CMM 24-32-03

COMPONENT MAINTENANCE MANUAL
40176-4 / 40176-7
COMPONENT MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
40176-4 / 40176-7
Title Page – page 1
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Original Issue Date: July 30/75

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THIS 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 07/30/75 07/30/75 Saft
2 09/30/98 09/30/98 Saft
3 04/15/02 04/15/02 Saft
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RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE BY DATE BY

REV. No. NUMBER DATE REMOVED
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SERVICE BULLETIN LIST
NUMBER BRIEF DESCRIPTION TYPE AFFECTED
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LIST OF MAJOR REPAIRERS
TRADE NAME ADDRESS

For a complete list contact Saft
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LIST OF EFFECTIVE PAGES
CONTENT PAGE REVISION CONTENT PAGE REVISION

DATE DATE
TITLE PAGE 1 Apr 15/2002 TESTING AND FAULT 1014 BLANK
2 BLANK ISOLATION (Cont’d)
RECORD OF REVISIONS 1 Apr 15/2002 SCHEMATIC AND 2001 Apr 15/2002

2 BLANK WIRING DIAGRAMS 2002 BLANK
RECORD OF 1 Apr 15/2002 DISASSEMBLY 3001 Apr 15/2002

TEMPORARY REVISIONS 2 BLANK 3002 Apr 15/2002
3003 Apr 15/2002
SERVICE BULLETIN LIST 1 Apr 15/2002 3004 BLANK
2 BLANK
CLEANING 4001 Apr 15/2002
LIST OF MAJOR REPAIR 1 Apr 15/2002 4002 Apr 15/2002
STATIONS 2 BLANK 4003 Apr 15/2002
4004 BLANK
LIST OF EFFECTIVE 1 Apr 15/2002
PAGES 2 Apr 15/2002 CHECK 5001 Apr 15/2002
5002 Apr 15/2002
TABLE OF CONTENTS 1 Apr 15/2002 5003 Apr 15/2002
2 Apr 15/2002 5004 Apr 15/2002
5005 Apr 15/2002
TABLE OF 1 Apr 15/2002 5006 Apr 15/2002
ILLUSTRATIONS 2 BLANK 5007 Apr 15/2002
5008 Apr 15/2002
INTRODUCTION 1 Apr 15/2002
2 Apr 15/2002 REPAIR 6001 Apr 15/2002
3 Apr 15/2002 6002 BLANK
4 Apr 15/2002
ASSEMBLY 7001 Apr 15/2002
DESCRIPTION AND 1 Apr 15/2002 7002 Apr 15/2002
OPERATION 2 Apr 15/2002 7003 Apr 15/2002
3 Apr 15/2002 7004 BLANK
4 BLANK
FITS AND CLEARANCES 8001 Apr 15/2002
TESTING AND FAULT 1001 Apr 15/2002 8002 BLANK
ISOLATION 1002 Apr 15/2002
1003 Apr 15/2002 SPECIAL TOOLS, 9001 Apr 15/2002
1004 Apr 15/2002 FIXTURES AND 9002 Apr 15/2002
1005 Apr 15/2002 EQUIPMENT 9003 Apr 15/2002
1006 Apr 15/2002 9004 Apr 15/2002
1007 Apr 15/2002
1008 Apr 15/2002 ILLUSTRATED PARTS 10001 Apr 15/2002
1009 Apr 15/2002 LIST 10002 BLANK
1010 Apr 15/2002
1011 Apr 15/2002
1012 Apr 15/2002
1013 Apr 15/2002
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CONTENT PAGE REVISION

DATE
INTRODUCTION 10003 Apr 15/2002

10004 Apr 15/2002
10005 Apr 15/2002
10006 Apr 15/2002
VENDOR CODE INDEX 10007 Apr 15/2002

10008 BLANK
ALPHA NUMERICAL 10009 Apr 15/2002

INDEX 10010 Apr 15/2002
DETAILED PARTS LIST 10011 Apr 15/2002

10012 Apr 15/2002
10013 Apr 15/2002
10014 BLANK
10015 Apr 15/2002
10016 Apr 15/2002
STORAGE AND 15001 Apr 15/2002

SHIPPING 15002 Apr 15/2002
15003 Apr 15/2002
15004 Apr 15/2002
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TABLE OF CONTENTS
PAGE
INTRODUCTION Intro Page 1
1 – General Intro Page 1
2 – How to Use the Manual Intro Page 1
3 – Measure Intro Page 1
4 – Units of Measure Intro Page 2
5 – Abbreviations Intro Page 3
6 – Definition Intro Page 3
7 – Disposal Intro Page 4
DESCRIPTION AND OPERATION OP Page 1

1 – Description OP Page 1
TESTING AND FAULT ISOLATION 1001

1 – General 1001
2 – Testing 1001
3 – Charge 1004
4 – Electrolyte level and adjustment 1006
5 – Discharge 1007
6 – Temperature Sensor Testing 1008
7 – Fault Isolation 1009
SCHEMATIC AND WIRING DIAGRAMS 2001

1 – General 2001
2 – Sensor Schematic 2001
DISASSEMBLY 3001
1 – General 3001
2 – Safety 3001
3 – Risks 3001
4 – Safety Measures 3001
5 – Disassembly 3002
CLEANING 4001
1 – General 4001
2 – Equipment 4001
3 – Materials 4001
4 – Cleaning procedure 4001
5 – Lubrication 4003
CHECK 5001
1 – General 5001
2 – Maintenance in workshop 5001
REPAIR 6001
1 – General 6001
2 – Equipment 6001
3 – Repairs 6001
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ASSEMBLY 7001
1 – General 7001
2 – Assembly procedures 7001
FITS AND CLEARANCES 8001

1 – General 8001
2 – Torque Specifications 8001
SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

1 – General 9001
2 – Special tools, fixtures and equipment 9001
3 – Consumables 9004
ILLUSTRATED PARTS LIST 10001

1 – Introduction 10003
2 – Vendor Code Index 10007
3 – Alpha-Numeric Index 10009
4 – Detailed Parts List 10011
SPECIAL PROCEDURES NOT APPLICABLE
REMOVAL NOT APPLICABLE
INSTALLATION NOT APPLICABLE
SERVICING NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION 15001

1 – General Storage Information 15001
2 – Preparation for Storage 15001
3 – Active Stand-By Storage 15001
4. – Trickle Charging 15003
5 – Inactive Long-Term Storage 15004
6 – Preparation for Use after Storage 15004
7 – Packing and Transporting 15004
REWORK (Service Bulletin Instructions) NOT APPLICABLE
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TABLE OF ILLUSTRATIONS
PAGE
Figure 1 40176-4 / 40176-7 Battery OP Page 3
Figure 2 Identification plate OP Page 3
Figure 3 Overall dimensions OP Page 4
Figure 1001 Insulation Test 1002
Figure 1002 Insulation Test Parameters 1003
Figure 1003 Electrolyte Level Adjustment 1006
Figure 1004 Functional Test Flow 1009
Figure 2001 Sensor Schematic 40176-4 2001
Figure 2002 Sensor Schematic 40176-7 2001
Figure 5001 Periodic Check 5003
Figure 5002 Regular Check 5005
Figure 5003 General Overhaul 5008
Figure 7001 Liner Spacer Kit Installation 7002
Figure 7002 Cell Installation 7003
Figure 8001 Torque Specifications 8001
Figure 9001 Vent-Valve Wrench (T01) 9002
Figure 9002 Syringe with Nozzle (T02) 9002
Figure 9003 Equalizing Resistor (T03)` 9002
Figure 9004 Cell Extraction Tool (T04) 9003
Figure 9005 Vent-Valve Testing Tool 9003
Figure IPL 1 40176-4 / 40176-7 Battery & Cell Hardware Configurations 10013-10015
Figure 15001 Charge Retention 15002
Figure 15002 Return to Service Procedures 15004
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INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and the AECMA Simplified English
standards. S.I. units of measure are used in this manual, with imperial units (U.S.) in
parenthesis.
B. This manual describes maintenance on components in a workshop. It does not describe

maintenance on components when they are installed in the aircraft.
C. Only approved technicians with the necessary skills should perform maintenance as
described in this manual.
D. Aircraft Maintenance Task Oriented Support System (AMTOSS) is not supported in this
manual.
E. This manual contains the following:

- Technical data for components
- Maintenance and repair procedures for components
- An Illustrated Parts List (IPL) with data for parts and components. Parts are identified in all
sections of the manual by the IPL figure 1 item number.
F. Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY

procedures is accomplished by performing the procedures in the manufacturing facility.
2. How to use this manual
A. Verify this manual contains information applicable to your model battery. Look for the model
number on the Title Page.
B. If you need to identify a part of find a part number, refer to the IPL, which has an introduction
chapter detailing the procedure.
C. The instructions in this manual must be used for maintenance of all components. Read all
the applicable WARNING and CAUTION notations before you perform work on the
component.
3. Measures
Measures given in this manual are taken from the original manufacturing drawings. Quantities are
given in S.I. units followed by U.S. imperial units in parenthesis.
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4. Units of Measure
A. S.I. Units
A Ampere
Ah Ampere hour
C1A Battery rated current
C1Ah Battery rated capacity for one hour
g Gram
N Newton
N·m Newton-Meter
Pa Pascal
VDC Volt direct-current
°C Degree Celsius
% Per cent
W Ohm
mm Millimeter
B. U.S. Units (Imperial)
Ft Foot
In Inch
Lb Pound
Lb●in Inch pound
Lb●ft Foot pound
InHg Inches of mercury
2
Psi Pounds per in
°F Degree Fahrenheit
C. Multiplying Prefixes
m Micro
m Milli
Da Deca
k Kilo
M Mega
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5. Abbreviations
The abbreviations given below may be used in this manual:
AECMA The European Association of Aerospace Industries

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
V Voltage
6. Definition
This paragraph describes the notations used in this manual.
A. WARNINGS call attention to the use of materials, procedures, or limits that must be followed
to avoid personal injury. Warnings will appear directly above the procedure they apply to.
B. CAUTIONS call attention to procedures that must be followed to avoid damage to the
equipment.
C. NOTES call attention to procedures that make the job easier or include special information
that pertains to the procedure.
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7. Disposal
Ni-Cdâ batteries contain:

- Nickel
- Cadmium
- Potassium Hydroxide
Local legislation concerning disposal or recovery must be followed. For more information,
contact your local Saft supplier.
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DESCRIPTION AND OPERATION
1. Description
A. General
The alkaline battery has 20 vented nickel-cadmium VP400KH cells with welded polyamide
cases.
The battery is connected to the aircraft system and can be used:
- To start the engine or the APU used in the aircraft system.

