285ch - R01 - 27 Jun 2019 - SAFT

(F6177)
26 quai C. Pasqua - 92300 Levallois-Perret - France

Tél. +33 1 58 63 16 90 - Fax: +33 1 58 63 16 18
MAINTENANCE MANUAL
WITH ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
285CH
416526
date of creation: Mar 29/2018
24-38-58 edition 1
Jun 27/2019
Component Maintenance Manual
285CH
This document and all information contained herein are the property of
Saft. Its use is restricted solely to the maintenance of Saft batteries and
may under no circumstances be used for any other manufacturer's prod-
ucts. No person may, in whole or in part, duplicate, use or disclose this
information for any other purpose without the prior written consent of
Saft.
Copyrights SAFT 2019

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RECORD OF REVISIONS
Inserted Inserted
Rev. n° Issue date Rev. n° Issue date
Date By Date By
0 May 14/2018 May 14/2018 Saft
1 Jun 27/2019 Jun 27/2019 Saft

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PAGE INTENTIONALLY LEFT BLANK
24-38-58 BLANK
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RECORD OF TEMPORARY REVISIONS
Inserted Inserted
Rev. n° Issue date Rev. n° Issue date
Date By Date By

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285CH
24-38-58 BLANK
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SERVICE BULLETIN LIST
Incorporation into
Service bulletin
CMM Title
Number Rev. Date Rev.

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24-38-58 BLANK
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LIST OF EFFECTIVE PAGES
TITLE PAGE 1 Jun 27/2019 DESCRIPTION AND 1 Jun 27/2019

2 Jun 27/2019 OPERATION 2 Jun 27/2019
3 Jun 27/2019
RECORD ROR-1 Jun 27/2019 4 Blank
OF REVISIONS ROR-2 Blank
TESTING AND FAULT 1001 Jun 27/2019
RECORD OF TEMPO- RTR-1 Jun 27/2019 ISOLATION 1002 Jun 27/2019
RARY REVISIONS RTR-2 Blank 1003 Jun 27/2019
1004 Blank
SERVICE BULLETIN SBL-1 Jun 27/2019
LIST SBL-2 Blank DISASSEMBLY 3001 Jun 27/2019
3002 Jun 27/2019
LIST OF EFFECTIVE LEP-1 Jun 27/2019
PAGES LEP-2 Jun 27/2019 CLEANING 4001 Jun 27/2019
4002 Jun 27/2019
TABLE OF CONTENTS TOC-1 Jun 27/2019
TOC-2 Jun 27/2019
TOC-3 Jun 27/2019
TOC-4 Blank
LIST OF ILLUSTRATIONS LOI-1 Jun 27/2019

LOI-2 Blank
INTRODUCTION Intro-1 Jun 27/2019

Intro-2 Jun 27/2019
Intro-3 Jun 27/2019
Intro-4 Jun 27/2019
Intro-5 Jun 27/2019
Intro-6 Blank

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INSPECTION/CHECK 5001 Jun 27/2019 ILLUSTRATED 10001 Jun 27/2019

5002 Jun 27/2019 PARTS LIST 10002 Jun 27/2019
5003 Jun 27/2019 10003 Jun 27/2019
5004 Jun 27/2019 10004 Jun 27/2019
5005 Jun 27/2019 10005 Jun 27/2019
5006 Jun 27/2019 10006 Blank
5007 Jun 27/2019
5008 Jun 27/2019 STORAGE (INCLUDING 15001 Jun 27/2019
5009 Jun 27/2019 TRANSPORTATION 15002 Jun 27/2019
5010 Blank 15003 Jun 27/2019
15004 Jun 27/2019
ASSEMBLY 7001 Jun 27/2019
7002 Jun 27/2019
7003 Jun 27/2019
7004 Blank
FITS AND CLEARANCES 8001 Jun 27/2019

8002 Blank
SPECIAL TOOLS, 9001 Jun 27/2019

FIXTURES, 9002 Jun 27/2019
EQUIPMENT
AND CONSUMABLES

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TABLE OF CONTENTS
RECORD OF REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ROR-1
RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RTR-1
SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SBL-1
LIST OF EFFECTIVE PAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LEP-1
TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TOC-1
LIST OF ILLUSTRATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOI-1
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -INTRO-1
1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
2. Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
3. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
3-1. Physical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
3-2. Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
3-3. Chemical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-1
4. Aircraft Conversions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
5. Ground Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
6. Placing a new battery in service - initial commissioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
7. Battery Ratings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
7-1. Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
8. Recycling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-2
9. End of life cells - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
10. Measurements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
10-1. Units of Measure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-3
10-2. Measurement Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
10-3. Temperature Conversion Table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
10-4. Abbreviations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTRO-4
DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

1. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
2. Technical data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
2-1. Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
3. Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1
4. Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
4-1. climatic requirement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
4-2. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
5. Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
5-1. Constant Current Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2
5-2. Rapid Partial Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
5-3. Constant Potential Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
5-4. Other methods of charging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
1-1. Battery electrical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001
1-2. Cell faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1002
1-3. Physical faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1003
DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001

SAFT confidential and proprietary information 24-38-58 Page TOC-1
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285CH
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001

3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4. Disassembly procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-1. Removing the cover (020) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-2. Removing the cells (140) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-3. Removing the vent valves (190) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-4. Removing the connector (230) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001
4-5. Disassembly of the battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3002
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
3-3. Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
4. Light Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
4-1. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
5. Thorough Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
5-1. Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4001
6. Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4002
INSPECTION/CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2. Maintenance intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-1. Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-2. Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
2-3. General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
3. Recording - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
4. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
5-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5001
6. Periodical check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5002
6-1. Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
6-2. Insulation check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
6-3. Nut tightness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5003
6-4. Polarization test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-5. Residual discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-6. Adjust electrolyte level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5004
6-7. Supplementary test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5005
7. Regular check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5006
7-1. Cell shorting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
7-2. Capacity check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5007
8. General overhaul - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5008
8-1. Component inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
8-2. Replacement of faulty components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
8-3. Vent valve test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
9. Return to Service After Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5009
ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3. Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
3-2. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
4. Battery Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7001
4-1. Installation of the liner spacer kit (200) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7002
4-2. Installation of the cells (140) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003
4-3. Installation of the vent valve (190) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003

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4-4. Installation of the connector (230) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003

4-5. Recording - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003
FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
2. Torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES - - - - - - - - - - - - - - 9001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9001
2. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9001
3. Special tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
4. Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9002
ILLUSTRATED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10001
1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10001
1-2. Numerical Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10001
1-3. Detailed Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10001
2. Alpha numerical index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10003
3. Detailed part list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10004
STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15001

1. Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
1-1. General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
1-2. Storage room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
1-3. Temperature conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
2. Inactive long term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15001
3. Inactive stand-by storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002
3-1. Definition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002
3-2. Ambient temperature with 'topping' or 'refresh charge' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15002
3-3. Action at the end of the standby period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
4. Active stand-by mode (= use of a trickle charge) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
5. Spares - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
5-1. Spare Cells - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
5-2. Spare O-rings, gaskets and vent valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
5-3. Other spares - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15003
6. Servicing after discharged storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15004
7. Transportation procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15004

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LIST OF ILLUSTRATIONS
INTRO-1 Universal Recycling Symbols INTRO-2

1 285CH Nickel-Cadmium Aircraft Battery 2
5001 Periodical check 5002
5002 Position of Syringe in Cell Vent Seat 5004
5003 Regular check 5006
5004 General overhaul 5008
7001 Liner spacer kit installation 7002
10001 285CH Nickel-Cadmium Aircraft Battery 10004
15001 Short term storage 15002

