To:
Holders of 4579 (Saft 018550-000) batteries
Revision No. 4 Dated July 13, 2001
HIGHLIGHTS
Pages which have been added or revised are outlined below together with the
highlights of the revision. Remove and insert the affected pages as listed and
ensure the Record of Revisions page has noted Revision No. 4 dtd July 13/01.
Chapter/Section
and Page Number
List of Effective Pages
Pages 1 & 2
Introduction
Page Intro 1
Testing and Fault
Isolation
Page 111
Page 112
Illustrated Parts List
Page 1002
Page 1005
Description of Change
Effectivitity
Revised to indicate
added, revised and/or
deleted pages
All Models
Revised address and
updated phone numbers
All Models
Added testing
parameters for shunt
connection in
Temperature Sensor
Assembly
All Models
Defined parameter for
“open” circuit in K(6).
Added phone numbers
and website address
All Models
Various
Saft America, Inc.
711 Industrial Boulevard, Valdosta, Georgia 31601
229-247-2331 phone // 229-247-8486 fax
SAFT AMERICA INC.
711 INDUSTRIAL BOULEVARD
VALDOSTA, GEORGIA 31601
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
Nickel Cadmium Battery
4579
(BA06 ELDEC PART NUMBER)
(S282T002-1 BOEING PART NUMBER)
(SAFT PART NUMBER 018550-000)
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
RECORD OF REVISIONS
REV
NO.
1
2
3
4
ISSUE
DATE
02/28/84
06/15/91
01/30/98
07/13/01
INSERT
DATE
03/01/84
07/01/91
01/30/98
BY
REV
NO.
ISSUE
DATE
INSERT
DATE
BY
Saft
Saft
Saft
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV NO
PAGE
NUMBER
ISSUE DATE
BY
DATE
BY
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COMPONENT MAINTENANCE MANUAL
4579
SERVICE BULLETIN LIST
SERVICE BULLETIN
NUMBER
REVISION NUMBER
DATE BULLETIN
INCORPORATED INTO
MANUAL
PRODUCT IMPROVEMENTS
Product Improvements have been incorporated using service bulletins entered in the
service bulletin list. Service bulletin highlights are as follows:
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
SUBJECT
PAGE
DATE
Title Page
T-1
T-2
July 13/01
Blank
Cleaning
Record of Revisions
RR-1
RR-2
July 13/01
Blank
401
402
403
404
Jan 30/98
Jan 30/98
Jan 30/98
Blank
Check
Record of Temporary
Revisions
RTR-1
RTR-2
Jan 30/98
Blank
501
502
503
504
Jan 30/98
Jan 30/98
Jan 30/98
Blank
Service Bulletin List
SBL-1
SBL-2
Jan 30/98
Blank
Repair
601
602
Jan 30/98
Jan 30/98
LEP-1
LEP-2
July 13/01
Blank
Assembly
Table of Contents
TC-1
TC-2
Jan 30/98
Blank
Introduction
INTRO-1
INTRO-2
Jul 13/01
Blank
701
702
703
704
705
706
707
708
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Jan 30/98
Jan 30/98
Jan 30/98
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Blank
Description and
Operation
1
2
Jan 30/98
Jan 30/98
Fits and Clearances
801
802
Jan 30/98
Blank
Testing and Fault
Isolation
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
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Jan 30/98
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July 13/01
July 13/01
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Jan 30/98
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Special Tools,
Fixtures, and
Equipment
901
902
Jan 30/98
Jan 30/98
Illustrated Parts List
1001
1002
1003
1004
1005
1006
Jan 30/98
Jan 30/98
Jan 30/98
Jan 30/98
July 13/01
Blank
301
302
Jan 30/98
Jan 30/98
List of Effective Pages
Disassembly
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
TABLE OF CONTENTS
PARAGRAPH TITLE
PAGE
Description and Operation
1
Testing and Fault Isolation
101
Automatic Test Requirements (ATLAS)
N/A
Disassembly
301
Cleaning
401
Check
501
Repair
601
Assembly (Including Storage)
701
Fits and Clearances
801
Special Tools, Fixtures, and Equipment
901
Illustrated Parts List
1001
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
INTRODUCTION
The instructions in this manual provide the information necessary for an experienced shop
technician to perform shop type repair with no specialized training.
The manual is divided into separate sections:
1.
Title Page
2.
Record of Revisions
3
Record of Temporary Revisions
3.
List of Effective Pages
4.
Table of Contents
5.
Introduction
6.
Procedures and IPL Sections
The disassembly, repair, and assembly sections generally contain only specific instructions
to be used on the equipment covered herein. Most standard aerospace practices are not
described herein.
An explanation of the use of the Illustrated Parts List (IPL) is provided in the Introduction to
that section.
Every effort has been taken to provide complete and accurate component maintenance
instructions. However, if a situation should arise that is not adequately covered by this
manual, please contact Saft at one of the following addresses:
Saft
711 Industrial Boulevard
Valdosta, Georgia 31601
Saft
12 Avenue Sadi Carnot
93170 Bagnolet, France
Telephone:
FAX:
Telephone:
FAX:
(229) 247-2331
(229) 247-8486
33 1 49 93 19 18
33 1 43 93 19 56
Verification:
Testing / Fault Isolation:
Disassembly:
Assembly:
June 15, 1991
June 15, 1991
June 15, 1991
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
DESCRIPTION AND OPERATION
1.
Description
The Nickel Cadmium Battery provides power either to the standby system or to start the
auxiliary power unit (APU). It is a nickel-cadmium type with sintered plate construction, and
uses a potassium hydroxide electrolyte. The battery consists of a case and cover, 20 cell
assemblies, and a temperature sensor assembly. The sensor assembly includes a
thermoswitch mounted on a plate against the end of the center row of cells. A charge control
thermistor is located between cells 6 and 9 in the center row of cells.
2.
Operation
The battery is charged on the aircraft by an on-board charger. The charge control thermistor
provides a signal to the charger to compensate the charge according to the battery
temperature. The thermostat will cut off the charger if the battery temperature exceeds a safe
operating limit.
Battery
Cover
Battery
Receptacle
Battery
Case
Temperature
Sensor
Assembly
Connector
Nickel-Cadmium Battery
Figure 1
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COMPONENT MAINTENANCE MANUAL
4579
Voltage:
Nominal
Open Circuit Voltage, fully charged
Weight
24
Volts
26 ±1 Volts
96 lb. (43.64 Kg)
Dimensions (Maximum):
Height
Length (including side brackets)
Width (including handles)
11.4” (285 mm)
13.0” (325 mm)
11.0” (275 mm)
Cell Assembly Terminal
M10 X 1.25
Number of Cell Assemblies
20
Cell Model
VHP450KA-1
Rated Capacity
End of Life Capacity
40 Ah (1 hour rate)
40 Ah (1 hour rate)
Venting Pressure
Cell Assembly Case Material
Battery Case Material
Electrolyte
2 to 10 psi (0.14 to 0.7 bar)
Polyamide
Stainless Steel
Potassium Hydroxide
Leading Particulars
Figure 2
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COMPONENT MAINTENANCE MANUAL
4579
TESTING AND FAULT ISOLATION
1.
General
This section contains battery functional tests and fault isolation information. Test procedures
are written in a step-by-step format following Fig 102. Fault isolation information is
presented in chart form (Fig 106).
NOTE:
2.
All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
Required Test Equipment
NOTE:
Test equipment having equivalent specifications can be used.
