Ercoupe Service Memorandum 44
ERCOUPE 415-C · Service Bulletins
Overview
This document is a service memorandum for the Ercoupe 415-C aircraft, specifically focusing on the care and maintenance of its electrical system. It provides detailed instructions for battery maintenance, battery box assembly checks, voltage regulator operation, and inspections for corrosion and damage due to battery acid.
- Proper maintenance of the electrical system is crucial to prevent structural damage.
- Battery checks should be performed every 25 hours or 30 days.
- Inspect the battery box for leaks and corrosion regularly.
- Voltage regulator operation should be checked during engine runs.
- Corrosion from battery acid must be addressed immediately.
- Use specific cleaning solutions for corrosion on aluminum structures.
- Baggage compartment inspections should coincide with battery electrolyte level checks.
- Replace any damaged control cables or bearings affected by battery acid.
Document
Source
Originally published by univair.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Service Bulletins
- File size ·
- 250 KB
- Publisher ·
- univair.com
- Language ·
- en
Specifications & performance
Extracted from this document.
Specifications
- Battery model ·
- R-24-7
- Battery box model ·
- 415-54035
- Voltage regulator model ·
- Delco-Remy No. 1118-259
What is the Ercoupe Service Memorandum 44?
The Ercoupe Service Memorandum 44 is a service bulletins for the ERCOUPE 415-C.
Where does the Ercoupe Service Memorandum 44 come from?
This copy of the Ercoupe Service Memorandum 44 was originally published by univair.com and is hosted on Sprinkle as a free, searchable reference copy.
Most owners only have the POH. Here's the essential set for the ERCOUPE 415-C.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
More ERCOUPE 415-Cmanuals & documents
- Ercoupe POHPilot's Operating Handbook
- Ercoupe Service Bulletin 33 Revision AService Bulletins
- Ercoupe Service Bulletin 32Service Bulletins
- Ercoupe Service Memorandum 46Service Bulletins
- Ercoupe Service Memorandum No. 41Service Bulletins
- Ercoupe Service Memorandum 51Service Bulletins
- Ercoupe Service Bulletins & Ltrs. by topicService Bulletins
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In this document
Battery Maintenance
Instructions for checking battery terminals, charge levels, and electrolyte levels, including specific gravity readings and maintenance intervals.
Battery Box Assembly
Guidelines for inspecting the battery box for leaks, corrosion, and proper attachment, along with a note on an upcoming modification.
Voltage Regulator
Instructions for checking the operation of the generator and voltage regulator during engine runs.
Miscellaneous Electrical Equipment
Recommendations for checking the operation of other electrical components and ensuring proper wiring.
Airplane Structure
Procedures for inspecting and treating corrosion on the aircraft structure due to battery acid spills.
Baggage Compartment
Inspection requirements for the baggage compartment to check for damage from battery acid.
Safety notes
- Malfunctioning electrical systems can cause considerable structural damage.
- Electrolyte levels must be monitored to prevent battery damage.
- Corrosion must be treated immediately to prevent further damage.
- Do not allow cleaning solutions to contact organic materials.
- Control cables or bearings affected by battery acid should be replaced.
Full document text
ERCOUPE SERVICE MEMORANDUM No. 44 Electrical System Care and Maintenance of This Memorandum is prepared to provide instruc- tions on the care and proper maintenance of the Ercoupe electrical system, the installation of which was covered in Service Memorandum No. 23. The proper maintenance of the electrical system is very important because its malfunctioning can cause considerable structural damage. This Memorandum affects Ercoupes Serial Nos. !13 and subsequent. The system should be checked within the next. 60 days and at each 100 hour inspection thereafter. I. Battery: (Reading R-24-7) ( 415-54044-20). Reference-Storage Battery Technical Service Manual, distributed by Reading Batteries, Inc., Reading, Penna. a. Check battery externally for loose terminals, bad cable connections, cracked case, cracks in top sealing compound, damaged filler hole and vent plug. b. Check charge of battery with hydrometer. (Readings taken at standard temperature of 80°F.) A fu!ly charged battery hydrometer reading is 1.275 to 1.300. If the reading is below 1.225, the battery should be bench re- charged. Instructions for bench recharging will be found on the side of the battery case. If there is more than 25 points oi specific gravity difference between any cells, this is an indication that the battery is probably on the verge of failure. c. Check electrolyte level in battery. (This must be done at 25 hour intervals or 30 days which- ever occurs sooner.) Batteries both with and without horizontal level plates have been used in Ercoupes. The electrolyte level in batteries having a horizontal level plate (with a single hole in each cell) shall be no higher than flush with the plate. The electrolyte level in batteries without horizontal plates should not be more than 1/4" above separators. Too high an e!ectrolye level may result in battery acid overflowing or spilling. Capillary action of acid in vent tube, motion in rough air, or boiJ. ing of electrolyte due to overcharging, will cause spilling of acid in batteries with too high an electrolyte level. An electrolyte level al- lowed to drop below the separators may re- sult in the following: plates and separators damaged due to sulphation caused by expo- sure to air, sulphuric acid becomes too con- centrated causing damage to both separators and plates, and low battery output. 