To: Holders of 4579 (Saft 018550-000) Batteries Subject: CMM Revision No. 8 Dated Mar 15/19 Highlights Chapter/Section and Page Number Description of Change Effectivity

To: Holders of 4579 (Saft 018550-000) batteries
Subject: CMM Revision No. 8 Dated Mar 15/19
HIGHLIGHTS
Discard any previous revision of the CMM and use the current revision dated Mar 15/19.
NOTE: The CMM can be downloaded from the internet at www.saftbatteries.com
Chapter/Section and
Page Number Description of Change Effectivity
Title Page Add Revision 8 with Date All Models
Page T-1
Record of Revisions Add Revision 8 All Models
Page ROR-1
List of Effective Pages Corrected/Changed pages All Models
Page LEP-1
List of Illustrations Updated Figures All Models
Page LOI-1
List of Tables Added more definition on table All Models
Page LOT-1
Introduction Corrected to Warning callouts All Models
Page Intro-2
Introduction Clarified step of electrolyte ingestion All Models
Page Intro-3
Description Correction and updated figure All Models
Page 1
Testing and Fault Isolation Corrected Flow chart All Models
Page 1002
Testing and Fault Isolation Added clarification information and updated All Models
Page 1003 paragraph title
Testing and Fault Isolation Provided procedural clarity and updated page All Models
Page 1004 - 1006 information
Testing and Fault Isolation Updated page information and provide step All Models
Page 1007 - 1008 clarification
Testing and Fault Isolation Added information clarification on cell All Models
Page 1009 replacement recommendations. Updated
page information
Testing and Fault Isolation Updated page information. Added All Models
Page 1010 clarification on criteria for acceptable
capacity. Updated temperature and
resistance values to better represent room
temperature
Testing and Fault Isolation Updated page information. Error Correction. All Models
Page 1011 Added information clarification on cell
replacement recommendations.
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Highlights Page 1 of 2
Mar 15/19
Chapter/Section and
Page Number Description of Change Effectivity
Testing and Fault Isolation Updated page information and table callouts All Models
Page 1012 - 1016
Check Moved battery voltage check paragraph. All Models
Page 5003 Updated temperature and resistance values
to better represent room temperature
Assembly Updated page information, clarification to All Models
Page 7001 - 7004 prevent cell movement, and update figure.
Illustrated Parts Lists Updated table and quantities per assembly All Models
Page 10003
Illustrated Parts Lists Add title information to figures All Models
Page 10004 - 10006
Storage Update information for Inactive long-term All Models
Page 15001 -15003 storage and change page breaks to keep
information together
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Highlights Page 2 of 2
Mar 15/19
ECCN: EAR99
Cage Code 09052
711 GIL HARBIN INDUSTRIAL BOULEVARD
VALDOSTA, GEORGIA 31601
Phone: 1 (229) 247-2331 Fax: 1 (229) 247-8486
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
Nickel Cadmium Battery
4579
(BA06-01 ELDEC PART NUMBER)

(S282T002-1 BOEING PART NUMBER)
(SAFT PART NUMBER 018550-000)
Website: www.saftbatteries.com
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4579
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 07/13/01 Saft
5 06/16/17 06/16/17 Saft
6 10/02/17 10/02/17 Saft
7 Sep 6/18 Sep 6/18 Saft
8 Mar 15/19 Mar 15/19 Saft
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4579
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 Mar 15/19 Disassembly 3001 Sep 6/18

T-2 Blank 3002 Sep 6/18
Record of Revisions RR-1 Mar 15/19 Cleaning 4001 Sep 6/18

RR-2 Blank 4002 Sep 6/18
Record of Temporary RTR-1 Sep 6/18 Check 5001 Sep 6/18

Revisions RTR-2 Blank 5002 Sep 6/18
5003 Mar 15/19
Service Bulletin List SBL-1 Sep 6/18 5004 Sep 6/18
SBL-2 Blank 5005 Sep 6/18
5006 Blank
List of Effective Pages LEP-1 Mar 15/19
LEP-2 Blank Assembly 7001 Mar 15/19
7002 Mar 15/19
Table of Contents TOC-1 Sep 6/18 7003 Mar 15/19
TOC-2 Blank 7004 Mar 15/19
List of Illustrations LOI-1 Mar 15/19 Fits and Clearances 8001 Sep 6/18
LOI-2 Blank 8002 Blank
List of Tables LOT-1 Mar 15/19 Special Tools, 9001 Sep 6/18
LOT-2 Blank Fixtures, and 9002 Blank
Equipment
Introduction Intro-1 Sep 6/18
Intro-2 Mar 15/19 Illustrated Parts List 10001 Sep 6/18
Intro-3 Mar 15/19 10002 Sep 6/18
Intro-4 Sep 6/18 10003 Mar 15/19
10004 Mar 15/19
Description and 1 Mar 15/19 10005 Mar 15/19
Operation 2 Sep 6/18 10006 Mar 15/19
10007 Sep 6/18
Testing and Fault 1001 Sep 6/18 10008 Blank
Isolation 1002 Mar 15/19
1003 Mar 15/19 Storage 15001 Mar 15/19
1004 Mar 15/19 15002 Mar 15/19
1005 Mar 15/19 15003 Mar 15/19
1006 Mar 15/19 15004 Sep 6/18
1007 Mar 15/19 15005 Sep 6/18
1008 Mar 15/19 15006 Blank
1009 Mar 15/19
1010 Mar 15/19
1011 Mar 15/19
1012 Mar 15/19
1013 Mar 15/19
1014 Mar 15/19
1015 Mar 15/19
1016 Mar 15/19
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TABLE OF CONTENTS
PARAGRAPH TITLE PAGE
Introduction Intro-1
Description and Operation 1
Testing and Fault Isolation 1001
Disassembly 3001
Cleaning 4001
Check 5001
Repair N/A
Assembly 7001
Fits and Clearances 8001
Special Tools, Fixtures, and Equipment 9001
Illustrated Parts List 10001
Storage (Including Transportation) 15001
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LIST OF ILLUSTRATIONS
Figure Description Page
Intro 1 Universal Recycling Symbols Intro-4
1 Nickel Cadmium Battery 1
1001 Process Flow for Battery Restoration Procedures 1002
1002 Position of Syringe in Cell Vent Seal 1007
7001 Battery Liner Kit 7003
7002 Cell Number and Polarity Orientation 7004
10001 Battery, Exploded View (#1 or 4) 10004
15001 Charge Retention 15002
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LIST OF TABLES
Table Description Page
1 Leading Particulars 2
1001 Discharge Times 1004
1002 Current Charge Rates 1006
1003 Overcharge Minimum Voltage 1006
1004 Fault Isolation (#1 or 5) 1012
8001 Torque Table 8001
9001 Special Tools 9001
15001 Topping or Refresh Charge 15003
15002 Return to Service Following Storage 15005
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INTRODUCTION
1. General
A. This manual is written to the ATA Specification 100 and in AECMA Simplified
English. International Standard units of measure are used in this manual, with
imperial units in parentheses.
B. This manual describes maintenance on components in a workshop. It does not
describe maintenance on components when they are installed in aircraft.
C. Only approved personnel with the necessary skill can do maintenance tasks
described in this manual.
D. This manual contains:
(1) Technical data for components
(2) Maintenance procedures for components
(3) An Illustrated Parts List (IPL) with data for parts of components. Parts are
identified in all sections of the manual by IPL figure and item number.
E. We make sure of DISASSEMBLY, TESTING AND FAULT ISOLATION, and
ASSEMBLY procedures by doing them.
F. The manual is divided into separate sections:
(1) Title Page
(2) Record of Revisions
(3) Record of Temporary Revisions
(4) List of Effective Pages
(5) Table of Contents
(6) Introduction
(7) Procedures and IPL Sections
The disassembly and assembly sections generally contain only specific instructions used on
the equipment covered herein. Most standard aerospace practices are not described
herein.
This manual provides the information necessary for an experienced shop technician to
maintain Saft nickel-cadmium batteries. It describes construction of the battery, as well as
techniques used to operate, maintain, and generally care for the battery. Following these
instructions will enhance the ability to obtain optimum performance and maximum life from
Saft batteries.
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4579
All aircraft batteries require checking and maintenance to make sure they are safe when
installed and they perform their required functions especially in emergency conditions on
board the aircraft. Maintenance checks also permit any problems to be identified and
corrected. The maintenance interval is the period for which correct operation is assured
with a low probability of failure and allows high levels of MTBUR and MTBF to be achieved.
Every effort has been made to provide complete and accurate instructions. If a situation
should arise that is not adequately described in this manual, please contact Saft via the
internet at www.saftbatteries.com or at one of the following addresses:
Saft America Inc. (V09052) Saft (F6177)