NOMENCLATURE
APPLICATION
DC Power Supply, regulated,
35 Vdc 0-60A minimum
Testing / Fault Isolation
Precision Multi-meter,
(precision +0.5%),
0-2 V, 0-5 V, and 0-50 V scales
required
Testing / Fault Isolation
DC Load Bank (0-60A Minimum)
Testing / Fault Isolation
Thermometer, Immersion
Testing / Fault Isolation
Megohmmeter 250 Vdc
Testing / Fault Isolation
Required Test Equipment
Figure 101
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COMPONENT MAINTENANCE MANUAL
4579
NEW OR
FROM
STORAGE
REMOVED
FROM
AIRCRAFT
CHECK CELL NUT
TORQUE
PG 801
CHECK CELL NUT
TORQUE
PG 801
CHARGE
INITIAL
DISCHARGE
ADJUST
ELECTROLYTE
RESIDUAL
DISCHARGE
ALL CELLS
>1.50V
*
ANY CELL
<1.50V
RECHARGE
INITIAL
DISCHARGE
CAPACITY TEST
GOOD
REST
10 - 12 HRS.
CHARGE
NO-GOOD
ALL CELLS
>1.50V
SPECIAL
TESTING
CONTINUE
AT RESIDUAL
DISCHARGE
UNDER
“REMOVED
FROM AIRCRAFT”
ADJUST
ELECTROLYTE
PLACE IN
SERVICE
NOT GOOD
CHARGE
LEVEL
ELECTROLYTE
ALL CELLS
>1.50V
INSULATION
CHECK
CHECK CELL NUT
TORQUE
PG 801
SECOND
DISCHARGE
GOOD
*
ANY CELL
<1.50V
ANY CELL
<1.50V
SPECIAL
TESTING
INSULATION
CHECK
*
CHECK CELL NUT
TORQUE
PG 801
RETURN TO
SERVICE
N O T E S : Record all discharge data in battery log book.
* = Reentry point from SPECIAL TESTING
Note: All procedures are found in Testing and Fault Isolation
Test Procedure Flow Diagram
Figure 102
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COMPONENT MAINTENANCE MANUAL
4579
3.
Testing
A.
Test Conditions
(1)
Facilities and equipment
CAUTION:
(2)
B.
FUMES FROM LEAD ACID BATTERIES OR SMALL
TRACES OF SULFURIC ACID ENTERING A NI-CD
BATTERY CAN CAUSE PERMANENT DAMAGE.
(a)
Service facilities for Ni-Cd batteries must be entirely separate from
those for lead acid batteries.
(b)
Equipment used to service lead acid batteries must not be used to
maintain Ni-Cd batteries.
For optimum results, conduct all tests with the battery temperature at 77°F
(25°C).
Test Equipment
Refer to Section 9 (Special Tools, Fixtures, and Equipment) for a complete list of all
test equipment required for proper maintenance of a Ni-Cd battery.
C.
Initial Discharge (Capacity Test)
The purpose of this discharge procedure is to determine the initial capacity of a
battery when it is removed from the aircraft, either for routine maintenance or for
investigation of a malfunction. The test also is used in the commissioning of a new
battery to verify performance before being entered into service. The results of this
initial discharge will determine the steps that should be taken.
(1)
Discharge the battery at a rate listed in Figure 103 until the battery reaches
20.0 V.
(2)
Record the time at the start of the discharge and the discharge current.
(3)
Monitor individual cell voltages periodically during the discharge.
(4)
Record the time that the first cell reaches 1.0 V.
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COMPONENT MAINTENANCE MANUAL
4579
NOTE
It is not a cause for concern if a cell goes to zero volts or
reverses polarity during the battery discharge. Simply short out
the cell’s terminals for the remainder of the discharge.
(5)
When the battery terminal voltage reaches 1.0 volts per cell (20.0 V), stop the
discharge, and record the time.
(6)
Interpretation of the Initial Discharge Results.
Based on the amount of time to discharge the first cell to 1.0 V the following
will apply:
(a)
The first cell discharged to 1.0 V in greater than the minimum time
listed in Figure 103, the battery and all cells are considered above rated
capacity. Proceed to with maintenance per Fig 102.
(b)
The first cell discharged to 1.0 V in less than the minimum time listed
in Figure 103, (indicating that there is a problem with at least one cell
in the battery). These results can be due to any of the following:
1
The battery was used to power equipment after the last landing.
2
The battery cells have temporarily or permanently lost
electrochemical capacity.
3
A condition of cell capacity imbalance has developed.
Proceed with Residual Discharge, Charge and Second Discharge as
described in TESTING and FAULT ISOLATION. Performing a deep
cycle will often correct any imbalance or temporary loss in capacity.
NOTE:
It may be necessary to perform a deep cycle several
times to correct a severe imbalance or loss of capacity.
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COMPONENT MAINTENANCE MANUAL
4579
DISCHARGE RATE
(AMPS)
10
20
40
45
D.
DISCHARGE TIMES
MINIMUM TIME FOR FIRST CELL TO
DISCHARGE TO 1 VOLT
BATTERY WITH
PRIOR SERVICE
FROM STORES OR
AIRCRAFT
260.0 MINUTES
130.0 MINUTES
64.5 MINUTES
60.0 MINUTES
Discharge Times
Figure 103
NEW BATTERY
270.0 MINUTES
135.0 MINUTES
67.0 MINUTES
60.0 MINUTES
Residual Discharge
Discharge each cell in the battery to zero volts using one of the first two procedures
that follow.
NOTE:
It is not necessary to have a rest period between discharge and residual
discharge.
(1)
Continue to discharge the battery. After battery voltage drops to <1.0 V,
connect a 1.0 ohm (3.0 watt minimum) resistor across each cell’s terminals.
Leave the resistor in place for 16 to 24 hours to allow each cell to completely
discharge. The resistors should be fitted with alligator clips to ensure a firm
connection.
(2)
Continue to discharge the battery. After battery voltage drops to <0.5 V dc,
insert a shorting clip between its terminals. Leave these clips on for 16 hours to
allow the cells to completely discharge and the battery to cool.
(3)
Remove the shorting devices and continue with testing per Fig 102.
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COMPONENT MAINTENANCE MANUAL
4579
E.
Charge
CAUTION: ATTEMPTING TO CHARGE BATTERIES WITH LOW
ELECTROLYTE LEVELS IN ANY CELL MAY CAUSE
PERMANENT DAMAGE TO THAT CELL.
NOTE:
The battery must be allowed to cool 1-2 hours before charging the
battery following a discharge procedure.
(1)
Remove the cover (8), pad (9) and formed insulator (10).
(2)
Loosen, but do not remove, all vent valves (1).
CAUTION:
CHECK INDIVIDUAL CELL VOLTAGES AT THE
BEGINNING OF THE CHARGE. IF ANY CELL
INDICATES AN IMMEDIATE VOLTAGE RISE ABOVE
1.50 VOLTS, ADD ABOUT 10 CC'S OF DISTILLED OR
DEMINERALIZED WATER THROUGH THE VENT
VALVE OPENING OF THAT CELL.
(3)
Charge using one of the two methods shown in Figure 104.
(4)
During the last 15 minutes of the overcharge cycle, adjust the electrolyte level.
