Ah Rated capacity for an hour
g Gram
min Minute
N Newton
N.m Newton meter
VDC Volt direct current
C Degree Celsius
% Per cent
Ohm
B. U.S. Units
ft Foot
in Inch
lb Pound
lbf.in Pound force inch
F Degree Fahrenheit
C. Multiplying Prefixes
Micro
m Milli
da Deca
k Kilo
M Mega
INTRO Page 2
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151CH1/151CH2
5. Abbreviations
This manual uses the abbreviations given below.
ATA AIR TRANSPORT ASSOCIATION OF AMERICA

DIA DIAMETER
FIG. FIGURE
IPL ILLUSTRATED PARTS LIST
MAX. MAXIMUM
MFR MANUFACTURER
MIN. MINIMUM
NO. NUMBER
OD OUTSIDE DIAMETER
P/N PART NUMBER
PARA. PARAGRAPH
REF. REFER TO
S/A SUBASSEMBLY
TBD TO BE DEFINED
6. Definition
This paragraph gives the warnings of this manual.
Warnings call attention to use of materials, steps procedures, or limits, which must be followed pre-
cisely to prevent injury to persons.
Cautions call attention to steps procedures which must be followed to prevent damage to equipment.
Notes call attention to procedures which make the job easier.
INTRO Page 3
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151CH1/151CH2
7. Disposal
Ni-Cd batteries contain :
- nickel,
- cadmium,
- potassium hydroxide.
You must therefore discard or use them again, in agreement with local legislation. For more informa-
tion, contact your local SAFT supplier.
INTRO Page 4
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151CH1/151CH2
DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline batteries 151CH1 and 151CH2 have each one 20 semi-open nickel-cadmium
CVH 150KH cells with welded polyamide cases.
The battery is connected to the aircraft systems.You can use it:
(1) To start the engine or the APU in reference to the aircraft system.
(2) On the ground, before electrical power is supplied to the aircraft systems.
(3) In flight, if a malfunction or a failure occurs in the power supply system.
NOTE: The 28 VDC electrical system charges the battery in the aircraft.
In this chapter, the figure and item numbers correspond to those of the ILLUSTRATED PART
LIST.
B. Characteristics
(1) Technical data
Nominal voltage 24 V
Rated capacity C1Ah 15 Ah (see Note below)
Battery terminals Two M8 terminal
Consumable volume of electrolyte 15 cm3 (0.92 in3)
Maximum dimensions of the batteries :
- Length 307 mm (12.09 in)
- Width 147 mm (5.78 in)
- Height 210 mm (8.27 in)
151 CH1 Battery maximum weight 15 kg (33 lbs)
151 CH2 Battery maximum weight 15.2 kg (33.5 lbs)
NOTE: 15 Ah at 1 h rate noted as 15 C1Ah or 15 C1Ah.

Current value equivalence : 15 A = 1 C1A and 1.5 A = 0.1 C1A for these
15 C1Ah batteries.
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151CH1/151CH2
(2) One complete temperature sensor set with:
(a) For battery P/N 151CH1

- 1 thermostat closing at 71C + 2.8C (160F + 5F) on temperature rise with a 2.2 k
resistor in parallel,
- 1 thermal sensor 300 k at 25C (77F).
(b) For battery P/N 151CH2

- 1 thermostat closing at 71C + 2.8C (160F + 5F) on temperature rise with a 2.2 k
resistor in paralell,
- 1 thermostat opening at 8C + 2.8C (46.4F + 5F) when temperature is 8C + 2.8C
(46.4F + 5F) with a heater (maximum voltage 230 V AC - 50 Hz)
- 1 thermal sensor 300 k at 25C (77F).
(3) Serviceable characteristics
(a) Operate temperature:
- 40 to + 71 C (- 40 to + 160 F)
(4) Electrical characteristics
The list below gives the servicing values of the batteries:
Item Value Use for
1 C1A 15 A Charge/Discharge
0.5 C1A 7.5 A Charge
0.1 C1A 1.5 A Charge
C. Detailed description
Each battery has 20 CVH 150KH cells (01-140) and (02-140), housed in a stainless steel box.
The box (01-290) and (02-290) is lined with thin sheets of insulation and wedges (01-200) and
(02-200). The cells are kept upright by means of a molded silicone elastomer part (01-070) and
(02-070) attached to the cover which presses against the top of the cells. Rigid, nickel-plated
copper links (01-110 thru 01-130) and (02-110 thru 02-130) connect cells.
Two terminals (01-210) and (02-210), installed at the end of cells, and two nuts (01-020 and 030)
and (02-020 and 030) connect the battery to the aircraft.
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151CH1/151CH2
The cover (01-010) and (02-010), that you can remove, is attached to the box (01-290)
and (02-290) by four washers (01-050) and (02-050) and four screws (01-040) and (02-
040).
Negative nut Cover

Screw
Filling instruction plate
Positive nut
SAFT label plate
Sensor
heater
Range plate
Sensor
thermostat Box
151CH2 Battery
Figure 1/TASK 24-33-96-991-001
Identification plate
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151CH1/151CH2
Identification plate
Figure 2/TASK 24-33-96-991-002
Amendment plate
Figure 3/TASK 24-33-96-991-003
Page 4
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151CH1/151CH2
Overall dimensions
Figure 4/TASK 24-33-96-991-004
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151CH1/151CH2
Page 6
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151CH1/151CH2
TESTING AND FAULT ISOLATION
1. General
This chapter gives the tests and inspections necessary to find the condition of the unit removed for
unscheduled maintenance. The TESTING AND FAULT ISOLATION TABLE gives the test procedure.
Each test refers to a specific procedure that gives all parameters you must apply, and those you must
inspect.
The figure and item numbers in this chapter correspond to those of the ILLUSTRATED PARTS LIST.
TASK 24-33-96-700-801
2. Testing
A. Equipment
(1) Standard tools
- Standard mechanics tools.

- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Air compressor with manometer (graduation 0.1 to 1 Bar).
(2) Special tools
When special tools are used in this chapter, they are identified by a code number listed in the
chapter SPECIAL TOOLS, FIXTURES AND EQUIPMENT.
- charge/discharge bench (constant current 0 - 60 A).

- power supply: 0 - 45 V, range 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V - 50 V, accuracy 1%.

- A megohmeter, range 0 - 50 M (voltage 250 VDC), accuracy 3%.
Page 1001
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151CH1/151CH2
(4) Check conditions
- Ambient temperature: 23 + 5 C.
- Pressure: 85 to 106 kPa.
- Relative humidity: < 85 %.
B. Precautions
You must always do regular maintenance. It is then necessary to obey the precautions below to
make sure of the correct operation of the battery:
- Do not install the battery in an aircraft which is too hot.
- Carefully obey the instructions given by the aircraft procedure to make sure of a good flow of air.
- Make sure of the capacity of the battery regularly.
- Charge the battery in a battery shop.
- You must do the maintenance (Refer to CHECK chapter), in particular to make sure of:
- Level of electrolyte. Specially when ambient temperature is high, time between mainte-
nance must decrease.
- Tightness of the connection nuts.
- Correct charging.
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151CH1/151CH2
SUBTASK 24-33-96-720-001
C. Preliminary Functional Tests (Ref. Fig. 1001)
1
Discharge at 1 V/cell
Tighten the nuts (01-090) 1 cell shorting 12 h
and (02-090)
charge at 1 C1A (15 A)
box or cells Yes see para. 5.B (6)
damaged note the voltage of each
cell during the charge
No
salt or electrolyte Yes see para. 5.C (1) more than Yes
10 ml added in all see para. 5.B (1)
traces
cells
No No
Topping up at the end
electrolyte in Yes see para. 5.C (2) of charge
the box
No more than
Yes see para. 5.B (2)
10 ml added
metallic parts Yes see para. 5.C (3) in 1 cell
corroded No
No 1 or more
cell has a voltage > 0.1 V Yes see para. 5.B (3)
battery Yes see para. 5.A (1) than the others
voltage = 0 V No
No
voltage of 1 cell Yes see para. 5.B (4)
Yes see para. 5.B (7) < 1.55 V
1 or more cell = 0 V
No
No
capacity check Yes see para. 5.B (5)
Yes < 100% C1Ah
1 or more cell < 0 V see para. 5.B (5)
No
No
a link or a Yes
insulation see para. 5.C (4)
nut is too hot
between cell and box
Yes see para. 5.A (3)
No
< 250 k
No do a General Overhaul
to detect battery fault or
external cause
Preliminary Functional Tests

