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SAFT (F6177) 12 rue Sadi Carnot - 93170 Bagnolet - FRANCE Tél. (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

AIRCRAFT BATTERY P/N 23491 & 23491-3

24-30-00 Initial issue : Jun 01/1994

Title page - Page 1 Feb 09/2006

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

RECORD OF REVISIONS REVISION No. 1

ISSUE DATE Feb 09/2006

INSERTED DATE BY SAFT

REVISION No.

ISSUE DATE

INSERTED DATE BY

RR Pages 1/2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SERVICE BULLETIN LIST NUMBER

BRIEF DESCRIPTION

TYPE AFFECTED

SBL Pages 1/2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

LIST OF EFFECTIVE PAGES

Title page

1

DATE OF LATEST REVISION Feb 09/2006

Description and operation

1 2 3 4

DATE OF LATEST REVISION June 01/94 June 01/94 June 01/94 June 01/94

Record of revisions

1 2

Feb 09/2006 Blank

Record of temporary revisions

1 2

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Testing and fault isolation

101 102 103 104

June 01/94 June 01/94 June 01/94 June 01/94

Service bulletin list

1 2

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Disassembly

301 302

June 01/94 June 01/94

List of effective pages

1 2

Feb 09/2006 Feb 09/2006

Cleaning

401 402

June 01/94 June 01/94

Check Table of Contents

1 2

June 01/94 Blank

List of illustrations

1 2

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501 502 503 504 505 506 507 508

June 01/94 June 01/94 June 01/94 June 01/94 June 01/94 June 01/94 June 01/94 June 01/94

Repair

601 602

June 01/94 June 01/94

Assembly and storage

701 702 703 704 705 706

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CONTENT

Foreword 2 Blank

PAGE

1

CONTENT

June 01/94

PAGE

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

LIST OF EFFECTIVE PAGES CONTENT Special tools and equipment

PAGE

LATEST

901 902 903 904

June 01/94 June 01/94 June 01/94 June 01/94

TP 1001

1 2

June 01/94 Blank

INTRO 1001

1 2 3 4 5 6

June 01/94 June 01/94 June 01/94 June 01/94 June 01/94 Blank

VCI 1001

1 2

Feb 09/2006 Blank

NI/NUM 1001

1 2

Feb 09/2006 Feb 09/2006

DATE OF CONTENT REVISION

PAGE

DATE OF LATEST REVISION

Illustrated parts list

DETAILED PARTS LIST

1001 1001-0 1001-1 1001-2 1001-3

June 01/94 Feb 09/2006 Feb 09/2006 Feb 09/2006 Feb 09/2006

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

TABLE OF CONTENTS PAGE DESCRIPTION AND OPERATION 1 - Description 2 - Operation

1 2

TESTING AND FAULT ISOLATION 1 - Testing 2 - Fault isolation

101 101

DISASSEMBLY 1 - Disassembly

301

CLEANING 1 - Light cleaning 2 - Full cleaning 3 - Lubrication

401 401 402

CHECK 1 - Regular checks 2 - Maintenance steps in workshop 3 - General overhaul

501 501 506

REPAIR 1 - Battery condition 2 - Polarisation test 3 - Added electrical test before repair

601 601 602

ASSEMBLY AND STORAGE 1 - Assembly 2 - Storage

701 703

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1 - Special tools 2 - Materials and different products

ILLUSTRATED PARTS LIST Introduction Vendor code index Numerical index Detailed parts list

901 904

INTRO 1001-1 VCI 1001-1 NI/NUM 1001-1 1001

TC Pages 1/2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

LIST OF ILLUSTRATIONS

PAGE Figure 501 - Level adjustment with a syringe and calibrated nozzle

502

Figure 701 - 23491 battery circuit

705

Figure 702 - 23491-3 battery circuit

705

Figure 901 - Polyamide key for vented filler cap made of polyamide

902

Figure 902 - Syringe with nozzle

902

Figure 903 - Equalizing resistor

902

Figure 904 - Cell removal tool

903

Figure 1 - Battery 20 VO23KH P/N 23491

1001-0

Figure 2 - Battery 20 VO23KH P/N 23491-3

1001-1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

FOREWORD 1. General This manual supplies the maintenance data and the Illustrated Parts List of the Saft type 23491 & 23491-3 batteries. These instructions agree with specification ATA No. 100 for the manufacturer's technical manuals. They are included in chapters in this sequence : 1-100

Description and operation

101-200

Testing and fault isolation

201-300

(Not used)

301-400

Disassembly

401-500

Cleaning

501-600

Check

601-700

Repair

701-800

Assembly and storage

801-900

(Not used)

901-1000

Special tools, fixtures and equipment

1001-1100 Illustrated parts lists. Note : The instructions in this manual cannot be used as a specification for an acceptance test; use these instructions for OPERATION and CHECK of an item which is temporarily unserviceable and to REPAIR for overhaul.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

DESCRIPTION AND OPERATION

1. Description A. General The alkaline battery has 20 semi-open nickel-cadmium VO23KH cells with welded polyamide cases. The battery is connected to the aircraft systems. It can be used: - To start - On the ground, before electrical power is supplied to the aircraft systems - In flight, if a malfunction or a failure occurs in the power supply system. The 28 VDC electrical system charges the battery in the aircraft.