- On the ground, to supply electrical power to the aircraft.
- In flight, if a malfunction or a failure occurs in the onboard power supply system.
NOTE: The 28 VDC electrical system charges the battery onboard aircraft
The figure and item numbers in this chapter correspond to those in the ILLUSTRATED
PARTS LIST.
B. Characteristics
(1) Technical data
Nominal Voltage 24 V
Rated capacity C1Ah 36 Ah
(see note below for more info)
Main Power Connector Connector compliant with ISO 5064/II or
MS 3509
3 3
Consumable volume of electrolyte 25 cm (1.525 in ) per cell
Maximum dimensions of the battery
case
- Length (base) 248 mm (9.76 in)
- Width (base) 256 mm (10.08 in)
- Height 264 mm (10.39 in)
Battery maximum weight 37.7 Kg (83 lb)
NOTE: Current values can be expressed in: 36 A = 1C1A,

18 A = 0.5C1A, and 3.6 A = 0.1C1A for this 36 C1Ah battery.
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(2) Operational characteristics
- Operating temperature: -40°C to +71°C (-40°F to +160°F)
(3) Electrical characteristics
Below is a listing of values used to service the battery:
Item Value Used For

1 C1A 36 A Charge / Discharge
0.5 C1A 18 A Charge
0.1 C1A 3.6 A Charge
C. Detailed Description
The battery has 20 VP400KH (13) cells housed in a stainless steel case (box) (1).
The case (box) (1) is lined with liners and spacers (kit (43)). The cells are kept upright by a
molded silicone elastomer pad fastened to the cover that presses against the top of the cells.
Cells are interconnected by rigid, nickel-plated copper links (22 thru 27).
The main power connector (28) connects the battery to the aircraft.
The cover (2) that can be removed is attached to the case (1) by four latches.
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40176-4 / 40176-7 Battery

Figure 1
Identification Plate (typical – may not be specific to this battery)

Figure 2
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305 mm
12.00 in
257 mm Includes
10.11 in handles &
bracket
248 mm 253 mm
9.76 in 9.96 in
Overall Dimensions
(drawing may not be representative of specific battery)
Figure 3
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TESTING AND FAULT ISOLATION
1. General
This chapter provides the tests and inspections required to determine the condition of a unit removed
for maintenance (scheduled or unscheduled). The table in section 7 (Fault Isolation) can be used to
assist in isolating and detecting faults noted during the maintenance process.
2. Testing
A. Equipment
(1) Standard tools
- Standard mechanics tools

- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron
- Compressed air with manometer (0.1 to 1 bar (1.45 to 14.5 psi))
(2) Special tools
When special tools are used in this chapter, a code number that can be found in
SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.
- Discharge bench: constant current 0-50 A

- Power supply: 0-45 V, range 0-50 A
(3) Instruments
- A multimeter, range 2 V to 50 V, 1% accuracy

- A megohmeter, range 0-50 MW @250 VDC, 3% accuracy
(4) Environmental conditions for testing
- Ambient temperature: 20°C ± 15°C (68°F ± 27°F)

- Pressure: 85 to 106 Kpa (25.1 to 31.3 inHg)
- Relative humidity < 85%
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B. Precautions
Maintenance should be performed regularly per the aircraft manufacturer’s recommendations,

or as specified in this manual. The following precautions should be observed to insure the
proper operation of the battery:
- Do not install the battery in an aircraft that is too hot (>60°C (140°F)).
- Carefully follow aircraft installation instructions to ensure good airflow.
- Verify the capacity of the battery at specified intervals.
- Charge the battery in a battery shop.
- Maintenance should be performed per instructions found in the CHECK chapter to verify:
ü Level of electrolyte
ü Torque on the connection nuts
ü Correct onboard charging
ü Battery capacity
D. Testing procedures
(1) Insulation test
(a) Place the leads of the megohmeter as indicated below. Check from the outer
case (1) to each cell terminal. See Figure 1002 for information regarding
minimum values.
+
MW
-
Insulation Test
Figure 1001
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250 KW 2 MW 10 MW
Can wait until next
Unacceptable To be cleaned OK
maintenance
In battery maintenance shop Minimum value after

cleaning and drying
Cleaning Required Cleaning
Recommended Acceptable
Fault Isolation
Insulation Test Parameters

Figure 1002
(2) Polarization Test
(a) Charge the battery at 3.6 A for 1.5 hours
(b) Keep the battery in open circuit condition for 1 hour
(c) Measure the open circuit voltage of each cell
(d) If the open circuit voltage of any cell is 0 V (or negative polarity), perform a
Special Test (refer to paragraph (4)) and repair if necessary.
(e) If every cell has an open circuit voltage that is greater than 0 volts, charge
the battery (refer to section 3).
(3) Vent-Valve (20) Test
During charge, before putting the vent-valve (20) back onto the cells, verify proper
operation.
(a) Install the vent-valve (20) with its O-ring (21) on the end of a testing
apparatus (Refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT – Fig
9005).
(b) Connect the apparatus to a supply of compressed air through an adjustable

reducing valve.
(c) Adjust the pressure to 0.5 bar (7.25 psi) and put the vent-valve into a
container of water. Air bubbles will come out when the valve opens. If there
are no bubbles, increase the pressure until you see bubbles and note the
pressure.
(d) Decrease the pressure slowly to 0.1 bar (1.45 psi) and note the pressure at
which the bubbles stop.
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(e) Reject all vent-valves that have an opening pressure greater than 0.7 bar (10
psi) and/or remain open at a pressure less than 0.14 bar (2 psi).
(f) Install the vent-valve (20) (Refer to ASSEMBLY).
(4) Special Test
CAUTION: WHEN YOU CHARGE THE BATTERY MORE THAN NECESSARY,

YOU DECREASE THE LIFE OF THE CELLS. PERFORM THIS
SPECIAL TEST ONLY WHEN SPECIFIED IN SECTION CHECK.
(a) If the battery is discharged, charge the battery fully (refer to section 3) then
continue to step (b). If already charged, continue to step (b).
(b) Continue to charge the battery at 3.6 A for an additional 5 hours, regularly
recording the voltage of each cell.
NOTE: The temperature of cells that have damaged separators will

increase significantly and continuously, and the voltage will
continually decrease (over 0.1 V).
(c) At the end of the additional 5-hour charge, mark any cell with a voltage less
than 1.50 V for replacement.
(d) With current still flowing, adjust the electrolyte in all cells.
(e) Discharge the battery down to 0 V (Initial and Residual discharges) (Refer to
section 5)
(f) Replace any defective cells (Refer to DISASSEMBLY and ASSEMBLY).
(g) Charge the battery (Refer to section 3).
3. Charge
A. Flight Charge
The battery charge is normally maintained onboard by the electrical system or a dedicated
onboard charger.
NOTE: The decrease of water from the cells is in direct proportion to the overcharge
the battery receives.
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B. Ground Charge
The following charging procedures are to be carried out in an appropriately equipped

workshop.
CAUTION: REMOVE THE COVER TO CHARGE THE BATTERY. THIS IS TO MAKE

SURE THAT HYDROGEN GAS WILL NOT COLLECT IN THE BATTERY
CASE.
CAUTION: WHEN THE BATTERY IS CHARGED IN EXCESS OF THE TIMES AND

RATES LISTED IN THE TABLE BELOW, THE LIFE OF THE CELLS IS
DECREASED.
(1) Constant current charge
(a) To charge a fully discharged battery, perform one of the Main Charge
procedures listed in the table below followed by a corresponding Final
Charge procedure.
CONSTANT CURRENT CHARGE

Main Charge Final Charge (overcharge)
3.6 A (0.1 C1A) until 30.0 V as battery voltage 3.6 A (0.1C1A) for 4 hours
Min: 10 hr
All cells must be above 1.50 V at end of
Times:
charge
Max: 12 hr
18 A (0.5 C1A) until 31 V as battery voltage 3.6 A (0.1C1A) for 4 hours

Min: 2 hr
Times:
charge
Max: 2 hr 30 min
36 A (1C1A) until 31.4 V as battery voltage 3.6 A (0.1C1A) for 4 hours