Figure 1001/TASK 24-33-96-991-005
Page 1003
24-33-96 Feb 15/2001
151CH1/151CH2
SUBTASK 24-33-96-720-002
D. Testing procedure
(1) Insulation check
- Put the megohmeter as the figure below shows:
Insulation Check
Figure 1002/TASK 24-33-96-991-006
- 250 k under 250 VDC = Min value.
- > 10 M under 250 VDC = value after cleaning and drying.
Page 1004
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151CH1/151CH2
250 K 2 M 10 M
Can wait until next

problem Necessary to clean maintenance OK
In battery maintenance shop Always necessary after

cleaning and drying
Cleaning necessary Cleaning necessary
Acceptable
Check the cause

(overcharge)
Insulation Parameters
Figure 1003/TASK 24-33-96-991-007
(2) Polarization test
Charge the battery at 1.5 A for 1.5 hours.
Keep the battery in "open-circuit" condition for 1 hour.
Measure the open-circuit voltage of each cell.
If open circuit voltage of any cell is 0 V (or negative), do a second test (refer to
paragraph 4). Then repair.
If each cell has an open-circuit voltage that is more than 0 volt, charge the battery.
Page 1005
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151CH1/151CH2
(3) Vent valve test
Before you put the vent valve back on the cells, make sure that they operate correctly.
Do these steps:
1. Install the complete vent valve (01-190) and (02-190) with its O-ring on the end of a
metal tube which has an applicable end-piece.
2. Connect this tube to a supply of compressed air through an adjustable reducing valve.
3. Adjust the pressure to 0.5 bar (7.25 psi) and put the complete vent valve into a con-
tainer of water. Air bubbles come out when the valve opens. If there are no bubbles,
increase the pressure until you see bubbles. Then decrease the pressure slowly to
0.1 bar (1.45 psi) and monitor the pressure at which the bubbles stop.
4. Reject all complete vent valves that have an opening pressure of more than
0.7 bar (10 psi) or less than 0.14 bar (2 psi).
5. Install the vent valve (01-190) and (02-190) (Refer to ASSEMBLY chapter).
(4) Second test before repair
The first test charge can be unsatisfactory if the electrolyte level is too low in some cells
(because the level is not adjusted until the end of this charge). If you find faults, adjust
the electrolyte level and do the test below:
NOTE: If you charge the battery more than necessary, you decrease the life of
the cells. Thus, do this special test only if a battery malfunction occurred
in the aircraft, or faults are found during shop maintenance.
- Charge the battery (Refer to one of the procedures given in chapter TESTING AND
FAULT ISOLATION). At the end of the total charge time, continue to charge at 1.5 A
for 5 more hours. Regularly record the voltage of the cells. The temperature of cells that
have damaged separators quite and continuously increases. The voltage of these cells
continuously decreases to less than 1.55 V.
- Adjust the electrolyte level during the last 30 minutes of charge.
- Discharge at 15 A down to 1 V/cell.
- After this test, discard the defective cells:

- Cells with a voltage of less than 1.55 V at the end of the charge.
- Cells with a voltage that decreases to less than 1 V before one hour of discharge
(during the last test discharge).
- Short-circuited cells (zero volt).
Page 1006
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151CH1/151CH2
TASK A24-33-96-800-801
3. Charge
SUBTASK 24-33-96-820-001
A. Flight charge
The decrease of water from the electrolyte is in direct proportion to the overcharge current.
SUBTASK 24-33-96-820-002
B. Ground charge
Do all battery maintenance or overhaul steps in a workshop.
NOTE: In addition to the constant-current procedure of charging, you can use other pro-
cedures that fully charge the battery. BUT, IN EACH CASE, YOU MUST DO CELL
VOLTAGE CHECKS (U > 1.55 V) AND ELECTROLYTE ADJUSTMENTS BY THE
MEAN OF A FINAL CHARGE SEQUENCE AT CONSTANT CURRENT: 1.5 A AT
0.1 C1A. If special instructions are not given in the charger operating manual, you
must first contact SAFT.
WARNING: REMOVE THE COVER TO CHARGE THE BATTERY ON THE GROUND. THIS IS
TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX.
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Cell connections battery 151CH1

Figure 1004/TASK 24-33-96-991-008
Page 1007
24-33-96 Feb 15/2001
151CH1/151CH2
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Cell connections battery 151CH2

Figure 1005/TASK 24-33-96-991-009
(1) Constant-current charge (Battery fully discharged)
(a) To charge a fully discharged battery, do one of these procedures:
Page 1008
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151CH1/151CH2
CONSTANT-CURRENT CHARGE
Main charge Final charge
1.5 A (0.1 C1A) until 30 V as battery voltage
mini 10 h 1.5 A (0.1 C1A) for a 4 h period
Periods:
maxi 12 h
7.5 A (0.5 C1A) until 31 V as battery voltage
Periods:
maxi 2 h 30 minutes
15 A (1 C1A) until 31.4 V as battery voltage
Periods:
maxi 1 h 15 minutes
NOTE: If the battery voltage does not increase sufficiently during the maximum char-
ge time: Refer to the chapter TESTING AND FAULT ISOLATION.
NOTE: If you charge the battery more than in the table above, you decrease the life of
the cells.
(b) Battery not fully discharged and discharge condition not known.
Discharge at 15 A (1 C1A) down to 20 V. Refer to paragraph DISCHARGE.

Charge : refer to B (1) (a) above constant current charge.
Page 1009
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151CH1/151CH2
TASK 24-33-96-800-802
4. Discharge
Rated capacity 15 Ah : minimum value obtained for a fully charged bat-

(C1Ah) tery, when discharged at 15 A, down to 20 V.
Other rates
Depending on temperature and time: up to 25 C1A.
(C1A)
TASK 24-33-96-700-802
5. Fault isolation
SUBTASK 24-33-96-760-001
A. Battery electrical faults
PROBLEM PROBABLE CAUSE CORRECTION

(1) Zero battery open-circuit volt- (a) Defective electrical connector Examine electrical contacts,
age (no contact made) links and tightness of nuts (refer
to CHECK chapter).
(b) Link loose or broken Make sure the nuts are tight
(refer to CHECK chapter).
(2) Zero volt with the battery set (a) Battery fully discharged Charge the battery again.
to "discharge" Do an insulation check (refer to
CHECK chapter).
(b) Battery circuit open or con- Examine the contacts and links.
tacts defective Make sure the terminal nuts are
tight (refer to CHECK chapter).
(c) Cell fully dry Refer to applicable subsequent

steps.
(3) Low insulation (a) Leakage of electrolyte Disassemble and clean the bat-
tery (refer to DISASSEMBLY
AND CLEANING chapters).
Do an electrolyte level check
Page 1010
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151CH1/151CH2
SUBTASK 24-33-96-770-001
B. Cell faults

(1) Too much water decrease for (a) Charge much more than the Examine the cause of excessive
all battery cells. limit or too much charge at high charge.
temperature. If necessary, adjust to normal
operating temperature (refer to
DESCRIPTION AND OPERA-
TION chapter).
(2) Water decrease in cell(s) is (a) More than 30% or more than Do a leak of the cells (refer to
very different from the other cells the average : leaks from the CHECK chapter).
in the battery. cell(s).
(b) 30% (or less) of the Do the second test (refer to

average: cell(s) with damaged CHECK chapter). If necessary,
separator(s). replace the cell(s).
(3) A cell has an unsually high (a) Dry cell. When the defect occurs, add
voltage at the start of the charge. 5 cm3 (5 ml) of distilled water to
the cell. Do not adjust more
accurately until the end of the
charge.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can
cause the temperature increases very much.
(4) A cell has an unsually low (a) The cell was operate Replace the cell (refer to DISAS-
voltage at the end of the charge d at temperatures and charge SEMBLY, ASSEMBLY AND
(Less than 1.55 V at 1.5 A at rates outside the limits, and the STORAGE chapters).
+ 20 C (+ 68 F) separator is damaged.
(5) Low capacity cell (The cell (a) Usual wear after long opera- Replace the cell (refer to DISAS-
shows a reversed voltage or a tion. SEMBLY, ASSEMBLY AND
correct polarity voltage of less STORAGE chapters).
than 1 V after a discharge of
1 hour at 1 C1A). (b) Unusual operation, operation Do the applicable procedure
at high temperature or operation (refer to CHECK chapter).
with low electrolyte.
(6) Cell with a swollen case. (a) Cell operated with low elec- Replace the cell (refer to DISAS-
trolyte level ; deterioration of SEMBLY chapter).
separators and damaged plates.
(7) Cell with zero voltage when (a) Short-circuited cell. Replace the cell (refer to DISAS-
the battery circuit is open. SEMBLY chapter).
Page 1011
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151CH1/151CH2
SUBTASK 24-33-96-750-001
C. Physical faults

(1) Leakage of electrolyte (a) Incorrect adjustment of level. Disassemble and clean the bat-
and CLEANING chapters). Do
an electrolyte level check (refer
to CHECK chapter).
(b) Cell polarity incorrect during
high-rate discharge (for exam- Examine the cause of excessive
ple, during the engine start). charge.
Disassemble and clean the bat-
and CLEANING chapters).