B. Data (1) Technical data - Nominal voltage : 24 volts - Rated capacity : 23Ah at a rate of 1h - Connector : MS 18093 - Electrolyte : Sol. KOH s.g. 1.30 - Consumable volume of electrolyte: 21cm3 (ml) per cell. - Maximum dimensions of the battery base :

L=254mm (10.00in), W=198mm (7.80in), H=240mm (9.45in).

- 23491 battery, maximum weight : 24.7kg (54.4lb). - 23491-3 battery, maximum weight : 24.7kg (54.4lb). - One temperature sensor with: - 1 thermostat closes at 71°±2.8°C (160°±5°F) temperature rise, - 1 thermostat closes at 57°±2.8°C (135°±5°F) temperature rise, - 1 resistance of 143 Ω ±5% at 25°C (77°F) (for 23491-3 battery).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

(2) Operational data - Operating temperature: -40 to +71°C (-40 to +160°F) - Maximum instantaneous power : - at +23°C (+74°F): 12V 15s 8.3kW, - at -18°C (+ 0°F): 12V 15s 4.7kW. C. Detailed description (Refer to pages 1001-0 to 1001-7) The battery has 20 VO23KH (490A) cells housed in a stainless steel box. The box (020A) has a lining of thin sheets of insulation (120A). A molded part (050A) made of silicone elastomer keeps the cells vertical. This part is attached to the box cover which pusches down the top of the cells. Rigids links (420A thru 480A), made nickel-plated copper, connect the cells together. Rigid connections (420A and 440A) connect the end cells to an electrical connector (310A). This connector connects the battery to the aircraft. The box (020A) has: - a cover (030A) that you can remove and which has a non return valve (060A), - a vent tube, - a handle.

2. Operation A. Charge (1) Flight charge Adjust the recharger to make sure the battery is correctly charged in flight. Do a recharger check as frequently as possible. At the usual temperature of +20°C (+68°F), the constant charge voltage must be 28.5 volts. If the climatic or battery operating conditions cause the cell temperature to increase to +40°C (+104°F), adjust the recharger to 27.5 to 28 volts. This is to prevent a fast loss of the electrolyte reserve and a shorter life for the cells. For a given voltage adjustment, the higher the battery temperature, the higher the remaining charge current. The consumption of water from the electrolyte is directly in proportion to the remaining charge current. Thus it is necessary to accurately know the usual operating temperature of the batteries to permit the batteries to be charged in the best conditions. Page 2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

(2) Ground charge Do all battery maintenance or overhaul steps in a workshop. Note: In addition to the constant current and constant voltage methods of charging other methods, such as combinaison of both or pulse charging, can be used. If the specific instructions are not given in the operating manual, SAFT should first be contacted. WARNING: REMOVE THE COVER TO CHARGE THE 23491 & 23491-3 TYPE BATTERIES ON THE GROUND. THIS IS TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX. - Constant current charge (Battery fully discharged): To charge a fully discharged battery, do one of these procedures:

CONSTANT CURRENT CHARGE Main charge End of charge 2.3 amps (0.1C1A) until 30V as battery voltage + 2.3 amps (0.1C1A) for a 4h time mini 10h Time: maxi 12h 11.5 amps (0.5C1A) until 31V as battery voltage + 2.3 amps (0.1C1A) for a 4h time mini 2h Time: maxi 2h 30min 23 amps (1C1A) until 31.4V as battery voltage + 2.3 amps (0.1C1A) for a 4h time mini 1h Time: maxi 1h 15min NOTE: If the battery voltage does not increase sufficiently during the maximum charge time: Refer to "TESTING AND FAULT ISOLATION"..

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

Battery not fully discharged and discharge condition unknow. Discharge at 23 amps (1C1A) down to 20V. Charge: refer to A (2) above constant current charge. - Constant voltage charge Charge at 28.5V at ambient temperature during 4 to 5h Adjusted charge voltage: for a +5°C (41°F) battery temperature: 29V for a +35°C (95°F) battery temperature: 28V

B. Discharge Rated capacity

one hour discharge at 23 amps down to 20V

(C1Ah) Others rates (C1A)

23Ah for a fully charged battery in relation temperature and time : up to 25 C1A

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

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 TESTING AND FAULT ISOLATION

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

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

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

CORRECTION Examine the electrical contacts and links. Make sure the nuts are tight (CHECK).

Zero volt with the battery set to "discharge".

Battery fully discharged.

Charge the battery (DESCRIPTION AND OPERATION). Do an insulation check (CHECK).

Battery circuit open or defective contacts.

Examine the contacts and links. Make sure the terminal nuts are tight (CHECK).

Cell fully dry

Refer to the related subsequent steps.

Incorrect adjustment of level

Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

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

Examine the aircraft circuit which charges the battery.

Leakage of electrolyte.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FAILURES

POSSIBLE CAUSES

CORRECTION Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

Too much charge at high temperature or too much current

Examine the aircraft circuit which charges the battery. If necessary, adjust to normal operating temperature (DESCRIPTION AND OPERATION). Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

Electrolyte found in the battery box.

Damaged cell case.