711 Gil Harbin Industrial Boulevard 26, quai Charles Pasqua
Valdosta, Georgia 31601 92300 Levallois-Perret, France
Telephone: (229) 247-2331 Telephone: 33 1 58 63 16 00

FAX: (229) 247-8486 FAX: 33 1 58 63 16 18
2. Definitions
Warnings call attention to use of materials, procedures, or limits which must be followed
precisely to avoid injury to persons.
Cautions call attention to procedures which should be followed to avoid damage to
equipment.
Notes call attention to procedures which make the job easier.
3. Safety
WARNING: Except for those steps that require the battery to be charged, do all steps on
discharged batteries (refer to Initial Discharge and Residual discharge) to
avoid the possibility of electric shock. Tighten vent valves (3) prior to
beginning discharge. Battery cells deliver very high current when short-
circuited. Exercise caution. Remove rings, watches, necklaces, metallic belts
and other jewelry to avoid electric shock.
WARNING: Do not tilt the battery during maintenance, any contact of skin with electrolyte
can cause severe burns.
Safety rules are different from one country to another. Always follow local safety
regulations.
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There are three types of risks.
A. Physical
(1) Handling: the battery is heavy. When you lift it, bend your legs and not your
back.
(2) Use protective shoes.
B. Electrical
(1) Do not wear rings, watches, chains, belt buckles, necklaces, or any other
metallic objects.
(2) Use insulated tools.
C. Chemical
(1) For a complete listing of hazards, refer to the safety information sheet
available on Saft's website at www.saftbatteries.com.
(2) Electrolyte is very corrosive and can damage the skin: use gloves and an
apron. If it touches the skin, flush affected part with large quantity of water.
Remove contaminated clothing, after flushing begins.
(3) Electrolyte is very dangerous for eyes, use protective goggles. If the
electrolyte comes in contact with an eye, flush it with water and get medical
attention immediately.
(4) Electrolyte ingestion can cause damage to the throat and the respiratory
tract. Do not try to vomit and get medical attention immediately.
(5) Skin contact with nickel can cause chronic eczema.
(6) Inhalation of cadmium oxide can cause dry throat, headaches, vomiting,
chest pain. If inhaled, move to fresh air. If not breathing, give artificial
respiration. If breathing is difficult, give oxygen and get medical attention
immediately.
(7) Potassium hydroxide in the electrolyte can cause eczema.
4. New Battery Commissioning
NOTE: Whether or not the battery has been subject to disassembly and reassembly,
before going into service and installation, the tightness of all upper nuts / screws
must be checked to verify that torque values correspond with those specified (refer
to the Table 8001).
Saft batteries are shipped discharged. A visual inspection, torque check, charge procedure,
electrolyte check, and insulation test should be done prior to the battery being placed into
the aircraft for service. Refer to the Figure 1001.
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5. Battery Ratings
A. Capacity
Nickel-cadmium batteries are rated in terms of capacity in ampere-hours (Ah) (rated
capacity).
Other definitions for battery ratings can be found in EN2570, IEC 60952, and RTCA
DO 293.
6. Recycling
All batteries eventually lose their ability to perform and are eligible for scraping and
recycling. Saft takes environmental matters seriously and advocates proper recycling of
nickel-cadmium batteries and their components. To that end, Saft operates recycling
facilities in both Europe and North America.
Nickel-cadmium batteries contain nickel, cadmium, and potassium hydroxide and should be
disposed of properly. In all cases, rely on local and national regulations for proper battery
disposal and/or shipping to an appropriate recycling location.
Universal Recycling Symbols

Figure Intro 1
You can find the nearest recycling collection point on our website at www.saftbatteries.com.
Verification:
Testing / Fault Isolation: June 15, 1991

Disassembly: June 15, 1991
Assembly: June 15, 1991
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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 harness assembly. The harness 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.
Nickel-Cadmium Battery
Figure 1
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4579
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
Cell Rated Capacity (C1) 45 Ah (1-hour rate)

Battery Nameplate Capacity 40 Ah
Consumable volume of water per cell 80 cm3
Venting Pressure 2 to 10 psi (0.14 to 0.69 bar)
Cell Assembly Case Material Polyamide
Battery Case Material Stainless Steel
Electrolyte Potassium Hydroxide
Leading Particulars
Table 1
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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 Figure 1001. Fault isolation
information is presented in chart form (Table 1004).
NOTE: All ( ) part identification numbers herein are IPL, Figure 10001 item numbers.
2. Required Test Equipment

NOTE: Test equipment having equivalent specifications can be used.
Refer to Special Tools, Fixtures, Equipment for listing of Standard Tools
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RECEIVED
Insulation Check FAIL C B

[CHECK 3. B.]
PASS
< 1.5V Cell Voltage

Light Clean [TESTING 3.
Assembled Battery G. (4]
[CLEANING 2.]
> 1.5V
Check Cell Nut

Torque <100%
[CHECK 3. C.] FAIL Special Testing Capacity Test
[TESTING 3. J.] [TESTING 3. I.]
PASS > 100%

Total Voltage at Main
<21V
Connector
[CHECK 3. D.]
Charge
> 21V [TESTING 3. G.]
PASS PASS FAIL

Harness Assembly
[CHECK 3. F.]
Polarization Test
[TESTING 3. C.]
A
Adjust Electrolyte
[TESTING 3. H.]
FAIL
DISASSEMBLY
[Page 3001]
Initial and Residual
Discharge PASS
[TESTING 3. D. and
A < 1.5V Cell Voltage
3. E.] [TESTING 3.
G. (4]
FAIL
Harness Assembly
[TESTING 3. K.] > 1.5V
Clean and Test
C
Vent Valves
[TESTING 3. F.]
Insulation Check
Clean Disassembled [CHECK 3. B.]
Battery
[CLEANING 3.]
Charge
[TESTING 3. G.] Check Cell Nut
Torque
ASSEMBLY
[CHECK 3. C.]
[Page 7001]
Adjust Electrolyte
[TESTING 3. H.] Return To Service
Process Flow for Battery Restoration Procedures