(c) Too much charge at high tem-
perature or too much current. Examine the cause of excessive
charge. If necessary, adjust to
normal operating temperature
(refer to DESCRIPTION AND
OPERATION chapter).
Disassemble and clean the bat-


(2) Electrolyte found in the bat- (a) Damaged cell case Do a leak test of the cells (refer
tery box. to CHECK chapter).
Replace the cell if necessary and

refer to applicable subsequent
steps.
(b) Leakage of electrolyte Disassemble and clean the bat-


Page 1012
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151CH1/151CH2

(3) Corrosion on the links. (a) Operation in acid air Make sure the battery test bench
and the storage areas have no
materials which can release acid
fumes.
(b) Mechanical damage to nickel Replace the damaged links

plating (refer to DISASSEMBLY,
ASSEMBLY AND STORAGE
chapters).
(4) The links are too hot. (a) Loose terminals nuts Make sure the nuts are torqued
SUBTASK 24-33-96-750-002
D. Vent valve faults

Valve open pressure > 0.7 bar or Clogged valve. Change the valve.
the valve stays open.
Valve stays open for a pressure Pierced valve. Change the valve.
< 0.14 bar or not closed.
Page 1013
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151CH1/151CH2
Page 1014
24-33-96 BLANK
151CH1/151CH2
SCHEMATIC AND WIRING DIAGRAMS
1. General
This chapter gives all electrical schematics of battery sensor.
2. Schematic sensor
Schematic sensor Battery 151CH1

Figure 2001/TASK 24-33-96-991-009
Page 2001
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151CH1/151CH2
Schematic sensor Battery 151CH2

Figure 2002/TASK 24-33-96-991-010
Page 2002
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151CH1/151CH2
DISASSEMBLY
1. General
NOTE: Refer to chapter TESTING AND FAULT ISOLATION to find the condition of the
component or the possible cause of its malfunction. This will give the necessary
standard of disassembly.
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT

ISOLATION CHAPTER).
The figures and items numbers in this chapter correspond to those of the ILLUSTRATED PARTS
LIST.
2. Safety
Different countries have diferent safety rules. Obey the local rules.
3. Risks
There are three types of risks.
A. Physical
- Handling:The battery is heavy. When you lift it, bend your legs, not your back.
- Put on protective shoes.
B. Electrical
- Dont keep on you rings, watches, chains, belt buckles.

- Use insulated tools.
C. Chemical
- Electrolyte can cause corrosion and dangerous damage to the skin: put on gloves.
- Contact with eyes is very dangerous, put on protective goggles.
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151CH1/151CH2
4. Safety measure
- The electrolyte compound is caustic and can cause severe burns. If it comes in contact with the skin,
flush the touched part with water and make the solution neutral with acetic solution, vinegar or lemon
juice, or with boric acid solution at 10% concentration.
- If the electrolyte touches the eyes, flush them with water for minimum 15 minutes and call a doctor.
- Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit.
Mix the solution with water or, if possible, with milk. Call a doctor immediately. Do not try to make
someone unconscious drink . Touching nickel can cause chronic eczema. Breathing cadmium oxide
can cause a dry throat, make you cough, cause headaches, vomiting, or pain in your chest. Persons
having breathed cadmium oxide fumes must get fresh air or have oxygen, or must have artificial
respiration.
- Potash can cause eczema.
TASK 24-33-96-000-801
5. Disassembly
A. Equipment
(1) Standard tools

- Safety gloves.
- Protectives goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
SUBTASK 24-33-96-020-001
B. Disassembly procedure
WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES (TESTING AND FAULT

ISOLATION CHAPTER).
(1) Removal of the cover:
Page 3002
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151CH1/151CH2
(a) Remove the nuts (01-020, 01-030) and (02-020,02-030), and the spring washers
(01-100) and (02-100).
(b) Remove the screws (01-040) and (02-040) and washer (01-050) and (02-050).
(c) Then remove the cover (01-060) and (02-060).
(2) Removal of a cell
NOTE: To prevent a short-circuit, remove a link (01-110, 02-110) between two cells.
(a) Remove the nuts (01-090) and (02-090) and the spring washers (01-100) and (02-100)
that attach the links to the cell.
(b) Cut cable grip (01-280) and (02-280).
(c) Remove all links (01-110 thru 01-130) and (02-110 thru 02-130).
(d) Remove from battery 151CH1 the temperature sensor (01-220).
(e) Remove from battery 151CH2 the sensor thermostat (02-220)
(f) Fully engage the end of the special threaded tool (T04) onto one of the cell terminals.
Then pull up to remove the cell.
(g) Remove the sensor heater (02-230).
NOTE: The complete vent valve must stay tight when you remove the cell.
(3) Removal of a complete vent valve (safety cap)
(a) Loosen the complete vent valve (01-190) and (02-190) with the special tool (T01).
(b) Remove the complete vent valve with its O-ring.
(4) Disassembly of the battery
(a) Remove
1. The cover (01-060) and (02-060).
2. The cells (01-140) and (02-140).
3. The liner spacers kit (01-200) and (02-200).
Page 3003
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151CH1/151CH2
Page 3004
24-33-96 BLANK
151CH1/151CH2
CLEANING
1. General
The figure and item numbers in this chapter correspond to those of the ILLUSTRATED PARTS LIST.
2. Necessary equipment
- Safety gloves.
- Safety shoes.
- Eye washing.
- Protective apron.
3. Materials
- Ordinary water.
- Distilled water.[MO1]
- Neutral soap.[MO2]
- Non-fluffy swab.
- Non-wire brush.
TASK 24-33-96-100-801
4. Cleaning procedure
WARNING: THE ELECTROLYTE IS DANGEROUS. BE CAREFUL WHEN MOVING

ELECTROLYTE AND PREVENT SPLASHING. IT IS A STRONG CAUSTIC AGENT
AND CAN CAUSE SEVERE BURNS. ALWAYS WEAR FACE AND EYE PROTECTION
(PREFERABLY A TRANSPARENT FACE MASK, RUBBER GLOVES AND LONG
SLEEVED CLOTHING). IN CASE OF CONTACT WITH SKIN, FLUSH IMMEDIATELY
WITH MUCH WATER. IN CASE OF CONTACT WITH EYES, FLUSH WITH WATER 15
MINUTES MINIMUM AND, IN EACH CASE, GET IMMEDIATE MEDICAL ATTENTION.
SUBTASK 24-33-96-160-001
A. Light cleaning
Remove the cover.
If a clean, filtered supply of compressed air is available, do this procedure to clean the cells easily
and quickly: blow with much force across the tops of the cells to remove all dust and light traces
of mineral salts from the box. To prevent short circuits, use a rubber tube or an insulating nozzle.
Page 4001
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151CH1/151CH2
SUBTASK 24-33-96-160-002
B. Full cleaning
Disassemble the battery (refer to "DISASSEMBLY" chapter) and then clean all components.
(1) Cells
Make sure that the complete vent valve (01-190) and (02-190) (safety cap) is tight.
Do not soak the cells in water.
To easily remove all the electrolyte and mineral salts from the terminals, the cover and the
sides of the cell cases: clean in warm water with a soft brush.
Rub the cell with a cloth and let dry.
(2) Box
Clean with lightly soapy water, rub with a cloth and let dry.
(3) Nuts, spring washers and links
Clean in warm water with a brush and let dry.
(4) Liner spacer kit and sensor
Clean in warm water and let dry.
(5) Vent valve
CAUTION: YOU MUST CLEAN THE VENT VALVE (01-190) WHEN THE CELLS ARE AS-
SEMBLED IN THE BOX.
(a) Remove the complete vent valve (01-190) and (02-190) (Refer to "DISASSEMBLY
chapter).
(b) Put swab on the cell holes to keep out unwanted material.
(c) Soak the vent valve for some time (during the night, for example) in a container of dis-
tilled water. Do that to remove all salts from the vent hole.
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS.
Page 4002
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151CH1/151CH2
TASK 24-33-96-600-801
5. Lubrication
When the battery is clean (and after installation of the vent valve), put a thin layer of neutral petrola-
tum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.
Page 4003
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151CH1/151CH2
Page 4004
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151CH1/151CH2
CHECK
1. General
You must do the checks which are necessary to use the SAFT batteries in flight and on the ground.
These maintenance steps must be done in a battery shop between 23 C 5 C ( 73 9 F):
- Periodical check: adjustment of electrolyte levels.