(5)
Verify all cell voltages are above 1.50 V
CONSTANT CURRENT CHARGE
Main Charge
Overcharge
Method 1: 4.5 Amps until battery reaches
4.5 Amps – all cells > 1.5 V
30 V
Time:
Time:
Minimum:
10 hours
4 hours
Maximum:
12 hours
Method 2: 22.5 Amps until battery reaches 4.5 Amps – all cells > 1.5 V
31 V
Time:
Time:
Minimum:
2 hours
4 hours
Maximum:
2 hours 30 min.
Current Charge Rates
Figure 104
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COMPONENT MAINTENANCE MANUAL
4579
F.
Second Discharge (Capacity Check)
The purpose of this discharge procedure is to verify that the initial battery
maintenance of discharge and charge has corrected any low capacity and/or cell
imbalance that existed in the battery when the initial discharge was performed.
NOTE:
It may be necessary to perform a deep cycle several times to correct a
severe imbalance or loss of capacity.
(1)
Discharge the battery at a rate listed in Figure 103 until the battery reaches
20.0 V.
(2)
Record the time at the start of the discharge and the discharge current.
(3)
Monitor individual cell voltages periodically during the discharge.
(4)
Record the time that the first cell reaches 1.0 V.
NOTE
It is not a cause for concern if a cell goes to zero volts or
reverses polarity during the battery discharge. Simply short out
the cell’s terminals for the remainder of the discharge.
(5)
When the battery terminal voltage reaches 1.0 volts per cell (20.0 V), stop the
discharge, and record the time.
(6)
Interpretation of the Second Discharge (Capacity Check) Results
The results obtained from the Second Discharge will determine the next
procedure per (a) or (b) below.
(a)
Regardless of the results obtained in the first discharge, the battery is in
good condition if:
1
The time required to discharge all cells to 1 volt exceeds the
minimum time listed in Figure 103.
2
The end of charge voltage of all cells was between 1.50 and 1.7
volts.
Therefore, the battery may be placed back into service after it is
charged and the electrolyte level adjusted.
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COMPONENT MAINTENANCE MANUAL
4579
(b)
G.
The following two results are indications that the battery requires
Special Testing, or refer to Fault Isolation:
1
The time to discharge all cells is less then the minimum time as
listed in Figure 103.
2
The end of charge voltage of any cell was less than 1.50 volts
or more than 1.7 volts.
Cell-to-Case Insulation Test
A breakdown in electrical insulation between the cells and the battery case will result
in a “leakage” current, which over a period of time, can discharge the battery. The
most common cause for the loss of insulation is the leakage of electrolyte from the
cells which can act as a conductor between the cell plates (or terminals) and the
battery container. Because the leakage current can affect battery performance, it is
necessary that it is kept to a minimum.
H.
(1)
Set up the analog volt-ohmmeter for a measurement of 500 mA.
(2)
Connect the negative lead to the battery container, and the positive lead to the
positive terminal of the battery, then to the positive terminal on each cell.
(3)
If while performing the above, there is any deflection of the needle (indicating
a reduction in insulation resistance), the battery should be disassembled fully
and cleaned (DISASSEMBLY, CLEANING, ASSEMBLY).
(4)
If, after cleaning and assembly, a leakage current is still indicated by the test
described in steps (1) through (3), one or more cells are defective. Isolate and
replace the defective cell(s) (DISASSEMBLY and ASSEMBLY).
Special Testing
These procedures are to be followed for a new battery that has been stored, a battery
with prior service that does not meet capacity, an in-service battery that does not
regain capacity, and/or a battery with an end of charge voltage <1.50 V/cell during the
second charge.
NOTE:
If three cells are replaced during a service cycle or five cells are
replaced over the life of the battery, it is recommended that the battery
be replaced.
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COMPONENT MAINTENANCE MANUAL
4579
NOTE:
Except for batteries from long term storage, it is recommended that if a
battery requires Special Testing more than 3 times that the battery be
replaced.
NOTE:
For a battery from long term storage, several complete
charge/discharge cycles may be required to restore performance.
(1)
Completely discharge the battery to 0 volts:
a
Discharge the battery to 1 volt using one of the rates and times listed in
Fig 103.
b
Continue to discharge the battery to 0 volts using one of the methods
found in the section entitled “Residual Discharge”.
(2)
Charge the battery at 4.5A for 10-12 hours per Figure 104.
(3)
Overcharge the battery at 4.5A for an additional 4 hours. Total charge time
will be approximately 18-20 hours.
(4)
Monitor individual cell voltages each 15-20 minutes during additional
overcharge and record OCV (Open Circuit Voltage) readings.
(5)
Note any cells that express a drop in voltage during overcharge and mark those
cells for replacement.
NOTE:
I.
A drop in voltage during overcharge indicates a defect in the
gas barrier which is not recoverable nor repairable. Cells with
this condition must be replaced (DISASSEMBLY,
ASSEMBLY).
(6)
Replace marked cells (if required)(DISASSEMBLY, ASSEMBLY).
(7)
Return to ( * ) re-entry point in Figure 102.
Electrolyte Level Adjustment
This procedure is to be carried out during overcharge at 4.5 amps during the last 15
minutes of charge cycle.
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COMPONENT MAINTENANCE MANUAL
4579
WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE
LOOSENED OR REMOVED; CONTACT OF ELECTROLYTE
WITH SKIN CAN CAUSE SEVERE BURNS.
NOTE:
BATTERY MUST BE FULLY CHARGED BEFORE ADJUSTING
ELECTROLYTE LEVEL TO AVOID OVERFILLING.
(1)
Remove the vent valves (3) with the special, plastic vent valve wrench (P/N
093382-000) supplied with the battery.
(2)
Immerse the valves (3) and their O-rings (4) in distilled or de-ionized water,
and let them soak to dissolve any salts.
(3)
Cover the cells (2) with a clean damp cloth to prevent entry of foreign matter.
(4)
Check the liquid level in the cell:
(a)
Insert the syringe (P/N 020915-004) into the cell opening until the
shoulder of the nozzle rests on the valve seat (See Fig 105).
(b)
Withdraw the plunger and check for any liquid in the syringe.
1
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.
2
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.
Position of Syringe in Cell Vent Seat
Figure 105
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COMPONENT MAINTENANCE MANUAL
4579
(5)
Replenish low electrolyte:
NOTE:
J.
Use only distilled or demineralized water. The quantity (in
cm3) of distilled water required to fill the cell to the correct
level will serve as an approximate guide to the amount required
for the remaining cells. The water in each cell, however, must
be adjusted individually to the correct level. If the quantity of
water added per cell exceeds 80 cm3 check the charging system.
If the charger is functioning properly, shorten the period
between servicing.
(a)
Draw 5 cm3 of the distilled water into the syringe and inject it into the
cell.
(b)
With the syringe nozzle resting on the valve seat, slowly withdraw the
plunger in the syringe.
(c)
If the syringe remains empty, repeat steps (a) and (b), counting the
number of 5 cm3 injections required to achieve the correct level.
(d)
At the point in step (b) 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 later disposal.
Charge Control Thermistor Test
The charge control thermistor is part of the temperature sensor assembly (22). It is
permanently mounted on a sensor plate (23) between cells #6 and #9. Disassembly is
required to test the charge control thermistor (DISASSEMBLY). Check the function
of the charge control thermistor as follows:
(1)
Connect an ohmmeter to pins 1 & 3 of the connector at room temperature
[70°F (±5°F) (21.1°C (±2°C)]. Ohmmeter reading should indicate a closed
circuit (<1MΩ).