Do a leak test of the cells (CHECK). Replace the cell if necessary and refer to the related subsequent steps.

Leakage of electrolyte.

Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FAILURES Too much water consumption for all the battery cells.

POSSIBLE CAUSES Charge much more than the limit or too much charge at high temperature.

CORRECTION Examine the aircraft circuit which charges the battery. If necessary, adjust to normal operating temperature (DESCRIPTION AND OPERATION).

more than 30% more than the average

Leaks from the cell(s).

Do a leak test of the cells (CHECK).

30% (or less) of the average

Cell(s) with damaged separator(s)

Do the added test (REPAIR). If necessary, replace the cell(s).

Corrosion on the links.

Operation in acid air

Make sure the battery test bench and the storage areas have no materials which can give off acid fumes.

Mechanical damage to nickel plating

Replace the damaged links (DISASSEMBLY, ASSEMBLY AND STORAGE).

The links are too hot.

Loose terminal nuts.

Make sure the nuts are tight (CHECK).

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

Dry cell

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

Cell(s) the water consumption of which is very different from that of the other cells in the battery:

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FAILURES

POSSIBLE CAUSES

CORRECTION NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can cause temperature to increase very much.

A cell has an unusually low voltage at the end of the charge (Less than 1.5 V at 2.3 amps at + 20°C (+68°F) or 1.47V at) +35°C (95°F).

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

Replace the cell (DISASSEMBLY, ASSEMBLY AND STORAGE).

Low capacity cell (The cell shows an opposite voltage or a correct polarity voltage of less than 1 V after a discharge of 1 hour at 23 amps).

Usual wear after long operation.

Replace the cell (DISASSEMBLY, ASSEMBLY AND STORAGE).

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

Do the applicable procedure (REPAIR).

Cell with a swollen case.

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

Replace the cell (DISASSEMBLY, ASSEMBLY AND STORAGE)

Cell with zero voltage when the battery circuit is open.

Short-circuited cell.

Replace the cell.

Low insulation.

Leakage of electrolyte.

Disassemble and clean the battery (DISASSEMBLY and CLEANING). Do an electrolyte level check (CHECK).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 DISASSEMBLY

1. Disassembly

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

A. Remove a cover (030A).

B. Removal of an vented filler cap (safety cap): - Loosen the vented filler cap (500A) with the special tool (Refer to figure 901). - Remove the vented filler cap with its O-ring (510A). C. Removal of a cell: (refer to fig. 1 and fig. 2) - Remove the nuts (520A) that attach the links (420A thru 480A) to the cells. Remove the spring washers (530A). - Remove the links from the cell terminals. - Fully engage the end of the special threaded tool (Refer to figure 904) on one of the cell terminals. Then pull up to remove the cell. D. Removal of the electrical connector: (310A) NOTE: In order to avoid a short-circuit, remove a link between two cells. - Remove the nuts (400A and 520A) that attach the links (420A and 440A) to the connector. Remove the four spring washers (530A and 410A). - Remove the two links (420A and 440A). - Remove the four screws (390A) and their four lock washers from the connector complete (310A). - Remove the connector complete (310A) from the box (020A).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

E. Removal of the temperature sensor. - Cut the cable grip (660A). - Remove: - the electrical connector complete (310A) (ref. to paragr. D), - the six cells in front (refer to fig. 701, fig. 702 and to paragr. C), - (23491 battery): the nuts (520A) that attach the two thermostat links (460A) (refer. to figure 1 and fig. 701) , - (23491-3 battery): the nuts (520A) that attach the two thermostat links (460A) and the sensor link (470B) (refer. to figure 2 and fig. 702), - the spring washers (530A), the thermostat links (460A), the sensor link (470B from the 23491-3 battery), - the self locking nuts (610A) that attach the two thermostats on the thermostat links (460A) - (23491-3 battery): the screws (680B), the washers (690B), the spring washers (700B), the clamp (670B), - the nut (640A), the flat washer (620A) and then take out the complete temperature sensor (590A for the 23491 battery) or (600B for the 23491-3 battery).

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

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 CLEANING

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

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

WARNING: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. - Before you put the vented filler caps back into the cells, make sure that they operate correctly. Do these steps: - Install the vented filler cap (500A) with its O-ring (510A) on the end of a metal tube that has a correct end-piece. - Connect this tube to a supply of compressed air through a vented filler cap of the adjustable reducing type. - Adjust the pressure to 0.5 bar (7.25 psi) and put the vented filler cap into a container of water. Air bubbles come out if the vented filler cap is in good condition. If there are no bubbles, increase the pressure until you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi) and monitor the pressure at which the air flow stops. - Reject all vented filler caps that have an operating pressure of more than 0.7 bar (10 psi) (after the check done before to make sure that the related cap operates correctly) or less than 0.14 bar (2 psi). - Install the vented filler caps (Refer to "ASSEMBLY"). 3. Lubrication When the battery is clean (and after installation of the vented filler caps), put a thin layer of neutral petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 CHECK

1. Regular checks You must do the checks which are necessary to use the SAFT 23491 and 23491-3 batteries in flight and on the ground. But you must also do these maintenance steps during operation: - Periodical check (in a workshop): adjustment of electrolyte levels - Regular check (in a workshop): electrical treatment, adjustment of electrolyte levels, and capacity test.