- Regular check: electrical treatment, adjustment of electrolyte level, and capacity test.
- General overhaul: disassembly, full cleaning, assembly and regular check.
TASK 24-33-96-200-801
2. Maintenance steps in workshop
A. Equipment
(1) Standard tools

- Safety gloves.
- Safety shoes.
- Eye wash.
- Protective apron.
(2) Special tools
- Power supply 0 - 45 V, 0 - 60 A.
- Discharge bench, constant current 0 - 60 A.
(3) Instruments
- A multimeter, range 2 V and 50 V, accuracy 1%.

- A megohmeter, range 0 - 50 M (voltage 250 VDC), accuracy 3%.
(4) Check conditions
- Ambient temperature: 23 + 5 C.
- Pressure: 85 to 106 kPa.
- Relative humidity: < 85 %.
Page 5001
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151CH1/151CH2
(5) Referenced information
REFERENCE DESIGNATION
Insulation check
Polarisation test
24-33-96-720-002
Vent valve test
Supplementary test
SUBTASK 24-33-96-210-001
B. Periodical check
Regularly (with sufficient period between checks so that approved quantities are not surpassed):
- Obey the differents steps shown in Fig 5001.
- Clean the battery (See "CLEANING" chapter).
- Measure the voltage Ubat (in open circuit) at the terminal of the battery. If Ubat < 21 V do a po-
larization test.
- Adjust the electrolyte level.
(1) Charging the battery and adjusting the electrolyte level:
(a) Remove the cover.
(b) Discharge the remaining capacity at 15 A down to a voltage of 20 V at the battery

terminals.
(c) When the battery temperature is + 20 C to + 25 C (+ 68F to + 77 F) (usual tempera-

ture range), charge the battery (refer to one of the procedures given in the chapter TEST-
ING AND FAULT ISOLATION for a fully discharged battery).
(d) During the last 1/2 hour of the charge (while the charge current continues to flow), adjust
the level of electrolyte in the cells. Then measure the voltage of each cell. Write down
the quantity of water that is added to each cell. The electrolyte level changes with the
battery charge. The level changes as if the plates absorbed a part of the electrolyte dur-
ing the discharge and released it during the charge. Therefore the level checks are only
satisfactory if they are done almost at the end of the charge (but during the charge).
Leakage can occur during operation if you do not obey these instructions when you add
liquid. The level is correct when the distance between the seat of the complete vent valve
and the electrolyte is 20 mm (0.79 in) (distance measured in the condition given above)
(Fig. 5002).
(e) If necessary, add distilled or demineralized water to adjust the level to this value.
Page 5002
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151CH1/151CH2
PERIODICAL CHECK 2.B

Light cleaning
Cleaning yes U > 21 V no

no cell with reversed
polarity
yes
dust only?
Nut tigthness POLARIZATION TEST
no
Residual discharge
Salt or electrolyte traces 1 V/cell
1 cell shorting
overnight
no Insulation check yes

General overhaul
figure 5004 > 2 M
Recharge
Cell voltage before

end of charge
no U > 1.55 V yes
FAULT ISOLATION Adjustment of elec-
trolyte level before
end of charge
(volume < 60 cm3)
Supplementary test removal < 30 %
OK?
yes
Add 5 h overcharge
U > 1.55 V Vent cleaning
Adjust electrolyte
no
General overhaul Nut tightness
figure 5004
with replacement of
faulty components.
If more than 5* original
cells, then change all Battery accepted after
cells. * If 3 or more cells changed during periodical check
the same check, change all cells
Periodical check
Figure 5001/TASK 24-33-96-991-010
Page 5003
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151CH1/151CH2
WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte
levels in nickel-cadnium cells. A very small quantity of acid is sufficient to
cause permanent damage.
The easiest tool to use to adjust the level is a plastic syringe tube (equivalent to that used for
medical injections, with a plastic nozzle on the conical end).
The length of the nozzle which goes into the cell must be 20 mm (0.79 in); this is the distance
necessary between the seat of the complete vent valve and the electrolyte (Refer to figure
5002).
To adjust the level, keep the shoulder of the syringe nozzle against the seat of the complete
vent valve and pull the plunger up.
20 mm (0.79 in)
Level adjustment with a syringe and calibrated nozzle
Page 5004
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151CH1/151CH2
Figure 5002/TASK 24-33-96-991-011
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 sy-
ringe nozzle against the seat of the complete vent valve.
(2) Results of the above procedure
The battery operates correctly if:
(a) The voltage of each cell measured during the last hour of charge at 1.5 A is not less than
1.55 V.
(b) Approximately the same quantity of distilled water is added to each cell. This quantity
must be less than 15 cm3 (0.92 in3).
If the quantity of water added to all the cells is more than 15 cm3 (0.92 in3), make sure
that the voltage adjustment in relation to the temperature during the charge is correct.
Also do the electrolyte level check more frequently.
Do a full overhaul of the battery (refer to paragraph 3 "General overhaul"):
- If the quantity of water necessary for one or more cell(s) is much higher or smaller than for
the other cells.
- If the voltage of each cell measured at the end of a 1.5 A charge is less than 1.55 V (refer
to the chapter TESTING AND FAULT ISOLATION).
(3) Clean the complete vent valve (01-190) and (02-190) (Refer to "CLEANING" chapter) when
you adjust the electrolyte levels.
(4) Make sure that all the nuts that attach the links are torqued (refer to the chapter FITS AND
CLEARANCES).
Page 5005
24-33-96 Feb 15/2001
151CH1/151CH2
(5) Do an insulation check. The insulation resistance measured between the block of cells and
the metal box must be minimum 2 M under 250 VDC if the battery has not gone through a
general overhaul. If not else refer to CHECK chapter.
SUBTASK 24-33-96-210-002
C. Regular check (Ref Fig. 5003)
AFTER A MAXIMUM OF ONE YEAR, do this battery test (follow the different steps shown
fig 5003):
(1) Remove the cover.
(2) Clean the battery.
(3) Measure the voltage in open circuit at the terminal of the battery. If Ubat < 21 V, then do the
polarization test.
(4) Discharge the remaining capacity at 15 A down to a voltage of 20 V at the battery terminals.
Measure the time from the start of discharge to the time when the voltage reaches 20 V.
(5) Do an insulation test.
(6) Connect a resistor approximately 1 3 W (T03) across each cell and continue to discharge.
Resistors with crocodile clips attached to their leads can easily be attached to the cell termi-
nals. Keep the resistors in position for 12 hours.
(7) Remove all resistors, charge the battery (refer to the chapter TESTING AND FAULT ISOLA-
TION for a fully discharged battery).
(8) Adjust the electrolyte level in the cells.Then measure the voltage of each cell during the last
hour of charge. Also, write down the quantity of distilled water added to each cell.
(9) Immediately after the charge and the level adjustment, discharge the battery again at 15 A
down to 20 V; measure the terminal voltage of each cell. Write the time necessary for the sec-
ond discharge.
(10) Clean the complete vent valves (01-190) and (02-190) (Refer to CLEANING chapter) when
you adjust the electrolyte levels.
(11) Make sure that all nuts that attach the links are torqued (refer to FITS AND CLEARANCES
chapter).
(12) Charge the battery (refer to the chapter TESTING AND FAULT ISOLATION).
Page 5006
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151CH1/151CH2
Light cleaning
REGULAR CHECK 2.C
yes U > 21 V no
no cell with reversed
Cleaning polarity
Nut tigthness POLARIZATION TEST

yes
dust only? Residual discharge
1 V/cell
no
Salt or electrolyte traces 1 cell shorting
overnight
General overhaul Insulation check yes