B Figure 1001
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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 +
18°F + (25.0 + 10°C), unless otherwise noted in this manual.
B. Test Equipment
Refer to Section (Special Tools, Fixtures, and Equipment) for a complete list of all
test equipment required for proper maintenance of a Ni-Cd battery.
C. Polarization Test
(1) Charge the battery at 0.1C1 for 1.5 hours.
(2) Keep the battery in open circuit for 1 hour.
(3) Measure the open circuit voltage of each cell.
(a) If any cell is zero (0) V or negative polarity, mark for replacement any
cell(s). See Cell Replacement on page 1011 which requires
disassembly to replace marked cells.
(b) If all cells are greater than 0V, then continue with Figure 1001.
D. Initial Discharge / Capacity Check
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 placed 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 Table 1001 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 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) If the first cell discharge time at the specified rate is greater or equal
to the minimum time listed in Table 1001, the battery and all cells are
considered above rated capacity, “PASS”. Proceed to Figure 1001.
(b) If the first cell discharge time at the specified rate is less than the
minimum time listed in Table 1001, the battery capacity does not
comply, “FAIL”. Proceed to Figure 1001.
DISCHARGE TIMES
DISCHARGE FIRST CELL MINIMUM DISCHARGE TIME TO 1 VOLT
RATE (AMPS) BATTERY WITH PRIOR SERVICE NEW BATTERY
FROM STORES OR AIRCRAFT
10 260.0 MINUTES 270.0 MINUTES
Discharge Times
Table 1001
E. Residual Discharge
Discharge each cell in the battery to 0V using one of the first two procedures
methods that follow.
NOTE: It is not necessary to have a rest period between initial discharge and
residual discharge.
(1) Method 1
Continue to discharge the battery at a rate listed in Table 1001 until the
battery voltage <1.0 V, connect a 1.0 Ω (3.0 watt minimum) resistor (T03)
across each cell’s terminals. Leave the resistor (T03) in place for 16 to 24
hours to allow each cell to completely discharge.
(2) Method 2
Continue to discharge the battery at a rate listed in Table 1001 until the
battery voltage drops to <0.5 V, 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.
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(3) Remove the shorting devices.
(4) If no cells are marked for replacement, then return to Figure 1001 utilizing
the PASS or FAIL results of the Initial Discharge / Capacity Check.
(5) If cells were marked for replacement, then return to Special Testing.
F. Vent Valve Test
NOTE: This test can be omitted if the vent valves are replaced annually.
Check the operation of the vent valve assemblies as follows:
(1) Use the pressure test fixture (T05) or 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 0.69 bar).
(5) Reuse only those vent valves that open in the 2 psi to 10 psi (0.14 to 0.69
bar) range. Re-soak those valves that do not open at 10 psi. Discard valves
that are not gas tight at low pressure.
G. Charge
NOTE: The battery temperature at the start of a charge procedure must be at
room temperature 22.8 ± 7.2°C (73 ± 13°F). A 2-3 hour rest is required
following a discharge procedure. The rest period between the end of
charge and the start of discharge procedures must be between 1 hour
and 24 hours to ensure a valid capacity test.
CAUTION: ATTEMPTING TO CHARGE BATTERIES WITH LOW
ELECTROLYTE LEVELS IN ANY CELL MAY CAUSE PERMANENT
DAMAGE TO THAT CELL.
(1) Remove the cover (8), pad (9) and formed insulator (10).
(2) Loosen, but do not remove, all vent valves (3).
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 CM3
OF DISTILLED OR DEMINERALIZED WATER THROUGH
THE VENT VALVE OPENING OF THAT CELL.
(3) Charge using one of the two methods shown in Table 1002 and during the
during the last 30 minutes of the overcharge cycle, adjust the Electrolyte
Level.
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CONSTANT CURRENT CHARGE
Method Main Charge Overcharge
4.5 Amps until battery reaches 30 V 4.5 Amps – all cells > 1.5 V
Time:
1 Minimum: 10 hours Time:
*Maximum: 12 hours 4 hours
*New batteries may take 2.5 hours longer to reach the specific voltage
22.5 Amps until battery reaches 31 V 4.5 Amps – all cells > 1.5 V
Time:
2 Minimum: 2 hours Time:
**Maximum: 2 hours 30 min. 4 hours
**New batteries may take 30 minutes longer to reach the specific voltage
Current Charge Rates
Table 1002
(4) During the last 30 minutes of overcharge check that the cell voltages meet
the value shown in Table 1003 mark all cell(s) that do not comply, perform
Special Testing.
CELL VOLTAGE
Last 30 minutes at 0.1C1A
> 1.50V
Overcharge Voltage Limit
Table 1003
H. Electrolyte Level Adjustment

This procedure is to be carried out during overcharge at 0.1C1 amps during the last
30 minutes of charge cycle.
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) (29) supplied with the battery or T01.
(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 (T02) into the cell opening until the shoulder of the
nozzle rests on the valve seat (See Figure 1002).
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(b) Withdraw the plunger and check for any liquid in the syringe (T02).
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 (T02)
until the electrolyte is level with the end of the nozzle. This is the
correct level for the electrolyte.
0.79” (20 mm)
Position of Syringe in Cell Vent Seat