(2)
Connect an ohmmeter to connector pins 11 and 12 of the temperature sensor
assembly (22). Verify the ohmmeter reads 2360Ω to 3050Ω at room
temperature [70°F (±5°F) (21.1°C (±2°C)].
(3)
Immerse the thermistor plate in a beaker containing a mixture of ice and water.
(4)
Insert a thermometer or other suitable temperature-measuring device, in the
container in contact with the plate.
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4579
(5)
Verify the ohmmeter indicates 7355Ω ±74Ω at 32°F ±3°F (0°C ±1.5°C).
(6)
Following the low temperature test, slowly raise the temperature to 140°F
±5°F.
(7)
Verify the ohmmeter indicates 560Ω ±12Ω at 140°F ±5°F.
NOTE:
(8)
K.
At 160°F (71°C) the thermistor resistance shall be 382 ±74Ω.
If the thermistor fails any of the above tests, replace the temperature sensor
assembly (22) with a factory new.
Overtemperature Thermoswitch
The overtemperature thermoswitch is part of the Temperature Sensor Assembly (22).
It is mounted on the plate (23) in contact with the face of cell #4. Disassembly is
required in order to test the thermoswitch (DISASSEMBLY). Check the function of
the overtemperature thermoswitch as follows:
(1)
Connect an ohmmeter to connector pins 8 and 9 of the temperature sensor
assembly (22). Ohmmeter should read >1MΩ (open thermoswitch contacts) at
room temperature [70°F (±5°F) (21.1°C (±2°C)].
(2)
Suspend the thermoswitch plate (23) with thermoswitch in a beaker of water
with the thermoswitch a minimum of 2 inches from the bottom and 1 inch
from the top of the water surface.
(3)
Insert a thermometer, or other suitable temperature-measuring device in the
water with the bulb adjacent to the thermoswitch.
(4)
Slowly raise the water temperature to 150°F (65.55°C) while observing the
ohmmeter (still connected to pins 8 and 9). Ohmmeter should read >1MΩ at
temperatures below 150°F (65.55°C).
(5)
Continue to raise the water temperature to 160°F (71.11°C) and allow the
temperature to stabilize at that temperature. The thermoswitch should close
(<1MΩ resistance) by the end of 5 minutes at a stabilized temperature of
160°F (71.11°C).
(6)
Slowly add cool water to the beaker to reduce the water temperature to 135°F
(57.22°C). The thermoswitch should open (>1MΩ) within 5 minutes at a
stabilized temperature of 135°F (57.22°C).
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(7)
L.
If the thermoswitch fails to meet any of the above criteria, replace the
temperature sensor assembly (22) with factory new.
Vent Valve Pressure Test
Check the operation of the vent valve assemblies as follows:
(1)
Prepare a fixture from stainless steel tubing with an end adapter threaded on
the inside to match the vent valve threads (M8 x 1.00). The adapter can be
made from 1/2 inch round stock with 1/4 inch I.D. hole.
(2)
Screw the valve (3) with its o-ring (4) into the adapter end of the pressure test
fixture.
(3)
Attach the fixture to a compressed air line through an adjustable pressure
reducing valve limited to 20 psi (1.4 bar).
(4)
Immerse the valve and end of fixture in water, and slowly raise the pressure.
Make sure the valve opens between 2 psi and 10 psi (0.14 to 0.7 bar).
(5)
Reuse only those vent valves that open in the 2 psi to 10 psi (0.14 to 0.7 bar)
range. Re-soak those valves that do not open at 10 psi. Discard valves that are
not gas tight at low pressure.
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4.
Fault Isolation
Fault isolation information is presented in Figure 106 as a guide in locating a cause of
malfunction and isolating the cause to a specific component.
FAULT
Zero volt with battery set to
"charge"
Zero volt with battery set to
"discharge”
POSSIBLE CAUSE
REMEDY
Defective electrical
connector (not making
contact).
Check electrical contacts, links and
tightness of nuts (CHECK)
Link loose or broken.
Replace if necessary, torque all
upper terminal nuts (CHECK)
Battery fully discharged
Recharge battery (TESTING and
FAULT ISOLATION)
Battery circuit open or
defective contacts.
Check insulation (TESTING and
FAULT ISOLATION)
Check contacts, links and torque of
terminal nuts
Cell(s) completely dry
Adjust electrolyte level (TESTING
and FAULT ISOLATION)
Fault Isolation
Table 106 (Page 1 of 5)
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FAULT
Leakage of Electrolyte
POSSIBLE CAUSE
REMEDY
Incorrect adjustment of level Disassemble and clean the battery
(DISASSEMBLY, CLEANING
and TESTING and FAULT
ISOLATION)
Check electrolyte level (TESTING
and FAULT ISOLATION)
Cell polarity reversed during Disassemble and clean the battery
(DISASSEMBLY AND
high rate discharge (e.g.
CLEANING)
during starting)
Check electrolyte level (TESTING
and FAULT ISOLATION)
Retighten vent-valve
Loose or damage vent-valve
Overcharge at high
temperatures or using
excessive current
Test vent valve (TESTING AND
FAULT ISOLATION)
Check the on-board charging circuit
and if necessary adjust
Disassemble and clean battery
(DISASSEMBLY AND
CLEANING)
Check electrolyte level (TESTING
and FAULT ISOLATION)
Traces of electrolyte in battery
box
Damaged cell case
Check sealing of cells (CHECK)
Fault Isolation
Figure 106 (Page 2 of 5)
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FAULT
POSSIBLE CAUSE
Leakage of electrolyte
REMEDY
See “Electrolyte Leakage” in this
section.
Excessive water consumption in Heavy overcharge or
all battery cells
overcharge at high
temperatures
Check the on-board charging circuit
and adjust if necessary
Defective thermistor
Test temperature sensor harness
assembly (TESTING AND FAULT
ISOLATION).
Leaking cell(s)
Check sealing of cell(s) (CHECK)
One or several cells whose
water consumption differs
significantly from that of other
cells in the battery:
more than 30% above
average
Disassemble and clean the battery
(DISASSEMBLY and
CLEANING)
Check electrolyte level (TESTING
and FAULT ISOLATION)
25% or less of the average
value
Corrosion on links
Cell(s) with damaged
separator(s)
Perform special testing (TESTING
and FAULT ISOLATION) If
necessary, replace with new Saft
cell (DISASSEMBLY,
ASSEMBLY)
Operation in acid
atmosphere
Make sure that battery test bench
and storage areas are free from
materials which may produce acid
fumes
Fault Isolation
Figure 106 (Page 3 of 5)
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FAULT
POSSIBLE CAUSE
REMEDY
Mechanical damage to
nickel plating
Replace damaged links
(DISASSEMBLY and
ASSEMBLY)
Indications of link overheating
Loose terminal nuts
Check torque
Cell with abnormally high
voltage at start of charge
Cell dry or insufficient
electrolyte level
As soon as the fault is observed add
10 cm3 of distilled water to the cell.
Do not adjust precisely until the end
of charge
NOTE: A cell charging with
insufficient electrolyte may also
show considerable temperature rise
Main charge cut off voltage
Battery not fully discharged Perform a regular check (CHECK)
reached before minimum time or strongly unbalanced
or not reached at the maximum
time
Cell with abnormally low
voltage at end of charge (Less
than 1.50 V)
Exposure to high
temperatures, high charge
rates or separator damage
Low capacity cell (reversed
Normal wear after long
polarity, or a normal polarity
service
voltage of less than 1 V at the
end of a 64 minute discharge at
40A)
Exceptionally heavy use
(frequent self-starting;
operation at high
temperatures, with low
electrolyte level, etc.)