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INTRODUCTION
1. General
This manual provides the information necessary for an experienced shop technician to maintain Saft nickel-cadmium batteries.
It describes construction of the battery, as well as techniques used to operate, maintain, repair, overhaul, and generally care
for the battery. Following these instructions will enhance the ability to obtain optimum performance and maximum life from Saft
batteries.
All aircraft batteries require checking and maintenance in order to make sure they are safe when installed and they perform
their required functions especially in emergency conditions on board the aircraft. Maintenance checks also permit any prob-
lems to be identified and corrected. The maintenance interval is the period for which correct operation is assured with a low
probability of failure and allows high levels of MTBUR and MTBF to be achieved. Apart from the question of safety, the avoid-
ance of failure on board the aircraft, with consequent costly impact on delays, reduces operational costs.
Every effort has been made to provide complete and accurate instructions. If a situation should arise that is not adequately
described in this manual, please contact Saft at [email protected] or at one of the following addresses:
Saft America Inc. (V09052) Saft (F6177)
711 Gil Harbin Industrial Boulevard 26 quai C. Pasqua
Valdosta, Georgia 31601 - USA 92300 Levallois-Perret - France
Tel: +1 (229) 247-2331 Tel : +33 1 58 63 16 00
Fax: +1 (229) 247-8486 fax: +33 1 58 63 16 18
Website All Saft technical documentation, distributors and repair shops can be found at www.saftbatteries.com/cmm .
2. Definitions
Warnings call attention to use of materials, procedures, or limits, which must be followed precisely to avoid injury to persons.
Cautions call attention to procedures which must be followed to avoid damage to equipment.
Notes call attention to procedures which make the job easier.
3. Safety
CAUTION: Except for those steps that require the battery to be charged, do all steps on discharged batteries (refer to
Residual discharge paragraph) to avoid the possibility of electric shock. Tighten vent-valves (190) prior to be-
ginning discharge. Battery cells deliver very high current when short-circuited. Exercise caution. Remove rings,
watches, necklaces, metallic belts or other jewelry to avoid electric shock.
CAUTION: Do not tilt the battery while doing maintenance, any contact of skin with electrolyte can cause severe
burns.
Safety rules are different from one country to another. Always follow local safety regulations.
There are three types of risks.
3-1. Physical
- Handling: the battery is heavy. When you lift it, bend your legs and not your back.
- Use protective shoes.
3-2. Electrical
- Do not wear rings, watches, chains, belt buckles, necklaces or any other metallic objects.
- Use insulated tools.
3-3. Chemical
- For a complete listing of hazards, refer to the safety information sheet available on Saft's website at www.saftbatter-
ies.com/cmm
- Electrolyte is very corrosive and can damage the skin: use gloves and an apron. If it touches the skin, flush affected
part with large quantity of water. Remove contaminated clothing, after flushing begins.
- Electrolyte is very dangerous for eyes, use protective goggles. If the electrolyte comes in contact with an eye, flush it
with water for 15 to 30 minutes. Get medical attention immediately.
- Saft recommend the use of an amphoteric solution (both acidic and basic behavior) and chelator (able to trap cations
as a chelate complex) according to the local regulation.
- Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not try to vomit. Get medical atten-
tion immediately.
- Skin contact with nickel can cause chronic eczema.

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- Inhalation of cadmium oxide can cause dry throat, headaches, vomiting and chest pain. If inhaled, remove go to fresh
air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately.
- Potassium hydroxide in the electrolyte can cause eczema.
4. Aircraft Conversions
Saft aircraft batteries come in a wide variety of configurations that are approved for installation on selected aircraft. When re-
placing a lead-acid battery with a Saft nickel-cadmium aircraft battery, it is vitally important to clean all mounting and holding
fixtures in the aircraft prior to installation. All traces of acid and salt should be removed by washing with a neutralizing agent
such as sodium bicarbonate (baking soda) in water. Once the area has been fully cleaned and prepared, the surface should
be painted with an alkaline resistant paint. This preparation should ensure that your new Saft battery will not be harmed by
sulfuric acid residue.
5. Ground Applications
Your Saft battery can be used in such ground applications as starting gas turbine generators, ground mobile equipment, or in
shop testing equipment. The same principles used in flight operations apply when the battery is used in ground applications.
Ventilation of the battery during ground use can be accomplished through a ventilation system or by simply removing the cover
(only in a well-ventilated area). Check with your local authorities for regulations in effect for your area.
6. Placing a new battery in service - initial commissioning

NOTE: Whether or not the battery has been subject to disassembly and reassembly, before its issue to service and
installation, the tightness of all upper nuts / screws must be checked to verify that torque values correspond
with those specified (refer to the Nut tightness chapter).
Saft batteries are shipped discharged. A visual inspection, torque check, charge procedure, electrolyte check, and insulation
test should be done prior to the battery being placed into the aircraft for service. Refer to the Inspection/check chapter.
If the battery has been stored for longer than 3 months, refer to Servicing after discharged storage.
7. Battery Ratings
7-1. Capacity
Nickel-cadmium batteries are rated in terms of capacity in ampere-hours (Ah) (rated capacity).
American Standard AS8033 defines capacity as "the dischargeable ampere-hours (Ah) available from a fully charged cell/bat-
tery at any specified discharge rate/temperature condition".
Other definitions for battery ratings can be found in EN2570, IEC 60952 and RTCA DO 293.
A battery rated for 1C1 Ah indicates that the battery is rated at a value based upon a discharge time of 1 hour at 23 °C  3 °C
(73.4 °F  5.4 °F).
8. Recycling
All batteries eventually lose their ability to perform and are eligible for scrap and recycling. Saft takes environmental matters
seriously and advocates proper recycling of nickel-cadmium batteries and their components. To that end, Saft operates recy-
cling facilities in both Europe and North America.
Nickel-cadmium batteries contain nickel, cadmium, and potassium hydroxide and should be disposed of properly. In all cases,
rely on local and national regulations for proper battery disposal and/or shipping to an appropriate recycling location.
Figure INTRO-1 Universal Recycling Symbols
You can find the nearest recycling collection point on our website at www.saftbatteries.com.

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9. End of life cells

EASA and FAA regulations ‘Part 145‘, require that end of life cells must be disposed of in a manner that does not allow them
to be returned to service. The following procedure provides a means of complying with these regulations.
While other authority requirements may be less explicit, Saft recommends that the following procedures be adopted in order
to ensure that end of life cells cannot be re-used:
- Ensure that appropriate protective measures (refer to Safety paragraph and the Battery Information Sheet (BIS)) are tak-
en..
- Ensure that the cell is fully discharged (refer to Cell shorting paragraph)
- Put one of the terminals from the cell between the two sides of a bench vice and bend until the terminal breaks. In the
event of electrolyte leakage, ensure that appropriate clean up measures as described in the Battery Information Sheet
(BIS) are observed.
- Dispose of the cell in accordance with applicable transport, health and safety and recycling regulations (Refer to Recycling
paragraph).
10. Measurements
The measurements which are given in this manual come from the original manufacturer drawings.
This CMM uses the “Systeme International” (S.I.) units for quantities and values. It also gives the imperial units in parentheses.
10-1. Units of Measure

10-1-1. I.S. Units
A Ampere
Ah Ampere hours
C1A Rated current
C1Ah Rated capacity for an hour
g Gram
m Meter
min Minute
N Newton
N.m Newton meter
Pa Pascal
VDC Volt direct current
°C Degree Celsius
% Per cent
W Ohm
10-1-2. U.S. Units
ft Foot
in Inch
inHg Inch of mercury
lb Pound
lbf.in Pound force inch
°F Degree Fahrenheit
10-1-3. Multiplying Prefixes
 Micro
m Milli
da Deca
k Kilo
M Mega

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10-2. Measurement Conversion Table

10-2-1. From U.S. Standard System to I.S. Measurement
1 kPa 0.1450 psi

1 cm 0.3937 in
1 cm² 0.1550 in²
1N 0.2248 lbf
1g 0.0353 oz
1 kg 2.2046 lb
1 mm 0.0394 in
1 N.m 8.8507 lbf/in
10-2-2. From U.S. Standard System to I.S. Measurement
1 psi 6,8948 kPa

1 in 2,54 cm
1 in 25,4 mm
1 in² 6,4516 cm²
1 lbf 4,4482 N
1 oz 28,3495 g
1 inHg 3,3864 kPa
1 lb 0,4536 kg
1 gal (U.S.) 3,7854 l/min
1 lbf.in 0,1130 N.m
1 lbf.ft 1,3558 N.m
10-3. Temperature Conversion Table

