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arcing may result with possible harm to personnel and damage to the tools and a cell or cells in
the battery.
Rings, metal watchbands and identification bracelets should be removed. In contact with intercell
connectors of opposite polarity, metal objects may fuse themselves to the connectors and cause
severe skin burns. Keep flames away from the battery.
11.1 Battery Disassembly
Before disassembling the battery, make sure that all cells are completely discharged. This may
be accomplished as follows:
1. Discharge the battery to approximately 0.5 volts per cell, and attach shorting clips (Refer to
Paragraph 7.0 and Paragraph 8.0).
2. After all cells have been discharged, remove the shorting clips. Remove all intercell connecting
links. The cells may now be removed. Use a cell puller if necessary. When removing cells from
a battery. Always tighten the puller to the cell and use an even, straight-up pull.
11.2 Battery Reassembly
1. Lightly polish the cells’ terminal surfaces with an eraser and wipe clean.
2. Reassemble the cells into the battery can. Position the cells correctly with respect to polarity as
shown on the illustrated parts list (IPL) applicable to the particular battery being serviced. DO
NOT HAMMER TIGHT CELLS INTO THE BATTERY CAN: USE A STEADY FORCE ON THE
TERMINALS TO PRESS THEM INTO PLACE. FOR EASIEST ASSEMBLY, THE CELL AT THE
MIDDLE OF A ROW SHOULD BE INSERTED LAST.
3. Place intercell connectors, and other components, in their correct position as shown on the
Illustrated Parts List (IPL).
4. Install all hardware finger-tight.
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 Page 1102
APR 15/06
Starting at the positive terminal of the battery, tighten each terminal screw to the torque specified in
Table 2.
CARE SHOULD BE TAKEN TO INSURE THAT THE TERMINAL SCREW IS NOT BINDING,
DUE TO THREAD DAMAGE, OR BOTTOMING, BUT IS ACTUALLY TIGHTENING THE
CONNECTOR. IMPROPER TORQUE MAY RESULT IN DAMAGE TO THE BATTERY.
Some batteries contain flat-sided washers as part of the terminal hardware. The flat side serves
as a visual indicator during torquing. During initial thread engagement the washer rotates, and
upon tightening, rotation stops. This indicates to the operator that the screw is tightened in the
terminal and was not binding or bottoming when the proper torque was reached.
It is good practice to follow the battery assembly IPL during final retightening as this is a good
double check of the correct electrical order. Do not skip around over cells; do not leave the job
partially completed and come back to it. Finish the complete battery reassembly once it is
started. Forgetting where the tightening job was stopped is a good way to miss a screw or nut.
One loose connection can permanently damage a battery and may cause an explosion.
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 Page 1201
APR 15/06
12.0 Battery Maintenance Flow Chart
BATTERY MAINTENANCE FLOW CHART
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 Page 1202
APR 15/06
BATTERY RECONDITIONING FLOW CHART
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 Page 1301
APR 15/06
13.0 TROUBLE-SHOOTING
TROUBLE-SHOOTING HINTS
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
APPARENT LOSS OF
CAPACITY
Very common when recharging on a
constant potential bus, as in aircraft.
Usually indicates imbalance between
cells because of difference in
temperature, charge efficiency, selfdischarge
rate, etc., in the cells.
Electrolyte level too low. Battery not
fully charged.
RECONDITIONING WILL ALLEVIATE
THIS CONDITION.
CHARGE. ADJUST ELECTROLYTE
LEVEL. CHECK AIRCRAFT VOLTAGE
REGULATOR. IF O.K., REDUCE
MAINTENANCE INTERVAL.
COMPLETE FAILURE TO
OPERATE
Defective connection in equipment
circuitry in which battery is installed -
such as broken lead, inoperative
relay or improper receptacle
installation.
End terminal connector loose or
disengaged. Poor intercell
connections.
Open circuit or dry cell.
CHECK AND CORRECT EXTERNAL
CIRCUITRY.
CLEAN AND RETIGHTEN HARDWARE
USING PROPER TORQUE VALUES.
REPLACE DEFECTIVE CELL
EXCESSIVE SPEWAGE OF
ELECTROLYTE
High charge voltage
High temperature during charge
Electrolyte level too high
Loose or damaged vent cap
Damaged cell and seal
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Operating and Maintenance Manual For Nickel-Cadmium Aircraft(16)
