CMM 24-31-05 PDF

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 Description of Change Effectivitity
List of Effective Pages
Pages 1 & 2 Revised to indicate All Models
added, revised and/or
deleted pages
Introduction
Page Intro 1 Revised address and All Models
updated phone numbers
Testing and Fault
Isolation
Page 111 Added testing All Models
parameters for shunt
connection in
Temperature Sensor
Assembly
Page 112 Defined parameter for

“open” circuit in K(6).
Illustrated Parts List
Page 1002 Added phone numbers All Models
and website address
Page 1005 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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RECORD OF REVISIONS
REV ISSUE INSERT BY REV ISSUE INSERT BY

NO. DATE DATE NO. DATE DATE
1 02/28/84 03/01/84 Saft
2 06/15/91 07/01/91 Saft
3 01/30/98 01/30/98 Saft
4 07/13/01
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RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE DATE BY DATE BY

REV NO NUMBER
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SERVICE BULLETIN LIST
SERVICE BULLETIN REVISION NUMBER DATE BULLETIN

NUMBER 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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LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page T-1 July 13/01 Cleaning 401 Jan 30/98

T-2 Blank 402 Jan 30/98
403 Jan 30/98
Record of Revisions RR-1 July 13/01 404 Blank
RR-2 Blank
Check 501 Jan 30/98
Record of Temporary RTR-1 Jan 30/98 502 Jan 30/98
Revisions RTR-2 Blank 503 Jan 30/98
504 Blank
Service Bulletin List SBL-1 Jan 30/98
SBL-2 Blank Repair 601 Jan 30/98
602 Jan 30/98
List of Effective Pages LEP-1 July 13/01
LEP-2 Blank Assembly 701 Jan 30/98
702 Jan 30/98
Table of Contents TC-1 Jan 30/98 703 Jan 30/98
TC-2 Blank 704 Jan 30/98
705 Jan 30/98
Introduction INTRO-1 Jul 13/01 706 Jan 30/98
INTRO-2 Blank 707 Jan 30/98
708 Blank
Description and 1 Jan 30/98
Operation 2 Jan 30/98 Fits and Clearances 801 Jan 30/98
802 Blank
Testing and Fault 101 Jan 30/98
Isolation 102 Jan 30/98 Special Tools, 901 Jan 30/98
103 Jan 30/98 Fixtures, and 902 Jan 30/98
104 Jan 30/98 Equipment
105 Jan 30/98
106 Jan 30/98 Illustrated Parts List 1001 Jan 30/98
107 Jan 30/98 1002 Jan 30/98
108 Jan 30/98 1003 Jan 30/98
109 Jan 30/98 1004 Jan 30/98
110 Jan 30/98 1005 July 13/01
111 July 13/01 1006 Blank
112 July 13/01
113 Jan 30/98
114 Jan 30/98
115 Jan 30/98
116 Jan 30/98
117 Jan 30/98
118 Jan 30/98
Disassembly 301 Jan 30/98

302 Jan 30/98
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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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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 Saft
711 Industrial Boulevard 12 Avenue Sadi Carnot
Valdosta, Georgia 31601 93170 Bagnolet, France
Telephone: (229) 247-2331 Telephone: 33 1 49 93 19 18

FAX: (229) 247-8486 FAX: 33 1 43 93 19 56
Verification:
Testing / Fault Isolation: June 15, 1991

Disassembly: June 15, 1991
Assembly: June 15, 1991
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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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Voltage:
Nominal 24 Volts
Open Circuit Voltage, fully charged 26 ±1 Volts
Weight 96 lb. (43.64 Kg)
Dimensions (Maximum):
Height 11.4” (285 mm)
Length (including side brackets) 13.0” (325 mm)
Width (including handles) 11.0” (275 mm)
Cell Assembly Terminal M10 X 1.25
Number of Cell Assemblies 20
Cell Model VHP450KA-1
Rated Capacity 40 Ah (1 hour rate)

End of Life Capacity 40 Ah (1 hour rate)
Venting Pressure 2 to 10 psi (0.14 to 0.7 bar)

Cell Assembly Case Material Polyamide
Battery Case Material Stainless Steel
Electrolyte Potassium Hydroxide
Leading Particulars
Figure 2
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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: All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
2. Required Test Equipment
NOTE: Test equipment having equivalent specifications can be used.
NOMENCLATURE APPLICATION
DC Power Supply, regulated, Testing / Fault Isolation

35 Vdc 0-60A minimum
Precision Multi-meter, Testing / Fault Isolation

(precision +0.5%),
0-2 V, 0-5 V, and 0-50 V scales
required
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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NEW OR REMOVED
FROM FROM
STORAGE AIRCRAFT
CHECK CELL NUT CHECK CELL NUT