2. Battery Box Assembly: ( 415-54035). Leaking of batte_r:y: acid from the bc;ttery box assembly, after sp1llmg from battery wlll cause corrosion of structural members around battery box and deterioration of the baggage compartment. A modification is being prepared to improve the bat· tery box assembly. The Bulletin on this modifica. tion will be issued as soon as prepared, to facili· tate field modification of the battery box. a. Check Battery Box for leakage, loose attach- ment to support, chipped acid proof paint, ex· cessive corrosion, bent or loose brackets, or loose or deteriorated drain tube. b. Check length of battery box drain tube as per instructions in Service Bulletin No. 8. (At least I /2" extension below skin.) c. C~eck bat~ery box cover ( 415-54040) for ch1pped ac1d proof paint, excessive corrosion, or damaged wing bolts ( 415-54037), bumper pads and elastic grommets ( 415-54040-2). d. Ch<;ck for new decal ( 415-54062) with battery mruntenance instructions in lieu of one with in- structions· for weight and balance only. (See Bulletin No. 22, part A.) 3. Voltage Regulator: (Delco-Remy No. I !18· 259) c415-53016-15). Reference-Operators Manual for Delco-Remy Aircraft Electrical Equipment published by the Delco-Remy Division, General Motors Corp., An· derson, Indiana. (Supplied with all new Ercoupes since August 1946.) a. Check operation of generator and voltage regulator by running engine and observing ammeter readings. See Service Memorandum No. 23 for proper readings and if faulty, refer regulator to authorized De!co-Remy Repair Station. Pap 2-MEMORANDUM No. 44 4. .Miscellaneous f/ectrlca/ Equipment: a. Check remaining electrical equipment for proper operation, electrical wir!ng for pr~per taping of connectors and terrrunals. Contmu- ity tests should be made on any doubtful wir- ing and worn wires should be replaced. In- spect 30 amp. fuse in the generator circuit. Check switch and circuit breake_r in n~'Iati~n light circuit. A schematic electncal cucu1t dia- gram is included with Memorandum No. 23. 5. Baggage Compartment: a. The baggage compartment shall be inspected each time electro! yte level is checked for deterioration that may occur from spilled bat- tery acid. Damaged areas may be mended by hand or machine sewn patches. 6. Airplane Structure: a. The aluminum alloy structure. especially adja- cen I to and aft of the battery box, shall be carefully examined for corrosion due to spilled acid. When corrosion is discovered it is of ut- most importance that immediate steps be tak<:n to neutralize active acid and salt crystals. Th1s may be accomplished by washing the affected area with a saturated solution of Bicarbonate of Soda or a solution of Ammonia water (I part household Ammonia, 4 parts water). Neither of these solutions are dangerous to handle, however, they must be diluted to an inactive state by thoroughly flushing wfth water followed by drying. When using either of these solutions it is imperative that ferrous metals be immediately treated with a protec- tive coating to prevent oxidizing (rusting). The above should be followed immediatefy upon the discovery of any corrosion, to pre- vent further damage. b. The determination of the extent of the damage to the base metal in the affected area wfll re- quire complete removal of all of the products of corrosion (scale, loose metal flakes, pow- der and salt crystals). When removing the products of corrosion caution must be taken to remove only enough of the base metal to obtain a clean surface. Chemical treatments
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are definitely preferred but polishing is per- missible for small areas. Chromic acid solu- tion or an Alcohol.,Phosphoric Acid solution may be used lor chemical cleaning. It is im- perative, however, that neither of these ma- terials be allowed to come into contact with organic materials or be permitted to pene- trate between frayed surfaces or into blind openings. They are not especially dangerous to personnel. c. The Chromic Acid Solution consists of 5% Chromic Acid dissolved in tap water and heated to 120°F. to 140°F. The wash may be applied with either a brush or a soft cloth. The solution should be allowed to remain on the corroded area for five to ten minutes. Remove the solution by rinsing wfth hot water while scrubbing lightly with a bristle brush. The area cleaned may then be polished with ISO mesh emery sand paper or abrasive cloth, or wet or dry sand paper using water solvent as lubricant. d. The Alcoholic Phosphoric Acid solution con- sists of a mixture as follows : Material Butyl Alcohol Isopropyl Alcohol Phosphoric Acid (S5% solution) Water Quantity by Volume 40% 30% 10% 20% This solution is used in the manner described lor chromic acid except that the solution should not be allowed to remain on the alumi- num for more than 1 to 2 minutes. e. After the above operations the affected areas should be protected from normal deterioration by painting with zinc chromate before reas- sembly. Exterior surfaces may be given a coat of clear lacquer lor protection. I. II at any time battery acid has spilled in con- trol cables or bearings, they should be re- moved and replaced. We do not recommend any neutralizing steps lor the above. g. Affected steel parts should be removed from the airplane. The oxidization and corrosion removed with ISO mesh emery sandpaper, abrasive cloth or wet or dry sandpaper using water solvent as lubricant. Steel parts should then. be coated wfth zinc chromate primer and re-installed.