Figure 1002
(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, then it is recommended to shorten the period
between battery maintenance.
(a) Draw 5 cm3 of the distilled water into the syringe (T02) and inject it
into the cell.
(b) With the syringe nozzle resting on the valve seat, slowly withdraw the
plunger in the syringe (T02).
(c) If the syringe (T02) 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 (T02), the correct level for that cell has been reached. Expel
the excess liquid into a separate container for later disposal.
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I. Capacity Check (Second Discharge)
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.
(1) Discharge the battery at one of the rates listed in Table 1001 until the battery
reaches 20.0 V.
(a) Record the time at the start of the discharge and the discharge
current.
(b) Monitor individual cell voltages periodically during the discharge.
(c) 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.
(2) Interpretation of the Capacity Check (Second Discharge) Results
(a) Regardless of the results obtained in the first discharge, the battery
capacity is > 100% when the discharge time for first cell to 1.0 volt
meets or exceeds the minimum time listed in Table 1001. Refer to
Figure 1001.
(b) If the discharge time for first cell to 1.0 volt is less than the minimum
time listed in Table 1001, the capacity is <100%. Refer to Figure
1001. This would require Special Testing, or refer to Fault Isolation.
J. 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 overcharge.
NOTE: It is best to assume that all the original cells are or soon will be in
unsatisfactory condition due to length of service, heat, overcharge, etc. and
Saft strongly recommends all cells should be replaced with new Saft cells if:
• three cells or more cells are replaced during the same maintenance
interval
Or
• one or more cells required replacement after five cells were replaced
over the life of the battery
The following conditions are not to be counted in determining for the above
recommendation:
- Mechanical failure such as terminal thread damage,
- Cell leakage,
- Cell short-circuit
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NOTE: Except for batteries from long-term storage, it is recommended that a
battery requiring Special Testing more than 3 times that it be replace by a
Saft battery.
NOTE: For a battery from long-term storage, several complete charge/discharge
cycles may be required to restore performance.
(1) The vent valves (3) should be installed on top of each cell, then discharge
the battery to 1 volt/cell using one of the rates listed in Table 1001.
a. If the battery has completed the above step three times, then it is
recommended to mark for replacement any cell(s) that do not meet the
times listed for the Table 1001 rates.
(2) Continue to discharge the battery to 0V using section entitled Residual
Discharge.
(3) Replace all cell(s) marked for replacement per Cell Replacement.
(4) Loosen, but do not remove, all vent valves (3) and charge the battery per
Method 1 per Table 1002.
(5) Continue charging at 4.5A for an additional 4 hours. During the last 30
minutes adjust the Electrolyte Level.
(6) Monitor and record individual cell voltages every 15-20 minutes during the
additional 4 hour overcharge.
(7) Mark any cells for replacement that do not comply with Table 1003.
(8) Discharge the battery at one of the current rates and times shown in Table
1001 until the battery reaches 20.0V. Record the time the first cell reaches
1.0V.
(9) If no cell(s) requirement replacement and the time the first cell reaches 1.0V
equals or exceeds the values shown in Table 1001, then return to Figure
1001.
(10) If cell(s) are marked for replacement or the time the first cell reaches 1.0V is
less than the values shown in Table 1001, then repeat this procedure Special
Test or refer to Fault Isolation.
K. Harness Assembly
NOTE: A climate chamber or alternate method may be used provided the
temperatures below are achieved.
(1) Charge Control Thermistor Test
The charge control thermistor is part of the harness 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:
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(a) Ensure that the internal battery temperature is at 73°F ± 9°F (22.8°C
± 5.0°C). Connect an ohmmeter to pins 1 & 3 of the connector and
verify the ohmmeter reading indicates a closed circuit (<1MΩ).
(b) Connect an ohmmeter to connector pins 11 and 12 of the harness
assembly (22). Verify the ohmmeter reads 1854Ω to 3116Ω at 73°F
± 9°F (22.8°C ± 5.0°C).
(c) Immerse the thermistor plate in a beaker containing a mixture of ice
and water.
(d) Insert a thermometer or other suitable temperature-measuring
device, in the container in contact with the plate.
(e) Verify the ohmmeter indicates 7355Ω ± 672Ω at 32°F ± 3°F (0.0°C ±
1.7°C).
(f) Following the low temperature test, slowly raise the temperature to
140°F ± 5°F (60.0°C ± 2.8°C).
(g) Verify the ohmmeter indicates 560Ω ±60Ω at 140°F ± 5°F (60.0°C ±
2.8°C).
NOTE: At 160°F ±5°F (71.1°C ± 2.8°C) the thermistor resistance shall
be 380 ± 38Ω.
(h) If the thermistor fails any of the above tests, replace the harness
assembly (22) with a factory new.
(2) Overtemperature Thermoswitch
NOTE: A climate chamber or alternate methods may be used provided the
The overtemperature thermoswitch is part of the harness assembly (22). It
is mounted on the plate (23) in contact with the face of cell #4. Disassembly
is required to test the thermoswitch (Disassembly). Check the function of the
overtemperature thermoswitch as follows:
(a) Connect an ohmmeter to connector pins 8 and 9 of the harness
assembly (22). Ohmmeter should read open (> 1MΩ) at 73°F ± 9°F
(22.8°C ± 5.0°C).
(b) 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.
(c) Insert a thermometer, or other suitable temperature-measuring
device in the water with the bulb adjacent to the thermoswitch.
(d) Slowly raise the water temperature to 150°F (66°C) while observing
the ohmmeter (still connected to pins 8 and 9). Ohmmeter should
read >1 MΩ at temperatures below 150°F (66°C).
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(e) Continue to raise the water temperature and allow the temperature to
stabilize at 68°C ± 5.0°C (155°F ± 9°F). The thermoswitch should
close (< 5Ω resistance) at a stabilized temperature of 68°C ± 2.8°C
(155°F ± 5°F).
(f) Slowly add cool water to the beaker to reduce the water temperature
to 131°F ± 9°F (55°C ± 5.0°C). The thermoswitch should open (>1
MΩ) at a stabilized temperature of 131°F (55°C).
(g) If the thermoswitch fails to meet any of the above criteria, replace the
harness assembly (22) with factory new.
L. Cell Replacement
NOTE: It is best to assume that all the original cells are or soon will be in
unsatisfactory condition due to length of service, heat, overcharge, etc. and
Saft strongly recommends all cells should be replaced with new Saft cells if:
• three cells or more cells are replaced during the same maintenance
interval
Or
• one or more cells required replacement after five cells were replaced
over the life of the battery
The following conditions are not to be counted in determining for the above
recommendation:
- Mechanical failure such as terminal thread damage,
- Cell leakage,
- Cell short-circuit
(1) Discharge the battery completely by performing Residual Discharge.
(2) Remove upper cell terminal nuts (5A), connector nuts (20) if required,
washers (6), washers (21) if required, and intercell connecting links (11
through 15) from the cell to be replaced.
(3) Attach cell puller tool (T04) to the cell’s terminal and remove cell from the
case using a steady upward pull.
(4) Insert a new Saft cell into the case and pushing it downward on the cell
terminals (with a small block of soft wood if necessary)
NOTE: New cell must be discharged before installation is performed.
(5) Attach intercell connecting links (11 through 15), washer (6), washers (21) if
required, upper cell terminal nuts (5A), connector nut (20) if required, and
torque nuts per Table 8001.
(6) Continue with battery maintenance as outlined in Figure 1001.
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4. Fault Isolation
Fault isolation information is presented in Table 1004 as a guide in locating a cause of
malfunction and isolating the cause to a specific component.
FAULT POSSIBLE CAUSE REMEDY
Zero volts with battery on Defective electrical Check electrical contacts, links
“charge" connector (not making and tightness of nuts (Check)
contact).
Link loose or broken. Replace if necessary, torque all

upper terminal nuts (Check)
Zero volts with battery on Battery fully discharged Do an Insulation Check

"discharge”
Battery circuit open or Check contacts, links and torque

defective contacts. of terminal nuts (Check)
Cell(s) completely dry Adjust Electrolyte Level (Testing

and Fault Isolation)
Fault Isolation
Table 1004 (#1 of 5)
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Leakage of Electrolyte Incorrect adjustment of Disassemble and clean the

level battery (Disassembly, Cleaning
and Testing and Fault Isolation)
Adjust Electrolyte Level (Testing

Disassemble and clean the

battery (Disassembly AND
Cell polarity reversed Cleaning)
during high rate discharge
(e.g. during starting) Adjust Electrolyte Level (Testing
Retighten vent-valve
Test vent valve (Testing and Fault

Loose or damage vent- Isolation)
valve
Overcharge at high Check the on-board charging
temperatures or using circuit 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
Leakage of electrolyte See “Electrolyte Leakage” in this
section.
Fault Isolation
Table 1004 (#2 of 5)
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Excessive water consumption Heavy overcharge or Check the on-board charging

in all battery cells overcharge at high circuit and adjust if necessary
temperatures
Defective thermistor Test harness assembly (Testing