2. Maintenance steps in workshop A. Periodical check Periodically (at flight hour intervals such that the allowable water consumption is not exceeded): - Clean the battery (See "CLEANING") - Adjust the electrolyte level (Refer to (1)). (1) Charge of the battery and adjustment of the electrolyte level: - Discharge the remaining capacity at 23 amps down to a voltage of 20 volts at the battery terminals. - When the battery temperature is +20°C to +25°C (+68°F to +77°F) (usual temperature range), charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION" for a fully discharged battery). - During the last hour of the charge (while the charge current continues to flow), adjust the level of the electrolyte in the cells. Then measure the voltages of each cell. Write the quantity of water that is added to each cell. - The electrolyte level changes with the battery charge. Thus you do not get the maximum level until the battery is fully charged. The level changes as if the plates absorbed a part of the electrolyte during the discharge and released it during the charge.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

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

20 mm

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

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 - If the level is not sufficient, the syringe tube stays empty when you pull the plunger. - If there is too much liquid, this liquid is removed by the syringe until the level aligns with the end of the nozzle. If this check shows that the level is not sufficient in some cells, add distilled water to these cells. (The syringe is small ; it can thus be necessary to do this step more than one time for each cell). The level is correct when only a small quantity of liquid goes into the syringe when you pull the plunger. To do this check (after water is added to the cell), keep the shoulder of the syringe nozzle against the seat of the vented filler cap. - Results of the above procedure: - The battery operates correctly if: - The voltage of each cell measured during the last hour of charge at 2.3 amps is not less than 1.50 volt (1.47 volt at +35°C (95°F)). - Approximately the same quantity of distilled water was added to each cell. This quantity must be less than 21cm3 (1.29in3). - If the quantity of water added to all cells is more than 21cm3 (1.29in3): make sure that the voltage adjustment in relation to the temperature during the charge is correct. Also do the electrolyte level check more frequently. - Do a full overhaul of the battery (Refer to paragraph 3 "General overhaul"): - If the quantity of water necessary for one or more cell(s) is much higher or smaller than for the other cells. - If the voltage of each cell measured at the end of a 2.3 amps charge is less than 1.50 volt (1.47 volt at +35°C (95°F)) (Refer to "TESTING AND FAULT ISOLATION"). (2) Clean the vented filler caps (Refer to "CLEANING") when you adjust the electrolyte levels. (3) Make sure the cell terminal nuts are tight. Make sure that all the nuts that attach the links are torqued to 8 ±2N.m (5.90 ±1.47ft.lbf). (4) Do an insulation check (Refer to paragraph 3.E).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

B. Regular check 1) At the time of a second periodical check OR AFTER A MAXIMUM OF SIX MONTHS, do this battery test (also do the steps given in paragraph 2.A): - Discharge the remaining capacity at 23 amps down to a voltage of 20 volts at the battery terminals. - Measure the time from the start of discharge to the time when the voltage is 20 volts. - Connect a resistor of approximately 1 Ω 3 W (refer to fig. 903) across each cell and continue to discharge. Resistors with crocodile clips attached to their leads can be easily attached to the cell terminals. - Let the resistors stay in position for the night. 2) Remove all resistors, charge the battery (Refer to "DESCRIPTION AND OPERATION" for a fully discharged battery). - Adjust the electrolyte level in the cells (Refer to paragraph 2.A (1)). Then measure the voltage of each cell during the last hour of the charge. Also write the quantity of distilled water added to each cell. - Immediately after the charge and the level adjustment, discharge the battery again at 23 amps down to 20 volts; measure the terminal voltage of each cell. Write the time that is necessary for this second discharge. - Results of the above tests: The battery operates correctly if: - The time necessary for the first discharge (paragraph 2.B (1)) is more than 30 minutes, - The time necessary for the second discharge (paragraph 2.B (2)) is not less than 51 minutes, - The voltage of each cell measured during the last hour of the charge at 2.3 amps is not less than 1.50 volt (1.47 volt at +35°C (95°F)), - The quantity of distilled water added to each cell is approximately equal to or less than 21cm3 (1.29in3).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

- If the first discharge time is less than 30 minutes but the second discharge time is correct: the battery is in good condition but was not fully charged when removed from the aircraft. This condition can be caused by: - An incorrect charge in the aircraft. - And/or a discharge caused by an unusual operation of the battery after landing. Do a full overhaul of the battery (paragraph 3) if: - The second discharge time is less the correct one or one cell has a voltage of less than 1 volt (or incorrect polarity before 1 hour of discharge). - The voltage of each cell measured during the last hour of charge at 2.3 amps is less than 1.50 volt (1.47 volt at +35°C (95°F)). - The quantity of distilled water necessary for one or more cell(s) is much higher or smaller than for the other cells. NOTE: The consumption of water by a SAFT nickel-cadmium cell is in proportion to the unwanted charge. Thus, the consumption must be the same for all the 20 cells in the battery. The quantity of water necessary for one or more cell(s) (in the same battery) can be much higher (or smaller) than the other cells. Then there is a defect: - High consumption is usually caused by a leakage. - Low consumption is caused by a damaged separator. - The consumption is incorrect when it is 25 % more or less than the average.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