TORQUE TORQUE
PG 801 PG 801
CHARGE INITIAL
DISCHARGE
ADJUST RESIDUAL
ELECTROLYTE DISCHARGE
ALL CELLS
>1.50V
ANY CELL
<1.50V
*
RECHARGE
INITIAL
DISCHARGE ALL CELLS ANY CELL
CAPACITY TEST >1.50V <1.50V
SPECIAL SECOND
GOOD NO-GOOD
TESTING DISCHARGE
REST CONTINUE
10 - 12 HRS. AT RESIDUAL GOOD NOT GOOD
DISCHARGE
UNDER
CHARGE
“REMOVED
FROM AIRCRAFT”
* CHARGE
ADJUST LEVEL
ELECTROLYTE ELECTROLYTE
ALL CELLS ANY CELL

INSULATION
>1.50V <1.50V
CHECK SPECIAL
TESTING
INSULATION
CHECK
CHECK CELL NUT
TORQUE
PG 801
CHECK CELL NUT

*
TORQUE
PLACE IN PG 801
SERVICE
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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3. Testing
A. Test Conditions
(1) Facilities and equipment
CAUTION: 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.
(2) For optimum results, conduct all tests with the battery temperature at 77°F
(25°C).
B. 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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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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DISCHARGE TIMES
DISCHARGE RATE MINIMUM TIME FOR FIRST CELL TO
(AMPS) DISCHARGE TO 1 VOLT
BATTERY WITH NEW BATTERY

PRIOR SERVICE
FROM STORES OR
AIRCRAFT
10 260.0 MINUTES 270.0 MINUTES
Discharge Times
Figure 103
D. 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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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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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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(b) 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.
G. 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.
(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).
H. 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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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: 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.
I. 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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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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(5) Replenish low electrolyte:
NOTE: 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.
J. 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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(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: At 160°F (71°C) the thermistor resistance shall be 382 ±74Ω.
(8) If the thermistor fails any of the above tests, replace the temperature sensor
assembly (22) with a factory new.
K. 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) If the thermoswitch fails to meet any of the above criteria, replace the
temperature sensor assembly (22) with factory new.
L. 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 POSSIBLE CAUSE REMEDY
Zero volt with battery set to Defective electrical Check electrical contacts, links and
"charge" connector (not making tightness of nuts (CHECK)
contact).
Link loose or broken. Replace if necessary, torque all

upper terminal nuts (CHECK)
Zero volt with battery set to Battery fully discharged Recharge battery (TESTING and
"discharge” FAULT ISOLATION)
Battery circuit open or Check insulation (TESTING and

defective contacts. 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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Leakage of Electrolyte Incorrect adjustment of level Disassemble and clean the battery
(DISASSEMBLY, CLEANING
and TESTING and FAULT
ISOLATION)
Check electrolyte level (TESTING

Cell polarity reversed during Disassemble and clean the battery

high rate discharge (e.g. (DISASSEMBLY AND
during starting) CLEANING)

Retighten vent-valve
Loose or damage vent-valve
Test vent valve (TESTING AND
FAULT ISOLATION)
Overcharge at high Check the on-board charging circuit

temperatures or using and if necessary adjust
excessive current
Disassemble and clean battery

(DISASSEMBLY AND
CLEANING)

Traces of electrolyte in battery Damaged cell case Check sealing of cells (CHECK)
box
Fault Isolation
Figure 106 (Page 2 of 5)
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Leakage of electrolyte See “Electrolyte Leakage” in this

section.
Excessive water consumption in Heavy overcharge or Check the on-board charging circuit
all battery cells overcharge at high and adjust if necessary
temperatures
Defective thermistor Test temperature sensor harness

assembly (TESTING AND FAULT
ISOLATION).
One or several cells whose

water consumption differs
significantly from that of other
cells in the battery:
more than 30% above Leaking cell(s) Check sealing of cell(s) (CHECK)
average
Disassemble and clean the battery
(DISASSEMBLY and
CLEANING)

25% or less of the average Cell(s) with damaged Perform special testing (TESTING
value separator(s) and FAULT ISOLATION) If
necessary, replace with new Saft
cell (DISASSEMBLY,
ASSEMBLY)
Corrosion on links Operation in acid Make sure that battery test bench
atmosphere and storage areas are free from
materials which may produce acid
fumes
Fault Isolation
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Mechanical damage to Replace damaged links

nickel plating (DISASSEMBLY and
ASSEMBLY)
Indications of link overheating Loose terminal nuts Check torque
Cell with abnormally high Cell dry or insufficient As soon as the fault is observed add
voltage at start of charge electrolyte level 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 Exposure to high Replace cell (DISASSEMBLY,

voltage at end of charge (Less temperatures, high charge ASSEMBLY)
than 1.50 V) rates or separator damage
Low capacity cell (reversed Normal wear after long Perform Regular Check (CHECK)
polarity, or a normal polarity service
voltage of less than 1 V at the Replace with new SAFT cell
end of a 64 minute discharge at (DISASSEMBLY, ASSEMBLY)
40A)
Exceptionally heavy use Perform Regular Check (CHECK)