10-3-1. SI MEASUREMENT Degrees Celsius (°C)
Celsius = (Fahrenheit - 32) x 0.5555
10-3-2. U.S. STANDARD SYSTEM Degrees Fahrenheit (°F)
Fahrenheit = (Celsius x 1.8) + 32
10-4. Abbreviations
The abbreviations given below are used in this manual:
AECMA European Association of Aerospace Industries

ATA Air Transport Association of America
dia. diameter
EASA European Air Safety Authority
FAA Federal Aviation Authority
fig. figure
IATA International Transport Air Association
IMDG International Maritime Dangerous Goods
ipl illustrated parts list
max. maximum
mfr manufacturer
min. minimum
MTBF Mean time between failure
MTBUR Mean time between unscheduled removal
n° number
p/n part number
para. paragraph
ref. refer to

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s/a subassembly
TBD to be defined
V Voltage

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DESCRIPTION AND OPERATION
1. Description
1-1. General
The batteries are connected to the aircraft system:
- According to the aircraft manufacturer, to start the engine or the APU.
- On the ground, to provide power before electrical power is supplied to the aircraft systems.
- In flight, if a malfunction or a failure occurs in the power supply system.
2. Technical data
2-1. Characteristics
The most important characteristics are indicated in the table below.
Technical data Values

Type of cells CVH280KA
Number of cells 20
Nominal voltage 24 V
Rated capacity C1Ah (Ah) 28 Ah
Charge or discharge current 1 C1A 28 A
Charge current 0.5 C1A 14 A
Charge current 0.1 C1A 2.8 A
Electrolyte Solution of KOH

Electrolyte level (mm) 17 mm (0.67 in)
Consumable volume 55 cm3 (3.35 in3)
of electrolyte per cell
End of charge voltage 1.55 V / per cell
End of life criterion in % of rated capacity 100%
End of life criteria in hour or minutes 1 hour
Battery maximum weight 28.22 kg (62.21 lbs)
Battery terminals MS3509 connector
3. Description
NOTE: The item numbers are those of the detailed parts list chapter (Refer to Detailed part list).
The 285CH Saft nickel-cadmium battery consists of a box (060), containing 20 individual cells CVH280KA. These cells are
connected in series to obtain 24 V nominal. Individual cells are enclosed in a polyamide container that provides insulation,
allowing them to be fitted side-by-side in the battery box. Interconnection of cells is via rigid, highly conductive, nickel-plated
copper links (100 to 130). Each link is held in place by nickel-plated copper nuts (080) on the cells’ terminals. Inside the battery
box, individual cells are held in place by partitions, liners and spacers (200), and a cover (020).
The connector (230) connects the battery to the aircraft DC power.

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The cover (020), which can be removed, is attached to the box (060) by 4 latches.
Cover complete
Filling instruction plate
Connector
Box
Identification plate
Figure 1 Nickel-Cadmium Aircraft Battery
4. Operation
4-1. climatic requirement
Unless otherwise stated, charge and discharge testing should be done when the battery temperature is between + 15 °C and
+ 30 °C.
4-2. Maintenance
All maintenance, including charging, discharging, should be done specifically in accordance with the instructions contained in
this manual.
5. Charge
5-1. Constant Current Charge
Starting with a discharged battery:
- Remove the cover complete (020).
- Loosen, but do not remove, all vent-valves (190).

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- Charge using one of the methods shown in the table below.

NOTE: Check cell voltage at the beginning of the charge. If any cell indicates an immediate voltage rise above 1.5 V,
add 5 cm3 of distilled or deionized water to that cell.
- During the last 15-30 minutes of the overcharge cycle, Adjust electrolyte level.
Main charge Final charge

Minimum Current
Current End of main charge Minimum voltage
duration and time
2.8 A 10 h Every cell > 1.5 V or 12 h 2.8 A for 4 h 1.55 V / per cell
which ever comes first
14 A 2h Every cell > 1.55 V or 2.5 h 2.8 A for 4 h 1.55 V / per cell
28 A 1h Every cell > 1.57 V or 1.25 h 2.8 A for 4 h 1.55 V / per cell
Table 1 - Charge Rates
5-2. Rapid Partial Charge

One of the following two procedures can be used in an emergency situation to charge the battery to approximately 80% of its
capacity. Do not use these procedures for charging the battery during normal maintenance.
- Charge the battery at 14 A until the battery reaches an average of 1.55 V/cell. Do not charge for more than 2 hours
and 30 minutes
or
- Charge the battery at 28 A until the battery reaches an average voltage of 1.57 V/cell. Do not charge for more than 1
hour and 15 minutes.
5-3. Constant Potential Charge

CAUTION: Constant potential charging should not be attempted if the open circuit battery voltage is below 1.0 V per
cell.
In an emergency, a partially discharged battery may be recharged using a constant potential charging system such as exists
on the aircraft. Do not use this procedure for charging the battery during normal maintenance:
With the use of a constant potential system, it is imperative that the charge rate be checked periodically for accuracy, and that
the charger be set according to the average ambient operating temperature.
NOTE: A maintenance check of the battery should be done at the earliest opportunity to verify battery performance.
Connect the battery to the constant potential power source. Charge for a minimum of 1 hour at 1.425 V/cell to obtain approx-
imately 90% of the rated capacity of the battery.
NOTE: A maintenance check of the battery should be done at the earliest opportunity to verify battery performance.
5-4. Other methods of charging

In addition to the constant current method of charging, other methods that fully charge the battery can be used. However, in
any case, individualcell voltage checks (U ≥1.55 V / per cell) and electrolyte adjustments must be carried out using a final over-
charge sequence at constant current 2.8 A during 4 hours. If specific instructions are not given in the charger operating manual,
you must first contact Saft.

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TESTING AND FAULT ISOLATION
1. Introduction
This chapter gives the tests and inspections required to find the cause of faulty condition of the unit either removed for unsched-
uled maintenance or during scheduled maintenance. The test procedure is given in the tables below. For each test refer to the
indicated procedures which specify all necessary information.
1-1. Battery electrical faults
Problem Probable cause Correction

(1) Zero battery open-circuit (a) Defective electrical connector (no Check electrical contacts, links and tight-
voltage contact made) ness of nuts (refer to Inspection/check).
(b) Link broken
(2) Zero volt with the battery (a) Battery fully discharged Do an insulation check (refer to Inspec-
set to "discharge" tion/check)
(b) Battery circuit open or contacts Examine the contacts and links.
defective Make sure the terminal nuts are tight
(refer to Inspection/check).
Refer to related subsequent steps.
(c) Cell completely dry Replace the cell.
(3) Low insulation (a) Leakage of electrolyte Disassemble and clean the battery (refer
to Disassembly and Cleaning).
Do an electrolyte level check (refer to
Inspection/check).
Table 1 - Battery electrical faults