Min: 1 hr
Times:
charge
Max: 1 hr 15 min
NOTE: If during the Main Charge, the battery has not increased to the required voltage in the
maximum charge time, proceed to the Final Charge. Do not continue to charge the
battery at the high rate. If at the end of the Final Charge, all cells are not above the
required voltage, refer to Fault Isolation.
(b) For a battery not fully discharged or when the level of charge is unknown:
1 Discharge at 36 A (1C1A) down to 20 V (refer to section 5)
2 Charge: Refer to B (1)(a) for constant current charging instructions.
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(2) Other types of Charging: In addition to the constant current method of charging,
other methods that fully charge the battery can be used. HOWEVER, IN EVERY
CASE, CELL VOLTAGE CHECKS (V > 1.5 V) AND ELECTROLYTE
ADJUSTMENTS MUST BE CARRIED OUT USING A FINAL CHARGE AT
CONSTANT CURRENT: 3.6 A AT 0.1C1A. If specific instructions are not given in the
charger operating manual, Saft should be contacted before charging.
4. Electrolyte Check and Adjustment
The easiest tool to use to adjust the level of the electrolyte is a plastic syringe (T02) with a plastic
nozzle on the conical end.
The length of the nozzle that goes into the cell must be 20 mm (0.79 in). This is the distance
necessary between the seat of the vent-valve (20) and the electrolyte (refer to Figure 1003).
3 3
NOTE: The maximum consumable amount of electrolyte for this battery is 25 cm (1.525 in )
per cell (refer to DESCRIPTION AND OPERATION).
Electrolyte Level Adjustment

Figure 1003
CAUTION: DO NOT USE ACID OR ACIDULATED WATER TO ADJUST THE ELECTROLYTE

LEVEL IN NICKEL-CADMIUM BATTERIES. A VERY SMALL QUANTITY OF ACID
IS SUFFICIENT TO CAUSE PERMANENT DAMAGE. USE ONLY DISTILLED OR
DEIONIZED WATER (M01) (Refer to SPECIAL TOOLS, FIXTURES AND
EQUIPMENT)
A. Insert the nozzle into the cell until the nozzle rests on the seat of the vent-valve opening. Pull
the syringe plunger up. If the level is not sufficient, the syringe tube stays empty when you
pull the plunger up. If there is too much electrolyte, the electrolyte is removed by the syringe
until the level aligns with the end of the nozzle. Discard any liquid drawn into the syringe
when leveling, do not reuse the liquid in other cells.
B. If in check 4.A there is no liquid removed by the syringe, the level is not sufficient. Perform
the following to adjust the electrolyte:
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(1) Add a measured amount (5 ml) of distilled or deionized water (M01) into the syringe
and inject it into the cell. Keep record of how much distilled or deionized water (M01)
is being injected into the cell during this procedure.
NOTE: The amount of distilled or deionized water (M01) required to level the
first cell will serve as a guide to the amount required for the
remaining cells in the battery. However, each cell must be adjusted
individually to ensure the correct level is achieved in each cell.
(2) Repeat check 4.A to check for correct level.
5. Discharge
A. Initial Discharge and Capacity Test
The initial discharge can also be used to determine the capacity of the battery. The battery
should be discharged at a rate equal to its rated capacity.
(1) For Initial Discharge (from aircraft or storage):
(a) Discharge the battery at 1C1A down to 20 V, monitoring the time from the
start of the discharge to the time the battery voltage (at the main terminals)
reaches 20 V.
The time should be greater than 30 minutes. If not, one of the following may
be the cause:
- There was a discharge performed after the last use of the battery onboard
the aircraft
- The aircraft charger may not be functioning properly
- If the battery was left idle for a time, self-discharge occurred
- The battery cells may be imbalanced and need servicing
(2) For Capacity Test
(a) Discharge the battery at 1C1A, monitoring the time from the start of the
discharge to the time any of the cells voltage falls below 1 V. Mark the time
any cell in the battery reads below 1 V.
Each cell in the battery should maintain a voltage higher or equal to 1 V for a
full 60 minutes of discharge at 1C1A (refer to Discharge Table). If one or
more cells should fall below 1 V in less than 60 minutes, refer to Section 7
(FAULT ISOLATION).
NOTE: Repeating the charge and full discharge of a battery that

does not pass capacity test may recover lost capacity.
However, if the capacity continues to decline, refer to Section
7 (FAULT ISOLATION).
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Discharge Table
Battery Type 1C1A Discharge Rate Minimum Time
40176-4 36 60 Min
40176-7 36 60 Min
B. Residual Discharge
The Residual Discharge will clear the battery of all “residual” energy left in the battery after
the Initial Discharge or the Capacity Test. This procedure is to be performed after the battery
has been discharged to 1 V per cell.
(1) As each cell is discharged to 1 V, connect a resistor approximately 1 W 3 W (T03)

across the cell terminals and continue to discharge each cell in the battery. Keep
these resistors in position for 12 to 16 hours, allowing the battery to cool.
6. Temperature Sensor and Heater Control Thermostat Testing
Testing of the temperature sensor and heater control thermostat may require the use of a climatic
chamber or other device that will allow raising or lowering the temperature of components in the
temperature sensor.
Refer to the SCHEMATIC AND WIRING DIAGRAM section for information on the specific layout of
the temperature sensor.
A. Testing of the sensor (both 40176-4 & 40176-7)
(1) Perform the following tests at the temperature specified.
(2) This sensor is normally open at room temperature.
Test Pins Required Values

Thermostat 1-2 > 1 MW (normally open) @ 21.1°C ±2°C (70°F ±5°F)
Thermostat 1-2 < 1 MW (close on rise) @ 60°C (140°F) (stabilized temp)
Thermostat 1-2 > 1 MW (open again on fall) @ 51.6°C (125°F) (stabilized temp)
B. Heater Control Thermostat Test (40176-7 only)
(1) Perform the following tests at the temperature specified.
(2) The heater control thermostat is normally open at room temperature.
Test Pins Required Values

Thermostat 3-4 > 1 MW (normally open) @ 21.1°C ±2°C (70°F ±5°F)
Thermostat 3-4 < 1 MW (close on fall) @ below -1.1°C (30°F) (stabilized temp)
Thermostat 3-4 > 1 MW (open again on rise) @ 10°C (50°F) (stabilized temp)
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7. Fault Isolation
Box or cells Yes More than

See para. 7.C (5) Yes
damaged usual added in See para. 7.B (1)
all cells
No No
Salt or Yes
electrolyte See para. 7.C (1) More than 25% Yes
average added in See para. 7.B (2)
traces
1 cell
No
No
Electrolyte in Yes
See para. 7.C (2) 1 or more cells Yes
the case See para. 7.B (3)
voltage different
by >0.1V
No
No
Metallic parts Yes

See para. 7.C (3) Voltage of 1 Yes
corroded See para. 7.B (4)
cell <1.50 V
No
No
Battery voltage Yes

See para. 7.A (1) Capacity test Yes
=0V See para. 7.B (5)
<100% C1Ah
No
No
1 or more cells Yes

See para. 7.B (7) Link or nut is Yes
=0V See para. 7.C(4)
overheated
No
No
Yes
1 or more cells
See para. 7.B (5)
<0V
No
Cell to case Yes

Perform a General
insulation < See para. 7.A(3) Overhaul to detect
250KW and repair any
battery fault noted
No
Functional Test Flow

Figure 1004
Page 1009
24-32-03 April 15/2002

40176-4 / 40176-7
A. Battery Electrical Faults
PROBLEM PROBABLE CAUSE CORRECTION

(1) Zero battery open-circuit (a) Defective electrical Check electrical contacts, links
voltage connection (no contact made). and torque of nuts (refer to FITS
AND CLEARANCES).
(b) Link loose or broken Verify the nuts have the proper
torque (refer to FITS AND
CLEARANCES).
(2) Zero volts with the battery set (a) Battery fully discharged Perform an Insulation Test and
to “discharge” recharge the battery (refer to
TESTING AND FAULT
ISOLATION).
(b) Battery circuit open or Examine the connection and

connection defective links. Verify the terminal nuts
have proper torque (refer to FITS
AND CLEARANCES).
See section B (Cell faults).

(c) One or more cells dry Check electrolyte level (refer to
TESTING AND FAULT
ISOLATION).
(3) Low insulation (a) Leakage of electrolyte Disassemble and clean the
battery (refer to DISASSEMBLY
and CLEANING). Perform an
electrolyte level check (refer to
TESTING AND FAULT
ISOLATION).
B. Cell Faults
PROBLEM PROBABLY CAUSE CORRECTION

(1) Excessive water (a) Excessive charge or charging Examine the cause of the
consumption. at high temperatures. excessive charge. If necessary,
adjust the maintenance interval.
Page 1010
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40176-4 / 40176-7

(2) The variation of water (a) More than 25% than the Perform an Insulation Test.
consumption in individual cells average: cell leakage Disassemble and replace faulty
exceeds ±25% of the average components as necessary
consumption for all cells.
(b) 25% (or less) than the Perform the Special Test (refer
average: cell(s) with damaged to TESTING AND FAULT
separators ISOLATION). Replace cells if
necessary
(c) Previous maintenance was Note the cell location and check
not performed or performed the level of water consumption
incorrectly versus other cells at the next
maintenance interval
3
(3) A cell has an unusually high (a) Dry cell Add 5 cm of distilled or
voltage at the start of the charge deionized water (M01) to the cell.
Do not add more unless voltage
continues to be exceptionally
high. Level electrolyte at final
level at the end of charge (refer
to TESTING AND FAULT
ISOLATION).
NOTE: If a cell is charged with low electrolyte levels, it may cause overheating and permanent
damage to the cell and adjacent cells.
(4) A cell has an unusually low (a) The cell was operated at Replace the cell (refer to
voltage at the end of the Final temperatures and charge rates DISASSEMBLY and
Charge (less than 1.50 V) outside the limits, and the ASSEMBLY)
separator is damaged
(b) The cell has reached its end

of serviceable life.
(5) Low capacity cell (the cell (a) Usual wear after long service Replace the cell (refer to
shows a reversed voltage or a life. DISASSEMBLY and
correct polarity voltage of less ASSEMBLY)
than 1 V after a discharge of 60
minutes at 1C1A). (b) Unusual operation, operating Perform the Special Test (refer
at high temperatures or with low to TESTING AND FAULT
electrolyte. ISOLATION). If necessary,
replace the cell(s).
(6) Cell with an excessively (a) Cell operated with low Replace the cell (refer to
swollen case. electrolyte level; deterioration of DISASSEMBLY and
separators and damaged plates ASSEMBLY).
(7) Cell with zero voltage when (a) Short-circuited cell. Replace the cell (refer to
the battery circuit is open DISASSEMBLY and
ASSEMBLY).
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40176-4 / 40176-7
C. Physical Faults