Replace cell (DISASSEMBLY,
ASSEMBLY)
Perform Regular Check (CHECK)
Replace with new SAFT cell
(DISASSEMBLY, ASSEMBLY)
Perform Regular Check (CHECK)
Replace with new Saft cell
(DISASSEMBLY, ASSEMBLY)
Fault Isolation
Figure 6 (Page 4 of 5)
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FAULT
POSSIBLE CAUSE
REMEDY
Cell with swollen case
Cell operated with low
electrolyte level,
deterioration of separator
and damaged plates
Replace with new SAFT cell
(DISASSEMBLY, ASSEMBLY)
Cell with zero voltage when
battery circuit is open
Short circuited cell
Replace with new Saft cell
(DISASSEMBLY, ASSEMBLY)
Low insulation resistance
Leakage of electrolyte
Disassemble and clean battery
(DISASSEMBLY AND
CLEANING)
Check electrolyte level (TESTING
and FAULT ISOLATION)
Fault Isolation
Figure 106 (Page 5 of 5)
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DISASSEMBLY
1.
General
Prior to disassembly, see TESTING and FAULT ISOLATION to determine condition of the
battery, cause, and remedy of malfunction. Disassemble only to the extent necessary to effect
repair and replacement.
NOTE:
2.
All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
Detailed Instructions
WARNING: BATTERY CELL ASSEMBLIES DELIVER VERY HIGH CURRENTS
WHEN SHORT-CIRCUITED. EXERCISE CAUTION. REMOVE RINGS,
WATCHES OR OTHER JEWELRY FROM HANDS AND ARMS.
WARNING: BATTERY MUST BE COMPLETELY DISCHARGED BEFORE CELL
ASSEMBLIES CAN BE REMOVED DUE TO POSSIBLITY OF ELECTRIC
SHOCK.
WARNING: USE CARE NOT TO TILT BATTERY WHILE VENT VALVES ARE
LOOSENED; CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE
SEVERE BURNS.
A.
Completely discharge the battery (TESTING and FAULT ISOLATION).
B.
Remove cover (8), pad (9) and formed insulator (10) assembly by opening latches and
lifting from case.
C.
Remove upper nuts (20) and washers (21) from terminals of cell assemblies (2) and
main connector (16).
D.
Remove intercell terminal links (11 through 15) from terminals of cell assemblies (2)
and main connector (16) being careful not to damage the nickel plating.
E.
Remove the battery connector receptacle (16) from the battery case (7) by removing
screws (18).
F.
Remove connector receptacle gasket (17) from the battery case (7).
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G.
Using the vent valve wrench (P/N 093382-000), loosen the vent valves (3) of all cells
to relieve any pressure; then re-tighten vent valves (use only finger pressure on
wrench when installing).
H.
Using cell removal tool (P/N 017556-000), remove cell assemblies (2) from the
battery case (7) by tightening the cell puller on cell terminals and removing cell with a
steady straight up pull.
I.
Disassembly of the cell assemblies (2) is restricted to replacing defective vent valve orings (4) and the lower terminal o-rings (not shown)(see REPAIR).
J.
Remove the temperature sensor assembly (22):
K.
(1)
Remove the thermoswitch mounting nuts (25) from the thermoswitch plate
(23).
(2)
Remove the temperature sensor connector mounting screws (24) and nuts (25)
and lift the temperature sensor connector assembly (22) out of the battery case
(7).
Remove all spacers (27) from the battery case (7).
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CLEANING
1.
General
CAUTION: DO NOT USE PETROLEUM SPIRITS, TRICHLOROETHYLENE OR
OTHER SOLVENTS FOR CLEANING THE BATTERY. USE OF THESE
PRODUCTS MAY DETERIORATE THE INTEGRITY OF METAL PARTS.
A.
The following items are required to perform the cleaning procedures (equivalent
substitutes can be used):
Stiff bristle brush (nonmetallic)
Dry compressed air source, less than 20 psi (1.4 bar)
Safety goggles
Lubricant (non-acid petroleum jelly)
Soft, clean cloth (two required)
Isopropyl alcohol (or non petroleum based) degreasing agent
Running water
Soap
Distilled or de-ionized water
2.
Light Cleaning (Assembled Battery)
A.
Discharge the battery.
NOTE:
All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
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B.
Remove the battery cover (8), pad (9) and formed insulator (10).
WARNING: USE CARE NOT TO TILT BATTERY WHILE VENT VALVES
ARE LOOSENED; CONTACT OF ELECTROLYTE WITH SKIN
CAN CAUSE SEVERE BURNS.
CAUTION:
C.
Using vent valve wrench (P/N 093382-000), make sure that the vent valves (3) of all
cell assemblies (2) are closed and secure. Do not over-tighten.
CAUTION:
D.
VENT VALVES MUST BE CLOSED TO PREVENT DIRT AND
FOREIGN MATTER FROM ENTERING CELLS DURING
CLEANING. VENT VALVES SHOULD BE CLOSED AT ALL
TIMES (TO AVOID EXPOSURE TO CO2), EXCEPT AS
DIRECTED OTHERWISE HEREIN. OVEREXPOSURE TO CO2
WILL AFFECT BATTERY PERFORMANCE OVER TIME.
DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS. CELLS
MAY BE DAMAGED.
Remove white deposits (potassium carbonate) from tops of all cell assemblies (2)
using a stiff bristle nonmetallic brush.
WARNING: TO PREVENT INJURY WHEN USING COMPRESSED AIR,
DIRECT STREAM AWAY FROM BODY. USE SAFETY
GOGGLES TO PREVENT INJURY TO EYES FROM FINE DUST
PARTICLES.
3.
E.
Disperse residual dust and particles from the battery with blasts of clean, dry,
compressed air not over 20 psi (1.4 bar).
F.
Coat cell assembly terminal nuts (5) and all intercell terminal links (11 through 15)
with a light film of non-acid petroleum jelly.
G.
Clean the exterior surfaces of the battery cover (8) and battery case (7) using a soft,
clean cloth, moistened with water. Dry with compressed air or a dry, clean cloth.
Thorough Cleaning (disassembled battery)
A.
Discharge the battery (TESTING and FAULT ISOLATION).
B.
Disassemble the battery (DISASSEMBLY).
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C.
Remove greasy residue from battery connector receptacle (16) with isopropyl alcohol.
D.
After ensuring that the vent valves (3) are closed, wash each cell (2) in running water.
Do not allow any water to enter the cell. Dry with compressed air or a dry, clean
cloth.
E.
Wash the battery case (7), cover (8) and pad (9), spacers (27), gasket (17), and cell
hardware (5 through 11) in warm, soapy water to remove dirt and salt deposits. A
plastic scraper or a stiff bristle brush (nonmetallic) may be used to aid in the removal
of heavy deposits. Rinse away all soap, and dry with compressed air or a dry, clean
cloth.
CAUTION
THE LENGTH OF TIME VENT VALVES ARE REMOVED FROM
THE CELL ASSEMBLIES SHOULD BE KEPT TO A MINIMUM.
OVER EXPOSURE OF THE ELECTROLYTE TO THE
ATMOSPHERE WILL AFFECT BATTERY PERFORMANCE DUE
TO CO2 CONTAMINATION.
F.