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1-2. Cell faults

(1) Too much water decrease (a) Charge much more than the limit or Examine the cause of excessive charge.
for all battery cells. too much charge at high temperature. If necessary, adjust to normal operating
temperature (refer to Description and oper-
ation).
.
(b) Previous maintenance has not
been done.
(2) High water dispersion: (a) more than 30% above the average Dissassemble the battery (refer to Disas-
water consumption in one or value of added water in all cells: leak- sembly). Clean the battery (refer to Clean-
more cell(s) is very different ing cell(s). ing).. Replace the cell(s). Charge and do
from the other cells in the bat- an electrolyte level check (refer to Inspec-
tery. tion/check).
(b) less than 30% below the average Do the Supplementary test (refer to Inspec-
value of added water in all cells: cell(s) tion/check). If necessary, replace the
with damaged separator(s). cell(s).
Note the cell location and check the level of
water consumption versus other cells at the
next maintenance
(3) A cell has a higher voltage (a) Dry cell. When the defect occurs, add 5 cm3 (5 ml)
at the start of charge than is of distilled water to the cell. Do not adjust
defined in para. Charge chap- more accurately until the end of the charge.
ter Description and operation.
NOTE: If you charge a cell with a quantity of electrolyte which is not sufficient, this can cause the temperature
to increase too much.
(4) A cell has a lower voltage (a) The cell was operated at tempera- Replace the cell (refer to Disassembly,
at the end of charge than is tures and charge rates outside the lim- Assembly AND Storage (including trans-
defined in para. Charge chap- its, and the separator is damaged. portation)).
ter Description and operation.
(b) Usual wear after long operation
(5) Low capacity cell. (a) insufficient balancing Repeat Charge, discharge at 28 A and Cell
shorting up to three times
(b) Usual wear after long operation. Replace the cell (refer to Disassembly,
Assembly AND Storage (including trans-
portation)).
(c) Unusual operation, operation at Do the applicable procedure (refer to

high temperature or operation with low Inspection/check).
electrolyte.
(6) Cell with a swollen case. (a) Cell operated with low electrolyte Replace the cell (refer to Disassembly).
level ; deterioration of separators and
damaged plates.
(7) Cell with zero voltage (a) Short-circuited cell. Replace the cell (refer to Disassembly).
when the battery circuit is
open.
Table 2 - Cell faults

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1-3. Physical faults

(1) Leakage of electrolyte. (a) Incorrect adjustment of electrolyte Disassemble and clean the battery
level. (refer to Disassembly and Cleaning
chapters). Do an electrolyte level
check (refer to Inspection/check).
(b) Cell polarity incorrect during high- Disassemble and clean the battery
rate discharge (for example, during the (refer to Disassembly and Cleaning).
engine start). Do an electrolyte level check (refer to
Inspection/check).
(c) Too much charge at high tempera- Investigate the cause of excessive
ture or too much current. charge. If necessary, adjust to normal
operating temperature (refer to
Description and operation).
Disassemble and clean the battery
(refer to Disassembly and Cleaning).
(d) The lower nut is not correctly tight- Do an electrolyte level check (refer to
ened. Inspection/check).
Torque the lower nut (refer to Assem-
bly chapter)
(2) Electrolyte found in the battery (a) Damaged cell case. Replace the cell if necessary and refer
box. to related subsequent steps.
(b) Leakage of electrolyte. Disassemble and clean the battery

(refer to Inspection/check and Clean-
ing).
Do an electrolyte level check (refer to
Inspection/check).
(3) Corrosion on the links. (a) Operation in acidic air. Make sure the battery test bench and
the storage areas have no materials
which can give off acid fumes.
(b) Mechanical damage to nickel plat- Replace the damaged links (refer to
ing. Disassembly, Assembly AND Storage
(including transportation)).
(4) The links are too hot. (a) Loose terminals nuts. Make sure the nuts are torqued (refer
to Inspection/check).
Table 3 - Physical faults

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DISASSEMBLY
1. Introduction
NOTE: Refer to the Testing and fault isolation chapter to identify the possible cause of a malfunction. This will give
the necessary level of disassembly.
The instructions found in this section are designed to allow the maintenance person to completely disassemble the battery for
the purpose of General Overhaul. However, some maintenance operations do not require complete disassembly. Disassemble
only to the extent necessary to effect appropriate repair or replacement.
2. Safety
Refer to chapter Safety.
3. Equipment
3-1. Standard tools
Refer to chapter Standard tools in Special tools, fixtures, equipment and consumables.
3-2. Special tools

When special tools are used in this chapter, they are identified by a code number listed in Special tools, fixtures, equipment
and consumables chapter.
4. Disassembly procedures
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers and are using hypertext facility.
4-1. Removing the cover (020)

Unlock the 4 latches.
Remove the cover taking care to avoid contact between the cover and the cell terminals or links.
4-2. Removing the cells (140)

NOTE: Make note of the proper placement of the links (100 to 130) prior to removal.
To facilitate ease of removal, remove the center cell in each row first.
Remove the nuts (080), and the washers (090) that attach links to the cells.
Remove all links (100 to 130).
Fully screw the extractor tool (T04) onto a cell terminal then pull up to remove the cells (140).
4-3. Removing the vent valves (190)

Unscrew the vent valve with the special tool (T01).
Remove the vent valve (190) with its O-ring.
4-4. Removing the connector (230)

Unscrew the screws (220) and remove the washers (210).

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4-5. Disassembly of the battery

Remove the cover (020) according to para. Removing the cover (020).
Remove the connector (230) according to para. Removing the connector (230).
Remove the cells (140) according to para. Removing the cells (140).
Remove the liner spacer kit (200).
NOTE: Note placement prior to removal to ensure proper placement during re-assembly.

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CLEANING
1. Introduction
The instructions in this chapter are for the general cleaning of your Saft aircraft battery. The instructions under “Light Cleaning”
are to be done each time the battery is removed from the aircraft, and can be accomplished with no disassembly of the battery.
The section “Thorough Cleaning” includes the instructions for the cleaning of a disassembled battery for the purpose of a Gen-
eral Overhaul.
2. Safety
3. Equipment
3-1. Standard tools
3-2. Special tools

3-3. Consumables
When consumables are used in this chapter, they are identified by a code number listed in Special tools, fixtures, equipment
4. Light Cleaning
On an assembled battery.
CAUTION: Do not use solvent, trichloroethylene or other products containing chloride for cleaning the battery. The
use of solvents can degrade the metal and plastic parts.
NOTE: All ( ) part identification numbers herein are IPL Fig. 1 item numbers.
4-1. Procedure
CAUTION: To prevent injury when using compressed air, point airflow away from the body. Use safety goggles to
prevent eye injury from airborne particles.
- Remove the battery cover complete (020).
- Hand tighten the vent valves (190) with the Universal vent wrench (T01)
- Remove potassium carbonates (white deposits) from the top of all cells (140) using a stiff bristle, non-metallic brush.
- Disperse residual salts and dust particles from the battery using blasts of clean, dry compressed air.
- Coat all nuts (080) and links (100 to 130) with M02.
5. Thorough Cleaning
On a disassembled battery.
5-1. Procedure
Fully disassemble the battery (refer to Disassembly chapter).
5-1-1. Cells (140)
Make sure that the vent valve (190) is tight.
CAUTION: Do not soak the cells in water.
To easily remove all the electrolyte and mineral salts from the terminals, the cover and the sides of the cell cases: clean in
warm water with a soft brush.
Rub the cell with a cloth and let dry.
5-1-2. Box and cover (- 010)
Clean with lightly soapy water, rub with a cloth and let dry.
5-1-3. Nuts, spring washers and links

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Clean in lightly soapy water with a brush, rinse well with clean water and let dry.
5-1-4. Liner spacer kit (200)
Clean in warm water and let dry.
5-1-5. Vent valve (190)
CAUTION: The cleaning of the vent valve (190) must be done when the cells are assembled in the box.
Remove the vent valve (190) (Refer to Disassembly chapter).
Cover the cell holes to keep out unwanted material.
Soak the vent valve for some time (during the night, for example) in a container of distilled water to remove all salts from the
vent hole.
6. Lubrication
When the battery is clean (and after installation of the vent valve), coat all upper nuts (080), the washer (090) and links (100 to
130) with M02.

