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NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 TC-1
APR 15/06
TABLE OF CONTENTS
SUBJECT PAGE
Introduction INTRO-1
Description and Operation 1
Inspection 101
Electrical Leakage 201
Torque Requirements 301
Sensor Assembly Inspection 401
Charge 501
Electrolyte Level Adjustment 601
Capacity Test 701
Reconditioning 801
Cleaning 901
Replacement of Cells and Battery Repair 1001
Battery Disassembly and Reassembly 1101
Battery Maintenance Flow Chart 1201
Trouble-Shooting 1301
Storage 1401
Shipping 1501
Warranty Information 1601
Special Tools 1701
Record Keeping 1801
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 TC-2
APR 15/06
LIST OF FIGURES, ILLUSTRATIONS AND TABLES
PAGE #
Constant Current Charge Curve Figure 1 1
Typical Constant Current Discharge Curves Figure 2 3
Recommended Voltage Regulator Settings Table 1 103
Temperature Charge Voltage Relationship Figure 3 104
Torque Requirements Table 2 301
Temperature Sensor Specifications Table 3 402
Reflex and Constant Current Charge Rates Table 4 503
Syringe and Nozzle Assembly Figure 4 601
Syringe and Nozzle Assembly Application Table 5 601
Maximum Allowable Water Consumption Table 6 603
Proper Electrolyte Level Adjustment Figure 5 604
Water Loss at Various Rates of Overcharge Figure 6 605
Theoretical Water Loss and Volume of Gas Resulting from Overcharge Figure 7 605
Capacity test Rates Table 7 702
Inspection Gauge Figure 8 1701
One-Ohm power Resistor Figure 9 1701
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 INTRO-1
APR 15/06
INTRODUCTION
This manual contains shop verified instructions for proper installation, operation and maintenance of
MarathonNorco’s Nickel-Cadmium batteries. These instructions are grouped in topics shown in the Table
of Contents. They are for the operation, testing, and repair of MarathonNorco’s battery products.
WARNING: SERIOUS INJURY CAN RESULT FROM CARELESSNESS WHILE HANDLING AND
WORKING WITH NICKEL-CADMIUM BATTERIES. PLEASE OBSERVE THE
FOLLOWING SAFETY RULES WHILE WORKING WITH THESE BATTERIES.
1. Remove all metal articles such as bracelets and rings.
2. Metal tools must be insulated.
3. Wear protective clothing and eye protection. The electrolyte can cause burns if in contact with skin or
eyes.
4. Do not smoke or hold naked flames near batteries on charge. These batteries give off a mixture of
oxygen and hydrogen during charge, which, if allowed to accumulate in a confined space, could cause
an explosion. Do not charge the battery on the bench with the cover on.
5. Do not mix lead-acid and nickel-cadmium battery servicing in the same shop area.
6. Do not use petroleum spirits, trichloroethylene or other solvents.
READ AND UNDERSTAND THE CAUTIONS AND WARNINGS STATED THROUGHOUT THIS MANUAL
BEFORE PROCEEDING WITH SERVICING PROCEDURES.
CARELESSNESS MAY RESULT IN THE RAPID AND UNCONTROLLED RELEASE OF ELECTRICAL,
CHEMICAL OR HEAT ENERGY.
MarathonNorco Aerospace, Inc.
OPERATING and MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES
24-34-00 INTRO-2
APR 15/06
DEFINITIONS OF COMMONLY USED BATTERY TERMS
Ampere Hours
A unit of electrical measurement used to describe the
capacity of a cell or battery. The product of discharge
current (in amperes) X the time of discharge (in hours).
It is also used to describe the amount of electrical
energy put back into a battery during the charging
process. Abbreviated as Ah or Amp. hrs.
Capacity
A measure of the stored electrical energy that is
available from a charged battery. Generally expressed
in Ampere Hours, or as a % of the nominal (nameplate)
capacity
Constant Current Charging
A method used to charge a battery in which a
predetermined, fixed current is passed through it.
Constant Potential Charging (Constant Voltage)
This refers to a method in which a fixed voltage source is
applied across the battery terminals. The charge current
is variable and depends primarily upon the difference in
voltage between the voltage source and that of the
battery. The initial charge current is high and decreases
as the battery accepts the charge and its voltage
increases.
Trickle Charge
A continuous constant current, low-rate charge (slightly
more than the self-discharge rate) suitable to maintain a
battery in a fully charged condition.
Rated or Nominal Capacity
The nominal nameplate capacity rating of a nickelcadmium
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Operating and Maintenance Manual For Nickel-Cadmium Aircraft(2)