figure 5004 no
> 2 M
Recharge
Cell voltage before

end of charge
U > 1.55 V
FAULT ISOLATION no Adjustment of elec- yes
trolyte level before
end of charge
(volume < 60 cm3)
Supplementary test removal < 30 %
OK? yes
Add 5 h overcharge
U > 1.55 V
Adjust electrolyte FAULT ISOLATION no Capacity check yes
no
Supplementary test
OK?
General overhaul
Completed charge Vent cleaning
figure 5004
Add 5 h overcharge
with replacement of no Nut tigthness
U > 1.55 V
faulty components . yes
Adjust electrolyte
If more than 5* original Recharge
level.
cells, then change all
Discharge > 1 hour.
cells. Battery accepted after
regular check
* If 3 or more cells changed during
the same check, change all cells Regular check
Figure 5003/TASK 24-33-96-991-012
Page 5007
24-33-96 Feb 15/2001
151CH1/151CH2
Results of the above tests:
The battery operates correctly if:
- The time necessary for the first discharge is more than 30 minutes.
- The time necessary for the second discharge is not less than 1 hour.
- The voltage of each cell measured during the last hour of the charge at 4 A is not less than
1.55 V.
- The variation of water consumption in individual cell is not more than 30% of the average con-
sumption for all cells.The maximum limit is 15 cm3 (0.92 in3).
- 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 if:
- The second discharge time is less than the correct one or one cell has a voltage less than 1 V
(or incorrect polarity before 1 hour of discharge).
- The voltage of each cell measured during the last hour of charge at 4 A is less than 1.55 V.
- The quantity of water necessary for one or more cell(s) is much higher or smaller than for the
other cells.
NOTE: The decrease of water in a SAFT nickel-cadmium cell is in proportion to the over-
charge. Thus, the decrease should be the same for all 20 cells in the battery.
If the quantity of water necessary for one or more cell(s) (in the same battery) is much higher (or
smaller) than the other cells, that means that there is a defect:
- Heavy decrease is usually caused by leakage.
- Low decrease is caused by a damaged separator.
Page 5008
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151CH1/151CH2
SUBTASK 24-33-96-210-003
D. General overhaul
(minimum every year or in accordance with the aircraft manufacturers instructions )
Follow the different steps shown in Fig. 5004.
This overhaul includes electrical tests. It also includes disassembly and cleaning procedures to
do systematically for all battery components.
Do these steps:
- Disassemble the battery.
- Clean the battery.
- Do a battery inspection.
- Assemble the battery.
- Do an insulation test.
(1) Disassemble the battery (Refer to "DISASSEMBLY" chapter).
(2) Clean the battery (Refer to "CLEANING" chapter).
(3) Do a battery inspection.
(a) Cells
1. Make sure that the lower terminal nuts are tight (refer to "FITS AND CLEARANCES"
chapter).
2. Make sure that cell boxes show no leakage.
(b) Box
Make the sides of the box straight and remove dents.
(c) Nuts, links and spring washers
Discard the components that show signs of corrosion or damage.
(d) Packing parts
Discard all defective components
Page 5009
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151CH1/151CH2
(e) Connector
Make sure that the connector is in good condition (inner and outer surfaces). Replace it
if contacts are burned.
SUBTASK 24-33-96-280-001
E. Insulation resistance
Refer to the chapter TESTING AND FAULT ISOLATION .
SUBTASK 24-33-96-280-002
F. Checking of temperature sensor
Refer to SCHEMATIC DIAGRAM chapter.
Do this test in a climatic chamber with the sensor disassembled from the battery.
(1) For Battery P/N 151CH1.
CHECK OF BETWEEN VALUE

- 2.2 k 5 % at 25 C (77 F)
Thermostat T A-B - closes at 71 C 2.8 C (160 F 5 F)
when temperature increases
Thermistor C C-D R = 300 k 3 k at 25 C (77 F)
Shunt E-F 0
(2) For Battery P/N 151CH2.
CHECK OF BETWEEN VALUE

- 2.2 k 5 % at 25 C (77 F)
Thermostat T A-B - closes at 71 C 2.8 C (160 F 5 F)
when temperature increase
Thermistor C C-D R = 300 k 3 k at 25 C (77 F)
- 201 20 at 5 C (41 F) or less
Heater E-F - opens at 8 C 2.8 C (46.4 F 5 F)
when temperature increases
Page 5010
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151CH1/151CH2
GENERAL OVERHAUL 2.D
Scheduled On fault
yes U > 21 V no
no cell with rever- POLARIZATION TEST
sed polarity
Nut tightness
Residual discharge
1 cell shorting
overnight
Disassembly
Thorough cleaning
Component inspection Sensor check
Faulty component
replacement Charge
Assembly Cell voltage be-
Insulation check fore end of charge
no > 10 M yes U > 1.55 V
no yes
Adjustment of
electrolyte level
FAULT ISOLATION before end of
charge
Other test OK?
Add 5 h over- yes
no
charge U > 1.55 V
Adjust electrolyte no
FAULT ISOLATION Capacity check yes
Other test OK?

General overhaul Completed charge Vent cleaning
with replacement of faulty Add 5 h over-
components . Nut tightness
charge U > 1.55 V
If more than 5* original cells
then change all cells. no Adjust electrolyte yes Recharge
level. Discharge
> 1 hour. Battery accepted af-
* If 3 or more cells changed during ter general overhaul
the same check, change all cells General overhaul
Figure 5004/TASK 24-33-96-991-013
Page 5011
24-33-96 Feb 15/2001
151CH1/151CH2
NOTE: If more than 5 original cells have been replaced or more than 3 cells are defective in
the same maintenance, then replace all cells.
Page 5012
24-33-96 Feb 15/2001
151CH1/151CH2
REPAIR
1. General
As shown in the CHECK chapter, you must reject and replace by new parts the defective parts for
which no repair instructions are given.
The figure and item numbers in this chapter correspond with those of the ILLUSTRATED PARTS
LIST.
2. Equipment
A. Special tools
B. Standard tools
Standard mechanics tools.
C. Materials
Neoprene glue [M03]
3. Repairs
The only authorized repair applicable to the unit is:
- Replacing a cover gasket (01-080) and (02-080).
Page 6001
24-33-96 Feb 15/2001
151CH1/151CH2
REPAIR N1
TASK 24-33-96-900-801
1. Replacing a cover gasket
A. General
The cover gasket (01-080) and (02-080) can be replaced only one time.
B. Detailed procedure
- Remove the cover gasket (01-080) and (02-080).
- Clean the joint location.
- Apply paste to the flat side of the gasket.
- Let stay dry for 2 hours in a dry place.
- Put gasket on the bottom of the cover (01-070) and (02-070). Press firmly.
Page 6002
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151CH1/151CH2
ASSEMBLY
1. General
You must do the assembly of parts on a clean workbench in a clean, dry room. The parts will be pro-
tected from hit damage.
For tightening parts refer to the torque table in the chapter FITS AND CLEARANCES .
Check that the storage protection layer is removed from the new part before assembly.
WARNING: The figure and item numbers in this chapter correspond with those of the
ILLUSTRATED PARTS LIST.
To do check points, refer to CHECK chapter.
TASK 24-33-96-400-801
2. Assembly procedure
A. Equipment
(1) Special tools
When special tools are used in this chapter they are identified by a code number listed in the
(2) Standard tools

- Safety gloves.
- Safety shoes.
- Eye wash.
- Protective apron.
SUBTASK 24-33-96-420-001
B. Installation of the liner spacer kit of battery 151CH1 (01-200)
(1) Place the D insulator in the bottom of the box (01-290).
(2) Install the spacer A against the left and right panels.
(3) Install the spacer B (one or two as most as required) against front and back panels.
Page 7001
24-33-96 Feb 15/2001
151CH1/151CH2
(4) Install the spacer C (one or two at most as required) against B.
(5) Place and hold the spacer E in the middle of the box (01-310).
A Insulator 0.5x268x175 2
B Insulator 0.5x155x123 4
C Spacer 1x155x123 2
D Insulator 0.5x275x123 1
E Spacer 1x268x152 3
C. Installation of the liner spacer kit of battery 151CH2 (02-200)
(1) Place the D insulator in the bottom of the box (01-290).
(2) Install the spacer A against the left and right panels.
(3) Install the spacer B (one or two at most as required) against front and back panels.
(4) Install the spacer C (one or two at most as required) against B.
A Insulator 0.5x268x175 2
B Insulator 0.5x155x123 4
C Spacer 1x155x123 2
D Insulator 0.5x275x123 1
Page 7002
24-33-96 Feb 15/2001
151CH1/151CH2
B (1 maxi)
B
A C (1 maxi)
E
E
A
C (1 maxi) 200
B (1 maxi)
Battery 151CH1 liner spacer kit installation

Figure 7001/TASK 24-33-96-991-014
Page 7003
24-33-96 Feb 15/2001
151CH1/151CH2
Battery 151CH2 liner spacer kit installation