3. General overhaul This overhaul includes the electrical tests given in paragraph 2.B. It also includes the disassembly and cleaning procedures to be done systematically for all the battery components. Do an overhaul one time each year or during each most important servicing of the aircraft. Do these steps: - Disassemble the battery - Clean the battery - Do a battery test - Do an insulation test. A. Disassemble the battery (Refer to "DISASSEMBLY"). B. Clean the battery (Refer to "CLEANING"). C. Do a battery test: (1) Cells: - Make sure that the lower terminal nuts are tight: - Tightening torque: 5 ± 0.5 N.m (3.69 ± 0.369 ft.lbf). - Verify that cell boxes show no leakage. (2) Box: Make the sides of the box straight and remove the dents. (3) Nuts, links and spring washers: - Discard the components that show signs of corrosion or damage. (4) Packing parts: - Discard all defective components. (5) Connector: - Make sure that the connector is in good condition (inner and outer surfaces); replace it if the contacts are burned.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 D. Do a temperature sensor test:

Checking of temperature sensor can only be carried out when the battery is dismantled. 23491 battery and 23491-3 battery: pins of control connector Check of +71°C Th and +57°C Th

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

Between A and B

between C and D

circuit opened

─────── ───────

circuit opened circuit closes

─────── ───────

circuit opens

circuit closes

─────── ───────

circuit opens

─────── ───────

+71°C Th On 4°C to 10°C (7°F to 18°F) temperature decrease than precedent closing temperature On temperature rise between +51°C and +64°C (125°F and 145°F) +57°C Th On 4°C to 10°C (7°F to 18°F) temperature decrease than precedent closing temperature

(This range includes a ±3°C (±5°F) temperature precision and ±3°C (±5°F) thermostat precision 23491-3 battery: pins of control connector Check of

Temperature

Between E and F

at +20°C ±2°C (+68°F ±3.6°F)

137 Ω to 143 Ω ±0.6 Ω

at +70°C ±3°C (+158°F ±5.4°F)

162 Ω to 169 Ω ±0.8 Ω

143õ sensor

- The insulation of thermostat poles in relation to their metal housing must be greater or equal to 30 MΩ under 250 V continuous.

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

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REPAIR

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

2. Polarisation test - Charge the battery at 2.3 amps for 1.5 hour. - Keep the battery in the "open circuit" condition for 1 hour. - Measure the open voltage of every cell. If the cell open voltage is 0 volt (or opposite), do an added test (refer to paragraph 3). Then repair. If each cell has an open voltage that is more than 0 volt, charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery).

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3. Added electrical test before repair The first test charge can be unsatisfactory if the electrolyte level is too low in some cells (the level is not adjusted until the end of this charge). If you find defects, do a second test: - Charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery). At the end of the total charge time, continue to charge at 2.3 amps for 5 more hours. Regularly write the voltage and temperature of the cells. The temperature of the cells that have damaged separators increases very much and continuously. The voltage of these cells continuously decreases to less than 1.50 volt (1.47 volt at +35°C (95°F)).

NOTE: When you charge the battery more than necessary, you decrease the life of the cells. Thus, do this special test only if: - A battery malfunction occurred in the aircraft - Defects were found during shop maintenance. - Adjust the electrolyte level during the last one of the 5 last hours of charge. - Discharge at 23 amps down to 20 volts. After this test, discard the defective cells: - Cells with a voltage of less than 1.50 volt (1.47 volt at +35°C (95°F)) at the end of the charge. - Cells with a voltage that decreases to less than 1 volt before one hour of discharge (during the last test discharge). - Short-circuited cells (zero volt).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 ASSEMBLY AND STORAGE 1. Assembly

NOTE : Tooling and equipment are identified in the list of "SPECIAL TOOLS, FIXTURES AND EQUIPMENT". A. Installation of the vented filler caps: - Make sure the O-ring (510A) is in good condition; replace the O-ring if it is worn. - Install the safety vented filler cap (500A) with the special tool (Refer to figure 901); hold the special tool by its upper ribbed part. B. Installation of a cell: - Install the discharged cell and make sure its polarity is correct. - Carefully position the cell (490A) and push on the terminals with a piece of soft wood. - Install: - the links (Refer to fig. 1 and fig. 2 for their locations), - the spring washers (530A), - the nuts (520A) and torque them to 8 ±2 N.m (5.90 ±1.47 ft.lbf). C. Installation of the temperature sensor: - Install: - the O-ring (630A) on the temperature sensor connector, - the temperature sensor connector on the box (020A) with the washer (620A) and the nut (640A), - (23491 battery and 23491-3 battery): the two thermostats on their links (460A) (refer to fig. 701 and fig. 702) with the self-locking nuts (610A), - (23491-3 battery): the sensor on the link (470B) (refer to fig. 702) with the clamp (670B), the washers (690B, 700B) and the screws (680B), - the six cells in the front of the box (refer to fig. 701, fig. 702 and paragr. B),

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

- the links (460A) (for the 23491 battery and the 23491-3 battery), - the link (470B) (for the 23491-3 battery), - the washers (530A), - the nuts (520A) and torque them to 8 ±2 N.m (5.90 ±1.47ft.lbf). - The cable grip (660A) (refer to fig. 701 and fig 702).