(frequent self-starting;
operation at high Replace with new Saft cell
temperatures, with low (DISASSEMBLY, ASSEMBLY)
electrolyte level, etc.)
Fault Isolation
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Cell with swollen case Cell operated with low Replace with new SAFT cell
electrolyte level, (DISASSEMBLY, ASSEMBLY)
deterioration of separator
and damaged plates
Cell with zero voltage when Short circuited cell Replace with new Saft cell
battery circuit is open (DISASSEMBLY, ASSEMBLY)
Low insulation resistance Leakage of electrolyte Disassemble and clean battery

(DISASSEMBLY AND
CLEANING)

Fault Isolation
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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.
2. 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 o-
rings (4) and the lower terminal o-rings (not shown)(see REPAIR).
J. Remove the temperature sensor assembly (22):
(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).
K. 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.
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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: 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.
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: DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS. CELLS

MAY BE DAMAGED.
D. 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.
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.
3. 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:
(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.
2. 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: 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.
3. 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: 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.
4. 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
If any part of the temperature sensor harness assembly (22) is damaged, the entire assembly
must be replaced (DISASSSEMBLY/ASSEMBLY).
2. Cell Assembly
NOTE: 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.
A. 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: 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.
B. 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) Replace o-ring and torque lower terminal nut per Figure 801.
B. 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 O-
ring (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.
3. 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:
(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).
C. 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: 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.
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: 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.
3. 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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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.
4. 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: 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.
(3) Mount the washers (6) (IPL Fig 1) and upper nuts (5) (IPL Fig 1).
NOTE: Cell terminals should be lightly greased prior to installation of

nuts.
(4) Torque upper nuts per Fig 801.
5. 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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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) 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.
C. 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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(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 SERVICE PROCEDURE

Less than 3 months 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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Battery Liners
Figure 702
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Cell Polarity
Figure 703
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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 Torque Value Name, Location

IPL Fig 1 5 87 ±17.4 lbs.-in (10 ±2 N•m) Nut, Terminal, Upper
IPL Fig 1 5 43.5 ± 17.4 lbs.-in (5 ±0.5 Nm) Nut, Terminal, Lower
IPL Fig 1 18 20 lbs.-in (2.30Nm) Screws, Receptacle
Torque Table
Fig 801
2. Fits and Clearances Table
No fits and clearances required.
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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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APPLICATION
T D C C R A
E I L H E S
S S E E P S
T A A C A E
/ S N K I M
PART NUMBER NOMENCLATURE F S I R .
A E N /
U M G S
L B T
T L O
Y R
E
093382-000 Wrench, Vent Valve X X X X X X
020915-004 Syringe, 20cm3 (1.22in3) (fig. 111) X X X
017556-000 Wrench, Cell Extraction X X
Constant Current Power Unit X X X

(0-60 Amp)
Constant Current Load Bank X X X X

(0-60 Amp)
Equalizing resistors X X
(1Ω 3W Minimum)
Megohmmeter X X
(0-50MΩ, 0-250 V continuous)
Precision Multimeter X X X X
(volt, Ω, mA)
Torque Wrench X X X X
(0-250 lb-in)
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4579
1. Introduction
A. Purpose
(1) This section provides illustrations and parts breakdown of the 4579 battery,
which can be disassembled, repaired or replaced, and reassembled.
B. 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.
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) 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)
(b) 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.
(8) Vendors
The vendor of all parts shown in the parts list is as follows:
Vendor Code NAME / ADDRESS Vendor Code NAME / ADDRESS