Figure 7002/TASK 24-33-96-991-015
Page 7004
24-33-96 Feb 15/2001
151CH1/151CH2
SUBTASK 24-33-96-420-002
D. Installation of the vent valve (01-190) and (02-190)
(1) Make sure the vent valves (01-190) and (02-190) are in good condition. Replace the vent
valves if they are worn.
(2) Install the vent valve (01-190) and (02-190) with the special tool (T01). Hold the special tool
by its upper ribbed part.
SUBTASK 24-33-96-420-003
E. Installation of a cell of battery 151CH1 (Ref. Fig. 7003 and 7004)
(1) Put five cells (01-140) onto the two corners.
(2) Put four cells (01-140) onto the two corners
(3) Put two cells (01-140) in the middle of each compartment.
Battery 151CH1 cells assembly

Figure 7003/TASK 24-33-96-991-016
Page 7005
24-33-96 Feb 15/2001
151CH1/151CH2
(4) Move the last cell into position (if it is difficult to put in the last cell, remove one or two
spacers).
(5) Put the temperature sensor (01-220) in place.
(6) Install the links (01-110 thru 01-130).
(7) Install the spring washers (01-100).
(8) Install the nuts (01-090) and torque them.
(9) Install the battery terminal (01-210).and torque them.
(10) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
brush).
(11) Install the sensor (01-220) on the link (01-130) and install the nut (01-270). Torque them.
(12) Install the screw (01-240), the spring washer (01-250) and the nut (01-260). Torque them.
(13) Install the cable grip (01-280), while respecting cable.
(14) Install the cover (01-060).
(15) Insert the spring washers (01-050) and the screws (01-040) into their respective holes.
Torque them.
(16) Put the spring washer (01-100) and the positive nut battery (01-020).
(17) Put the spring washer (01-100) and the negative nut battery (01-030).
Page 7006
24-33-96 Feb 15/2001
151CH1/151CH2
110
120
130
Polarity +
Polarity -
Temperature sensor
connector
Battery 151CH1 assembly

Figure 7004/TASK 24-33-96-991-017
SUBTASK 24-33-96-420-004
F. Installation of a cell of battery 151CH2 (Ref. Fig. 7005 and 7006)
(1) Put five cells (02-140) onto the two corners.
(2) Put four cells (02-140) onto the two corners
(3) Put two cells (02-140) in the middle of each compartment.
Page 7007
24-33-96 Feb 15/2001
151CH1/151CH2
Battery 151CH2 cells assembly

Figure 7005/TASK 24-33-96-991-018
(4) Move the last cell into position (if it is difficult to put in the last cell, remove one or two spac-
ers).
(5) Put the heater wiring in place.
(6) Install the links (02-110 thru 02-130).
(7) Install the spring washers (02-100).
(8) Install the nuts (02-090) and torque them.
(9) Install the battery terminal (02-210) and torque them.
(10) Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paint-
brush).
(11) Install the sensor thermostat (02-220) on the link (02-130) and install the screw (02-240) ,
the spring washer (02-250) and the nut (02-260). Torque them.
Page 7008
24-33-96 Feb 15/2001
151CH1/151CH2
(12) Install the sensor heater (02-230) on the link (02-130) and install the nut (02-270). Torque
them.
(13) Install the cable grip (02-280), while respecting cable.
(14) Install the cover (02-060).
(15) Insert the screw (02-040) and spring washers (02-050) into their respective holes. Torque
them.
(16) Put the spring washer (02-100) and the positive nut battery (02-020).
(17) Put the spring washer (02-100) and the negative nut battery (02-030).
SUBTASK 24-33-96-970-001
G. Inform
(1) Identification plate (01-310) and (02-310) if the box (01-290) and (02-290) has been replaced.
(2) Amendment plate. (01-350) and (02-350)
(3) Log book.
Page 7009
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151CH1/151CH2
Page 7010
24-33-96 BLANK
151CH1/151CH2
FITS AND CLEARANCES
TASK 24-33-96-400-802
1. Torque table
SUBTASK 24-33-96-420-001
A. Torque table
List of all applicable torque values necessary to assemble and do servicing of the battery:
NOTE: The values hereafter are "lube torque" values. The threads should be lightly
greased before installation and applying torque.
IPL TORQUE VALUE

FIG ITEM NAME
N N.m lbf.in
01-270 Nut 2.8 + 0.1 24.8 + 0.8

02-260 Nut 2.8 + 0.1 24.8 + 0.8
02-270 Nut 2 + 0.2 17.8 + 1.7
01-260 Nut 2 + 0.2 17.8 + 1.7
02-040 Nut 2.8 + 0.1 24.8 + 0.8
01-040 Nut 2.8 + 0.1 24.8 + 0.8
01-090 Nut 8 +2 70.9 + 17.8
02-090 Nut 8 +2 70.9 + 17.8
01-210 Nut 8 +2 70.9 + 17.8
02-210 Nut 8 +2 70.9 + 17.8
01-150 Nut 5 + 0.5 44.3 + 4.4
02-150 Nut 5 + 0.5 44.3 + 4.4
Page 8001
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151CH1/151CH2
Page 8002
24-33-96 BLANK
151CH1/151CH2
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General
This chapter is divided into two parts:
- The first part provides the list of SPECIAL TOOLS, AND FIXTURES AND EQUIPMENT necessary
to perform the steps listed in the order chapters.
- The second part provides the listing of Consumable Materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for TOOLS, FIXTURES AND EQUIPMENT,

- Mxx for Consumable Materials.
2. Special tools, fixtures and equipment
PART
CODE QTY DESCRIPTION USE
NUMBER
Polyamide key for polyamide DISASSEMBLY - CLEANING -

T01 1 015528
complete vent valve CHECK - ASSEMBLY
TESTING AND FAULT ISOLA-
T02 1 016544 Syringe assembly (with nozzle)
TION - CHECK
Equalizing resistors
T03 1 164829 TESTING - CHECK
(1 / 3 W)
T04 1 014735 Cell extraction tool DISASSEMBLY
Page 9001
24-33-96 Feb 15/2001
151CH1/151CH2
Polyamide key for vent valve (T01)

Figure 9001/TASK 24-33-96-991-016
Syringe with nozzle (T02)

Figure 9002/TASK 24-33-96-991-017
Page 9002
24-33-96 Feb 15/2001
151CH1/151CH2
Equalizing resistor (T03)

Figure 9003/TASK 24-33-96-991-018
Page 9003
24-33-96 Feb 15/2001
151CH1/151CH2
Cell extraction tool (T04)

Figure 9004/TASK 24-33-96-991-019
Page 9004
24-33-96 Feb 15/2001
151CH1/151CH2
3. Consumables
NOTE: You can use equivalent alternatives for listed items.
A
I D
R I
C A
L S S
MANUFACTU L R S
I A C T
DESIGNATION RER T E E S
N S H O
PARTNUMBER OR SUPPLIER E A P E
CODE E S E R
AND (NAME, S N A M
S E C A
SPECIFICATION ADDRESS, T I I B
M K G
CODE) N R L
C B E
G Y
O L
D Y
E
Distilled or deionized
water
clear, colourless, oderless
while boiling, resistivity
> 30 k/cm
5 < pH < 7
Absence of organic and
reducing substances.
M01 Reducing agent content Local vendor X X
(expressed in weight of
oxygen) < 30 mg/l (test
with permanganate).
Total of ions
SO42+ Cl- < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
M02 Soap Local vendor X