Remove the vent valves (3) from the cell assemblies (2), and submerge them and the
O-rings (4) in a clean container of distilled or deionized water. This treatment will
dissolve any salt deposits that may have accumulated in the vents of the valves or
around the O-ring seat. Cover the cells (2) with a damp, clean cloth, or take other
precautions to prevent any foreign particles from falling into the cells while the valves
are removed.
G.
Test the vent valve assemblies (3) to ensure they operate within the correct pressure
range (TESTING and FAULT ISOLATION).
H.
Install vent valve assemblies (3) with vent wrench.
I.
Assemble the battery (ASSEMBLY).
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CHECK
1.
Initial Commissioning
A.
Before the initial charge, thoroughly inspect the battery assembly to insure no damage
has occurred during shipping or storage as follows:
NOTE:
2.
All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
(1)
Inspect the battery case (7) and cover (8) for dents, distortion, or other
damage. Straighten with a small rubber mallet if necessary.
(2)
Remove the battery cover (8), pad (9) and formed insulator (10).
(3)
Visually verify the connector-receptacle (16) is present and undamaged.
(4)
Visually verify all cells (2) are positioned for proper polarity.
(5)
Visually verify all cells (2) are equipped with a vent valve (3).
(6)
Torque all upper cell nuts (5) per Fig 801.
(7)
Visually verify the temperature sensor assembly (22) is present and
undamaged.
B.
Charge the battery (TESTING and FAULT ISOLATION).
C.
Adjust the electrolyte (TESTING and FAULT ISOLATION).
D.
Place battery in service.
Assembled Battery
The following procedures are for an assembled battery (7) with battery cover (8), pad (9) and
formed insulator (10) removed.
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A.
Visually inspect battery for evidence of damage or electrolyte leakage. If damage to
any part(s) are visible, refer to REPAIR and/or TESTING and FAULT ISOLATION
for applicable procedures.
CAUTION:
3.
A BREAKDOWN IN ELECTRICAL INSULATION BETWEEN THE
CELLS AND THE BATTERY CASE WILL RESULT IN
“LEAKAGE” CURRENT, WHICH OVER A PERIOD OF TIME
CAN DISCHARGE THE BATTERY.
B.
Check the cell to case resistance (TESTING and FAULT ISOLATION).
C.
Check the torque on each upper terminal nut (5) per Fig 801.
D.
Check all ventilation openings to make sure that they are clean and clear.
Disassembled Battery
A.
Visually check each cell carefully for evidence of electrolyte leakage, cracks,
corrosion, burns, holes, or cross threaded terminals. Excessive salt around a terminal
post indicates leakage. Refer to REPAIR for replacement of lower terminal o-ring if
leakage is evident.
B.
Visually check each cell vent valve assembly (3) for defective o-rings, cracks, or other
physical damage. Replace defective o-rings (4). Vent valves that visually appear
damaged should be tested in accordance with the procedures in TESTING and
FAULT ISOLATION and/or discarded if necessary.
C.
Inspect intercell terminal links (11-15) for bends, tarnish, loss of nickel plating,
corrosion or burns. Tarnish can be polished off with a fine wire brush. Replace any
defective intercell links.
D.
Spacers (27) should be clean and free of cracks or holes. Replace any that are
defective.
CAUTION: A DEFECTIVE BATTERY CONNECTOR RECEPTACLE CAN
CAUSE BATTERY DISCHARGE, AS WELL AS IN SERVICE
LOW VOLTAGE.
E.
Check the battery connector receptacle (16) for evidence of arcing, corrosion, cracks
or cross threaded terminals. Using the same methods described in the cell to case
testing, test the battery connector receptacle by measuring the resistance between the
positive pin and the connector shell, and the negative pin and the connector shell.
Replace with factory new if found to be defective (DISASSEMBLY, ASSEMBLY).
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F.
Visually check the temperature sensor assembly (22) as follows:
(1)
Inspect electrical connector for bent or loose pins, corrosion, cracks, faulty
wire connections and evidence of arcing. Any evidence of the above
conditions however minor, is cause for replacement. Discard the damaged
unit and replace with factory new.
(2)
Inspect charge control thermistor and thermostat for damaged, loose or broken
wire connections, cracks, dents, or other physical defects. Any evidence of the
above conditions however minor, is cause for replacement. Discard the
damaged unit and replace with factory new.
(3)
Visually check all wiring for damage to insulation, cracked or broken wire and
other physical defects. Any evidence of the above conditions however minor,
is cause for replacement. Discard the damaged unit and replace with factory
new.
NOTE:
4.
The temperature sensor assembly (22) is a non-repairable item
and should be discarded if defective.
G.
Check all hardware items for damage.
H.
Check battery cover (8) and battery case (7) for damage.
Battery Maintenance
Battery maintenance may be carried out in accordance with the flow chart in Figure 102.
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REPAIR
1.
Temperature Sensor Harness Assembly
NOTE:
All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
If any part of the temperature sensor harness assembly (22) is damaged, the entire assembly
must be replaced (DISASSSEMBLY/ASSEMBLY).
2.
Cell Assembly
NOTE:
A.
If three cells are replaced during a service cycle, or five cells are replaced over
the life of the battery, it is Saft’s recommendation that the battery be replaced.
Replacement of the cell can be accomplished by:
(1)
Discharge the battery completely.
(2)
Remove upper cell terminal nuts (5) and intercell connecting links (11-15)
from the cell to be replaced.
(3)
Attach cell removal tool (P/N 017556-000) to the cell’s terminal and remove
cell from the case using a steady upward pull.
(4)
Replace cell with factory new by inserting the new cell into the case and
pushing downward on the cell terminals (with a small block of soft wood if
necessary)
NOTE:
B.
New cell should must be discharged before installation is
performed.
(5)
Attach intercell connecting links (11-15) and upper cell terminal nuts (5), and
torque nuts per Fig 801.
(6)
Continue with battery maintenance as outlined in Fig 102.
Repair to cell assembly (2) is limited to replacement of defective hardware (5 and 6),
the vent valve (3), the vent valve o-ring (4), and the lower terminal o-ring (not
shown). Defect of the cell itself requires cell replacement. To replace a defective
terminal o-ring:
(1)
Remove lower terminal nut and terminal o-ring being careful to prevent
anything from falling into the cell opening.
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(2)
B.
3.
Replace o-ring and torque lower terminal nut per Figure 801.
When inspection reveals electrolyte leakage from the cell at the vent hole opening,
replace the defective O-ring (4) as follows:
(1)
Using the vent-valve wrench (P/N 093382-000), loosen and remove the vent
valve (3) from the cell assembly (2).
(2)
Cover the cell with a damp, clean cloth to prevent any foreign particles from
falling into the cell.
(3)
Remove the defective O-ring (4) from the vent valve (3), and install a new Oring (4) onto the vent valve (3).
(4)
Remove the cloth from the cell, and insert the vent valve (3) into the cell
assembly (2). Using the vent valve wrench (P/N 093382-000), tighten the vent
valve securely in place. To ensure they are tightened properly, use only finger
pressure on the wrench.
(5)
Clean cell assembly (2) in accordance with CLEANING.
Physical damage
When necessary, remove minor dents in the battery cover (8) and battery case (7) using a hard
rubber mallet. Polish out minor pits or scratches using a fine grain abrasive porous cloth.
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ASSEMBLY
1.
General
This section contains assembly instructions necessary after disassembly and repair.
2.
Liners and Cells
NOTE:
Ensure all components are clean and dry before assembly.
A.