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INSPECTION/CHECK
1. Introduction
1-1. General
This chapter includes the checks, the maintenance procedures and the functional tests that must be done to use Saft batteries
in flight and on the ground.
2. Maintenance intervals
The aircraft manufacturer is responsible for defining the usage and function, including maintenance intervals, for aircraft bat-
teries installed in its aircraft. Saft only provides recommendations that require the agreement of the aircraft manufacturer.
NOTE: Maintenance steps must be completed in a battery shop.
Saft distinguishes between three types of maintenance
2-1. Periodical check

The periodical check consists essentially of voltage and insulation checks, discharge of residual capacity and charge with elec-
trolyte level adjustment. The main purpose of this periodical check is to replace water which is consumed by electrolysis during
battery overcharge. It is only applied between regular checks if the water consumption measured at the regular check is above
allowable limits.
2-2. Regular check

The regular check is the same as the periodical check except that the battery is also deep discharged ('balancing'), followed
by a capacity check cycle.
2-3. General overhaul

The general overhaul is the same as the regular check except that the battery is also disassembled and thoroughly cleaned
and inspected.
3. Recording
It is very important to record the battery check values (capacity, end of charge voltage, water consumption) for each cells as
required in the battery logbook for each maintenance. It is recommended that an operator tracks these maintenance data in
order to verify the interval is correct relative to that particular operation. This may also allow the interval to be extended if the
data justifies it.
4. Safety
5. Equipment
5-1. Standard tools
5-2. Special tools


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6. Periodical check
PERIODICAL CHECK Light Cleaning
yes
Visual Inspection OK? no yes
Insulation check
no
General overhaul
Nut tightness
U > 1.05 V/cell

no yes
no cell with reversed
polarity
no Polarization test OK yes Residual discharge
Vent valve cleaning

(refer to Cleaning)
Charge and Adjust electro-

lyte level
no yes
Testing and fault isolation Charge OK
no yes
Supplementary test OK?
no Nut tightness
General overhaul
with Replacement of faulty compo-
nents.
Battery accepted after
Periodical check
Figure 5001 Periodical check

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Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe-
cific intervals according to aircraft use, or if electrolyte consumption exceeds the approved consumption levels between 2 reg-
ular checks, do this periodical check according to the above figure.
NOTE: Time periods are given as a guideline. Modify in accordance with operational experience.
Periodic and Regular maintenance checks may be combined if operating hours permit.
6-1. Visual Inspection

Visual inspection should be done each time the battery is removed for maintenance.
- Remove the cover complete (020).
- Visually check each cell (140) for any evidence of electrolyte leakage. If there is salt or electrolyte traces do a General
overhaul. Excessive salts around a terminal post indicates possible leakage from the terminal O-ring. Verify the torque
of the lower nut (150) (refer to chapter Fits and clearances).
- Inspect the links (100 to 130) and all upper nuts (080), and washers (170), (090). The hardware should be free of
bends, tarnish, corrosion, burns, or any loss of nickel plating. Minor tarnish can be polished off with a fine wire brush.
Defective hardware should be replaced.
- Check the connector (230) for evidence of arcing, corrosion, cracks, or cross-threaded terminals. Replace the defec-
tive connector.
CAUTION: Worn aircraft terminals and/or loose connections can greatly affect the performance of the battery. A de-
fective connector (230) can cause battery self-discharge as well as low voltage in service.
- Inspect the electrical connector for bent or loose pins, corrosion, cracks, faulty wire connections, evidence of arcing,
or cracked or loose potting material.
- Inspect the battery box (060) and cover assembly (020) for any damage. Minor dents may be repaired with a small
rubber mallet. Ensure the cover gasket (040), is undamaged and fully secured to the cover assembly (030).
6-2. Insulation check

A breakdown in electrical insulation between the cells (140) and the battery box (060) will result in a “leakage” current, which
over time will discharge the battery. The most common cause for the loss of insulation is the leakage of electrolyte from the
cells (140) that acts as a conductor between the cells and the battery box (060). Because leakage current can affect battery
performance, it is necessary that it be kept to a minimum.
On a completely assembled battery, use a megohmmeter, set to 250 V DC, to mea-
sure the insulation resistance between the positive terminal of each cell (140) and
the battery box (060).
Refer to the table below for the acceptance criteria.

250 K 2 M 10 M
Must be cleaned. Acceptable but Acceptable for in ser- Mandatory level of

Do a General cleaning is recom- vice battery insulation for new or
Overhaul mended in service battery
Check the cause after cleaning
(overcharge…)
6-3. Nut tightness

Tighten and check the torque of all upper cell nuts (080) (refer to Fits and clearances)

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6-4. Polarization test

Charge the battery at 2.8 A for 1.5 hours.
Leave the battery on open circuit for 1 hour.
Measure the open circuit voltage of each cell. If any cell is zero (0) V or negative polarity, do a General overhaul. If all cells
are above zero (0) V, continue with maintenance as specified.
6-5. Residual discharge

Discharge the battery at a rate of 28 A rate until each cell in the battery is discharged to 1.0 volt or less.
6-6. Adjust electrolyte level

CAUTION: Using anything other than distilled or deionized water in nickel-cadmium cells will cause electrolyte con-
tamination and damage.
Always take appropriate precautions to prevent any foreign substances from entering the cell. Anything other than distilled or
deionized water that enters the cells will cause electrolyte contamination and will affect overall performance.
The amount of time that the vent-valves are removed from the cell for maintenance should be limited to prevent as much air
as possible from entering the cell. Carbon dioxide in the air will combine with the electrolyte to form potassium carbonate. Po-
tassium carbonate will increase the internal resistance of the cells and thus decrease the performance at low temperatures and
during high rate discharges. Always ensure that the vent-valves are properly secured while the battery is in use.
Electrolyte level adjustment must be done during the last 15-30 minutes of the 4 hours overcharge at 2.8 A rate of charge.
CAUTION: Take care not to tilt cells while vent-valves are loosened or removed. Contact of electrolyte with skin can
cause burns. If contact occurs, flush area with large amounts of water. Electrolyte in the eyes is very serious.
Flush with water and contact a doctor immediately.
CAUTION: The battery must be fully charged before adjusting the electrolyte level.
Use only distilled or deionized water (see chapter Special tools, fixtures, equipment and consumables).
Do not re-use water removed from cells.
The quantity (in cm3) required to level the first cell will serve as a guide for requirements of the remaining cells
but the amount of water required for each cell can vary, so carry out this check on a cell by cell basis. Each cell
must be leveled individually. If the quantity of water added per cell is above 80% of the electrolyte water volume
shown in the specification tables (refer to chapter Technical data), check the charging system. If it is functioning
properly, shorten the time period between servicing.
CAUTION: The maximum amount of added water is 55 cm3 (3.35 in3) per cell.
Adjust the level of electrolyte, one cell at a time, using the following instructions:
- 1. Remove the vent-valves (190) with the vent-valve wrench (T01)
- 2. Check the nozzle length before fitting it to the syringe
- 3. Insert the syringe (T02) into the cell opening until the shoulder of the nozzle rests on the vent-valve seat .
17 mm (0.67 in)
Figure 5002 Position of Syringe in Cell Vent Seat

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- 4. Withdraw the plunger and check for any liquid in the syringe.
Any excess liquid in the cell will be drawn into the syringe until the electrolyte is level with the end of the nozzle. This
is the correct level for the electrolyte.
If the liquid level is too low, the syringe will remain empty, indicating that the end of the syringe nozzle did not reach
the liquid in the cell. In this case, replenish low electrolyte:.
- 5. Draw 5 cm3 of the distilled water (M01) into the syringe and inject it into the cell.
- 6. With the syringe nozzle remaining on the vent-valve (190) seat, slowly withdraw the plunger in the syringe.
- 7. If the syringe remains empty, repeat steps 5 and 6, counting the number of 5 cm3 injections required to achieve the
correct level. Record the amount of water added to each cell on the maintenance record.
- 8. At the point in step 6 when some excess liquid is drawn into the syringe, the correct level for that cell has been
reached. Expel the excess liquid into a separate container for disposal. Do not re-use the liquid removed from cells.
Check with local authorities for proper disposal of hazardous waste.
6-7. Supplementary test

At the end of complete charge, continue to charge for 5 h at 2.8 A (refer to PARA Charge)
Measure the voltage of the individual cell voltages every 30 min. The individual cell voltages:
- must not decrease by more than 0.03V between two consecutive measurements during the 5 h test
- must be more than 1.55 V / per cell
- Adjust the electrolyte level during the last 30 min of the supplementary charge (refer to Adjust electrolyte level).

