24 34 01 (30475 002) MD

Component Maintenance Manual
With
Illustrated Parts List
For
Nickel-Cadmium Battery
Type SP-138
Part Number 30475-002
MarathonNorco Aerospace, Inc.

P.O. Box 8233 8301 Imperial Drive
Waco TX. 76714-8233 Waco, TX. 76712-6588
Phone: (254) 776-0650 Fax: (254) 776-6558
E-Mail: marathon@mptc.com
Website: www.mnaerospace.com
JAN 01/89
24-34-01 Rev 5 MAR 27/08
COMPONENT MAINTENANCE MANUAL
P/N 30475-002
THIS PAGE IS INTENTIONALLY BLANK
JAN 01/89
24-34-01 Rev 3 NOV 30/03
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RECORD OF REVISIONS
Original Issue Date: JAN 01/89
Rev Issue Date Rev Issue Date Rev Issue Dated

No. Date Inserted By No. Date Inserted By No. Date Inserted By
1 06/30/01
2 03/15/03
3 11/30/03
4 05/07/04
5 03/27/08 db
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RR-2
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RECORD OF TEMPORARY REVISIONS
Temporary Page Issue Date

Rev. No. Number Date By Removed By
RTR-1
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RTR-2
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SERVICE BULLETIN LIST
Number Revision Date
SBL-1
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SBL-2
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LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Page 504 NOV 30/03
Title T-1 MAR 27/08
T-2 NOV 30/03 Page 505 NOV 30/03
Page 506 NOV 30/03
Record of Revisions RR-1 MAR 27/08
RR-2 NOV 30/03 Repair Page 601 NOV 30/03
Page 602 NOV 30/03
Record of Temp RTR-1 NOV 30/03
Revisions RTR-2 NOV 30/03 Assembly Page 701 MAR 27/08
(Including Storage) Page 702 NOV 30/03
Service Bulletin List SBL-1 NOV 30/03
SBL-2 NOV 30/03 Special Tools, Page 901 MAR 27/08
Fixtures and Equipment Page 902 NOV 30/03
List of Effective Pages LEP-1 MAR 27/08
LEP-2 NOV 30/03 Illustrated Parts List Page 1001 NOV 30/03
Page 1002 MAR 27/08
Table of Contents TC-1 NOV 30/03 Page 1003 MAR 27/08
TC-2 NOV 30/03 Page 1004 MAR 27/08
Introduction INTRO-1 NOV 30/03

INTRO-2 NOV 30/03
INTRO-3 NOV 30/03
INTRO-4 NOV 30/03
INTRO-5 NOV 30/03
INTRO-6 NOV 30/03
Description and Page 1 NOV 30/03

Operation Page 2 NOV 30/03
Page 3 NOV 30/03
Page 4 NOV 30/03
Page 5 MAR 27/08
Page 6 NOV 30/03
Testing and Fault Page 101 NOV 30/03

Isolation Page 102 NOV 30/03
Page 103 NOV 30/03
Page 104 NOV 30/03
Page 105 NOV 30/03
Page 106 NOV 30/03
Page 107 NOV 30/03
Page 108 NOV 30/03
Disassembly Page 301 NOV 30/03

Page 302 NOV 30/03
Cleaning Page 401 NOV 30/03

Page 402 NOV 30/03
Check / Inspection Page 501 NOV 30/03

Page 502 NOV 30/03
Page 503 NOV 30/03
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LEP-2
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TABLE OF CONTENTS
SUBJECT PAGE
Introduction INTRO-1
Description and Operation 1
Testing and Fault Isolation 101
Disassembly 301
Cleaning 401
Check / Inspection 501
Repair 601
Assembly (Including Storage) 701
Special Tools, Fixtures and Equipment 901
Illustrated Parts List 1001
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INTRODUCTION
This manual contains shop verified instructions for maintenance and an illustrated list of component
parts for the nickel-cadmium battery, type SP-138 and its cell, type 38SP100. These instructions are
grouped in topics shown in the Table of Contents. They are for the operation, testing, repair and
overhaul of the battery.
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 eyeware. The electrolyte can cause burns if in contact with skin.
4. Do not smoke or hold naked lights 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.
6. Do not use petroleum spirits, trichloroethylene or other solvents.
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DEFINITIONS OF COMMONLY USED BATTERY TERMS
Ampere-Hours
A unit of electrical measurement generally Charge Efficiency
used to describe the capacity of a cell or The ratio of the ampere-hour capacity
battery. The product of discharge current (in removed from a battery to the number of
amperes) x the time of discharge (in hours), it ampere-hours put into the battery during
is also used to describe the amount of charge. Usually expressed as a percentage.
electrical energy put back into a battery during Ah Output
the charging process. Abbreviated as Ah or Ah Input X 100
Amp. Hrs.
Charge Retention
Battery The amount of capacity retained (or
One of the sources of direct current (D.C.) deliverable) by a fully charged battery after it
power; a device that converts stored chemical has been stored for a stated period of time.
energy directly into electrical energy Sometimes called shelf life.
(electricity). Strictly speaking, a battery
consists of two or more cells connected to Charging
form one unit. Through common usage, the The process of supplying electrical energy to a
terms “battery” and “cell” are now used rechargeable battery for the purpose of
interchangeably so that a battery may refer to converting its contents to stored chemical
one or more cells. energy in which form it is again ready for use.
Cadmium Electrode—See Negative Plate Closed Circuit Voltage

