Saft 4579 Component Maintenance Manual With Illustrated Parts List
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Saft 4579 Component Maintenance Manual With Illustrated Parts List

Nickel cadmium battery
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Holders of 4579 (Saft 018550-000) batteries
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
Pages 1 & 2
Page Intro 1
Testing and Fault
Isolation
Page 111
Page 112
Page 1002
Page 1005
Revision No. 4 Dated July 13, 2001

HIGHLIGHTS

Description of Change
Revised to indicate
added, revised and/or
deleted pages
Revised address and
updated phone numbers
Added testing
parameters for shunt
connection in
Temperature Sensor
Assembly
Defined parameter for
"open" circuit in K(6).
Added phone numbers
and website address
Various
Saft America, Inc.
711 Industrial Boulevard, Valdosta, Georgia 31601
229-247-2331 phone // 229-247-8486 fax
Effectivitity
All Models
All Models
All Models
All Models

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  • Page 1 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.
  • Page 3 SAFT AMERICA INC. 711 INDUSTRIAL BOULEVARD VALDOSTA, GEORGIA 31601 COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST Nickel Cadmium Battery 4579 (BA06 ELDEC PART NUMBER) (S282T002-1 BOEING PART NUMBER) (SAFT PART NUMBER 018550-000) 24-31-05 PAGE T-1/T-2 Blank July 13/01...
  • Page 5 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 RECORD OF REVISIONS ISSUE INSERT ISSUE INSERT DATE DATE DATE DATE 02/28/84 03/01/84 Saft 06/15/91 07/01/91 Saft 01/30/98 01/30/98 Saft 07/13/01 24-31-05 PAGE RR-1/RR-2 Blank July 13/01...
  • Page 7 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE DATE DATE REV NO NUMBER 24-31-05 PAGE RTR-1/RTR-2 Blank Jan 30/98...
  • Page 9 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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:...
  • Page 11 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 LIST OF EFFECTIVE PAGES SUBJECT PAGE DATE SUBJECT PAGE DATE Title Page July 13/01 Cleaning Jan 30/98 Blank Jan 30/98 Jan 30/98 Record of Revisions RR-1 July 13/01 Blank RR-2 Blank Check Jan 30/98...
  • Page 13 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 TABLE OF CONTENTS PARAGRAPH TITLE PAGE Description and Operation Testing and Fault Isolation Automatic Test Requirements (ATLAS) Disassembly Cleaning Check Repair Assembly (Including Storage) Fits and Clearances Special Tools, Fixtures, and Equipment 1001...
  • Page 15 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...
  • Page 17 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 DESCRIPTION AND OPERATION 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.
  • Page 18 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Voltage: Nominal 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...
  • Page 19 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 TESTING AND FAULT ISOLATION 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).
  • Page 20 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 N E W O R R E M O V E D F R O M F R O M S T O R A G E A I R C R A F T...
  • Page 21 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Testing Test Conditions Facilities and equipment CAUTION: FUMES FROM LEAD ACID BATTERIES OR SMALL TRACES OF SULFURIC ACID ENTERING A NI-CD BATTERY CAN CAUSE PERMANENT DAMAGE. Service facilities for Ni-Cd batteries must be entirely separate from those for lead acid batteries.
  • Page 22 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 NOTE It is not a cause for concern if a cell goes to zero volts or reverses polarity during the battery discharge. Simply short out the cell’s terminals for the remainder of the discharge.
  • Page 23 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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 260.0 MINUTES 270.0 MINUTES 130.0 MINUTES 135.0 MINUTES 64.5 MINUTES...
  • Page 24 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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.
  • Page 25 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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.
  • Page 26 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 The following two results are indications that the battery requires Special Testing, or refer to Fault Isolation: The time to discharge all cells is less then the minimum time as listed in Figure 103.
  • Page 27 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 NOTE: Except for batteries from long term storage, it is recommended that if a battery requires Special Testing more than 3 times that the battery be replaced. NOTE: For a battery from long term storage, several complete charge/discharge cycles may be required to restore performance.
  • Page 28 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 WARNING: USE CARE NOT TO TILT CELLS WHILE VENT VALVES ARE LOOSENED OR REMOVED; CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE SEVERE BURNS. NOTE: BATTERY MUST BE FULLY CHARGED BEFORE ADJUSTING ELECTROLYTE LEVEL TO AVOID OVERFILLING.
  • Page 29 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Replenish low electrolyte: NOTE: Use only distilled or demineralized water. The quantity (in ) 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.
  • Page 30 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Verify the ohmmeter indicates 7355Ω ±74Ω at 32°F ±3°F (0°C ±1.5°C). Following the low temperature test, slowly raise the temperature to 140°F ±5°F. Verify the ohmmeter indicates 560Ω ±12Ω at 140°F ±5°F. At 160°F (71°C) the thermistor resistance shall be 382 ±74Ω.
  • Page 31 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 If the thermoswitch fails to meet any of the above criteria, replace the temperature sensor assembly (22) with factory new. Vent Valve Pressure Test Check the operation of the vent valve assemblies as follows: 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).
  • Page 32 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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...