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7. Regular check
Light Cleaning
REGULAR CHECK
yes no yes
Visual Inspection OK? Insulation check
no
General overhaul Nut tightness
U > 1.05 V/cell

no yes
no cell with reversed
polarity
yes
no Polarization test OK yes Residual discharge

record the discharge time
no yes
Cell shorting residual discharge > 1 h
Charge Cell shorting

and Adjust electrolyte level
no yes
Charge OK
no yes
Capacity check OK
Vent valve cleaning

(refer to Cleaning)
Charge
and Adjust electrolyte level
no yes
Testing and fault isolation Charge OK
yes
Supplementary test OK? Nut tightness
no
General overhaul
with Replacement of faulty compo- Battery accepted after
nents. Regular check
Figure 5003 Regular check
Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe-
cific intervals according to aircraft use, or AFTER A MAXIMUM OF ONE YEAR, test the battery according to the above figure.

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NOTE: Time periods are given as a guideline. Modify in accordance with operational experience. Periodic and Regular
maintenance checks may be combined if operating hours permit.
7-1. Cell shorting

As each cell’s voltage drops below 1.0 V, connect an equalizing resistor (T03) across each cell’s terminals. Leave the resistors
in place for 12 to 16 hours to allow each cell to completely discharge and the battery to cool.
NOTE: As an alternative to the resistor a shorting clip can be applied when the voltage has dropped to 0.5 V.
7-2. Capacity check

Discharge the battery at 28 A until all cell individual voltages fall below 1.0 V. Record the time when each cell falls below 1.0 V
and the battery voltage falls below 20 V. This time must be equal or greater to 1 hour. If the criteria is not OK (1.0 V before
1 hour discharge) then refer to troubleshooting page 1002 para (5)(a).

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8. General overhaul
Scheduled GENERAL OVERHAUL On fault
yes U > 1.05 V/cell no Polarization test

no cell with reversed Polarization test
polarity
Nut tightness
Residual discharge
Charge and Adjust electro-
lyte level
Cell shorting no yes

Charge OK
Disassembly
Testing and fault isolation
Thorough Cleaning no yes

Component inspection no yes

Testing and fault isolation Capacity check OK
Vent valve test

no yes
Replacement of faulty Vent valve cleaning

components (refer to Cleaning)
Assembly
Charge and
Adjust electrolyte level
no yes
Insulation check
Nut tightness
General overhaul Battery accepted after

with Replacement of faulty compo- general overhaul
nents.
Figure 5004 General overhaul

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8-1. Component inspection

8-1-1. Cells
Make sure that the lower terminal nuts (150) are tight (refer to Fits and clearances chapter).
Verify that cell boxes show no leakage.
8-1-2. Box
Make the sides of the box straight and remove dents.
8-1-3. Nuts, links and spring washers
Discard the components that show signs of corrosion or damage.
8-1-4. Packing parts
Discard all defective components.
8-1-5. Connector
Check the connector (230) for evidence of arcing, corrosion, cracks, or cross-threaded terminals. Replace the defective con-
nector.
8-2. Replacement of faulty components

8-2-1. Cells - 3/5 cells rule
Saft strongly recommends to change all the cells or replace the complete battery if:
one or more cells are found to be faulty and 5 of the original cells in the battery had previously been changed,
or
3 or more cells are found to be faulty during the same maintenance.
The 3/5 cells rule does not apply to the following failures:
- mechanical failure such as terminal thread damage,
- cell leakage,
- cell short-circuit.
NOTE: All cells that are changed must be replaced by a new Saft cell.
8-3. Vent valve test

NOTE: Do the Vent Valve Test once a year of battery operation. It is not necessary if the full set of used vent valves
is replaced by a brand new one each year during the General Overhaul.
- This test should be done while the battery is on charge, just following the electrolyte leveling procedure. Check the
operation of the vent-valve assembly as follows: Place the vent valve (190) with its O-ring into the vent valve adapter
(T05) of the pressure test fixture.
- Immerse the vent-valve in water and slowly raise the air pressure.
- Test according to the table below, and change all vent valves that do not pass the test.
test Check
O-ring No distortion, split or cracks
air pressure < 0.14 bar (2 psi) Vent valve is closed
0.14 bar (2 psi) < air pressure < 0.7 bar (10 psi) Vent valve opens
Table 1 - Vent valve test
9. Return to Service After Storage

When a battery is to be returned to service after storage, procedures should be followed as given in chapter Storage (including
transportation).

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ASSEMBLY
1. Introduction
This section covers basic battery assembly procedures. In all cases, when reassembling a battery, all components should be
clean and dry.
2. Safety
Refer to chapter Safety..
3. Equipment
3-1. Standard tools
Refer to chapter Standard tools in Special tools, fixtures, equipment and consumables..
3-2. Special tools

and consumables. chapter.
4. Battery Assembly

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4-1. Installation of the liner spacer kit (200)

E
C (1+2max.)
G
D E
F (1+2max.)
C (1+2max.)
B C E
C (1+2max.)
D
200
D G
C (1+3max.)
F (1+2max.)
E
H A B
D
C (1+3max.)
E
Figure 7001 Liner spacer kit installation
- Put the differents spacers in position (Ref. fig. 7001).

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- Install the cells
Unit per assem-

Item Description Dimension (mm)
bly
A Spacer 0,3x248x243 1
B Spacer 0,3x236x160 2
C Spacer 1x179x76 18
D Spacer 1x179x70 4
E Spacer 0,5x179x76 5
F Spacer 1x245x179 6
G Spacer 0,5x245x179 2
H Spacer 1x102x78 1
4-2. Installation of the cells (140)

Put cells (140) in the compartments. Carefully position the cell (140) and push onto terminals with a piece of soft wood.
(if it is difficult to put in the last cell, remove one or two spacers).
Verify the polarity of each cell according to the figure 10001 285CH Nickel-Cadmium Aircraft Battery
Verify that the torque of the lower nuts (150) is correct according to Fits and clearances chapter.
Install the links (100 to 130).
Install the washers (090).
Install the upper nuts (080) and torque them according to Fits and clearances chapter.
Lightly lubricate the terminals and the links with M02 (use a non-metallic paintbrush).
Install the cover complete (020) and attach it with the latches.
4-3. Installation of the vent valve (190)

Make sure the vent valves (190) are in good condition. Replace the vent valves (190) if they are worn.
Install the vent valve (190) with the universal vent wrench (T01).
4-4. Installation of the connector (230)

Screw the connector (230) with the washer (210) and the screw (220).
4-5. Recording
Fill out identification plate (270) if the box (060) has been changed.
Fill out the log book.

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FITS AND CLEARANCES
1. Introduction
The torque values below are “lube torque” values. The thread of the terminals and attaching nuts (or screws) should be lightly
greased with (M02) prior to assembly and applying torque.
2. Torque table
IPL TORQUE VALUE

FIG ITEM NAME
N° N.m lbf.in
upper nut 080 Nut 12 to 14 106 to 124

lower nut 150 Nut 4.5 to 5.5 39.8 to 47.8

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SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES
1. Introduction
This chapter is divided into two parts:
- The first part provides the list of special tools, fixtures and equipments needed to do the steps listed in the other chapters.
- The second part provides the listing of consumable materials used in this manual.
All listed items are identified in this manual by a standard code number:
- Txx for tools, fixtures and equipment,
- Mxx for consumable materials.
2. Standard tools
The following tools are recommended to do the procedures necessary for the maintenance of Saft Ni-Cd batteries.
Not all the tools listed are necessarily essential to the procedures described in this manual. When necessary, equivalent sub-
stitutes may be used.
- Constant current charger (DC current range 0-60A, minimum open DC voltage 40V)
- Constant current load bank (DC current range 0-60 A, DC voltage range 1-40V)
- Megohmmeter (0-50 M @ 250 V continuous)
- Precision Multimeter (Volt, , mA) 2000 points 1% or better
- Climatic chamber (if the battery has a sensor)
- Torque Wrench (Fully insulated) 0-15 N.m (0-133 lbf.in)
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Stiff bristle brush (non-metallic)
- Small paintbrush (non-metallic)
- Dry, compressed air source [less than 1.4 bar (20 psi)]
- Soft, clean cloth (at least two required)