Insert one edge of bottom liner (27.10) (Fig 702) into battery case from either the left
or right side, then slide the liner under the cell partition.
B.
Install temperature sensor assembly (22) (IPL Fig 1) as follows:
C.
(1)
Insert the temperature sensor assembly connector into its mounting hole in the
case (7) (IPL Fig 1) and install the mounting screws (24) (IPL Fig 1) and nuts
(25) (IPL Fig 1).
(2)
Insert the thermoswitch liner (27.9) (Fig 702) and thermoswitch liner assembly
(27.11) (Fig 702) on the inside face of the center partition, take care to align
the holes in the liner with the hole in the partition.
(3)
Insert the thermoswitch plate (23) (IPL Fig 1) in back of liner assembly
(27.11) so that the liner assembly (27.11) (Fig 702) is between the
thermoswitch plate (23) (IPL Fig 1) and the thermoswitch liner (27.9) (Fig
702) against the partition.
(4)
Pass the thermoswitch end of the temperature sensor assembly (22) (IPL Fig 1)
through the hole in the partition, liner (27.9) (Fig 702), and liner assembly
(27.11) (Fig 702).
(5)
Attach the thermoswitch to the thermoswitch plate (23) (IPL Fig 1) with
mounting nuts (25) (IPL Fig 1).
Install the center row liners and cell subassemblies as follows:
(1)
Install liners (27.4 and 27.7) (Fig 702) on inside of cell partition.
(2)
Install five cell subassemblies (2) (IPL Fig 1) into positions 4, 5, 6, 9 and 10 in
the center partition of battery case (7) (IPL Fig 1). Be sure to maintain the
proper cell arrangement and polarity orientation per Fig 703. Install the charge
control thermistor plate between cells 6 and 9 as shown in IPL Figure 1.
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(3)
Install liners (27.5 and 27.8) (Fig 702) into the center partition of battery case.
(4)
Install a cell assembly (2) (IPL Fig 1) into position 13 in the center partition of
the battery case (7) (IPL Fig 1). Insertion of the last cell is sometimes
difficult, and may be assisted by pushing down on the terminals with a small
block of softwood.
NOTE:
D.
Install the left and right side row of cells and liners as follows:
(1)
Install liners (27.8, 27.5, 27.6 and 27.3) (Fig 702) into the battery case (7) (IPL
Fig 1) as shown in Fig 702.
(2)
Install six cell assemblies (2) (IPL Fig 1) in the left and right hand side of the
battery case (7) (IPL Fig 1). Be sure to maintain the proper cell arrangement
and polarity orientation per Fig 703.
(3)
Install the left and right end liners (27.8) (Fig 702) into the battery case (7)
(IPL Fig 1) at each end as shown in IPL Fig 702.
(4)
Install the remaining two cell assemblies (2) (IPL Fig 1) into the battery case
(7) (IPL Fig 1). Be sure to maintain the proper cell arrangement and polarity
orientation per Fig 703. Insertion of the last cell on each side is sometimes
difficult, and can be assisted by pushing down on the terminals with a small
block of softwood.
NOTE:
3.
Liners (27.1) (Fig 702) are used as required to ensure the center
row cells are retained securely in place. As indicated in Fig
702, the maximum quantity to be used is as shown.
Liners (27.1 and 27.2) (Fig 702) are used as required to ensure
the left and right hand row of cells are retained securely in
place. The maximum quantity to be used is shown in Fig 702.
Battery Connector Receptacle
Install the main connector (16) (IPL Fig 1) in the case (7) (IPL Fig 1) using the following
steps:
A.
Assemble connector gasket (17) (IPL Fig 1) to the adapter connector (16) (IPL Fig 1).
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4.
B.
Insert terminals of the adapter connector (16) (IPL Fig 1) through the oval mounting
hole in the front of the battery case (7) (IPL Fig 1).
C.
Attach the adapter connector (16) (IPL Fig 1) to the battery case (7) (IPL Fig 1) with
sems screws (18) (IPL Fig 1). Secure the receptacle by tightening the screws (18)
(IPL Fig 1) per Fig 801.
Hardware
Install the intercell connecting hardware using the following steps:
A.
Recheck all cell polarities.
B.
Mount the intercell connector links (11 through 15)(IPL, Fig 1).
(1)
Replace any intercell connector links that are bent, burnt, or have defective
nickel plating.
(2)
Using a small brush, lightly coat cell terminals and intercell links with neutral,
nonacid, petroleum jelly.
NOTE:
(3)
Mount the washers (6) (IPL Fig 1) and upper nuts (5) (IPL Fig 1).
NOTE:
(4)
5.
Excessive use of petroleum jelly on the terminals and connector
links will contribute to current leakage in high ambient
temperature operations. Extreme care should be exercised in
the use of this product.
Cell terminals should be lightly greased prior to installation of
nuts.
Torque upper nuts per Fig 801.
Storage
A.
General
The storage room should have an atmosphere free of acid, dust, or dampness. No
corrosive liquids or gases should be stored in the same room. Temperatures may
range from -75°F (-60°C) to +140°F (+60°C) without harming the battery. The most
desirable range for long term storage is between 32°F (0°C) to 86°F (30°C).
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
B.
Active stand-by storage
NOTE:
Due to a reduced risk of water depletion in the cells, this is the
preferred method of active standby.
NOTE:
Nickel-cadmium batteries automatically self-discharge at
approximately 0.25% per day at 68°F (20°C).
(1)
Saft vented cell batteries may be stored charged, ready for service in the
normal, upright or vertical position.
(a)
C.
Battery may be kept in a charged condition for a maximum period of
90 days after service under the following conditions:
1
Storage temperature of < 68°F (20°C).
2
Atmosphere free of acid, dust and dampness.
3
No corrosive liquids or gases stored in the same room.
4
After 90 days the battery must be charged and the water level
checked in accordance with procedures found in TESTING and
FAULT ISOLATION.
Inactive long term storage
Saft batteries are best kept discharged, in the same packing in which they were
shipped for long term storage.
D.
Shelf Life
Saft vented cell batteries may be stored, in the normal, upright or vertical position,
charged (they will self discharge over time) or discharged for a period of up to 10
years without damage.
E.
Preparation for use after storage (other than active standby storage)
(1)
Check all vent valves (3) (IPL Fig 1) for white salt deposits. If such deposits
are evident:
(a)
Remove, clean, and test the vent valves (3) (IPL Fig 1) (TESTING and
FAULT ISOLATION).
(b)
Reinstall the vent valves (3) (IPL Fig 1) in the cells.
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COMPONENT MAINTENANCE MANUAL
4579
(2)
The battery temperature should be allowed to equalize to a range of 60°F
(15°C) to 90°F (32°C) before charging.
(3)
Charge the battery (Ref Fig 701).
(4)
Adjust the electrolyte level (TESTING and FAULT ISOLATION).
(5)
Perform a Capacity Check per instructions in TESTING and FAULT
ISOLATION under the section “Second Discharge”.
(6)
Recharge the battery (TESTING and FAULT ISOLATION).
(7)
Repeat (if necessary) the above charge/discharge sequence until the unit
accepts a full charge and delivers its rated capacity.
STORAGE TIME
Less than 3 months
SERVICE PROCEDURE
Charge the battery (TESTING and FAULT
ISOLATION).
More than 3 months
Perform electrical tests and charge the battery
(TESTING and FAULT ISOLATION).
Return to Service Procedures
Figure 701
F.