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 Do Special Testing (Testing and
value separator(s) 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
Mechanical damage to Replace damaged links
nickel plating (Disassembly and Assembly)
Fault Isolation
Table 1004 (#3 of 5)
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Indications of link overheating Loose terminal nuts Check torque
Cell with abnormally high Cell dry or insufficient As soon as the fault is observed
voltage at start of charge electrolyte level 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 Repeat Charge, Discharge, and
reached before minimum time or strongly unbalanced Residual Discharge up to three
or not reached at the times
maximum time
Replace with new SAFT cell
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 Repeat Charge, Discharge, and
polarity, or a normal polarity service Residual Discharge up to three
voltage of less than 1 V at the times
end 1C1)
Replace with new SAFT cell
Exceptionally heavy use Repeat Charge, Discharge, and

(frequent self-starting; Residual Discharge up to three
operation at high times
temperatures, with low
electrolyte level, etc.) Replace with new SAFT cell
Fault Isolation
Table 1004 (#4 of 5)
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Cell with swollen case Cell operated with low Replace with new SAFT cell (Cell
electrolyte level, Replacement)
deterioration of separator
and damaged plates
Cell with zero voltage when Short circuited cell Replace with new Saft cell (Cell
battery circuit is open Replacement)
Low insulation resistance Leakage of electrolyte Disassemble and clean battery

(Disassembly AND Cleaning)

Fault Isolation
Table 1004 (#5 of 5)
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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 permit
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 POSSIBILITY 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 per Initial Discharge and Residual Discharge.
B. Remove cover (8), pad (9) and formed insulator (10) assembly by opening latches
and lifting from case.
C. Remove cell assembly upper terminal nuts (5A) , connector nuts (20) and washers
(6 & 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) (29) or T01, 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 puller tool (T04), remove cell assemblies (2) from the battery case (7) by
tightening the puller tool 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 (2A) .
J. Remove the harness assembly (22):
(1) Remove the thermoswitch mounting nuts (25) from the thermoswitch plate
(23).
(2) Remove the harness connector mounting screws (24) and nuts (25) and lift
the harness connector assembly (22) out of the battery case (7).
K. Remove all liners (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. Remove the battery cover (8), pad (9) and formed insulator (10).
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.
B. Using vent valve wrench (P/N 093382-000) (29) or T01, 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.
C. 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
AIRFLOW AWAY FROM BODY. USE SAFETY GOGGLES TO
PREVENT INJURY TO EYES FROM FINE DUST PARTICLES.
D. Disperse residual dust and particles from the battery with blasts of clean, dry,
compressed air not over 20 psi (1.4 bar).
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4579
E. Coat cell assembly upper terminal nuts (5A), connector nuts (20) and all intercell
terminal links (11 through 15) with a light film of non-acid petroleum jelly.
F. 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 (Initial Discharge and Residual Discharge).
B. Disassemble the battery (Disassembly).
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), liners (27), gasket (17), links (11
through 15), and cell hardware (5A and 6) 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 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 (Vent Valve Test).
H. Install vent valve assemblies (3) with vent wrench (P/N 093382-000) (29) or T01.
I. Assemble the battery (Assembly).
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CHECK
1. General
This section contains battery functional checks information. Check procedures are written
in step-by-step formats that follow the process flow outlined in Figure 1001. A request for
overhaul or restoration should follow this same procedure
2. 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: All ( ) part identification numbers herein are IPL, Figure 10001 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 per Figure 7002.
(5) Visually verify all cells (2) are equipped with a vent valve (3).
(6) Torque all upper cell nuts (5A) and connector nuts (20) per Table 8001.
(7) Visually verify the harness assembly (22) is present and undamaged.
B. Charge the battery per Charge on page 1005 and level electrolyte per Electrolyte
Leveling on page 1006.
C. Place battery in service.
3. Assembled Battery
NOTE: A request for overhaul or restoration should follow this same procedure.
Test procedures are written in step-by-step formats that follow the process
flow outlined in Figure 1001.
The following procedures are for an assembled battery (7) with battery cover (8), pad (9)
and formed insulator (10) removed.
A. Visually Inspection
Visually inspect the battery for evidence of damage or electrolyte leakage. If
damage to any part(s) are visible, refer to Testing and Fault Isolation for applicable
procedures.
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4579
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.
(1) When inspection reveals electrolyte leakage from the cell at the vent hole
opening, replace the defective O-ring (4) as follows:
(a) Using the vent-valve wrench (P/N 093382-000) provided with the
battery (29) or T01, loosen and remove the vent valve (3) from the
cell assembly (2).
(b) Cover the cell with a damp, clean cloth to prevent any foreign
particles from falling into the cell.
(c) Remove the defective O-ring (4) from the vent valve (3), and install a
new O-ring (4) onto the vent valve (3).
(d) 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)
(29) or T01), tighten the vent valve securely in place. To ensure they
are tightened properly, use only finger pressure on the wrench.
B. 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.
NOTE: Method A or B may be used to check with insulation breakdown.
(1) Method A
(a) Set up the multimeter for current measurement and 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.
(b) If while performing the above, the reading is greater than 500mA
(indicating a reduction in insulation resistance), the battery should be
disassembled fully and cleaned (Disassembly, Cleaning, Assembly).
(c) If, after cleaning and assembly, a leakage current is still indicated by
the test described in steps (1) through (2), one or more cells are
defective. Isolate and replace the defective cell(s) (Disassembly and
Assembly).
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4579
(2) Method B
(a) Measure the insulation resistance between the block of cells and the
metal box. The value measured must be greater than 10MΩ under a
DC voltage 250V continuous using a megohmmeter.
(b) If while performing the above, the criteria is not meet, the insulation
should be considered defective. The battery should be disassembled
fully and cleaned (Disassembly, Cleaning, Assembly).
(c) If after cleaning and assembly, the resistance is still less than 10MΩ,
one or more cells are defective. Isolate and replace the defective
cell(s) (Disassembly and Assembly).
C. Cell Nut Torque
Check the torque on each upper terminal nut (5A) and connector nuts (20) per Table
8001.
D. Battery Voltage
Measure the voltage at the battery connector and verify the voltage is greater than
21V, return to Figure 1001.
E. Check all ventilation openings to make sure that they are clean and clear.
F. Harness Assembly
NOTE: A climate chamber or alternate methods may be used provided the
NOTE: This harness assembly check may be substituted with the paragraph
Harness Assembly testing contained in TESTING and ISOLATION
section.
If any part of the harness assembly (22) is damaged, the entire assembly must be
replaced (Disassembly, Assembly).
(1) Connect an ohmmeter to pins 1 & 3 of the connector at 73°F ± 9°F (22.8°C ±
5.0°C). Ohmmeter reading should indicate a closed circuit (<1 MΩ). An
erratic reading represents a failure.
(2) Connect an ohmmeter to connector pins 11 and 12 of the harness assembly
(22). Verify the ohmmeter reads 1977Ω to 3081Ω at 73°F ± 9°F (22.8°C ±
5.0°C). An erratic reading represents a failure.
(3) Connect an ohmmeter to connector pins 8 and 9 of the harness assembly
(22). Ohmmeter should read open (> 1MΩ) at 73°F ± 9°F (22.8°C ± 5.0°C).
An erratic reading represents a failure.
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4579
4. 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 Cell Hardware on page 5005 for
replacement of lower terminal O-ring (2A) 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 through 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. Liners (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).
F. Visually check the harness 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 harness assembly (22) is a non-repairable item and should be
discarded if defective.
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4579
G. Cell Hardware.
Check all hardware items for damage
(1) Replacement of cell hardware is limited to 5A, 5B, 6, 6A, 6B, 6C, 6D , and
the lower terminal O-ring (2A) requires replacement, the cell assembly (2) is
limited to replacement of defective hardware. Defect of the cell itself
requires cell replacement. To replace a defective terminal O-ring:
(a) Remove lower terminal nut (5B), the polarity washer (6B or 6C), the
Belleville washers (6A) and terminal O-ring (2A) being careful to
prevent anything from falling into the cell opening.
(b) Replace O-ring (2A), install washer (6D), the 2 Belleville washers
(6A), the polarity washer (6B or 6C) and torque lower terminal nut
(5B) per Table 8001.
H. Check battery cover (8) and battery case (7) for 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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4579
ASSEMBLY
1. General
This section contains assembly instructions necessary after disassembly.
2. Liners, Harness Assembly, and Cells