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3. Special tools
NOTE: Equivalent tools can be used.
A special tool kit (P/N 416161) is available from Saft containing all special tools T01, T02, T03, and T04. The
tools are housed in a polypropylene box and each tool is insulated to ensure optimum safety for the technician.
F6177 V09052
CODE DESCRIPTION
P/N P/N
T01 Universal vent wrench 413876 093365-000
T02 Syringe assembly (with nozzle 17 mm (0.67 in)) 416230
T03 1  3 W equalizing resistors 164829
T04 Universal cell extraction tool 416159
T05 Vent valve adapter for M8 valve - 025098-000
4. Consumables
NOTE: Equivalent alternatives can be used for list items.
This paragraph describes the consumables used in the OMM.
MANUFAC-
DESIGNATION TURER
PARTNUMBER OR SUPPLIER
CODE
AND (NAME,
SPECIFICATION ADDRESS,
CODE)
M01 Distilled or deionized water (specification at 20°C) Local vendor
clear, colorless and odorless while boiling
Conductivity < 33 µS/cm
5 < pH < 7
COD < 30 mg/l (Chemical Oxygen Demand: methodology to eval-
uate organic or mineral pollution)
Chlorines Cl- < 5 mg/l
Sulfates SO4-- < 10 mg/l
Temperature for analysis and specifications are at 20°C.
STORAGE: dry and clean container without any corrosion and

damage; Temperature: 20 °C ± 5°C. Over 1 year of storage, do an
analyze of the liquid.
M02 Neutral petroleum jelly Mineral vaseline

Density @ 60°C (140°F) Range = 0.840 - 0.866 Kg/L NATO: S 743
Melting Point Range = 46°C - 52°C (115°F - 126°F) F: AIR 3565
Acidity/Alkalinity = Neutral to Litmus US: VV-P-236/A
UK: DEF 2333
M03 Soap Local vendor
Table 1 - List of consumables

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ILLUSTRATED PARTS LIST
1. Introduction
1-1. General
The Illustrated Parts List (IPL) contains a list and illustrations of the assemblies and detailed parts of the unit in disassembly
sequence.
To find the illustration for a part if the part number is known, refer to the Alpha numerical index and look for the part number
and the corresponding figure and item number. Refer to the Detailed part list and look for the first figure and item number found
in the Alpha numerical index for that part. If this figure shows the part in a section or system of the equipment other than the
one necessary, refer to the other figure numbers listed in the Numerical Index.
To determine the part number of a given part, refer to the illustration showing the assembly including this part. Note the item
number of the illustrated part and refer to the Detailed part list which indicates its part number and identification.
1-2. Numerical Index

In this index, part numbers are classified from left to right, each character (letter, number, hyphen) being considered separately.
The part number column contains all part numbers included in the Detailed part list.
1-3. Detailed Parts List

1-3-1. Figure and Item Number
Each assembly, sub-assembly and part holding a part number and included in the parts list is given as an item number.
The figure number linked to the item number is shown on the first line at the top of each page.
Assemblies, sub-assemblies numbered parts included in the list but not illustrated are identified by a hyphen (-) preceding the
item number.
An index letter shown before the item number refers to the figure showing the modified portion of the applicable part.
Manufacturer's Part Number: a manufacturer's part number is given to each assembly and detail part, whether illustrated or
not.
Nomenclature: the nomenclature is given with an indenture, to show how the parts and the assemblies and related to their next
higher assemblies. These are the details:
1234567
Assembly
. Detailed parts for assembly,
. Sub-assembly
. Attaching parts and/or storage parts for sub-assembly,
***
. . Detailed parts for sub-assembly
. . Sub-sub-assembly,
. . Attaching parts and/or storage parts for sub-sub-assembly,
***
. . . Detailed parts for sub-sub-assembly.
The attaching parts are shown directly after the assembly of the part thereof. They are listed under the same indent number as
the item they are attached to, and are identified by the words "Attaching Parts" and are followed by three asterisks.
The manufacturer's code or the abbreviation NP (not procurable) are placed at the extreme right- hand side of the first line of
the parts list column.
1-3-2. Effectivity code
An alphanumerical index indicates the effectivity of sub-assemblies and detailed parts lists in relation to the next higher assem-
bly (ies) or sub-assembly (ies).

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285CH
When the effectivity is fully applicable, the usage code column remains blank.
The use code for assemblies and detailed parts refers to the figure/item number of the next higher assembly (ies) or sub-as-
sembly (ies). Example: Effectivity 1A, 1B, 1C is written 1ABC.
1-3-3. Units per Assembly
The units per assembly column shows the quantity of units required for one next higher assembly.
In some cases, the information is replaced by the abbreviation RF (for reference) or AR

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2. Alpha numerical index
Airline Stock Figure Item Total Quantity

Part Number
Number Number Number Required
013294 110 2
062007 080, 150 82
100078 180 40
100094 090, 170 82
100430 210 4
100431 220 4
100694 160 20
100713 250 1
102392 230 1
113605 040 1
117026 260 1
166309 310 2
166925 240 1
280068 300 1
411070 100 15
411071 120 1
411108 270 1
411691 130 3
412488 050 2
413607 290 2
413609 280 2
415213 190 20
416527 020 1
416528 030 1
416529 010 1
416530 060 1
416532 070 1
416533 200 1
416548 140 20
416605 320 4

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3. Detailed part list
: Polarity +
110 : Polarity -
130
120 100
320
080
090
040
020 150
030
190 160
310
170
180
070
140
200
280
320
300
290
310
080
090
060
210
220 320
50
280
240
230 250 270 260
320 290
Figure 10001 285CH Nickel-Cadmium Aircraft Battery

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Figure Item Airline

Part Nomenclature Units per
Num- Num- Stock
Number 1234567 Assy.
ber ber Number
1 - 001 285CH BATTERY CVH280KA 285CH RF
drawing number 416526
- 010 416529 . Box and cover, complete 1
020 416527 . . Cover, complete 1
030 416528 . . . Cover, assembly 1
NP
040 113605 . . . Gasket cover 1
NP
050 412488 . . Handle 2
060 416530 . . Box assembly 1
070 416532 . . Spacer 1
080 062007 . . Nut, M10 x1.25 42
090 100094 . Washer, spring 42
100 411070 . Link, E34 15
110 013294 . Link, E36 2
120 411071 . Link, E49 1
130 411691 . Link, curved 3
140 416548 . Cell, CVH280KA assembly 20
150 062007 . . Nut, M10 x1.25 2
160 100694 . . Washer, positive polarity 1
170 100094 . . Washer, spring 2
180 100078 . . Washer, flat 2
190 415213 . . Vent valve assembly 1
200 416533 . Liner-spacer kit 1
210 100430 . Washer, lock 4
220 100431 . Screw, CL TF4-10 4
230 102392 . Connector 1
240 166925 . Protector 1
250 100713 . O-ring 1
260 117026 . Film, protector 1
270 411108 . Plate, identification 1
280 413609 . Plate, SAFT label 2
290 413607 . Plate, range label 2
300 280068 . Plate, recycling 2
310 166309 . Plate, filling instruction 2
320 416605 . Plate, SKYZEN 4
- : item non illustrated

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285CH
24-38-58 BLANK
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STORAGE (INCLUDING TRANSPORTATION)
1. Introduction
1-1. General
Storage preparation and packaging makes sure that the equipment is protected against any attack by atmospheric agents.
For a battery which has been cleaned and serviced and is not directly put into service on board an aircraft, different methods
can be recommended depending on the purpose and the environment conditions of the "storage".
The figure and item numbers are those of the Illustrated parts list chapter.
1-2. Storage room

Keep the batteries and spares in a dry and clean room.
1-3. Temperature conditions

The recommended temperature range is + 20 °C ±15 °C (68 °F ±27 °F). However, occasional excursion into the range of -55 °C
to +60 °C (-67 °F to +140 °F) is permitted.
2. Inactive long term storage

NOTE: There is no need of maintenance operation during the storage period.
The battery should be stored filled and discharged. It is not necessary that it be short circuited. No revalidation is required during
storage.
The storage life is 10 years, if using the following conditions:
- sealed packaging,
- temperature: +20 °C (68 °F) ±15 °C (±27 °F),
- humidity < 85%,
- normal vertical position,
- Isolated from detrimental agents: i.e. dirt, dust, dampness, vibration, corrosive atmosphere.
Lead batteries must not be stored in the same room.
Saft Ni-Cd batteries may be stored in temperatures ranging from -55 °C to +60 °C (-67 °F to +140 °F) for short periods of time
without harming the battery.
The standard cardboard packaging is considered unsealed and allows 2 years of storage under the above conditions.