V09052 Saft America Inc. F6177 Saft
711 Industrial Boulevard 12 Avenue Sadi Carnot
Valdosta, GA 31601 93170 Bagnolet
USA France
Phone: 229-247-2331 Phone: 33 1 49 93 19 18
Fax: 229-247-8486 Fax: 33 1 49 93 19 56
http://www.saftbatteries.com
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Jul 13/01
SAFT AMERICA INC.
4579
Figure 1 (#1 of 3)
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PAGE 1003
Jan 30/98
SAFT AMERICA INC.
4579
Figure 1 (#2 of 3)
--------------------------------------------------------------------------------------------------------------------------
Figure 1 (#3 of 3)
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PAGE 1004
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SAFT AMERICA INC.
4579
Nomenclature Units
Per
Fig Item Part Number 1234567 Eff Unit
Assy
....... Code
R 1 018550-000 Nickel-Cadmium Battery (V09052) RF
018550-000 is Ref/Code for Saft 4579
2 018520-000 . Cell Assembly (V09052 VHP450KA-1) EA 20
-2A 091181-002 . . O-Ring, Lower Terminal EA 2
3 015957-000 . . Valve, Vent EA 1
4 091180-008 . . . O-Ring, Vent Valve EA 1
5 015579-000 . . Nut, Terminal EA 4
6 022228-000 . . Washer, Terminal EA 4
7 018730-000 . Case, Battery EA 1
8 018552-003 . Cover, Battery Case EA 1
9 018553-000 . Pad, Hold Down EA 1
10 018559-000 . Insulator, Formed EA 1
11 015575-000 . Link, Flat, Terminal EA 5
12 018569-000 . Link, Curved, Terminal EA 3
16 022078-000 . Receptacle, Battery Conn. EA 1
17 009384-000 . Gasket, Conn. RCPT. EA 1
18 093616-000 . Screw & Washer, Sems (Conn. RCPT MTG) EA 4
20 015579-000 . Nut, Terminal Adapter EA 2
21 022228-000 . Washer, Terminal Adapter EA 2
22 018740-000 . Sensor Assembly, Temp EA 1
R 23 018737-000 . . Plate, Thermoswitch EA 1
24 092178-008 . . Screw, Conn. MTG EA 4
25 090064-000 . . Nut, Conn. and Thermo MTG EA 6
27 018951-000 . Liner, Spacer Kit EA 1
28 092508-001 . Spring, Shorting EA 1
29 093382-000 . Wrench, Vent Valve EA 1
- Not Shown
24-31-05
PAGE 1005//1006
Jul 13/01

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To: Holders of 4579 (Saft 018550-000) batteries

Revision No. 4 Dated July 13, 2001

Page 112 Defined parameter for

Page 1005 Various

Saft America, Inc.

COMPONENT MAINTENANCE MANUAL

ILLUSTRATED PARTS LIST

Nickel Cadmium Battery

(BA06 ELDEC PART NUMBER)

REV ISSUE INSERT BY REV ISSUE INSERT BY

TEMPORARY PAGE ISSUE DATE BY DATE BY

SERVICE BULLETIN REVISION NUMBER DATE BULLETIN

Title Page T-1 July 13/01 Cleaning 401 Jan 30/98

Disassembly 301 Jan 30/98

PARAGRAPH TITLE PAGE

Description and Operation 1

Testing and Fault Isolation 101

Automatic Test Requirements (ATLAS) N/A

Assembly (Including Storage) 701

Fits and Clearances 801

Special Tools, Fixtures, and Equipment 901

Illustrated Parts List 1001

The manual is divided into separate sections:

Telephone: (229) 247-2331 Telephone: 33 1 49 93 19 18

Testing / Fault Isolation: June 15, 1991

Cell Assembly Terminal M10 X 1.25

Number of Cell Assemblies 20

Cell Model VHP450KA-1

Rated Capacity 40 Ah (1 hour rate)

Venting Pressure 2 to 10 psi (0.14 to 0.7 bar)

2. Required Test Equipment

NOTE: Test equipment having equivalent specifications can be used.

DC Power Supply, regulated, Testing / Fault Isolation

Precision Multi-meter, 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

CHECK CELL NUT CHECK CELL NUT

ALL CELLS ANY CELL

CHECK CELL NUT

(1) Facilities and equipment

CAUTION: FUMES FROM LEAD ACID BATTERIES OR SMALL

C. Initial Discharge (Capacity Test)

The purpose of this discharge procedure is to determine the initial capacity of a

(3) Monitor individual cell voltages periodically during the discharge.

(6) Interpretation of the Initial Discharge Results.

2 The battery cells have temporarily or permanently lost

3 A condition of cell capacity imbalance has developed.

Proceed with Residual Discharge, Charge and Second Discharge as

NOTE: It may be necessary to perform a deep cycle several

BATTERY WITH NEW BATTERY

CAUTION: ATTEMPTING TO CHARGE BATTERIES WITH LOW

(2) Loosen, but do not remove, all vent valves (1).

CAUTION: CHECK INDIVIDUAL CELL VOLTAGES AT THE

(5) Verify all cell voltages are above 1.50 V

CONSTANT CURRENT CHARGE

NOTE: It may be necessary to perform a deep cycle several times to correct a

(3) Monitor individual cell voltages periodically during the discharge.

NOTE It is not a cause for concern if a cell goes to zero volts or

(6) Interpretation of the Second Discharge (Capacity Check) Results

1 The time required to discharge all cells to 1 volt exceeds the

Therefore, the battery may be placed back into service after it is