(1) Leakage of electrolyte. (a) Incorrect adjustment of Disassemble and clean the
electrolyte level battery (refer to DISASSEMBLY
and CLEANING).
(b) Cell polarity incorrect during Investigate the cause of the

high-rate discharge (for example, excessive discharge.
during the engine start). Disassemble and clean the
and CLEANING).
(c) Excessive overcharge or high Investigate the cause of

overcharge at high temperatures. excessive charge. If necessary,
adjust the maintenance interval.
Disassemble and clean the
and CLEANING).
(2) Electrolyte found in the (a) Damaged cell case Replace the cell if necessary.
battery case. Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
(b) Leakage of electrolyte Perform an electrolyte level

check and disassemble and
clean the battery (refer to
DISASSEMBLY and
ASSEMBLY)
(3) Corrosion on the links. (a) Operation in acid Make sure the battery test
environment bench, test room, and storage
areas contain no materials that
can release acid fumes.
(b) Mechanical damage to the Replace the damaged links (refer

nickel plating to DISASSEMBLY and
ASSEMBLY)
(4) The links show signs of (a) Loose terminal nuts Verify the torque on the nuts
overheating (refer to FITS AND
CLEARANCES)
(5) Case Deformed (a) Physical damage Disassemble and straighten case
(refer to DISASSEMBLY and
ASSEMBLY)
(b) Swollen cells Replace the cell if necessary.

Perform a General Overhaul.
(refer to DISASSEMBLY,
ASSEMBLY, and CHECK)
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40176-4 / 40176-7
D. Vent-valve Faults

(1) Valve open pressure > 0.7 (a) Clogged valve Clean the valve (refer to
bar (10 psi) or stays closed CLEANING).
Replace the valve if cleaning is

not successful.
(2) Valve stays open at a (a) Pierced valve Replace the valve
pressure <0.14 bar (2 psi).
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40176-4 / 40176-7
Page 1014
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40176-4 / 40176-7
SCHEMATIC AND WIRING DIAGRAMS
1. General
This chapter gives all electrical schematics of the battery temperature sensor
2. Sensor Schematic
Sensor Schematic 40176-4

Figure 2001
Sensor Schematic 40176-7

Figure 2002
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40176-4 / 40176-7
Page 2002
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40176-4 / 40176-7
DISASSEMBLY
1. General
WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A COMPLETELY

DISCHARGED BATTERY (REFER TO TESTING AND FAULT ISOLATION)
Refer to the TESTING AND FAULT ISOLATION chapter to determine the malfunction and necessary
level of disassembly required.
The figures and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2. Safety
The safety regulations are different from one country to another. Check local regulations for those
that apply.
3. Risks
There are three types of risks involved in nickel-cadmium battery maintenance:
A. Physical
- Handling: Lift with your legs and not your back

- Wear protective shoes
B. Electrical
- Don’t wear rings, watches, chains, or belt buckles

- Use insulated tools
C. Chemical
- Electrolyte is very corrosive and may cause severe burn to the skin: wear gloves and apron.
- Contact with the eyes is very dangerous; wear protective goggles.
4. Safety Measures
- The electrolyte is caustic and can cause severe burns. If electrolyte comes in contact with the skin,
flush the affected area with water and neutralize the solution with acetic solution, vinegar, lemon
juice, or with boric acid solution at 10% concentration.
- If the electrolyte comes in contact with the eyes, flush with water for at least 15 minutes and contact
a physician.
- Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the
solution with water or milk. Contact a physician immediately.
- Contact with nickel can cause chronic eczema.
- Inhalation of cadmium oxide can cause a dry throat, cough, headaches, vomiting, or pain in the
chest. Persons having inhaled cadmium oxide fumes must get fresh air, take oxygen, or have
artificial respiration. Contact a physician as soon as possible.
- Potash can cause eczema.
Page 3001
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40176-4 / 40176-7
5. Disassembly
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.

- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eyewash.
- Protective apron
(2) Special tools
B. Disassembly procedure
WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY

DISCHARGED BATTERY (TESTING AND FAULT ISOLATION).
(1) Remove the cover (2)
(a) Remove the cover by pulling up the tab on the latches that attach the cover
(2) to the case (1) and lifting the cover upward.
CAUTION: REMOVE THE VENT-VALVE (20) ONLY FOR CLEANING OR LEVELING

ELECTROLYTE. OVEREXPOSURE TO ATMOSPHERE WILL CAUSE
DETRIMENTAL CHEMICAL CHANGES IN THE ELECTROLYTE.
(2) Remove the vent-valve (20)
(a) Unscrew the vent-valve (20) with the special tool (T01).
(b) Remove the vent-valve (20) with its o-ring (21).
CAUTION: IN ORDER TO AVOID SHORT-CIRCUIT, REMOVE THE LINKS

ATTACHED TO THE CELL AND ADJACENT CELLS.
(3) Remove a cell (13)
(a) Remove the nuts (11) and the belleville or spring washers (12) that attach the
links to the cell.
(b) Remove all links (22 thru 27)
(c) Fully engage the end of the special threaded tool (T04) onto one of the cell
terminals. Pull up to remove the cell.
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40176-4 / 40176-7
(4) Remove the main power connector (28)
(a) Remove the nuts (11) and belleville or spring washers (12).
(b) Remove the screws (29) and washers (if equipped) (30).
(c) Remove the connector (28) with the gasket (not numbered).
(5) Remove the temperature sensor (4, 5)
(a) Remove the connector (28) (refer to section (4))
(b) Remove the attaching nut (8) and O-ring (9).
(c) Remove the nuts (11), belleville or spring washers (12), and brackets that
hold down any part of the temperature sensor.
(d) Disconnect (cut) any tie straps (not shown) holding parts of the temperature
sensor (if applicable).
(e) Remove the sensor (4, 5) with the O-ring (9) from the inside of the case (1).
(6) Disassembly of a complete battery
(a) Remove the cover (2) (refer to Section (1)).
(b) Remove the cells (13) (refer to Section (3)).
(c) Remove the liner-spacer kit (43) by pulling out the liners and spacers, making
sure to mark them to ensure correct placement during assembly.
(d) Remove the connector (28) (refer to Section (4)).
(e) Remove the sensor (4, 5) and O-ring (9) (refer to Section (5)).
Page 3003
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40176-4 / 40176-7
Page 3004
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40176-4 / 40176-7
CLEANING
1. General
This chapter provides instructions for the cleaning and preservation of the battery components.
The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS
LIST (IPL).
2. Equipment
- Safety gloves.
- Safety shoes.
- Eyewash.
- Protective apron.
- Compressed air
3. Materials
CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. SOME

CHEMICALS CAN DEGRADE METAL PARTS CAUSING PREMATURE FAILURE.
- Ordinary water.
- Distilled or deionized water (M01).
- Neutral soap (M02).
- Non-fluffy swab.
- Non-wire brush.
- Rubbing alcohol (isopropyl)
4. Cleaning Procedure
WARNING: BE CAREFUL WHEN HANDLING ELECTROLYTE AND AVOID SPLASHING.

ELECTROLYTE IS A STRONG CAUSTIC AGENT AND CAN CAUSE SEVERE
BURN. ALWAYS WEAR FACE AND EYE PROTECTION (PREFERABLY A
TRANSPARENT FACE MASK), RUBBER GLOVES AND LONG-SLEEVED
CLOTHING. IN CASE OF CONTACT WITH SKIN, FLUSH WITH WATER. IN
CASE OF CONTACT WITH EYES, FLUSH WITH WATER FOR AT LEAST 15
MINUTES AND SEEK MEDICAL ATTENTION.
A. Light Cleaning
(1) Remove the cover (2).
CAUTION: TO PREVENT SHORT-CIRCUIT, USE A RUBBER TUBE OR AN

INSULATED NOZZLE TO DISPENSE COMPRESSED AIR.
(2) Blow (with compressed air) across the tops of the cells to remove all dust and light
traces of mineral salts from the battery. Using a clean cloth, wipe off all temperature
sensor components.
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40176-4 / 40176-7
(3) Main Power Connector (28).
(a) Clean connector pins with rubbing alcohol to clean off any accumulated
grease and/or dirt. Inspect the pins for damage; pits, cracks, or scratches,
that allow copper to show through the nickel plating. Replace connectors
that are damaged with a Saft factory new unit.
B. Thorough Cleaning
WARNING: TO AVOID ELECTRIC SHOCK, DISASSEMBLY SHOULD ONLY BE