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3. Inactive stand-by storage

3-1. Definition
the battery is charged after being serviced then stored fully charged in a dedicated room in such a way that it can be installed
in the aircraft without further check. The battery may be kept in stand-by for the period corresponding to 80% available capacity
on figure 15001 (for example 24 days at 30 °C) with a maximum of 90 days.
100
CHARGE RETENTION
Aircraft Ni-Cd battery
90
AVAILABLE CAPACITY (%C1Ah)
5 °C
20 °C
80
25 °C
30 °C
70 Do not let the battery 35 °C

state of charge going
into this area
40 °C
60
0 10 20 30 40 50 60 70 80 90
REST TIME (days)
Figure 15001 inactive stand by storage
3-2. Ambient temperature with 'topping' or 'refresh charge'

The stand-by period defined in para. Inactive stand-by storage can be prolonged by applying a ’topping’ or ’refresh’ charge, at
the end of the period. The charge is defined as a short charge at 0.1 C1A, 0.5 C1A or 1 C1A until the voltage reaches the values
given in the table below:
VOLTAGE
CHARGE rate
(end of " refresh " charge)
0.1 C1A 30 V for 20 cells
0.5 C1A 31 V for 20 cells
1 C1A 31.4 V for 20 cells

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285CH
The battery can be 'refreshed' up to two (2) times (for example 24 days at +30°C can be prolonged to 72 days at +30°C).
CAUTION: The time necessary to reach the required voltage should be very short.
Do not do the 4 hours overcharge at 0.1 C1A (refer to PARA Charge) during this ’refresh’ charge opera-
tion.
3-3. Action at the end of the standby period

At the end of the stand-by period, if the battery is not immediately installed in the aircraft, do one of the following procedures:
If the battery has been subject to one period, or two successive periods of stand-by, it must be discharged and recharged (refer
to Periodical check) after which it can be subject to another period of up to 3 months stand-by. If it is to be put into long term
storage to para. Inactive long term storage
If the battery has been subject to three successive periods of stand-by, it must undergo electrical treatment (refer to Regular
check) after which it can be subject to another sequence of three stand-by periods of up to 3 months it is to be put into long
term storage refer to para. Inactive long term storage.
CAUTION: If the above conditions are not met, there is a risk of placing a battery on board the aircraft that does not
meet the emergency requirements.
If the battery has previously been stored at a temperature below that of the ambient, condensation may
occur. Before installing, verify the insulation resistance.
4. Active stand-by mode (= use of a trickle charge)

CAUTION: water consumption.
Principle: the battery is continuously charged, in an overcharge condition. Saft does not recommend this method, however
some operators take responsibility for its use.
This method is not reliable due to quantity and inaccuracy of water consumption.
Example: if a 40 Ah battery remains on a continuous trickle charge of 3 mA/Ah for one month, the total consumption of water
is 35 cm3/cell.
The operator must adjust the electrolyte level before placing the battery onboard the aircraft. Otherwise the risk of a battery
inci-dent exists (cells dried out before the normal end of the interval maintenance). This creates the conditions for a thermal
runaway with all its consequences (unscheduled removal with the possibility of the total loss of the battery and a delayed if not
cancelled flight).
5. Spares
5-1. Spare Cells
Spare cells must be stored filled and discharged (in a discharged cell, the electrolyte level is not visible). It is not necessary
that they be short circuited. The vent valves must not be removed. The storage conditions are the same as those given in para.
Inactive long term storage. No maintenance operation is needed during storage. Before installation in a battery, cells must be
visually inspected for damage or leakage and cleaned and repaired as necessary in accordance with the battery maintenance
documentation.
5-2. Spare O-rings, gaskets and vent valves

5-2-1. O-rings and gaskets
6 years of storage with storage conditions from date of manufacture unless otherwise specified on the packaging. They must
be protected from exposure of air, light and high humidity (< 70%). Storage life depends on temperature so it is recommended
to store in a cool area (<25 °C / 77 °F). At +35 °C / 95 °F, storage life is reduced to 5 years. Before use, O-rings must be in-
spected and any showing visible signs of damage, distortion or deterioration must be discarded.
5-2-2. Vent valves with O-rings
6 years of storage with storage conditions from date of manufacture unless otherwise specified on the packaging (the limitation
is due to the O-ring). Protected from exposure of air, light and high humidity (< 70%). Storage life depends on temperature so
it is recommended to store in a sealed container (non-PVC) in a cool area (<25°C / 77 °F). At +35 °C / 95 °F, storage life is
reduced to 5 years. Before use, O-rings must be inspected and any showing visible signs of damage, distortion or deterioration
must be discarded.
5-3. Other spares

Other spares, protected from external contamination (i.e. dirt, dust, dampness, vibration, corrosive atmosphere) and high hu-
midity (>70 %), may be stored for unlimited periods. Before use, they must be inspected and any showing visible signs of dam-
age, distortion or deterioration must be discarded.

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285CH
6. Servicing after discharged storage
Storage time Servicing procedure
Less than 3 months Visual Inspection

Insulation check
Nut tightness
Charge
Adjust electrolyte level
3 months to 1 year Charge followed by Periodical check
More than 1 year Charge followed by Regular check.
7. Transportation procedure
The battery is normally discharged before packing. If it is necessary to transport a charged battery, make sure that the output
terminals are protected against short circuit.
The battery should then be packed vertically in its original container. If the original container is not available, the international
and/or local packaging regulations applicable to the mode of transport and destination must be followed.
According to the IATA / IMDG dangerous goods regulations, Saft ships all existing nickel-cadmium batteries or cells for aircraft
under the classification UN2795 (wet, filled with alkali) according to packing instruction 800.

Jun 27/2019

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26 quai C. Pasqua - 92300 Levallois-Perret - France

date of creation: Mar 29/2018

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1 Jun 27/2019 Jun 27/2019 Saft

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RECORD OF TEMPORARY REVISIONS

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SERVICE BULLETIN LIST

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LIST OF EFFECTIVE PAGES

TITLE PAGE 1 Jun 27/2019 DESCRIPTION AND 1 Jun 27/2019

LIST OF ILLUSTRATIONS LOI-1 Jun 27/2019

INTRODUCTION Intro-1 Jun 27/2019

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INSPECTION/CHECK 5001 Jun 27/2019 ILLUSTRATED 10001 Jun 27/2019

FITS AND CLEARANCES 8001 Jun 27/2019

SPECIAL TOOLS, 9001 Jun 27/2019

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RECORD OF REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ROR-1

RECORD OF TEMPORARY REVISION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - RTR-1

SERVICE BULLETIN LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SBL-1

LIST OF EFFECTIVE PAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LEP-1

TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - TOC-1

LIST OF ILLUSTRATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LOI-1

DESCRIPTION AND OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

TESTING AND FAULT ISOLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1001

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3-1. Standard tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3001

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4-4. Installation of the connector (230) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7003

FITS AND CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES - - - - - - - - - - - - - - 9001

ILLUSTRATED PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10001

STORAGE (INCLUDING TRANSPORTATION) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15001

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INTRO-1 Universal Recycling Symbols INTRO-2

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6. Placing a new battery in service - initial commissioning

Figure INTRO-1 Universal Recycling Symbols

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9. End of life cells

10-1. Units of Measure

10-1-2. U.S. Units

10-1-3. Multiplying Prefixes

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10-2. Measurement Conversion Table

1 kPa 0.1450 psi

10-2-2. From U.S. Standard System to I.S. Measurement

1 psi 6,8948 kPa

10-3. Temperature Conversion Table

AECMA European Association of Aerospace Industries

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