NOTE: Ensure all components are clean and dry before assembly.
A. Insert one edge of bottom liner (B) (Figure 7001) into battery case from either the
left or right side, then slide the liner under the cell partition.
B. Install harness assembly (22) (Figure 10001) as follows:
(1) Insert the harness assembly connector into its mounting hole in the case (7)
Figure 10001 and install the mounting screws (24) Figure 10001 and nuts
(25) Figure 10001 and torque per Table 8001.
(2) Insert the liner assembly liner (A) (Figure 7001) 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) Figure 10001 in back of liner assembly (A)
(Figure 7001) so that the liner assembly is between the thermoswitch plate
(23) Figure 10001 and the liner assembly (A) against the partition.
(4) Pass the thermoswitch end of the harness assembly (22) Figure 10001
through the hole in the partition, liner assembly (A) (Figure 7001).
(5) Attach the thermoswitch to the thermoswitch plate (23) Figure 10001 with
mounting nuts (25) Figure 10001 and torque per Table 8001.
C. Install the center row liners and cell subassemblies as follows:
(1) Install liners (D) (Figure 7001) on inside of cell partition.
(2) Install five cell subassemblies (2) Figure 10001 into positions 4, 5, 6, 9 and
10 in the center partition of battery case (7) Figure 10001. Be sure to
maintain the proper cell arrangement and polarity orientation per Figure
7002. Install the charge control thermistor plate between cells 6 and 9 as
shown in Figure 10001.
(3) Install liners (F and H) Figure 7001 into the center partition of battery case.
(4) Install a cell assembly (2) Figure 10001 into position 13 in the center partition
of the battery case (7) Figure 10001. 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 (C) (Figure 7001) are used as required to ensure the center row
cells are retained securely in place. As indicated in Figure 7001, the
maximum quantity to be used is as shown to prevent free movement of
the cells.
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4579
D. Install the left and right side row of cells and liners as follows:
(1) Install liners (E, F, G, and H) (Figure 7001) into the battery case (7) Figure
10001 as shown in Figure 7001.
(2) Install six cell assemblies (2) Figure 10001 in the left and right hand side of
the battery case (7) Figure 10001. Be sure to maintain the proper cell
arrangement and polarity orientation per Figure 7002.
(3) Install the left and right end liners (H) (Figure 7001) into the battery case (7)
Figure 10001) at each end as shown in Figure 7001.
(4) Install the remaining two cell assemblies (2) Figure 10001) into the battery
case (7) Figure 10001. Be sure to maintain the proper cell arrangement and
polarity orientation per Figure 7002. 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 (C) (Figure 7001) 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 Figure 7001 to prevent
free movement of the cells.
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4579
Max. Unit
Item Description Dimension [in]
Per Assembly
A LINER ASSEMBLY 9.86 x 2.95 1
B LINER 9.52 x 10.72 x 0.032 1
C LINER 2.953 x 10.373 x 0.062 13
D LINER 9.108 x 9.861 x 0.032 2
E LINER 10.629 x 10.373 x 0.032 2
F LINER 2.953 x 10.373 x 0.032 6
G LINER 10.629 x 9.861 x 0.020 2
H LINER 2.953 x 10.373 x 0.020 3
Battery Liner Kit (27)
Figure 7001
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4579
3. Battery Connector Receptacle

Install the main connector (16) Figure 10001 in the case (7) Figure 10001 using the
following steps:
A. Assemble connector gasket (17) Figure 10001 to the adapter connector (16) Figure
10001.
B. Insert terminals of the adapter connector (16) Figure 10001 through the oval
mounting hole in the front of the battery case (7) Figure 10001.
C. Attach the adapter connector (16) Figure 10001 to the battery case (7) Figure
10001) with Sems screws (18) Figure 10001. Secure the receptacle by tightening
the screws (18) Figure 10001 per Table 8001.
4. Hardware
A. Recheck all cell polarities.
B. Mount the intercell connector links (11 through 15) Figure 10001.
(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.
(3) Mount the washers (6), washers (21), connector nuts (20), and upper
terminal nuts (5A) Figure 10001.
NOTE: Cell terminals should be lightly greased prior to installation of nuts
(5A). Torque upper nuts per Table 8001.
Cell Number and Polarity Orientation

Figure 7002
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4579
FITS AND CLEARANCES
1. Torque Table
Table 8001 is a listing of all pertinent torque values needed to assemble and service the
battery.
NOTE: The values listed in Table 8001 are “lube torque” values. The threads should
be lightly greased prior to installation and applying torque.
Figure Item Torque Value Name, Location
Number
Figure 10001 (#4 of 4) 5A 116 ± 6 lbs.-in (13.1 ± 0.7 Nm) Nut, Terminal, Upper
Figure 10001 (#4 of 4 5B 48.7 ± 4 lbs.-in (5.5 ± 0.5 Nm) Nut, Terminal, Lower
Figure 10001 (#1 of 4) 18 20 ± 4 lbs.-in (2.30 ± 0.5 Nm) Screws, Receptacle
116 ± 6 lbs.-in (13.1 ± 0.7 Nm) Nut, Terminal Adapter
Figure 10001 (#1 of 4) 20
5.0 ± 0.5 lbs.-in (0.56 ± 0.06 Nm) Screw, Conn; Nut, Conn
Figure 10001 (#3 of 4) 24, 25
Torque Table
Table 8001
2. Fits and Clearances Table
No fits and clearances required.
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4579
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
1. Special Tools
NOTE: Equivalent tools can be used.
The kit (P/N 416161) is available from Saft containing special tools T01, T02, T03, and T04.
The tools are housed in a polypropylene box and each tool is insulated to ensure optimum
safety for the technician.
The syringe (T02) is used in the electrolyte level adjustment and the cell puller tool (T04) is
used in cell removal Table 9001.
V09052 F6177
Item DESCRIPTION
P/N P/N
T01 Universal vent wrench 093365-000 413876
T02 Syringe assembly (with nozzle 20 mm (0.79 in)) 020915-004 416231
T03 1 Ω 3 W equalizing resistors - 164829
T04 Universal cell extraction tool or M10x1.25 tool 017556-000 416159
T05 Vent valve adapter for M8 valve 025098-000 -
Special Tools
Table 9001
2. Standard Tools
A. The following items are recommended to do the procedures described in this
manual. When necessary equivalent substitutes may be used.
- Constant current charger (DC current range 0 – 60A, minimum open DC
voltage 40V)
- Constant current load bank (DC current range 0 – 60 A, DC voltage range 1 –
40V)
- Megohmmeter (0 – 50 MΩ @ 250 V continuous)
- Precision Multimeter (Volt, Ω, mA) 2000 counts 1% or better
- Torque Wrench (Fully insulated) 0 – 15 N.m (0 – 133 lbf.in)
- Thermometer, Immersion
- Standard mechanic’s tools.
- Safety gloves.
- Protective goggles.
- Safety shoes.
- Eye wash.
- Protective apron.
- Stiff bristle brush (non-metallic)
- Small paintbrush (non-metallic)
- Dry, compressed air source [less than 1.4 bar (20 psi)]
- Soft, clean cloth (at least two required)
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4579
ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
(1) This section provides illustrations and parts breakdown of the 4579 battery,
which can be disassembled, 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 indicates 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.
(6) Items Not Illustrated
Items not illustrated are indicated by a dash ( - ) ahead of the item numbers
in the FIGURE and ITEM NO. column.
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4579
(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 NAME / Vendor NAME /

