Chapter 5: DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

TM 11-6140-203-14-3

CHAPTER 5

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

5-1. General Instructions

The direct support and general support maintenance procedures given in this chapter supplement those de-

scribed for organizational maintenance (chap. 4) and consist of the following.

Preparing a new battery for service (para 5-5).

Adjusting electrolyte level (para 5-6).

Periodic service procedures (quarterly or every 100 discharge-charge cycles) (para 5-7).

Troubleshooting (para 5-8).

Disassembly (para 5-9).

Reconditioning battery components (para 5-10).

Vent valve test (para 5-1 1).

New cell procedure (Para 5-12).

Filler vent valve test (ma 5-13).

5-2. Test Equipment, Tools, Additional Equipment and Supplies

Test equipment and tools authorized for the direct support and general support maintenance levels are listed in

the maintenance allocation chart, (app D). Expendable supplies and materials are listed in appendix E.

CAUTION

Maintenance personnel must wear a face shield (item 4, app E) or goggles (item 5) and an apron (item

6), while handling, servicing or making repairs to a battery.

5-3. Battery-Charger Equipment

The following battery charger equipment and cables are available for servicing nonaicraft nickel-cadmium batteries.

Charger, Battery PP-1659/G.

Generator set, gasoline engine (NSN 6115-00-475 0029), 3 kilowatts, 28 volts dc, MIL-G-52428

(used for battery charging where 115-volt or 230-volt ac power is not available).

Charger, Battery PP-1451/G.

Power Supply PP-1 104C/G with relay, reverse current cutoff (NSN 5945-00-824-5575).

Charger, Battery PP-6267 (for charging Battery, Storage BB-429/U).

Generator Set, Gasoline Engine PU-532/PPS-4 (for operating Radar Set AN/PPS-4 and charging

Battery, Storage BB-422/U).

Cable Assembly Set MX-4765/PPS-4 (for operating Radar Set AN/PPS-4 and charging Battery,

Storage BB-422/U).

Cable Assembly, Power Electrical CX-11935/U, (BB-501/U, BB-651/U only).

Charger/Analyzers such as the AN/(JSM 432, RF-80GT (Christie Electric) or AN/GSM-261 may be

used if available.

NOTE

Check Charger/Analyzer literature to determined the particular battery to be

charged can be operated on the specific charger.

5-4. Battery Rest Period After Charging

After the nonaircraft nickel-cadmium battery has been fully charged, it should be allowed to rest for

a minimum of 30 minutes to a maximum of 2 hours before checking the electrolyte level. If the 2-hour

maximum time is exceeded before the level of the electrolyte is checked, the battery must be brought back up

to the full charge state and allowed to rest again before performing the check.

The maximum rest time must be strictly adhered to. After the battery has been removed from the

battery charger, it will discharge gases trapped between the separators and plates during the rest period. At

this progresses, electrolyte solution is absorbed into the battery plates in place of the gases. It the battery has

rested longer than the maximum period of time, absorption could bring the electrolyte level to the point that

inspection would indicate than more should be added. Correction of the electrolyte level under these conditions

could overfill the cell and cause spewing when the battery is brought to a full charge while installed in the

equipment for service.

5-5. Preparing New Battery for Service

A new battery is a battery that has never been placed in use or a battery taken out of storage for use. Perform the

procedures given in a through g below to prepare a new battery for service.

Initial Inspection. Remove the cover and perform the following internal checks:

(1) Damage. See whether any electrolyte liquid has spilled into the battery case or shipping container. This

condition may be a sign of a damaged cell.

(2) Electrical Connections. Check all electrical connections for tightness. Test all screws on terminals to en-

sure tightness. Refer to paragraph 4-11 for correct ter- minal screw torque. Check any wing for proper connec- tion. Poor

electrical contact may result in damage to the battery.

(3) Electrolyte Level The batteries are normally shipped with the proper amount of electrolyte. Do not add dis-

tilled water or electrolyte until after the battery is charged. When a battery has been discharged or allowed to stand unused

over a period of time, the electrolyte becomes ab- sorbed into the plates. The batteries are shipped dis- charged and,

therefore, the electrolyte level may seem low. Charging the battery should cause this level to rise to the proper mark, which

is just above the tops (approximately one-fourth inch) of the plates. Do not charge cells of different capacities together.

Adjust if necessary in accordance with instructions in paragraph 5-6.

Clean Battery. Clean the battery by following the instructions contained in paragraph 4-7.

5-1