M03 Neoprene glue Local vendor X
NATO: S 743
F: AIR 3565
M04 Mineral vaseline X X
US: VLP 236
UK: DEF 2333
CAUTION: Use only distilled or deionized water.
Page 9005
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151CH1/151CH2
Page 9006
24-33-96 BLANK
151CH1/151CH2
ILLUSTRATED PARTS LIST
TP Page 10001
24-33-96 Feb 15/2001
151CH1/151CH2
TP Page 10002
24-33-96 BLANK
151CH1/151CH2
INTRODUCTION
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts
of the unit in disassembly sequence.
It includes the sections that follow:
- Introduction (INTRO),
- Numerical Index (NI),
- Detailed Parts List (DPL).
B. How to Use the illustrated Parts List
(1) To find the illustration for a part if the part number is known, refer to the Numerical Index and
look for the part number and the corresponding figure and item number. Refer to the Detailed
Parts List and look for the first figure and item number found in the Numerical Index for that
part. If this figure shows the part in a section or system of the equipment other than the one
necessary, refer to the other figure numbers listed in the Numerical Index.
(2) To determine the part number of a given part, refer to the illustration showing the assembly
including this part. Note the item number of the illustrated part and refer to the Detailed Parts
List which indicates its part number and identification.
2. Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and electronic
components of the items listed in alphanumeric order for the letters, numerical order for the figures.
Page 10003
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151CH1/151CH2
3. Numerical Index (NI)
In this index, part numbers are classified in this order:
Classification is made from left to right, each character (letter, number, hyphen) being considered
separately.
The first left row ordering is:
- hyphen
- alpha letter from A to Z (except for " O " and " I " to be considered as zero and one)
- numbers from 0 to 9.
The part number column contains all part numbers included in the Detailed Parts List. Part numbers
that have been deleted or superseded within the Detailed Part List are listed in the Numerical Index
and identified as deleted or superseded.
4. Detailed Parts List (DPL)
A. Figure and Item Number
Each assembly, sub-assembly and part holding a part number and included in the parts list is giv-
en a time number.
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 identi-
fied by a hyphen (-) preceding the item number.
An index letter shown before the item number refers to the figure showing the modified portion of
the applicable part.
B. Manufacturer's Part Number
A manufacturer's part number is given to each assembly and detail part, whether illustrated or not.
Page 10004
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151CH1/151CH2
C. Parts List
The parts list is represented with indenting showing the relationship of parts and assemblies to
their next higher assemblies as follows :
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
The attaching parts are shown directly after the assembly of the part thereof. They are listed under
the same indent number as the item they are attached to, and are identified by the words "Attach-
ing Parts" and are followed by three asterisks.
The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme right-
hand side of the first line of the parts list column.
D. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in re-
lation to the next higher assembly (ies) or sub-assembly (ies).
When the effectivity is fully applicable, the usage code column remains blank.
The usage code for assemblies and detailed parts refers to the figure/item number of the next
higher assembly (ies) or sub-assembly (ies).
Example : Effectivity 1A, 1B, 1C is written 1ABC.
Page 10005
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151CH1/151CH2
E. Units per Assembly
The units per assembly column showns the quantity of units required for one next higher assem-
bly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR (as re-
quired).
Page 10006
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151CH1/151CH2
5. Abbreviation used
ALT FROM PN XXX Part that is functionally and physically interchangeable with original part
after reworking.
AMDT Amendment
AR As required
DELETED Deleted part
DET Detail
DPL Detailed Parts List
EDI Equipment Designator Index
IPL Illustrated Parts List
LH Left hand
MFR Manufacturer or Optional Manufacturer in the IPL
MODIFIED FROM Part obtained by modifying another part
NHA Next higher assembly
NP Not procurable
OLD PN Old part number. This item has never been installed.
OPT PN Optional part number that is fully interchangeable with the part in the
part number column.
OPT SEE TABLE See optional table
ORDER OVRLGTH MPN Part number over fifteen characters
OVERSIZE Part with size exceeding its nominal dimension.
PN Part number.
POST SB After modification brought up by a Service Bulletin.
PRE SB Before modification brought up by a Service Bulletin.
R Modified
RF For reference.
RH Right hand.
SEE CMM See component Maintenance Manual.
SEE FIG FOR DET See figure for details.
SEE FIG FOR NHA See figure for next higher assembly.
SEL FROM Selected from. Part which is to be selected as necessary from collec-
tion of parts.
SUPSD BY Superseded by XXX.
SUPSDS Supersedes XXX.
UNDERSIZE Part with size smaller than its nominal dimension.
VL Vendors List.
Page 10007
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151CH1/151CH2
6. Updating
A. General
When an item is revised, added or deleted, the letter " R " is shown in the right-hand margin (the
date of issue changes).
B. Added items
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 is to be added at the end of the IPL.
C. Deleted items
Should a part number definitively deleted, the information given in the parts list zone is deleted.
The old part number always remains in the numerical index.
D. New Figure Number Added
Whenever new illustrations are necessary the alternative figures are inserted. They refer to the
same parts list.
The alternative figure is given with the basic figure number and letter. This letter precedes the item
number in the parts list.
Page 10008
24-33-96 Feb 15/2001
151CH1/151CH2
VENDOR CODE INDEX
VENDOR CODE NAME-ADDRESS

SAFT
12, Rue Sadi Carnot
93170 BAGNOLET
F6177
Telex - 235566 F
Phone: (33) (0)1 49 93 19 18
Fax: (33) (0)1 49 93 19 50
SAFT AMERICA INC.
711 Industrial Boulevard
Valdosta, GA 31601
V09052
USA
Phone: (1) 912 245 2331
Fax: (1) 912 245 2827
Page 10009
24-33-96 Feb 15/2001
151CH1/151CH2
Page 10010
24-33-96 BLANK
151CH1/151CH2
ALPHA NUMERICAL INDEX
AIRLINE STOCK FIG INDEX TOTAL

PART NUMBER
NUMBER NUMBER NUMBER REQUIRED
031282 1 340 1
031282 2 340 1
034031 1 370 1
034031 2 370 1
062007 1 160 2
062007 2 160 2
100078 1 190 2
100078 2 190 2
100111 1 110 40
100111 2 110 40
100593 1 220 1
100593 2 220 1
100693 1 180 1
100693 2 180 1
100694 1 170 1
100694 2 170 1
101229 1 130 9
101229 2 130 9
101279 1 120 8
101279 2 120 8
102013 1 280 1
102013 2 250 1
102077 1 270 1
102077 2 240 1
105405 1 260 1
Page 10011
24-33-96 Feb 15/2001
151CH1/151CH2

PART NUMBER
031282 1 340 1
105405 2 270 3
116056 1 300 1
116056 2 300 1
116711 1 50 4
116711 1 290 1
116711 2 50 4
116711 2 260 1
117026 1 320 1
117026 2 320 1
164584 1 20 1
164584 2 20 1
164585 1 30 1
164585 2 30 1
280068 1 -360 1
280068 2 -360 1
411108 1 330 1
411108 2 330 1
411810 1 100 38
411810 2 100 38
411996 1 200 2
411996 2 200 2
413607 1 360 2
413607 2 360 2
413609 1 350 2
413609 2 350 2
414400 1 150 20
414400 2 150 20
Page 10012
24-33-96 Feb 15/2001
151CH1/151CH2

PART NUMBER
031282 1 340 1
414417 1 310 1
414417 2 310 1
414418 1 70 1
414418 2 70 1
414419 1 80 1
414419 2 80 1
414425 1 240 1
414426 1 60 1
414426 2 60 1
414427 1 -10 1
414427 2 -10 1
414429 1 -1 PM
414475 1 230 1
414475 2 230 1
414480 1 140 2
414480 2 140 2
414482 1 90 2
414482 2 90 2
414519 1 40 4
414519 2 40 4
451215 2 210 1
415218 1 210 1
415236 2 280 1
415237 2 -1 PM
- Item not illustrated.
Page 10013
24-33-96 Feb 15/2001
151CH1/151CH2
DETAILED PARTS LIST
030
100
110
040 120
020 050
100
100
070 130
060
080
240
270
230 090
220 130
250
A 100
260
190
150
210
160
100 170
140
200
100
180
A
280
300
320
310
340
290
350 010 (with cover) 060
330
151CH1 BATTERY
Figure 1/TASK 24-33-96-991-020
Page 10014
24-33-96 Feb 15/2001
151CH1/151CH2
FIGURE AIRLINE NOMENCLATURE UNITS

PART EFF.
AND STOCK PER
NUMBER CODE
ITEM NUMBER 1234567 ASSY
01
-001 151CH1 Battery, 20 CVH 150KH PM
-010 414427 . Box and cover complete 1
020 164584 . . Nut, positive battery terminal 1
030 164585 . . Nut, negative battery terminal 1
040 414519 . . Screw, H M 4-8 4
050 116711 . . Washer, spring 4
060 414426 . Cover complete 1
070 414418 . . Cover, assembly 1
080 414419 . . Gasket, cover 1
090 411810 . Nut M8X1.25 38
100 100111 . Washer, spring 40
110 101279 . Link, intercell, E24 8
130 414480 . Link, intercell, E24 sensor 2
140 414400 . Cell, CVH150KH, assembly 20
150 413445 . . Nut, M8X1.25 2
160 100695 . . Washer, positive polarity 1
170 100696 . . Washer, negative polarity 1
180 100479 . . Washer, flat 2
190 415215 . . Vent valve, complete 1
200 414475 . Liner-spacer kit 1
210 414482 . Terminal, battery 2
220 414425 . Temperature sensor, complete 1
230 . . Temperature sensor, assembly NP
240 102013 . . Screw, CL M 4-10 1
250 116711 . . Washer, spring 1
260 102077 . . Nut, HM4 1
270 105405 . . Nut, 6/32" 1
280 116056 . Cable grip 1
290 414417 . Box, assembly 1
300 117026 . Film, protector 1
310 411108 . Plate, identification 1
320 031282 . Plate, filling instruction 1
330 413609 . Plate, SAFT label 2
340 413607 . Plate, range label 2
350 034031 . Plate, amendment 1
-360 280068 . Plate, recycling 1
Page 10015
24-33-96 Feb 15/2001
151CH1/151CH2
110
030
100
130
040
020 050
100
320 120
070
060
080
230
270
240 090
250 100
260 190
220
150 140
160
280 170
100
180
A
B
210
100
200
A
350 B
280
360
290(010 with cover 060)
320
330
340
300
151CH2 BATTERY
Figure 2/TASK 24-33-96-991-020
Page 10016
24-33-96 Feb 15/2001
151CH1/151CH2
FIGURE AIRLINE NOMENCLATURE UNITS