PERFORMED ON A FULLY DISCHARGED BATTERY (REFER TO
TESTING AND FAULT ISOLATION).
(1) Disassemble the battery (refer to DISASSEMBLY) and then clean all components
except the vent-valve (20) which must be cleaned while cells are in the case.
(a) Cells (13)
1 Make sure the vent-valve (20) is tight.
2 Remove lower terminal nut (14), polarity washer (15,16), belleville or

spring washers (17), flat washer (18), and clean in warm water if
necessary.
3 Inspect the terminal o-ring (19) for cracks, breaks or leakage and
clean in warm water. Replace if necessary.
4 Reassemble the dry hardware onto the cell and torque the lower
terminal nut (14) per FITS AND CLEARANCES.
CAUTION: DO NOT SOAK THE CELLS IN WATER. TAP WATER

ENTERING CELL WILL CONTAMINATE ELECTROLYTE.
5 To easily remove all the electrolyte and mineral salts from the
terminals, cover, and sides of the cell cases, clean in warm water
with a soft brush.
6 Rub the cell with a cloth and let dry.
(b) Case (1) and handle (if equipped)
1 Clean with light soap (M02) and water, rub with a cloth and let dry.
(c) Nuts, belleville or spring washers, flat washers, and links
1 Clean in warm water with a soft brush and let dry.
(d) Liner-spacer kit (43)
1 Clean in warm water with a soft brush and let dry.
Page 4002
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40176-4 / 40176-7
(e) Temperature Sensor (4, 5)
1 Wipe all parts with a damp cloth and let dry.
CAUTION: CLEANING OF THE VENT-VALVE (20) MUST BE DONE WHEN

THE CELLS ARE ASSEMBLED IN THE CASE (1).
(f) Vent-valve (20)
1 Remove the vent-valve (20) (refer to DISASSEMBLY) during the

Final Charge (refer to TESTING AND FAULT ISOLATION) at
0.1C1A.
2 Place a swab or soft cloth over the cell opening to keep out
unwanted material.
3 Soak the vent-valve (20) for 1-2 hours in a container of distilled or

deionized water to dissolve mineral salts from the vent-valve hole.
NOTE: To facilitate the cleaning process the water may be warmed

to 50°C (122°F).
(g) Main Power Connector (28)
1 Clean connector pins with rubbing alcohol to clean off any

accumulated grease and/or dirt. Inspect the pins for damage; pits,
cracks, or scratches, that allow copper to show through the nickel
plating. Replace connectors that are damaged with a Saft factory
new unit.
5. Lubrication
When the battery is clean (with the vent-valve installed), put a thin layer of mineral vaseline (M04) or
light oil on the terminals and on the links. Use of a paintbrush will make this procedure easier.
Page 4003
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40176-4 / 40176-7
Page 4004
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40176-4 / 40176-7
CHECK
1. General
The checks in this chapter are necessary to use the batteries in flight and on the ground. The
maintenance procedures in this chapter should be carried out in a battery shop. The three types of
maintenance that will be detailed in this chapter are:
- Periodic Check: adjustment of the electrolyte levels.

- Regular Check: electrical functional testing, adjustment of electrolyte, and capacity test.
- General Overhaul: disassembly, full cleaning, assembly and Regular Check.
2. Maintenance in workshop
A. Equipment
(1) Standard tools
- Standard mechanic’s tools.

- Safety gloves.
- Safety shoes.
- Eyewash.
- Protective apron.
(2) Special tools
(3) Instruments
- Power supply 0-45 V, 0-50 A

- Discharge bench, constant current 0-50 A
- Multi-meter, range 2 V and 50 V, accuracy 1%
- Megohmeter, range 0-50 MW (voltage 250 VDC), accuracy 3%
B. Conditions
- Ambient temperature: 20°C ± 15°C (68°F ± 27°F)

- Pressure: 85 to 106 Kpa (25.1 to 31.3 InHg)
- Relative humidity < 85%
Page 5001
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40176-4 / 40176-7
C. Periodic Check
If the electrolyte consumption exceeds the maximum consumable amount between two
Regular Checks, this Period Check may be performed to adjust the electrolyte. Maintenance
should be performed using Fig 5001 as a guide and will include the following steps:
- Clean the battery.

- Check the torque on nuts (11).
- Perform an Insulation Test.
- Measure the battery voltage.
- Discharge the battery.
- Charge the battery.
- Clean the vent valves (20).
- Adjust the electrolyte.
- Check the torque on nuts (11).
(2) Perform a Light Cleaning (refer to CLEANING).
(3) Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES).
(4) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION).
(5) Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test (refer to TESTING AND FAULT
ISOLATION).
(6) Perform an Initial Discharge at 36 A down to 20 V at the battery terminals, and allow
the battery to cool (refer to TESTING AND FAULT ISOLATION).
(7) Charge the battery (refer to TESTING AND FAULT ISOLATION).
(8) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (20) (refer to CLEANING).
(9) Level the electrolyte (refer to TESTING AND FAULT ISOLATION).
(10) Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES).
Page 5002
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40176-4 / 40176-7
Periodic Check
Check Torque
Light Cleaning
on all nuts
Yes
Dust Only
Cell to Case
No No
Insulation Test
> 2 Megohms
Electrolyte Traces
Yes
Total Voltage > 21V

General Overhaul No
At main power connector
No cells with reversed polarity
Yes
Polarization Test Initial Discharge
Fault Isolation
No Charge
For standard product
all cells > 1.50V
Special Test
Additional charge with up to Yes
5 hr overcharge Yes
For standard product Vent Valve Cleaning

all cells > 1.50V
Adjust Electrolyte
No during last 15 minutes of
No charge with constant
current flowing
General Overhaul
< 25% difference in
electrolyte levels
Yes
Check Torque
on all nuts
Battery Accepted
Periodic Check
Figure 5001
Page 5003
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40176-4 / 40176-7
D. Regular Check
After six months, or according to aircraft manufacturer’s specifications, perform this check
following the different procedures indicated in Figure 5002.
- Perform a Light Cleaning.

- Check the torque on all nuts (11).
- Measure the voltage of the battery.
- Perform an Initial Discharge.
- Perform a Residual Discharge.
- Test the temperature sensor.
- Clean the vent-valves (20).
- Perform a Capacity Test.
(2) Perform a Light Cleaning (refer to CLEANING).
(3) Check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
(4) Measure the voltage in open circuit at the battery terminals. If the battery voltage is
less than 21 V, perform a polarization test.
(5) Perform an Initial Discharge at 36 A down to a voltage of 20 V at the battery

terminals. Monitor the time from the start of the discharge to the time the battery
reaches 20 V (refer to TESTING AND FAULT ISOLATION).
(6) Perform a Residual Discharge (refer to TESTING AND FAULT ISOLATION).
(7) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION).
(8) Test the temperature sensor (4, 5). This will likely require partial disassembly (refer
to TESTING AND FAULT ISOLATION and DISASSEMBLY).
(10) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the
vent-valves (20) (refer to CLEANING).
(11) Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(12) Perform a Capacity Test (Refer to TESTING AND FAULT ISOLATION).
(13) Re-check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
Page 5004
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40176-4 / 40176-7
(14) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Regular Check
Check Torque
on all nuts
Light Cleaning
Yes Total Voltage > 21 V
Dust Only No At main power connector
No No cells with reversed polarity
Electrolyte Traces
Yes
Polarization Test Initial Discharge

General Overhaul
Residual Discharge
1 Ohm - 3W Min Resistor
12-16 hours on all cells
Cell to Case
Insulation Test
No > 2 Megohms Yes
Test Temperature
No Sensor Yes Charge
No all cells > 1.50V
Yes
Vent Valve Cleaning

Fault Isolation Adjust Electrolyte
during last 15 minutes of
charge with constant
No current flowing
Special Test
Additional charge with up to < 25% difference in
5 hr overcharge electrolyte levels
Yes Yes
all cells > 1.50V No Capacity Test
(Initial Discharge)
Clean Vent Valves if applicable
Yes
Adjust electrolyte at end of charge Check Torque
on all nuts
No
General Overhaul
Charge
No all cells > 1.50V
Adjust Electrolyte
at end of charge
Battery Accepted Yes
Regular Check
Figure 5002
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40176-4 / 40176-7
E. General Overhaul
The General Overhaul includes electrical tests contained in the Regular Check. It also
includes disassembly and cleaning of all components. Perform the General Overhaul every
12 months, or according to aircraft manufacturer’s instructions following the procedures
indicated in Figure 5003.

- Measure the voltage of the battery in open circuit at the main terminals.
- Perform an Initial Discharge.
- Perform a Residual Discharge.
- Disassemble the battery completely.
- Perform a Thorough Cleaning.
- Test the Temperature Sensor.
- Check torque on lower nuts (14).
- Assemble the battery.
- Clean the vent-valves (20) and test.
- Perform a Capacity Test.
- Charge the battery and perform a final electrolyte adjustment.
NOTE: If three cells are replaced during a single maintenance cycle, or five cells
over the life of the battery, Saft recommends that all cells be changed or the
battery be replaced.
(1) Check the torque on all nuts (11) (refer to TESTING AND FAULT ISOLATION).
(2) Measure the voltage of the battery at the main terminals. If the voltage is less than
21 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION).
(3) Perform an Initial Discharge at 36 A down to 20 V (refer to TESTING AND FAULT

ISOLATION).
(4) Perform a Residual Discharge with resistor clips (T03) down to 0 V (refer to TESTING
AND FAULT ISOLATION).
(5) Disassemble the battery completely (refer to DISASSEMBLY).
(6) Perform a Thorough Cleaning (refer to CLEANING) and inspect components.
(a) Verify the cells show no signs of leakage.
(b) Remove any small dents from the case (1).
(7) Test the Temperature Sensor and Heater Control Thermostat (4, 5) (refer to
(8) Assemble the battery (refer to ASSEMBLY).