  • Page 33 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 FAULT POSSIBLE CAUSE REMEDY Leakage of Electrolyte Incorrect adjustment of level Disassemble and clean the battery (DISASSEMBLY, CLEANING and TESTING and FAULT ISOLATION) Check electrolyte level (TESTING and FAULT ISOLATION) Disassemble and clean the battery...
  • Page 34 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...
  • Page 35 Low capacity cell (reversed Normal wear after long Perform Regular Check (CHECK) polarity, or a normal polarity service Replace with new SAFT cell voltage of less than 1 V at the (DISASSEMBLY, ASSEMBLY) end of a 64 minute discharge at 40A)
  • Page 36 COMPONENT MAINTENANCE MANUAL 4579 FAULT POSSIBLE CAUSE REMEDY 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...
  • Page 37 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 DISASSEMBLY General Prior to disassembly, see TESTING and FAULT ISOLATION to determine condition of the battery, cause, and remedy of malfunction. Disassemble only to the extent necessary to effect repair and replacement. NOTE: All ( ) part identification numbers herein are IPL, Fig 1 item numbers.
  • Page 38 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). 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.
  • Page 39 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 CLEANING 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. The following items are required to perform the cleaning procedures (equivalent...
  • Page 40 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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.
  • Page 41 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Remove greasy residue from battery connector receptacle (16) with isopropyl alcohol. 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.
  • Page 43 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 CHECK Initial Commissioning 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, Fig 1 item numbers.
  • Page 44 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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”...
  • Page 45 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Visually check the temperature sensor assembly (22) as follows: 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.
  • Page 47 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. Replacement of the cell can be accomplished by: Discharge the battery completely.
  • Page 48 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Replace o-ring and torque lower terminal nut per Figure 801. When inspection reveals electrolyte leakage from the cell at the vent hole opening, replace the defective O-ring (4) as follows: Using the vent-valve wrench (P/N 093382-000), loosen and remove the vent valve (3) from the cell assembly (2).
  • Page 49 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 ASSEMBLY General This section contains assembly instructions necessary after disassembly and repair. Liners and Cells NOTE: Ensure all components are clean and dry before assembly. 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.
  • Page 50 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Install liners (27.5 and 27.8) (Fig 702) into the center partition of battery case. 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.
  • Page 51 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 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). Attach the adapter connector (16) (IPL Fig 1) to the battery case (7) (IPL Fig 1) with sems screws (18) (IPL Fig 1).
  • Page 52 TESTING and FAULT ISOLATION. Inactive long term storage Saft batteries are best kept discharged, in the same packing in which they were shipped for long term storage. 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.
  • Page 53 Figure 701 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.
  • Page 54 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Battery Liners Figure 702 24-31-05 PAGE 706 Jan 30/98...
  • Page 55 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Cell Polarity Figure 703 24-31-05 PAGE 707/708 Blank Jan 30/98...
  • Page 57 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 FITS AND CLEARANCES 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.
  • Page 59 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. The following items in Figure 901 are the contents of the Saft Battery Maintenance Kit. Nomenclature...
  • Page 60 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 APPLICATION PART NUMBER NOMENCLATURE 093382-000 Wrench, Vent Valve 020915-004 Syringe, 20cm (1.22in ) (fig. 111) 017556-000 Wrench, Cell Extraction Constant Current Power Unit (0-60 Amp) Constant Current Load Bank (0-60 Amp) Equalizing resistors (1Ω...
  • Page 61 4579 ILLUSTRATED PARTS LIST Introduction Purpose This section provides illustrations and parts breakdown of the 4579 battery, which can be disassembled, repaired or replaced, and reassembled. Explanation and Usage of Section Assembly Order Indenture System The Indenture System used in the parts list shows the relationship of one part to another.
  • Page 62 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Items Not Illustrated Items not illustrated are indicated by a dash ( - ) ahead of the item numbers in the FIG. and ITEM NO. column. Alpha Variant Item Numbers Alpha variants A - Z (except I and O) are assigned to existing item...
  • Page 63 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Figure 1 (#1 of 3) 24-31-05 PAGE 1003 Jan 30/98...
  • Page 64 SAFT AMERICA INC. COMPONENT MAINTENANCE MANUAL 4579 Figure 1 (#2 of 3) -------------------------------------------------------------------------------------------------------------------------- Figure 1 (#3 of 3) 24-31-05 PAGE 1004 Jan 30/98...
  • Page 65 1 2 3 4 5 6 7 Unit Assy ..Code 018550-000 Nickel-Cadmium Battery (V09052) 018550-000 is Ref/Code for Saft 4579 018520-000 . Cell Assembly (V09052 VHP450KA-1) 091181-002 . . O-Ring, Lower Terminal 015957-000 . . Valve, Vent 091180-008 .

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