D. Installation of the electrical connector:(310A) - Install the connector complete (310A) on the box (020A) with the four screws (390A), - install the two links (420A and 440A) to the cell terminals and the connector terminals (refer to fig. 1 and fig. 2), - Put the four spring washers (410A and 530A), - Install the nuts (400A and 520A) and torque them to 8 +2N.m (5.90 +1.47 ft.lbf).

E. Assembly of the battery Install these components in the box (020A): - the bottom insulator (210A) - the liner-spacer kit (120A). (refer to fig. 1 and fig. 2 for the location of spacers). The liner-spacer kit includes these spacers: Item *130A *140A *150A 160A *170A 180A 190A 200A *210A

Designation Spacer Spacer Spacer Insulatorr Spacer Insulator Insulator Slotted insulator Bottom insulator

Units per assy 4 5 5 1 1 1 4 1 1

Dimensions 195x45x0.5 195x45x1 195x75x0.5 210x64x1 195x75x1 189x140x1 210x75x1 210x69x1 247x191x1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

Item *220A *230A 240A 250A 260A 270A 280A 290A 300A

Units per assy 9 7 2 2 2 1 1 2 1

Designation Spacer Spacer Slotted Spacer Spacer Insulator Spacer Spacer Slotted Spacer Insulator (U form piece)

Dimensions 210x75x0.5 210x75x1 210x75x0.5 210x190x0.5 205x188x0.3 195x190x1 195x190x0.5 210x75x1 190x145x85

* (Caution, put only the number that is necessary to wedge each cell row). Install: - Twenty VO23KH cells (490A) (refer to paragr. B), and make sure their polarities are correct as shown in figure 701 and fig. 702). - The electrical connector complete (310A) (Refer. to paragr. D) - (23491 battery): The temperature sensor (590A) (Refer. to paragr. C) - (23491-3 battery): The temperature sensor (600B) (Refer. to paragr. C) - All links (420A thru 480A) on the cell terminals with the spring washers (410A and 530A) and the nuts (400A and 520A). Torque the nuts to 8 ±2N.m (5.90 ±1.47ft.lbf). Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush). - Install the cover (030A).

2. Storage A. Preparation of the battery before storage - Adjust the electrolyte levels (Refer to "CHECK", paragraph 2.A. Then discharge at a constant current of 23 amps down to a terminal voltage of 20 volts.

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

- Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the connector contacts and all the components that can be damaged by atmospheric corrosion. - Put the battery in its usual vertical position. B. Storage room: Keep the SAFT 23491 & 23491-3 batteries in a dry and clean room. C. Temperature conditions: Keep the batteries at a temperature of -60°C to +60°C (-76°F to +140°F). But the best temperature range is between 0 and +30°C (+32°F and +86°F). D. Packing The SAFT 23491 & 23491-3 batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommend that you put the batteries in a welded plastic container. In this type of container, the batteries can be kept for 10 years in the best storage conditions. E. Transportation It is important that you move the nickel-cadmium SAFT 23491 & 23491-3 batteries in the vertical position. Thus, the containers must be identified with "TOP" and "BOTTOM" marks that can be read easily. F. Servicing after storage Storage time Less than 3 months

Servicing procedure Charge the battery (Do one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2)) for a fully discharged battery)

3 months to 1 year

Do the Periodical check (Refer to "CHECK" 2.A).

More than 1 year

Do the Regular check (Refer to "CHECK" 2.B).

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

23491 battery circuit Figure 701

23491-3 battery circuit Figure 702

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1. Special tools. Manufact. P/N

015528

016544 105112

014735 164829

DESIGNATION

T E S T / F A U L T

D I S A S S E M B L Y

C L E A N I N G

Polyamide key vented filler for caps made of polyamide (Refer to figure 901)

X

X

X

Syringe nozzle (Refer to figure 501 and 902) Syringe: 20 cm3 (1.22in3) (Refer to figure 902)

USE C H E C K

X

X

X

X

X

X

X

X

Cell removal tool (Refer to figure. 904)

X

Equalizing resistor (1 Ω 3 W) (Refer to figure. 903)

R E P A I R

X

X X

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

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Polyamide key for vented filler caps made of polyamide Figure 901

Syringe with nozzle Figure 902

Equalizing resistor Figure 903 Page 902

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Cell removal tool Figure 904 Page 903

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 2. Materials and different products. DESIGNATION Mineral petrolatum

Grease

1-OTAN 3-US 1- S.743 2- AIR 3565 3- VLP 2336 4- DEF 2333 1- G.392 3- MIL-G4343 4- DTD 5610

SPECIFICATION 2-F 4-UK

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

Glue

3 M FRANCE EC1236

Distilled water

Local supply

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ILLUSTRATED PARTS LIST

TP 1001 Page 1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

INTRODUCTION

1. General The Illustrated Part List (IPL) agrees with the ATA 100 specification. It is used to identify all the components of the unit. The Illustrated Parts List includes these sections: - Introduction - Vendors Code Index - List of Circuit Symbols (if applicable) - Alphanumeric Index of Manufacturer's Part Numbers - Detailed Parts List.