Page 5006
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40176-4 / 40176-7
(9) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value
measured after a Thorough Cleaning should be at least 10 MW.
(11) During the Final Charge, clean and test the vent-valves (20) (refer to CLEANING and
(12) Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION).
(13) Perform a Capacity Test (refer to TESTING AND FAULT ISOLATION).
(14) Check the torque on all nuts (11) (refer to FITS AND CLEARANCES).
(15) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND
FAULT ISOLATION).
Page 5007
24-32-03 April 15/2002

40176-4 / 40176-7
General Overhaul
Total Voltage > 21V

At main power connector Check Torque
No cells with reversed polarity on all nuts
Residual Discharge
Initial Discharge 1 Ohm Resistor
12 hours on all cells
Polarization Test
Disassembly
and Thorough Cleaning
Visual Inspection
Assembly Temperature Sensor Test
Check - Disassembled Battery
Cell to Case
Insulation Test
No > 10 Megohms Yes Charge
all cells > 1.50V
No
Yes
Vent Valve Cleaning/Test
Adjust Electrolyte
during last 15 minutes of
Fault Isolation charge with constant
No current flowing
< 25% difference in
Special Test
electrolyte levels
Complete charge with
Additional charge with up to
Yes
5 hr overcharge
Yes No
Capacity Test
Yes
All cells > 1.50V
Check Torque
on all nuts
No
Full Discharge
Charge
Replace faulty components For standard product
and return to charge No all cells >1.50V
Adjust Electrolyte
at end of charge
Yes
Battery Accepted
General Overhaul
Figure 5003
Page 5008
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40176-4 / 40176-7
REPAIR
1. General
Defective parts for which no repair instructions are given shall be rejected and replaced by Saft
factory new parts only.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2. Equipment
A. Special Tools
When special tools are used in this chapter, a code number that can be found in SPECIAL
TOOLS, FIXTURES AND EQUIPMENT, identifies them.
B. Standard Tools
Standard mechanics tools.
C. Materials
Neoprene glue (M03)
3. Repairs
The only authorized repair(s) applicable to this unit:
- Re-affixing the Cover Gasket (not shown).
A. Cover Gasket
The Cover Gasket (3) can only be re-glued one time.
(1) Remove the Cover Gasket (3) completely.
(2) Clean all traces of glue from the cover (2).
(3) Apply the glue (M03) to the flat side of the cover (2).
(4) Let dry for 2 hours in a dry place (or as specified by manufacturer’s instructions).
(5) Place Cover Gasket (3) on the bottom of the cover (2) and press firmly to seat.
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40176-4 / 40176-7
ASSEMBLY
1. General
Battery assembly is to be performed in a clean, dry room where all parts are protected from any
impact from other parts or tools. Any protective layers applied to replacement parts must be removed
prior to assembly.
The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED
PARTS LIST (IPL).
2. Assembly Procedures
A. Equipment
(1) Special Tools
(2) Standard Tools
- Standard mechanic’s tools

- Safety gloves
- Protective goggles
- Safety shoes
- Eyewash
- Protective apron
B. Installation of the Temperature Sensor (4, 5)
(1) Insert the sensor (4, 5) with the O-ring (9) and attach with nut (8).
NOTE: Lay the remaining portion of the sensor to the side of the case, these
components will be attached either during or after the cells are
installed.
C. Installation of the Main Power Connector (28)
(1) Insert the main power connector (28) with the gasket (not numbered) into position in
the battery case (1) and attach with screws (29) and washers (if equipped)(30).
D. Installation of the liner spacer kit (43)
(1) Insert the bottom liner into the bottom of the case (1).
(2) Follow the assembly shown in Fig 7001, inserting liners and spacers in each position.
NOTE: Additional liners and spacers may be necessary to keep cells (13)
tight in the case (1).
Page 7001
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40176-4 / 40176-7
Liner Spacer Kit Installation

Figure 7001
E. Installation of Cells (13)
(1) Torque all lower terminal nuts (14) (refer to FITS AND CLEARANCES).
(2) Cells should be installed in rows. Install all but the center cell in each row according
to their polarity as found in Fig. 7002. Make sure to install any liners and spacers
(refer to Fig 7001) and/or temperature sensor plates (as applicable) that are needed
in between the cells at this time.
(3) Carefully position the last cell (13) in each row and insert the cell (13) by pressing on
the terminals with a piece of soft wood. This cell should be difficult to insert, requiring
25-30 lb-ft of pressure to seat. If the cell is too loose, install additional liners and
spacers (43). If the cell is too difficult to insert, remove a liner or spacer (43) as
needed. Never lubricate the cells to facilitate assembly.
(4) Lightly lubricate all links (22-27), belleville or spring washers (12), nuts (11), and cell
terminals with a mineral vaseline (M04) or light oil using a paintbrush.
(5) Install the links (22-27), belleville or spring washers (12), and nuts (11).
(6) Torque all nuts (11) (refer to FITS AND CLEARANCES).
Page 7002
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40176-4 / 40176-7
¢ Negative
PolarityPolarity
+
Positive Polarity
Polarity -
Cell Installation
Figure 7002
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40176-4 / 40176-7
Page 7004
24-32-03 BLANK
40176-4 / 40176-7
FITS AND CLEARANCES
1. General
The FITS AND CLEARANCES section provides torque specifications for any components requiring a
specific torque value, or clearance values for moving parts that require specific clearance distance.
2. Torque Specifications
IMPORTANT: The values provided in the torque table (Fig 8001) are “lube torque” values. All
threads should be lightly lubricated with mineral vaseline (M04) or light oil prior to installation and
applying torque.
IPL FIG NOMENCLATURE TORQUE VALUE (lubricated)

ITEM (FROM IPL) N●m ±10% Lb●in ±10%
11 Upper Terminal Nut 10 87
14 Lower Terminal Nut 5 43.5
8 Temperature Sensor Nut 0.2 2
Torque Specifications
Figure 8001
Page 8001
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40176-4 / 40176-7
Page 8002
24-32-03 BLANK
40176-4 / 40176-7
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 General
This chapter provides pertinent specifications for any special tools that may be needed during battery
maintenance. It also supplies a listing of consumable items that may be useful during normal
servicing, repair, and use.
2. Special Tools, Fixtures and Equipment
PART PART
NUMBER NUMBER
CODE FIGURE QTY (where (where DESCRIPTION USE
applicable) applicable)
F6177 V09052
-DISASSEMBLY
-CLEANING
T01 9001 1 015528 093382-000 Vent-Valve Wrench
-CHECK
-ASSEMBLY
-TESTING AND
Syringe w/20 mm
T02 9002 1 016544 020915-004 FAULT ISOLATION
Nozzle
-CHECK
Equalizing -TESTING AND

T03 9003 1 164829 Resistors FAULT ISOLATION
1W 3 Watt -CHECK
Cell Extraction tool

T04 9004 1 013169 017556-000 -DISASSEMBLY
M10
Page 9001
24-32-03 April 15/2002

40176-4 / 40176-7
Vent-Valve Wrench (T01)

Figure 9001
Syringe with Nozzle (T02)

Figure 9002
Equalizing Resistor (T03)

Figure 9003
Page 9002
24-32-03 April 15/2002

40176-4 / 40176-7
Cell Extraction Tool M10 (T04)

Figure 9004
Vent-Valve Testing Tool

Figure 9005
Page 9003
24-32-03 April 15/2002

40176-4 / 40176-7
3. Consumables
NOTE: Equivalent alternatives may be used.
A
D
I
I A
R C
S S S
L L R
A C S T
DESIGNATION PART I T E E
MANUFACTURER S H E O
CODE NUMBER AND N E A P
OR SUPPLIER S E M R
SPECIFICATION E S N A
E C B A
T I I
M K L G
C N R
B Y E
O G
L
D
Y
E
Distilled or deionized water;
clear, colorless, odorless
while boiling, resistivity
>30 KW/cm
5 < pH > 7
Absence of organic and
reducing substances.
M01 X X
Reducing agent content Local Vendor
(expressed in weight of
oxygen) < 30 mg/l (test with
permanganate). Total of
2+ -
ions: SO4 Cl < 10 mg/l
Dry abstract < 15 mg/l
Silicium in SiO2 < 15 mg/l
Soap (non-abrasive – mild