Code ADDRESS Code ADDRESS
V09052 Saft America Inc. F6177 Saft

711 Gil Harbin Industrial Boulevard 126 quai Charles Pasqua
Valdosta, GA 31601 92300 Levallois-Perrot
USA France
Phone: (229) 247-2331 Phone: +33 1 58 63 16 00
Fax: (229) 247-8486 Fax: +33 1 58 63 16 18
http://www.saftbatteries.com
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4579
2. Alpha Numeric Index

Airline Stock Figure Item Units Per
Part Number Unit
Number Number Number Battery
009384-000 17 EA 1
015575-000 11 EA 5
015579-000 5A EA 40
015579-000 5B EA 40
015579-000 20 EA 2
015957-000 3 EA 20
018346-000 30 EA 1
018520-000 2 EA 20
018552-003 8 EA 1
018550-000 1 1 RF
018553-000 9 EA 1
018559-000 10 EA 1
018567-000 14 EA 10
018568-000 15 EA 1
018569-000 12 EA 3
018730-000 7 EA 1
018737-000 23 EA 1
018740-000 22 EA 1
018951-000 27 EA 1
021870-000 6D EA 40
021871-000 6A EA 80
022078-000 16 EA 1
022228-000 6 EA 40
022228-000 21 EA 2
023388-002 6C EA 20
023388-001 6B EA 20
026705-000 13 EA 2
REPL 015577-000
090064-000 25 EA 6
091180-008 4 EA 20
091181-002 2A EA 40
092178-008 24 EA 4
092508-001 28 EA 1
093382-000 29 EA 1
093616-000 18 EA 4
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4579
Battery, Exploded View

Figure 10001 ( #1 of 4)
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Mar 15/19
4579
Battery, Exploded View Figure 10001 (#2 of 4)
Battery, Exploded View Figure 10001 (#3 or 4)
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4579
Battery, Exploded View

Figure 10001 (#4 of 4)
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4579
3. Item Numeric Index

Nomenclature
Eff Units
Figure
Part Number 1234567 Unit Per
Item Code Assy
.......
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
5A 015579-000 . . Upper Nut, Terminal EA 2
5B 015579-000 . . Lower Nut, Terminal EA 2
6 022228-000 . . Washer, Terminal EA 2
6A 021871-000 . . Washer, Belleville EA 4
6B 023388-001 . . Washer, polarity, red EA 1
6C 023388-002 . . Washer, polarity, blue EA 1
6D 021870-000 . . Washer Flat EA 2
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
REPLS 015577-000
16 022078-000 . Receptacle, Battery Conn. EA 1
17 009384-000 . Gasket, Conn. RCPT. EA 1
18 093616-000 . Screw & Washer, Sems (Conn. RCPT) EA 4
20 015579-000 . Nut, Terminal Adapter EA 2
21 022228-000 . Washer, Terminal Adapter EA 2
22 018740-000 . Harness 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, Kit EA 1
28 092508-001 . Spring, Shorting EA 1
29 093382-000 . Wrench, Vent Valve EA 1
30 018346-000 . Connector, Cap Marked EA 1
- Not Shown
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4579
STORAGE (INCLUDING TRANSPORTATION)
1. Storage
A. General
Storage preparation and packaging makes sure the equipment is protected against
any attack by atmospheric agents. For a battery which has been cleaned and
serviced and is not directly put into service on board an aircraft, different methods
can be recommended depending on the purpose and the environment conditions of
the "storage".
B. Storage room
Keep the batteries and spares in a dry and clean room.
C. Temperature conditions
The recommended temperature range is + 20°C ± 15°C (68°F ± 27°F). However,
occasional excursion into the range of -55°C to +60°C (-67°F to +140°F) is
permitted.
2. Inactive long-term storage
NOTE: There is no need of maintenance operation during the storage period.
The battery should be stored filled and discharged. It is not necessary that it be short
circuited. No revalidation is required during storage.
The storage life is 10 years, if using the following conditions:
- sealed packaging,
- temperature: +41°F to +95°F (5°C to 35°C),
- humidity < 90 %,
- normal vertical position,
- Isolated from detrimental agents: i.e. dirt, dust, dampness, vibration, corrosive
atmosphere.
Saft Ni-Cd batteries may be stored in temperatures ranging from -67°F to +41°F or +95°F
to 140°F (-55°C to +5°C or +35°C to +60°C) for an accumulated exposure that does not
exceed 30 days.
Lead batteries must not be stored in the same room.
The standard cardboard packaging is considered unsealed and allows 2 years of storage
under the above conditions.
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Mar 15/19
4579
3. Inactive stand-by storage
A. Definition
The battery is charged after being serviced then stored fully charged in a dedicated
room in such a way that it can be installed in the aircraft without further check. The
battery may be kept in stand-by for the period corresponding to 80% available
capacity on Figure 15001 (for example 24 days at 30°C) with a maximum of 90
days.
Charge Retention
Figure 15001
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Mar 15/19
4579
B. Ambient temperature with topping or refresh charge