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

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

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

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

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- NP: Non procurable - OPT TO: Optional parts - ORDER OVERLGHT MPN: Part number longer than 15 characters - OVERSIZE: Oversize repair parts - POST SB: After the Service Bulletin is included - R - Changed - REF: For reference - SEE - SEL FROM: Select from parts - STORAGE PARTS - SUPSDS by: Superseded by - SUPSDS: Supersedes - UNDERSIZE: Undersize repair parts - T: tera 10E12 G: giga 10E9 M: mega 10E6 K: kilo 10E3

m: milli 10E-3 µ: micro 10E-6 n: nano 10E-9 p: pico 10E-12

4. Changes When an item is changed, added or removed, the letter "R" is shown in the right margin (the date of issue of the page changes). The letter "R" is shown opposite the page number (in the right margin) when all the item numbers are changed.

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

INTRO 1001

Page 1 to 4

Vendor Code Index

VCI 1001

Page 1

Numerical Index, Alphabetical

NI/ALPHA 1001

Page 1

Numerical Index Numerical

NI/NUM 1001

Page 1

Detailed Parts List

(figure xx)

Figure, Main

Page 10xx-O

Figure, Variant A

Page 10xx-OA

Figure, Variant B

Page 10xx-OB

Parts List (1st page of text)

Page 10xx-1

Parts List (2nd page of text)

Page 10xx-2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

VENDOR CODE INDEX VENDOR CODE

NAME-ADDRESS

VCI 1001 Page 1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 NUMERICAL INDEX PART NUMBER 015255 057012 062000 062000 062023 063410 080010 100111 100111 100430 100431 100479 100593 100695 100696 101228 101229 101229 101230 102226 104960 105405 105623 114724 114735 115266 115763 115764 116056 116642 117497 166309 23491 23491-3 410435 410436 410443 410496 411108 411996 412647 413049 413052 413053 413243 414928 415609 415690

AIRLINE PART NUMBER

FIG 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1 2 1&2 1&2 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 2 1 1&2 1 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 2 2 2 2 1&2 1&2 1&2

ITEM 070A 480A 400A 520A 560A 490A 500A 410A 530A 391A 390A 570A 510A 540A 550A 420A 430A 430B 440A -310A 700B 610A 450A 620A 460A 650A 640A 630A 660A 690B 590A 090A -001A -001B 110A 030A 040A 020A 080A 580A 120A 600B 670B 680B 470B 050A -010A 060A

TTL QTY 1 3 2 4 2 20 1 2 4 4 4 2 1 1 1 5 7 6 2 1 2 2 1 1 3 1 1 1 1 2 1 2

1 1 1 1 1 2 1 1 1 2 1 1 1 1

NI/NUM 1001 Page 1

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NI/NUM 1001 Page 2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

DETAILED PARTS LIST

Page 1001

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FIGURE 1 23491 BATTERY Page 1001-0

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3

FIGURE 2 23491-3 BATTERY Page 1001-1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FIG 1 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1 2 1&2 1&2

ITEM -001A -001B -010A 020A 030A 040A 050A 060A 070A 080A 090A 100A 110A 120A 130A 140A 150A 160A 170A 180A 190A 200A 210A 220A 230A 240A 250A 260A 270A 280A 290A 300A -310A 320A 330A 340A 350A 360A 370A 380A 390A 391A 400A 410A 420A 430A 430B 440A 450A

PART NUMBER

NOMEMCLATURE I I I I I I I

23491 23491-3 415609 410496 410436 410443 414928 415690 015255 411108 166309 DELETED 410435 412647 NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP 102226 DELETED DELETED DELETED DELETED DELETED DELETED DELETED 100431 100430 062000 100111 101228 101229 101229 101230 105623

Battery, V023KH Battery, V023KH . Box and Cover complete . . Box complete . . Cover complete . . . Cover, assembly . . . Gasket, cover . . . Inlet valve . Handle . Plate, identification . Plate, filling instruction . Plate, amendment . Filler block . Kit, spacer-liner . . Spacer 0.5x195x45 . . Spacer 1x195x45 . . Spacer 0.5x195x75 . . Insulator 1x210x64 . . Spacer 1x195x75 . . Insulator 1x210x190 . . Insulator 1x210x75 . . Insulator, slotted, 1x210x69 . . Insulator, bottom, 1x247x191 . . Spacer, 0.5x210x75 . . Spacer 1x210x75 . . Spacer, slotted, 0.5x210x75 . . Spacer, 0.5x210x190 . . Insulator 0.3x205x188 . . Spacer 1x195x190 . . Spacer 0.5x195x190 . . Spacer, slotted, 1x210x75 . . Insulator, 0.3x360x145 . Connector complete . . Base, connector . . Collar terminal block . . Connection, output . . Terminal, connector . . Nut . . Lockwasher . . Screw, F/90 M 3-6 . . Screw, F/90 M 4-8 . . Washer, lock . Nut, M 8 X 1.25 . Washer, spring . Link, intercell, E33 . Link, intercell, E27 . Link, intercell, E27 . Link, intercell, E28.5 . Link