M02 Local Vendor X
household)
Neoprene Glue (alkali

M03 Local Vendor X
resistant)
NATO: S 743
M04 Mineral Vaseline F: AIR 3565 X X
US: SLP 236
UK: DEF 2333
Page 9004
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40176-4 / 40176-7
Page 10001
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40176-4 / 40176-7
Page 10002
24-32-03 BLANK
40176-4 / 40176-7
1. Introduction
A. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed
parts of the unit.
It includes the following sections:
- Introduction
- Equipment Designator Index (EDI)
- Numerical Index
- Detailed Parts List (DPL)
- Vendor Code Index
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 figure and item number found in the
Numerical Index for that part to verify it is the part specified.
(2) To determine the part number of a given part, refer to the Illustrated Parts List figures.
Note the item number of the illustrated part and refer to the Detailed Parts List that
indicates the part number and identification.
C. Equipment Designator Index (EDI)
The Equipment Designator Index provides all circuit symbols given to the electrical and
electronic components of the items listed. If applicable, they are listed in alphanumeric order.
D. Numerical Index (NI)
In this index, part numbers are classified in the following order:
Classification is made from left to right, each character (letter, number, hyphen) being
considered separately.
The first row ordering is:
- Hyphen
- Alpha from A to Z (except for “O” and “I” which will be considered zero and one)
- Numbers from 0-9
The part number column contains all part numbers included in the Detailed Parts List. Part
numbers that have been deleted or superceded from the Detailed Parts List are listed in the
Numerical Index and identified as deleted or superceded.
Page 10003
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40176-4 / 40176-7
E. Detailed Parts List (DPL)
(1) Figure and Item Number
Each assembly, sub-assembly, and component designated a part number and

included in the part list is given a callout 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 identified by a hyphen (-) preceding the item number.
The letter “R” shown in the index before the item number refers to a modified item of
the Detailed Parts List.
(2) Manufacturer’s Part Number
A manufacturer’s part number is given to each part and/or assembly, whether

illustrated or not. To help our customers, we have included a second column giving
the equivalent Saft France and Saft America part numbers for parts having an
equivalent.
(3) Indenture
The parts list is represented with indenting showing the relationship of parts and
assemblies to their next higher assemblies as follows:
1234567
Assembly
Attaching parts for assembly
. Detailed parts for assembly
. Sub-assembly
. Attaching parts for sub-assembly
. . Detailed parts for sub-assembly
. . Attaching parts for sub-assembly
. . . Detailed parts for sub-sub-assembly
The attaching parts are shown directly after the assembly of the part they attach.
They are listed under the same indenture number as the item they are attached to,
and are identified by the words “Attaching Parts”, followed by three asterisks (*).
Page 10004
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40176-4 / 40176-7
(4) Effectivity Code
An alphanumeric index indicates the effectivity of sub-assemblies and detailed parts

list in relation to the next higher assembly(ies) or sub-assembly(ies).
When the part is applicable to all effective products, the usage column remains blank.
The usage code for assemblies and detailed parts refer to the figure/item number of
the next higher assembly(ies) or subassembly(ies).
Example: Effectivity 1A, 1B, 1C is written 1ABC.
(5) Units Per Assembly
The units per assembly column show the quantity of units required for one next
higher assembly.
In some cases, the information is replaced by the abbreviations REF (reference) or

AR (as required).
F. Abbreviations
The following abbreviations may be used in this section:
ALT FROM P/N XXX Interchangeable part

AR As required
ASSY Assembly
DPL Detailed Parts List
EDI Electronic Data Interchange
EFF Effectivity
FIG Figure
IPL Illustrated Parts List
LH Left-Hand
NHA Next-Higher Assembly
NP Not-Procurable
OPT P/N Optional Part Number
P/N Part Number
POST SB Post Service Bulletin
PRE SB Pre Service Bulletin
REF Reference
RH Right-Hand
SUPSD BY Superseded by
SUPSDS Supersedes
Page 10005
24-32-03 April 15/2002

40176-4 / 40176-7
G. Updating
(1) General
When an item is revised, added or deleted, the letter “R” is shown in the right-hand
margin (the date of issue in the footer also changes).
(2) Added Items
The basic sequence of the items given makes it impossible to add new items
between the old ones in the appropriate order of the breakdown. With the addition of
new items, a new number would be added at the end of the IPL.
(3) Deleted Items
Should a part number be deleted, the information given in the Detailed Parts List is
deleted. The old part number will always remain in the Numerical Index.
(4) New Figure Number
Whenever new illustrations are necessary, they are inserted in the appropriate place
within the manual. The new illustration will refer to the same parts list.
The new figure number is given with the basic figure number and a letter designation.
This letter precedes the item number in the parts list.
Page 10006
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40176-4 / 40176-7
VENDOR CODE INDEX
VENDOR CODE NAME — ADDRESS
F6177 Saft
12 avenue Sadi Carnot
93170 Bagnolet
France
Phone: (33) 1 49 93 19 18
Fax: (33) 1 49 93 19 56
Http:\\www.saftbatteries.com
V09052 Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
USA
Phone: (1) 229-247-2331
Fax: (1) 229-247-8486
Http:\\www.saftbatteries.com
Page 10007
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40176-4 / 40176-7
Page 10008
24-32-03 BLANK
40176-4 / 40176-7
ALPHANUMERIC INDEX
1. Listing by Saft France (F6177) part number.
PART NUMBER PART NUMBER AIRLINE FIGURE INDEX TOTAL

F6177 V09052 STOCK NUMBER NUMBER NUMBER REQUIRED
012374 015575-000 1&2 23 14
015266 015578-000 1&2 26 1
015539 015577-000 1&2 22 2
031282 1&2 41 2
057014 015576-000 1&2 24 3
062007 015579-000 1&2 11 42
062007 015579-000 3 14 2
063412 015602-000 3 13 20
080004 015957-000 3 20 1
100078 021870-000 3 18 2
100094 3 17 2
100094 1&2 12 42
100430 1&2 30 4
100431 1&2 29 4
100593 091180-008 3 21 1
100693 023388-002 3 15 1
100694 023388-001 3 16 1
102227 022078-000 1&2 28 1
105405 093169-000 1&2 6 1
112965 093169-000 1&2 7 1
112967 1&2 9 1
114767 015926-000 1&2 25 1
114880 015945-000 1&2 3 1
114881 015924-003 1&2 2 1
116109 016420-000 1&2 5 1
116112 016423-000 1&2 27 1
116312 015949-000 1&2 4 1
116390 1&2 42 1
116997 021751-000 1 1 1
119083 021752-000 2 1 1
- Item not illustrated
Page 10009
24-32-03 April 15/2002

40176-4 / 40176-7
2. Listing by Saft (V09052) part number.
PART NUMBER PART NUMBER AIRLINE FIGURE INDEX TOTAL

V09052 F6177 STOCK NUMBER NUMBER NUMBER REQUIRED
009384-000 1&2 ** 1
015575-000 012374 1&2 23 14
015576-000 057014 1&2 24 3
015577-000 015539 1&2 22 2
015578-000 015266 1&2 26 1
015579-000 062007 1&2 11 42
015579-000 062007 3 14 2
015602-000 063412 3 13 20
015924-003 114881 1&2 2 1
015926-000 144767 1&2 25 1
015945-000 114880 1&2 3 1
015949-000 116312 1&2 4 1
015957-000 080004 3 20 1
016420-000 116109 1&2 5 1
016423-000 116112 1&2 27 1
019736-000 1&2 43 1
021751-000 116997 1&2 1 1
021752-000 119083 1&2 1 1
021870-000 100078 3 18 2
021871-000 3 17 4
022078-000 102227 1&2 28 1
022228-000 1&2 12 42
023388-001 100693 3 15 1
023388-002 100694 3 16 1
091180-008 100593 3 21 1
091181-002 100594 3 19 2
093169-000 105405 1&2 6 1
093169-000 105405 1&2 7 1
093616-000 1&2 29 4
Page 10010
24-32-03 April 15/2002

40176-4 / 40176-7
DETAILED PARTS LIST
24 25
23
2
3
25
4 6 22 26
A
11
12
14
20 16
21 17
18
19
15
31 10
35 (2 max.) 33 (3 max.)
36 (3 max.) 34
39 (2 max.) 33 (3 max.)
38 34
31
32
37 35
32 36
37
31
4 A
11 12 42
143
41
29 30 28 8 9 40
40176-4 BATTERY
IPL FIGURE 1 (PAGE 1 OF 3)
Page 10011
24-32-03 April 15/2002

40176-4 / 40176-7
24 25
23
2
3
25
5 6 22 27
4
27
A 7 11
12
14
20 16
21 17
18
19
15
31 10
35 (2 max.) 33 (3 max.)
36 (3 max.) 34
39 (2 max.) 33 (3 max.)
38 34
31
32
37 35
32 36
37
31
5
A
11 12 42
143
41
29 30 28 8 9 40
40176-7 BATTERY
IPL FIGURE 2
Page 10012
24-32-03 April 15/2002

40176-4 / 40176-7
14 14
15 15
17
20 17
17
20 21 18
18
21
16 19
19
16
13
13
Saft Valdosta VP400KH Cell Saft France VP400KH Cell

V09052 F6177
VP400KH CELL HARDWARE CONFIGURATIONS

IPL FIGURE 3
Page 10013
24-32-03 April 15/2002

40176-4 / 40176-7
Page 10014
24-32-03 April 15/2002

40176-4 / 40176-7
DETAILED PARTS LISTING
FIGURE PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

AND STOCK CODE PER
ITEM F6177 V09052 NUMBER 1234567 ASSY
IPL Fig 1 116944 015920-000 Nickel-Cadmium Battery A REF
(V09052) 015920-000 is Ref/Code
for Saft 40176-4 Battery
IPL Fig 2 117481 016392-000 Nickel-Cadmium Battery B REF
(V09052) 016392-000 is Ref/Code
for Saft 40176-7 Battery
(F6177) 117481 is Ref/Code for
Saft 40176-7 Battery
1 116997 021751-000 . Case, 40176-4 A 1
1 119083 021752-000 . Case, 40176-7 B 1
2 116996 015924-003 . Cover 40176-4 / 40176-7 1
3 114880 015945-000 . Gasket, Cover 1
4 116312 015949-000 . Sensor, Temperature A 1
5 116109 016420-000 . Sensor, Temperature, and Heater B 1
Control Thermostat
6 105405 093169-000 . . Nut, Thermostat connecting 1
7 105405 093169-000 . . Nut, Thermostat connecting B 1
8 112965 NP . . Nut, Temperature Sensor 1
9 112967 NP . . O-Ring, Temperature Sensor 1
10 Reserved for future use
11 062007 015579-000 . . Nut, Hex (upper) 42
12 100094 . . Washer, Spring (F6177) 42
12 022228-000 . . Washer, Belleville (V09052) 42
13 063412 015602-000 . Cell, VP400KH (w/hardware) 20
14 062007 015579-000 . . Nut, Hex (lower) 2
15 100693 023388-002 . . Washer, Negative Polarity 1
16 100694 023388-001 . . Washer, Positive Polarity 1
17 100094 . . Washer, Spring (F6177) 2
17 021871-000 . . Washer, Belleville (V09052) 4
18 100078 021870-000 . . Washer, Flat 2
19 100594 091181-002 . . O-Ring, Terminal 2
20 080004 015957-000 . . Valve, Vent 1
21 100593 091180-008 . . . O-Ring, Vent-Valve 1
22 015539 015577-000 . Link, Cell to Receptacle 2
Page 10015
24-32-03 April 15/2002