PART EFF.
AND STOCK PER
NUMBER CODE
ITEM NUMBER 1234567 ASSY
02
-001 151CH2 Battery 151CH2, CVH150KH PM
-010 414427 . Box and cover complete 1
020 164584 . . Nut, positive battery terminal 1
030 164585 . . Nut, negative battery terminal 1
040 414519 . . Screw, CL M 4-8 4
050 116711 . . Washer, spring 4
060 414426 . Cover complete 1
070 414418 . . Cover, assembly 1
080 414419 . . Gasket, cover 1
090 411810 . Nut M8X1.25 38
100 100111 . Washer, spring 40
130 414480 . Link, intercell, E24, sensor 2
140 414400 . Cell, CVH150KH, assembly 20
150 062007 . . Nut M10X1.25 2
160 100694 . . Washer, positive polarity 1
170 100693 . . Washer, negative polarity 1
180 100078 . . Washer, flat 2
190 415215 . . Vent valve, complete 1
200 414543 . Liner-spacer kit 1
210 414482 . Terminal, battery 2
220 414425 . Temperature sensor, complete 1
230 . Temperature sensor, assembly NP
240 102013 . . Screw, CLS M 4-10 1
250 116711 . . Washer, spring 1
260 102077 . . Nut, HM4 1
270 105405 . . Nut, 6/32" 3
280 116056 . Cable grip 1
290 414417 . Box assembly 1
300 117026 . Film, protector 1
310 411108 . Plate, identification 1
320 031282 . Plate, filling instruction 1
330 413609 . Plate, SAFT label 2
340 413607 . Plate, range label 2
350 034031 . Plate, amendment 1
360 280068 . Plate, recycling 1
Page 10017
24-33-96 Feb 15/2001
151CH1/151CH2
Page 10018
24-33-96 Feb 15/2001
151CH1/151CH2
STORAGE (WITH TRANSPORTATION)
TASK 24-33-96-600-802
1. Storage
A. Preparation of the battery before storage
- Adjust the electrolyte level (Refer to "CHECK"), then discharge at a constant current of 15 A
down to 20 V.
- 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 batteries and spares in a dry and clean room.
C. Temperature conditions
The recommanded temperature range is + 20 C 15 C (68 F 27 F). However, occasional

excursions into the range of - 60 C to + 60 C (- 76 F to + 140 F) is permitted.
D. Packing
The batteries are usually put in cardboard boxes. For long storage or sea transportation, we rec-
ommend to put the batteries in a welded plastic container. In this type of container, with the re-
commanded temperature range, you can keep the batteries for 10 years.
TASK 24-33-96-600-803
2. Storage procedure
A. General
When the battery arrives in the battery shop for servicing:
- Visual inspection: if dust or salt do a General Overhaul compliant with procedure (refer to
CHECK chapter).
- Then light cleaning (refer to CLEANING chapter), then service as scheduled (periodical check,
regular check or general check) (refer to CHECK chapter).
Page 15001
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151CH1/151CH2
SUBTASK 24-33-96-610-001
B. Short term storage (Ref. Fig. 15001)
(1) Operations
- Put the charged battery (serviced compliant with CMM procedure) in a cool room or dis-
charge to 1 V/cell (refer TESTING AND FAULT ISOLATION chapter).
- Light greasing of cells terminals.
- Put in a storage room.
Page 15002
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151CH1/151CH2
Short term storage

Figure 15001/TASK 24-33-96-991-021
Page 15003
24-33-96 Feb 15/2001
151CH1/151CH2
SUBTASK 24-33-96-610-002
C. Long term storage
(1) Operations
- Discharge to 1 V/cell.
- Light greasing of cells terminals.
- Place in a storage room.
(2) Conditions
The battery should be stored filled and discharged.
The storage life is 10 years, if using the following conditions :
- Sealed packaging.
- Temperature: + 20 C 15 C (68 F 27 F).
- Humidity: < 70 %.
- Normal vertical position.
- Isolated from detrimental agents: ie. dirt, dust, clampness, vibration, corrosive atmosphere.
NOTE: Lead batteries must be stored in a different room.
CAUTION: Saft Ni-Cd batteries may be stored in temperatures ranging from - 60 C (- 67 F)

to + 60 C (+ 140 F) for short periods of time without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years
of storage under the above conditions.
No maintenance operation needs to be performed during the storage period.
The maximum battery life, with storage, for which Saft acknowledges respon-
sabilty is 12 years. The use of the battery after this period is only under the
responsability of the operator.
Page 15004
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151CH1/151CH2
TASK 24-33-96-600-804
3. Servicing after storage
Storage time Servicing procedure

Charge the battery (Do one of the procedures given in "TESTING
Less than 3 months
AND FAULT ISOLATION" chapter) for a fully discharged battery.
3 months to 1 year Do the Periodical check (refer to "CHECK" chapter).
More 1 year Do the Regular check (refer to "CHECK" chapter).
TASK 24-33-96-500-801
4. Transportation
You must discharge the battery before packing.
You must then pack the battery vertically in its original container. If the original container is not
available, you must obey the international and/or local packaging regulations applicable to the
mode of transport and destination.
Page 15005
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151CH1/151CH2
Page 15006
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151 CH 1

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151 CH 1

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(F6177)

12, Rue Sadi Carnot - 93170 Bagnolet - France

Date of initial issue: sep 15/1998 Title page - page 1

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Title page - page 2

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RECORD OF TEMPORARY REVISIONS

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SERVICE BULLETIN LIST

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LIST OF APPROVED REPAIRERS

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LIST OF EFFECTIVE PAGES

TABLE OF CON- 1 Feb 15/2001 CLEANING 4001 Feb 15/2001

LIST OF EFFECTIVE PAGES

FITS AND CLEA- 8001 Feb 15/2001

SPECIAL TOOLS, 9001 Feb 15/2001

ILLUSTRATED 10001 Feb 15/2001

INTRODUCTION 10003 Feb 15/2001

VENDOR CODE 10009 Feb 15/2001

ALPHA NUMERICAL 10011 Feb 15/2001

DETAILED 10014 Feb 15/2001

DESCRIPTION AND OPERATION 1

TESTING AND FAULT ISOLATION 1001

SCHEMATIC AND WIRING DIAGRAMS 2001

FITS AND CLEARANCES 8001

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

ILLUSTRATED PARTS LIST 10001

STORAGE (WITH TRANSPORTATION) 15001

Figure 2 - Identification plate 4

Figure 3 - Amendment plate 4

Figure 4 - Overall dimensions 5

Figure 1001 - Preliminary Functional Tests 1003

Figure 1002 - Insulation Check 1004

Figure 1003 - Insulation Parameters 1005

Figure 1004 - Cell connections battery 151CH1 1007

Figure 1005 - Cell connections battery 151CH2 1008

Figure 2001 - Schematic sensor Battery 151CH1 2001

Figure 2002 - Schematic sensor Battery 151CH2 2002

Figure 5001 - Periodical check 5003

Figure 5003 - Regular check 5007

Figure 7001 - Battery 151CH1 liner spacer kit installation 7003

Figure 7002 - Battery 151CH2 liner spacer kit installation 7004

Figure 7003 - Battery 151CH1 cells assembly 7005

Figure 7004 - Battery 151CH1 assembly 7007

Figure 7005 - Battery 151CH2 cells assembly 7008

Figure 9001 - Polyamide key for vent valve (T01) 9002

Figure 9002 - Syringe with nozzle (T02) 9002

Figure 9003 - Equalizing resistor (T03) 9003

Figure 9004 - Cell extraction tool (T04) 9004

Figure 1 - 151CH1 BATTERY 10014

Figure 2 - 151CH2 BATTERY 10016

Figure 15001- Short term storage 15003

E. This manual contains:

- Technical data for components.

F. We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY

2. How to Use this Manual

Quantities are given in I.S. Units followed by U.S. Units in parentheses.

This manual uses the abbreviations given below.

ATA AIR TRANSPORT ASSOCIATION OF AMERICA

This paragraph gives the warnings of this manual.

Notes call attention to procedures which make the job easier.