CODE

ASSY

A B

A B

1 1 1 1 1 1 1 1 2 1 1 1 4 5 5 1 1 1 4 1 1 9 7 2 2 2 1 1 2 1 1 1 1 2 2 2 2 4 4 4 2 2 5 7 6 2 1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FIG 1&2 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1 2 1&2 1&2 1&2 1&2 1&2 1&2 2 2 2 2

ITEM 460A 470B 480A 490A 500A 510A 520A 530A 540A 550A 560A 570A 580A 590A 600B 610A 620A 630A 640A 650A 660A 670B 680B 690B 700B

PART NUMBER 114735 413243 057012 063410 080010 100593 062000 100111 100695 100696 062023 100479 411996 117497 413049 105405 114724 115764 115763 115266 116056 413052 413053 116642 104960

NOMEMCLATURE I I I I I I I . Link, V . Link, sensor . Link, curved . Cell, VO 23KH, Assembly . . Filler cap, vented . . O-Ring . . Nut, M 8 X 1.25 . . Washer, spring . . Washer, positive polarity . . Washer, negative polarity . . Nut, M 8 X 1.25 . . Washer, flat . . O-Ring . Temperature sensor . Temperature sensor . . Nut, self locking . Washer . O-Ring . Nut . Cap . Cable grip . Clamp . Screw . Washer, Z3 . Washer, spring, dia. 3

CODE B

A B

B B B B

ASSY 3 1 3 20 1 1 4 4 1 1 2 2 2 1 1 2 1 1 1 1 1 1 2 2 2

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FIG 1 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1 2 1&2 1&2

ITEM -001A -001B -010A 020A 030A 040A 050A 060A 070A 080A 090A 100A 110A 120A 130A 140A 150A 160A 170A 180A 190A 200A 210A 220A 230A 240A 250A 260A 270A 280A 290A 300A -310A 320A 330A 340A 350A 360A 370A 380A 390A 391A 400A 410A 420A 430A 430B 440A 450A

PART NUMBER

NOMEMCLATURE I I I I I I I

23491 23491-3 415609 410496 410436 410443 414928 415690 015255 411108 166309 DELETED 410435 412647 NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP 102226 DELETED DELETED DELETED DELETED DELETED DELETED DELETED 100431 100430 062000 100111 101228 101229 101229 101230 105623

Battery, V023KH Battery, V023KH . Box and Cover complete . . Box complete . . Cover complete . . . Cover, assembly . . . Gasket, cover . . . Inlet valve . Handle . Plate, identification . Plate, filling instruction . Plate, amendment . Filler block . Kit, spacer-liner . . Spacer 0.5x195x45 . . Spacer 1x195x45 . . Spacer 0.5x195x75 . . Insulator 1x210x64 . . Spacer 1x195x75 . . Insulator 1x210x190 . . Insulator 1x210x75 . . Insulator, slotted, 1x210x69 . . Insulator, bottom, 1x247x191 . . Spacer, 0.5x210x75 . . Spacer 1x210x75 . . Spacer, slotted, 0.5x210x75 . . Spacer, 0.5x210x190 . . Insulator 0.3x205x188 . . Spacer 1x195x190 . . Spacer 0.5x195x190 . . Spacer, slotted, 1x210x75 . . Insulator, 0.3x360x145 . Connector complete . . Base, connector . . Collar terminal block . . Connection, output . . Terminal, connector . . Nut . . Lockwasher . . Screw, F/90 M 3-6 . . Screw, F/90 M 4-8 . . Washer, lock . Nut, M 8 X 1.25 . Washer, spring . Link, intercell, E33 . Link, intercell, E27 . Link, intercell, E27 . Link, intercell, E28.5 . Link

CODE

ASSY

A B

A B

1 1 1 1 1 1 1 1 2 1 1 1 4 5 5 1 1 1 4 1 1 9 7 2 2 2 1 1 2 1 1 1 1 2 2 2 2 4 4 4 2 2 5 7 6 2 1

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SAFT COMPONENT MAINTENANCE MANUAL 23491 & 23491-3 FIG 1&2 2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1&2 1 2 1&2 1&2 1&2 1&2 1&2 1&2 2 2 2 2

ITEM 460A 470B 480A 490A 500A 510A 520A 530A 540A 550A 560A 570A 580A 590A 600B 610A 620A 630A 640A 650A 660A 670B 680B 690B 700B

PART NUMBER 114735 413243 057012 063410 080010 100593 062000 100111 100695 100696 062023 100479 411996 117497 413049 105405 114724 115764 115763 115266 116056 413052 413053 116642 104960

NOMEMCLATURE I I I I I I I . Link, V . Link, sensor . Link, curved . Cell, VO 23KH, Assembly . . Filler cap, vented . . O-Ring . . Nut, M 8 X 1.25 . . Washer, spring . . Washer, positive polarity . . Washer, negative polarity . . Nut, M 8 X 1.25 . . Washer, flat . . O-Ring . Temperature sensor . Temperature sensor . . Nut, self locking . Washer . O-Ring . Nut . Cap . Cable grip . Clamp . Screw . Washer, Z3 . Washer, spring, dia. 3

CODE B

A B

B B B B

ASSY 3 1 3 20 1 1 4 4 1 1 2 2 2 1 1 2 1 1 1 1 1 1 2 2 2

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