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) 24-31-05 PAGE T-1/T-2 Blank July 13/01 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 24-31-05 PAGE RR-1/RR-2 Blank July 13/01 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 RECORD OF TEMPORARY REVISIONS TEMPORARY REV NO PAGE NUMBER ISSUE DATE BY DATE BY 24-31-05 PAGE RTR-1/RTR-2 Blank Jan 30/98 SAFT AMERICA INC. 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: 24-31-05 PAGE SBL-1/SBL-2 Blank Jan 30/98 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 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 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 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 July 13/01 July 13/01 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 Jan 30/98 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 24-31-05 PAGE LEP-1/LEP-2 Blank July 13/01 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 24-31-05 PAGE TC-1/TC-2 Blank Jan 30/98 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 24-31-05 PAGE INTRO-1/INTRO-2 BLANK Jul 13/01 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 24-31-05 PAGE 1 Jan 30/98 SAFT AMERICA INC. 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 24-31-05 PAGE 2 Jan 30/98 SAFT AMERICA INC. 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 24-31-05 PAGE 101 Jan 30/98 SAFT AMERICA INC. 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 24-31-05 PAGE 102 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 103 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 104 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 105 Jan 30/98 SAFT AMERICA INC. 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 24-31-05 PAGE 106 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 107 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 108 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 109 Jan 30/98 SAFT AMERICA INC. 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 24-31-05 PAGE 110 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 111 July 13/01 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 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). 24-31-05 PAGE 112 July 13/01 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 (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. 24-31-05 PAGE 113 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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) 24-31-05 PAGE 114 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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) 24-31-05 PAGE 115 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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) 24-31-05 PAGE 116 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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) 24-31-05 PAGE 117 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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) 24-31-05 PAGE 118 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 301 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 302 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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. 24-31-05 PAGE 401 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 402 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 403/404 BLANK Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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. 24-31-05 PAGE 501 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 502 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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. 24-31-05 PAGE 503/504 BLANK Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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. 24-31-05 PAGE 601 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 (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. 24-31-05 PAGE 602 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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. 24-31-05 PAGE 701 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 (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). 24-31-05 PAGE 702 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 24-31-05 PAGE 703 Jan 30/98 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. 24-31-05 PAGE 704 Jan 30/98 SAFT AMERICA INC. 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. 24-31-05 PAGE 705 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Battery Liners Figure 702 24-31-05 PAGE 706 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Cell Polarity Figure 703 24-31-05 PAGE 707/708 Blank Jan 30/98 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. 24-31-05 PAGE 801/802 Blank Jan 30/98 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 24-31-05 PAGE 901 Jan 30/98 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 24-31-05 PAGE 902 Jan 30/98 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. 24-31-05 PAGE 1001 Jan 30/98 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 24-31-05 PAGE 1002 Jul 13/01 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Figure 1 (#1 of 3) 24-31-05 PAGE 1003 Jan 30/98 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Figure 1 (#2 of 3) -------------------------------------------------------------------------------------------------------------------------- Figure 1 (#3 of 3) 24-31-05 PAGE 1004 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 24-31-05 PAGE 1005//1006 Jul 13/01