Packing and Transporting
The normal packing for shipment of Saft Ni-Cd batteries is with fiberboard or injected
foam packing enclosed in fiberboard or wooden outer containers. For overseas
shipments, wrapping in sealed plastic is recommended. Precautions must be taken to
keep batteries upright while in transit. All markings and documentation should
conform to current IATA regulations (UN2795 or UN2800 as applicable) governing
the shipment of vented Ni-Cd batteries.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
Battery Liners
Figure 702
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
Cell Polarity
Figure 703
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
FITS AND CLEARANCES
1.
Torque Table
Figure 801 is a listing of all pertinent torque values needed to assemble and service the
battery.
NOTE:
The values listed in Fig 801 are “lube torque” values. The threads should be
lightly greased prior to installation and applying torque.
Figure / Item Number
5
IPL Fig 1
5
IPL Fig 1
18
IPL Fig 1
2.
Torque Value
87 ±17.4 lbs.-in (10 ±2 N•m)
43.5 ± 17.4 lbs.-in (5 ±0.5 Nm)
20 lbs.-in (2.30Nm)
Torque Table
Fig 801
Name, Location
Nut, Terminal, Upper
Nut, Terminal, Lower
Screws, Receptacle
Fits and Clearances Table
No fits and clearances required.
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PAGE 801/802 Blank
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.
Special Tools
A.
Battery Maintenance Kit
(1)
The Battery Maintenance Kit (Saft P/N 17568-000) is required for
performance of the TESTING AND FAULT ISOLATION and
DISASSEMBLY procedures.
The syringe (P/N 020915-004) is used in the electrolyte level adjustment and
the cell puller (P/N 017556) is used in cell removal. Spare hardware, vent
valves, and O-rings are provided.
(2)
The following items in Figure 901 are the contents of the Saft Battery
Maintenance Kit.
Nomenclature
Saft Part Number
Cell Puller
017556-000
Syringe Assembly
020915-004
17mm Socket
093314-000
Vent Valve Wrench
093382-000
Washer, Spring
022228-000
O-Ring, Terminal
091181-002
Vent Valve Assembly
015957-000
Nut, Terminal
015579-000
Battery Maintenance Kit
Figure 901
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
PART NUMBER
NOMENCLATURE
T
E
S
T
/
F
A
U
L
T
APPLICATION
D
C
C
R
I
L
H
E
S
E
E
P
A
A
C
A
S
N
K
I
S
I
R
E
N
M
G
B
L
Y
X
093382-000
Wrench, Vent Valve
X
020915-004
Syringe, 20cm3 (1.22in3) (fig. 111)
X
017556-000
Wrench, Cell Extraction
Constant Current Power Unit
(0-60 Amp)
X
X
X
X
X
X
X
Constant Current Load Bank
(0-60 Amp)
X
X
X
X
X
X
X
X
X
Equalizing resistors
(1Ω 3W Minimum)
X
X
Megohmmeter
(0-50MΩ, 0-250 V continuous)
X
X
Precision Multimeter
(volt, Ω, mA)
X
X
Torque Wrench
(0-250 lb-in)
X
X
A
S
S
E
M
.
/
S
T
O
R
E
X
X
X
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
ILLUSTRATED PARTS LIST
1.
Introduction
A.
Purpose
(1)
B.
This section provides illustrations and parts breakdown of the 4579 battery,
which can be disassembled, repaired or replaced, and reassembled.
Explanation and Usage of Section
(1)
Assembly Order Indenture System
The Indenture System used in the parts list shows the relationship of one part
to another. For a given item, the number of indentures depicts the relationship
of the item to the associated next higher assembly.
(2)
Effectivity Code
Reference letters (A, B, C, etc.) are assigned in the EFF CODE column to each
top assembly. The reference letter of the applicable top assembly is also
shown in the EFF CODE column for each detail part and subassembly except
that no reference letter is shown for detail parts and subassemblies used on all
top assemblies.
(3)
Quantity Per Assembly
The UNITS PER ASSY column shows the total number of units required per
assembly, per subassembly, and per sub-subassembly as applicable. The
letters REF indicate the item is listed for reference purposes.
(4)
Parts Replacement Data
Interchangeability information will be provided in a future manual revision if
it becomes applicable.
(5)
Service Bulletin Incorporation
Service Bulletin incorporation information applicable to the parts list will be
provided in a future manual revision if it becomes applicable.
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
(6)
Items Not Illustrated
Items not illustrated are indicated by a dash ( - ) ahead of the item numbers in
the FIG. and ITEM NO. column.
(7)
Alpha Variant Item Numbers
(a)
(b)
(8)
Alpha variants A - Z (except I and O) are assigned to existing item
numbers when necessary to show:
1
Added items
2
Service Bulletin modifications
3
Configuration differences
4
Optional parts
5
Product improvement parts (non-service bulletin)
Alpha variant item numbers are not shown on the exploded view when
the appearance and location of the alpha variant item is the same as the
basic item.
Vendors
The vendor of all parts shown in the parts list is as follows:
Vendor Code
V09052
NAME / ADDRESS
Vendor Code
Saft America Inc.
F6177
711 Industrial Boulevard
Valdosta, GA 31601
USA
Phone: 229-247-2331
Fax: 229-247-8486
http://www.saftbatteries.com
NAME / ADDRESS
Saft
12 Avenue Sadi Carnot
93170 Bagnolet
France
Phone: 33 1 49 93 19 18
Fax: 33 1 49 93 19 56
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Jul 13/01
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
Figure 1 (#1 of 3)
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SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
Figure 1 (#2 of 3)
--------------------------------------------------------------------------------------------------------------------------
Figure 1 (#3 of 3)
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Jan 30/98
SAFT AMERICA INC.
COMPONENT MAINTENANCE MANUAL
4579
ILLUSTRATED PARTS LIST
Nomenclature
Fig Item
Part Number
1234567
.......
R
R
1
018550-000
2
-2A
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
23
24
25
27
28
29
018520-000
091181-002
015957-000
091180-008
015579-000
022228-000
018730-000
018552-003
018553-000
018559-000
015575-000
018569-000
015577-000
018567-000
018568-000
022078-000
009384-000
093616-000
015579-000
022228-000
018740-000
018737-000
092178-008
090064-000
018951-000
092508-001
093382-000
Nickel-Cadmium Battery (V09052)
018550-000 is Ref/Code for Saft 4579
. Cell Assembly (V09052 VHP450KA-1)
. . O-Ring, Lower Terminal
. . Valve, Vent
. . . O-Ring, Vent Valve
. . Nut, Terminal
. . Washer, Terminal
. Case, Battery
. Cover, Battery Case
. Pad, Hold Down
. Insulator, Formed
. Link, Flat, Terminal
. Link, Curved, Terminal
. Link, Flat, Terminal
. Link, Flat, Terminal
. Link, Flat, Terminal
. Receptacle, Battery Conn.
. Gasket, Conn. RCPT.
. Screw & Washer, Sems (Conn. RCPT MTG)
. Nut, Terminal Adapter
. Washer, Terminal Adapter
. Sensor Assembly, Temp
. . Plate, Thermoswitch
. . Screw, Conn. MTG
. . Nut, Conn. and Thermo MTG
. Liner, Spacer Kit
. Spring, Shorting
. Wrench, Vent Valve
Eff
Units
Per
Unit
Assy
Code
RF
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
20
2
1
1
4
4
1
1
1
1
5
3
2
10
1
1
1
4
2
2
1
1
4
6
1
1
1
- Not Shown
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