NOTE : Some Service Centers have used the Drive Shaft Lock Screws (part # 5120020000) instead of the Seal Pins. This would make disassembly easier.
| The Laube Battery Pack Repair Manual (LBP) | |
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| This section includes the Super, Regular and Lite Battery Packs | |
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| CAUTION: Before proceeding, all batteries should be discharged of power! | |
| How To Adjust The Battery Snap Connectors | To adjust the battery Connectors first make sure that the Battery Switch is set to the off position. Refer to the "SNAP CONNECTOR ADJUSTMENT DIAGRAM." On the bottom of the Battery Pack there are 4 Female Snap Connectors with 4 sides or tabs and a screw in the center. DO NOT ATTEMPT TO ADJUST THE SCREW! Place a tiny flat head screw driver between the tab and the inside wall of the Cover Cap. Slightly bend the tab toward it's own screw. DO NOT ADJUST THE TAB OVER 1/32" OF IT'S ORIGINAL POSITION. It is only necessary to move the tab 1/64" or less. Follow this same procedure with all 4 tabs on all 4 Connectors. Once this has been accomplished you may experience difficulty inserting the Battery into the Clipper Housing all the way so press hard. If the tabs are unwilling to self adjust to the Clipper then remove the Battery and readjust the tabs so that they are just a little more loose. You can do this by placing the screw driver between the tab and the screw in the center of the snap Connector and pressing out away from the center of the Snap Connector, using the screw as leverage. The Battery should still be a tight fit to the Clipper. |
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| How To Remove The Cover Cap Assembly From The Housing | To remove the Cover Cap Assembly from the Housing refer to the "BATTERY PACK DIAGRAM." Cover Cap Assemblies are held into place by 4 Seal Pins, part # 5200040000). These are easily pressed down into the Cover Cap with a hole punch and a small hammer. Do not use excessive force, lightly tap the Seal Pins down. If you do not have a hole punch, another Seal Pin can be placed over the existing one in the housing and tapped into it. This will press the existing Seal Pin into the Cover Cap and allow removal of of the Cover Cap Assembly. Follow this procedure on all four of the Seal Pins. To remove the Cover Cap Assembly, simply pry up lightly. You may be able to reuse the Cover Cap and Housing. Unsolder the three connections and remove the original Seal Pins. . |
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| How To Remove The Battery Pack Housing | To remove the Battery Pack Housing, follow the directions under "How To Remove The Cover Cap Assembly From The Housing." After you have followed those directions, simply unscrew the Switch Nuts from the Switch Protector and slide the Battery Cell Assembly out. |
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| How To Replace The Switches On The Laube Battery Pack | To replace the switch or switches on a Battery Pack, follow the direction under "How To Remove The Battery Pack Housing." After following those directions, the switches are now accessible. Unsolder the switch from the Circuit Board. If you are using a large soldering Iron you may wish to disconnect the Circuit Board Assembly from the Cell Assembly. If the circuit Board is cracked replace it. Install the new switch and ALWAYS trim the excess off of the P.C. Connections. At this point it is always good to check each Cell and to inspect for cracks, burns and damage. Check each Cell with a meter. Each Cell should be reading 1.2 DC volts (if the Battery is fully charged). If the Battery Pack is discharged you should receive identical readings on each individual Cell. If one or more of the Battery Cells are bad, replace them as needed (follow the directions under "How To Replace An Individual Battery Cell"). Place the Battery back into the Housing. Before sealing it, test it in a Laube Battery Charger. With the Battery Switches set to the "ON" and "HI" positions, the Charger light should come on and the light should dim when the Battery is switched from "HI" to "LO." Install the Cover Cap Assembly and Seal Pins (see "How To Install The Cover Cap Assembly"). For visual directions, refer to the "Laube Service Video." |
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| How To Replace The Thermostats | To replace the Thermostats follow the directions under "How To Remove The Battery Pack Housing." Once the Battery Cell assembly has been removed from the Housing, notice in the center of the Cell Assembly there is a double Thermostat (refer to the "BATTERY PACK WIRE DIAGRAM") Desolder both of the Thermostats from the Cover Cap Assembly. You will have to cut the solder tab that is welded to the Cell. DO NOT ATTEMPT TO PULL THE SOLDER TAB OFF OF THE CELL ONCE IT HAS BEEN WELDED. Leave a little excess of the solder tab to insure enough space to solder the new Thermostats. No metal should be exposed except what will be used to solder to make a good connection. YOU MUST REPLACE BOTH THERMOSTATS. Solder the new Thermostats into place. In order for Thermostats to work properly, you must place them in there original position in the center of the Cell Assembly (refer to the "2 SPEED BATTERY WIRE DIAGRAM" or the "VARIABLE BATTERY WIRE DIAGRAM"). Reassemble the Battery Pack. |
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| How To Replace An Individual Battery Cell | To replace an individual Battery Cell,first follow the directions under "How To Remove The Battery Housing" and the "BATTERY PACK DIAGRAM." Once this has been accomplished and the unwanted Cell has been identified, mark it to eliminate confusion. IMPORTANT: Notice the configuration the bad Cell is placed in so that the new Cell will be installed correctly. Unsolder any wires that may be attached and cut any soldering tabs that connect it to another Cell. After you have double checked that you are no longer longer making any kind of electrical connection, use a razor blade to cut the heat shrink around the Cell. Slide the unwanted Cell out and trim the heat shrink off of the Cell Assembly. Do NOT scratch, puncture or expose the metal of the existing Cells that are attached to the Cell Assembly. This will cause a full current flow and destroy the Battery Pack. Install the new Battery Cell in the same configuration as the original Cell. All Cell Assemblies are soldered in series with the Positive of one Cell soldered to the Negative of another Cell and so on. See the "2 SPEED BATTERY WIRE DIAGRAM" page A, BATTERY CELL ASSEMBLY. Very lightly ruff the surface of both the positive and negative side of the Battery Cell with emery paper to insure a good solder contact. Do not poke through or gouge the Cell because it will cause the Battery Cell to leak. Once this has been accomplished solder the new connection or at least an 18 gauge wire to the Cell. Use a quick dry adhesive like crazy glue, to bond the new Cell to the Battery Assembly. |
| How To Install A Battery Cover Cap Assembly |
To install a Battery Cover Cap Assembly, drill new holes in the Housing using a 3/64" drill bit for the correct size hole. Place the Cover Cap in the empty Housing so that it is flush with the end of the Battery Housing. No part of the Cover Cap Assembly should protrude past the Battery Housing. While the Cover Cap is in position, drill 4 holes equal distances apart. Install the Battery Cell Assembly and solder onto the proper connections (see the "2 SPEED BATTERY WIRE DIAGRAM"). Follow the EXACT solder configuration or damage may occur to the equipment. Place the Cover Cap Assembly back inside the Battery Housing and lightly tap in the Seal Pins with a small hammer.
NOTE : Some Service Centers have used the Drive Shaft Lock Screws (part # 5120020000) instead of the Seal Pins. This would make disassembly easier. |