40176-4 / 40176-7
FIGURE PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

AND STOCK CODE PER
ITEM F6177 V09052 NUMBER 1234567 ASSY
23 012374 015575-000 . Link 14
24 057014 015576-000 . Link 3
25 144767 015926-000 . Link 1
26 015266 015578-000 . Link A 1
27 116112 016423-000 . Link B 1
28 102227 022078-000 . Connector, Main Power 1
29 100431
. Screw, M4 x 10 (F6177) Cannot
be replaced with 093616-000
4
(attaching parts***) (used with (30))

29
093616-000 . Screw, Sems 8-32 (V09052)
Cannot be replaced with 0100431
4
(attaching parts***)
(no washer needed with this screw)
30 100430 . Washer, (F6177) 4
(attaching parts***)
(not required with 093616-000
(V09052) Sems Screw
31 NP NP .Liner (available in kit (43)) 4
41 031282 NP . Plate, Instruction 2
42 411108 NP . Plate, Identification 1
43 412240 019736-000 . Kit, Liner 1
** NP 009384-000 . Gasket, Main Power Connector 1
NP – Not Procurable
** Item not numbered
Page 10016
24-32-03 April 15/2002

40176-4 / 40176-7
Storage and Transportation
1. General Storage Information
CAUTION: STORAGE FACILITIES FOR NICKEL-CADMIUM BATTERIES SHOULD BE

ENTIRELY SEPARATE FROM THOSE FOR LEAD ACID BATTERIES. FUMES
FROM LEAD ACID BATTERIES OR TRACES OF SULFURIC ACID ENTERING A
NICKEL-CADMIUM BATTERY CAN CAUSE PERMANENT DAMAGE.
A nickel-cadmium battery storage location should be free of acid, dust, or dampness. No corrosive
liquids or gases should be stored in the same room. Temperatures may range from -60°C (-76°F) to
+60°C (+140°F) without harming the battery. The most desirable range for storage is between 0°C
(32°F) to +30°C (+86°F).
2. Preparation for Storage
A. In-service batteries to be stored for less than 90 days should undergo completion of the
Regular Check or General Overhaul and be left in an airworthy status. See Section 5
(CHECK).
B. In-service batteries to be stored longer than 90 days should be discharged and placed in a
container suitable to the duration of storage.
C. Factory new batteries may be stored as received for a period of up to 24 months. Longer
storage duration requires placement in sealed packaging prior to storage.
3. Active Stand-by Storage
Active stand-by storage is to be used when the battery must be charged and ready for service
onboard an aircraft in a short period of time. The length of time that a battery will retain a minimum
capacity (80%) will vary dependent upon the ambient temperature of the storage environment (refer
to Figure 15001). For storage longer than 90 days, see procedures for Inactive Storage.
NOTE: Saft vented-cell aircraft batteries may be stored charged, ready for service in the
normal, upright or vertical position.
NOTE: Nickel-cadmium batteries automatically self-discharge at about 0.25% per day at

20°C (68°F).
Page 15001
24-32-03 April 15/2002

40176-4 / 40176-7
100
90
AVAILABLE CAPACITY (%C1Ah)
80
CHARGE RETENTION
Aircraft Ni-Cd battery
70
Temp. (5°C) (41°F) Disch. (0%C1Ah)
60
0 10 20 30 40 50 60 70 80 90
Days
Charge Retention
Figure 15001
A. Storage at < 20°C (68°F).
(1) Place fully-serviced, airworthy battery into proper storage for a period not to exceed
90 days.
st
(2) After 90 days (on the 91 day), the battery must receive an electrolyte level
verification. See Section 1 (TESTING AND FAULT ISOLATION).
(3) After electrolyte leveling, the battery can be returned to storage for another period not
to exceed 90 days.
(4) It is possible to repeat Steps 2 and 3 a maximum of two times (three 90 day
intervals).
(5) If the battery has not been installed into an aircraft after three 90 day intervals, it must
undergo completion of the Regular Check or General Overhaul as required. See
Section 5 (CHECK).
Page 15002
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40176-4 / 40176-7
B. Storage at > 20°C (68°F).
(1) Storage duration is dependent upon ambient temperature. Minimum acceptable

available capacity retention may not be less than 80%.
(2) Refer to Figure 15001 to determine the maximum number of days a battery can be
stored before maintenance is required.
(3) Place a fully-serviced, airworthy battery into proper storage for a period not to exceed
the maximum number of days determined in step 2.
(4) One day past the maximum number of storage days, the battery must receive an
electrolyte level verification. See Section 1 (TESTING AND FAULT ISOLATION).
(5) The battery can then be returned to storage for a period not to exceed the maximum
duration for the ambient storage temperature.
(6) It is possible to repeat steps 4 and 5 a maximum of two times (three storage
intervals).
(7) If the battery has not been installed into an aircraft after three storage intervals, it
must undergo completion of the Regular Check or General Overhaul as required.
See Section 5 (CHECK).
4. Trickle Charging
The principle of trickle charging is to keep a battery in active stand-by condition by continuously
charging the battery in an over-charge condition. Saft does not recommend this method, however
some operators take responsibility for its use.
WARNING: USE OF A TRICKLE CHARGER WILL CONSUME WATER OVER TIME. FAILURE
TO VERIFY ELECTROLYTE LEVEL PRIOR TO INSTALLATION MAY RESULT IN
PREMATURE BATTERY FAILURE.
Example: If a 40 Ah battery remains on a continuous trickle charge of 3 mA/Ah for one month, the
3
total consumption of water is 35 cm /cell.
The operator must adjust the electrolyte level before placing the battery onboard the aircraft.
Otherwise, the risk of a battery incident exists; cells dry out before the normal end of the
maintenance interval.
Page 15003
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40176-4 / 40176-7
5. Inactive Long-term Storage
Saft nickel-cadmium aviation batteries can be stored in the original cardboard packaging for a period
of two years, and up to 10 years in sealed packaging under the following conditions:
A. Ambient temperature of 20°C ± 15°C (+68°F ± 27°F)
B. Humidity less than 70%
C. Normal upright, vertical position
D. Atmosphere free of dust, dirt, vibration or corrosive agents.
6. Preparation for Use After Storage (other than Active Stand-by Storage)
STORAGE TIME SERVICE PROCEDURE

Less than 3 months Perform a Periodic Check (CHECK - Fig 5001)
More than 3 months Perform a Regular Check (CHECK - Fig 5002)
Return to Service Procedures
Figure 15002
7. Packing and Transporting
The normal packing for shipment of Saft nickel-cadmium batteries is with fiberboard or injected foam
packing enclosed in fiberboard or wooden outer containers. For overseas shipments, wrapping in
sealed plastic is recommended. Precautions must be taken to keep batteries upright while in transit.
All markings and documentation should conform to current IATA regulations (UN2795 or UN2800 as
applicable) governing the shipment of vented nickel-cadmium batteries.
Page 15004
24-32-03 April 15/2002

CMM 24-32-03

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COMPONENT MAINTENANCE MANUAL

Title Page – page 1

24-32-03 April 15/2002

Original Issue Date: July 30/75

THIS PAGE INTENTIONALLY LEFT BLANK

Title Page – page 2

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24-32-03 April 15/2002

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TEMPORARY PAGE ISSUE BY DATE BY

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NUMBER BRIEF DESCRIPTION TYPE AFFECTED

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LIST OF MAJOR REPAIRERS

TRADE NAME ADDRESS

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LIST OF EFFECTIVE PAGES

CONTENT PAGE REVISION CONTENT PAGE REVISION

RECORD OF REVISIONS 1 Apr 15/2002 SCHEMATIC AND 2001 Apr 15/2002

RECORD OF 1 Apr 15/2002 DISASSEMBLY 3001 Apr 15/2002

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CONTENT PAGE REVISION

INTRODUCTION 10003 Apr 15/2002

VENDOR CODE INDEX 10007 Apr 15/2002

ALPHA NUMERICAL 10009 Apr 15/2002

DETAILED PARTS LIST 10011 Apr 15/2002

STORAGE AND 15001 Apr 15/2002

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DESCRIPTION AND OPERATION OP Page 1

TESTING AND FAULT ISOLATION 1001

SCHEMATIC AND WIRING DIAGRAMS 2001

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FITS AND CLEARANCES 8001

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 9001

ILLUSTRATED PARTS LIST 10001

SPECIAL PROCEDURES NOT APPLICABLE

REMOVAL NOT APPLICABLE

INSTALLATION NOT APPLICABLE

SERVICING NOT APPLICABLE

STORAGE (INCLUDING TRANSPORTATION 15001

REWORK (Service Bulletin Instructions) NOT APPLICABLE

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B. This manual describes maintenance on components in a workshop. It does not describe

E. This manual contains the following:

F. Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY

2. How to use this manual

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B. U.S. Units (Imperial)

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The abbreviations given below may be used in this manual:

AECMA The European Association of Aerospace Industries

This paragraph describes the notations used in this manual.

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Ni-Cdâ batteries contain:

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DESCRIPTION AND OPERATION