(1) The stand-by period defined in para. Inactive Stand-by Storage can be
prolonged by applying a ’topping’ or ’refresh’ charge, at the end of the
period. The charge is defined as a short charge at 0.1 C1A, 0.5 C1A or 1 C1A
until the voltage reaches the values given in the table below (Table 15001):
Charge Voltage
Rate (End of “Refresh” Charge
0.1C1A 30.0V for 20 Cells
Topping or Refresh Charge
Table 15001
(2) The battery can be “Topped or Refreshed” up to two (2) times (for example
24 days at +30°C can be prolonged to 72 days at +30°C).
CAUTION: The time necessary to reach the required voltage should be
very short. Do not do the 4-hour overcharge at 0.1C1A during
this charge operation.
(3) Action at the End of the Standby Period
(a) At the end of the stand-by period, if the battery is not immediately
installed in the aircraft, do one of the following procedures:
(b) If the battery has been subject to one period, or two successive
periods of stand-by, it must be Discharged and Charged after which it
can be subject to another period of up to 3 months stand-by. If it is to
be put into long term storage to para. Inactive Long-term Storage
(c) If the battery has been subject to three successive periods of stand-
by, it must be Discharged, Residual Discharge and Charged after
which it can be subject to another sequence of three stand-by periods
of up to 3 months it is to be put into long term storage refer to para.
Inactive Long-term Storage.
CAUTION: IF THE ABOVE CONDITIONS ARE NOT MET, THERE IS A RISK OF
PLACING A BATTERY ON BOARD THE AIRCRAFT THAT DOES NOT
MEET THE EMERGENCY REQUIREMENTS. IF THE BATTERY HAS
PREVIOUSLY BEEN STORED AT A TEMPERATURE BELOW THAT
OF THE AMBIENT, CONDENSATION MAY OCCUR. BEFORE
INSTALLING, VERIFY THE INSULATION RESISTANCE.
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4579
4. Active standby mode (trickle charge)
CAUTION: WATER CONSUMPTION OCCURS WHEN THE BATTERY IS
CONTINUOUSLY CHARGED, IN AN OVERCHARGE CONDITION.
SAFT DOES NOT RECOMMEND THIS METHOD, HOWEVER SOME
OPERATORS TAKE RESPONSIBILITY FOR ITS USE.
NOTE: This method is not reliable due to quantity and inaccuracy of water consumption.
Principle: the battery is continuously charged, in an overcharge condition. Saft does not
recommend this method, however some operators take responsibility for its use.
This method is not reliable due to quantity and inaccuracy of water consumption.
Example: A 40 Ah battery on a continuous trickle charge of 150 mA for one month will
consume over 36 cm3/cell of water. The reserve available per cell is provided in Table 1.
The operator must adjust the electrolyte level before placing the battery onboard the
aircraft. Otherwise the risk of a battery incident exists (cells dried out before the normal end
of the interval maintenance). This creates the conditions for a thermal runaway with all its
consequences (unscheduled removal with the possibility of the total loss of the battery and
a delayed if not cancelled flight).
5. Spares
A. Spare Cells
Spare cells must be stored filled and discharged (in a discharged cell, the electrolyte
level is not visible). It is not necessary that they be short circuited. The vent valves
must not be removed. The storage conditions are the same as those given in para.
Inactive long term storage. No maintenance operation is needed during storage.
Before installation in a battery, cells must be visually inspected for damage or
leakage and cleaned and repaired as necessary in accordance with the battery
maintenance documentation.
B. Spare O-rings, gaskets and vent valves
(1) O-rings and gaskets

Six (6) years of storage with storage conditions from date of manufacture
unless otherwise specified on the packaging. They must be protected from
exposure of air, light, and high humidity (< 70%). Storage life depends on
temperature, so it is recommended to store in a cool area (<25°C / 77°F).
At storage temperatures of +35°C / 95°F, the storage life is reduced to 5
years.
O-rings must be inspected before use and must be disregarded if there are
visible signs of damage, distortion or deterioration.
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Sep 6/18
4579
(2) Vent valves with O-rings

Six (6) years of storage with storage conditions from date of manufacture
unless otherwise specified on the packaging (the limitation is due to the O-
ring). Protected from exposure of air, light, and high humidity (< 70%).
Storage life depends on temperature, so it is recommended to store in a
sealed container (non-PVC) in a cool area (<25°C / 77°F). At storage
temperatures of +35°C / 95°F, the storage life is reduced to 5 years.
O-rings must be inspected before use and must be disregarded if there are
visible signs of damage, distortion or deterioration.
C. Other spares
Other spares, protected from external contamination (i.e. dirt, dust, dampness,
vibration, corrosive atmosphere) and high humidity (>70%), may be stored for
unlimited periods. Before use, they must be inspected and any showing visible signs
of damage, distortion or deterioration must be discarded.
6. Servicing after discharged storage

STORAGE TIME SERVICE PROCEDURE
Battery must have recently passed the capacity
criteria of Table 1001 before entering storage
Less than 3 months
Visual Inspection Check
Figure 1001 Entry Point “A”
Visual Inspection Check

3 months to 1 year Charge
Figure 1001 Entry Point “B”
More than 1 year Figure 1001 Entry Point “Received”
Return to Service Following Storage

Table 15002
7. Transportation procedure
The battery is normally discharged before packing. If it is necessary to transport a charged
battery, make sure that the output terminals are protected against short circuit.
The battery should then be packed vertically in its original container. If the original container
is not available, the international and/or local packaging regulations applicable to the mode
of transport and destination must be followed.
According to the IATA / IMDG dangerous goods regulations, Saft ships all existing nickel-
cadmium batteries or cells for aircraft under the classification UN2795 (wet, filled with alkali)
according to packing instruction 800.
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Page 15005 / 15006 Blank
Sep 6/18

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

Subject: CMM Revision No. 8 Dated Mar 15/19

COMPONENT MAINTENANCE MANUAL

ILLUSTRATED PARTS LIST

Nickel Cadmium Battery

(BA06-01 ELDEC PART NUMBER)

RECORD OF TEMPORARY REVISIONS

SERVICE BULLETIN LIST

LIST OF EFFECTIVE PAGES

Title Page T-1 Mar 15/19 Disassembly 3001 Sep 6/18

Record of Revisions RR-1 Mar 15/19 Cleaning 4001 Sep 6/18

Record of Temporary RTR-1 Sep 6/18 Check 5001 Sep 6/18

PARAGRAPH TITLE PAGE

Description and Operation 1

Testing and Fault Isolation 1001

Fits and Clearances 8001

Special Tools, Fixtures, and Equipment 9001

Illustrated Parts List 10001

Storage (Including Transportation) 15001

Figure Description Page

Intro 1 Universal Recycling Symbols Intro-4

1 Nickel Cadmium Battery 1

1001 Process Flow for Battery Restoration Procedures 1002

1002 Position of Syringe in Cell Vent Seal 1007

7001 Battery Liner Kit 7003

7002 Cell Number and Polarity Orientation 7004

10001 Battery, Exploded View (#1 or 4) 10004

10001 Battery, Exploded View (#2 or 4) 10005

10001 Battery, Exploded View (#3 or 4) 10005

10001 Battery, Exploded View (#4 or 4) 10006

15001 Charge Retention 15002

Table Description Page

1001 Discharge Times 1004

1002 Current Charge Rates 1006

1003 Overcharge Minimum Voltage 1006

1004 Fault Isolation (#1 or 5) 1012

1004 Fault Isolation (#2 or 5) 1013

1004 Fault Isolation (#3 or 5) 1014

1004 Fault Isolation (#4 or 5) 1015

1004 Fault Isolation (#5 or 5) 1016

8001 Torque Table 8001

9001 Special Tools 9001

15001 Topping or Refresh Charge 15003

15002 Return to Service Following Storage 15005

Saft America Inc. (V09052) Saft (F6177)

Telephone: (229) 247-2331 Telephone: 33 1 58 63 16 00

Universal Recycling Symbols

Testing / Fault Isolation: June 15, 1991

DESCRIPTION AND OPERATION

Cell Assembly Terminal M10 X 1.25

Number of Cell Assemblies 20

Cell Rated Capacity (C1) 45 Ah (1-hour rate)

TESTING AND FAULT ISOLATION

2. Required Test Equipment

Insulation Check FAIL C B

< 1.5V Cell Voltage

Check Cell Nut

PASS > 100%

PASS PASS FAIL

Process Flow for Battery Restoration Procedures

H. Electrolyte Level Adjustment

0.79” (20 mm)