The instantaneous voltage of a cell or battery
Can when a load is first applied.
The battery box which contains the cells,
associated intercell connectors, hardware and Constant Current Charging
sometimes electrical devices. A method used to charge a battery in which a
predetermined, fixed current is passed through
Capacity it. See also charging.
A measure of the stored electrical energy that
is available from a fully charged battery. Constant Potential Charging
Generally expressed in Ah. Sometimes called constant voltage charging,
this refers to a method in which a fixed
Cell voltage source is applied across the battery
As used in the battery industry, it is a device terminals. The charge current is variable and
which contains positive and negative polarity depends primarily upon the difference in
plates, separator and electrolyte. Enclosed in voltage between the voltage source and that of
a cell case and fitted with terminals, it is the the battery. The initial charge current is high
basic building block of the battery. and decreases as the battery accepts the
charge.
Cell Puller
A specially designed tool used to facilitate the
removal of cells from a battery.
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“C” Rate End-of-Charge Voltage

That discharge rate, in amperes, at which a The voltage of a battery at the conclusion of a
battery or cell will yield its capacity to a 1.0 charge measured while the battery is still on
volt per cell endpoint in one hour. Fractions charge.
or multiples of the C rate are also used. C/5
refers to the rate at which a battery will Endpoint (or End) Voltage
discharge its capacity in 5 hours; 2C is twice Voltage at which a charge or discharge is
the C rate or that rate at which a battery will normally terminated.
discharge its capacity in about 1/2 hour.
Example: a 25 Ah battery will have a C rate of Equalization—See Reconditioning
25 amperes, a C/5 rate of 5 amperes and a 2C
rate of 50 amperes. This rating system helps Fading
to compare the performance of different sizes The loss of capacity that occurs when a
of cells and batteries. battery is cycled using constant potential
charging.
Cut-Off Voltage—See Endpoint Voltage
Final Charge Voltage—See End-of-Charge
Cycle Voltage.
One charge-discharge sequence on a
rechargeable battery. Intercell Connectors
An electrically conductive bar or strap which
Discharge Current (or Rate) connects together individual cells in a battery;
The magnitude of current removed from a in nickel-cadmium batteries, usually made
battery, usually expressed in Amperes (Amps. from, nickel plated steel, or nickel plated
or A) or Millamperes (mA); sometimes copper.
expressed in terms of “C” rate.
Life
Discharging The duration of satisfactory performance of a
The removal of electrical energy from a battery, measured as the number of charge-
battery. discharge cycles; sometimes measured as
years of usage.
Electrodes
Poles (or plates) of a cell at which the Maintenance
electrochemical reactions occur and through The procedures required to keep a battery in a
which current flows. usable condition. These include inspections,
cleaning, reconditioning, and periodic water
Electrolyte additions to the electrolyte.
A conductive medium that provides for the
movement of ions (current flow) between the Negative Plate
positive and negative plates of a cell; an The plate from which electrons flow, through
alkaline solution in nickel-cadmium cells. See the external circuit when the battery is
also Potassium Hydroxide. discharging. In the nickel-cadmium battery, it
is the plate that contains cadmium which is
oxidized during discharge.
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Nominal Voltage chemically reduced to a lower oxidation state

The voltage of a fully charged cell or battery during discharge.
while delivering current. The nominal voltage
of a nickel-cadmium battery cell is 1.2 volts. Potassium Hydroxide
A chemical compound which is mixed with
Open Circuit Voltage pure water in exact proportions to form the
The voltage of a battery at rest, that is, with no electrolyte used in nickel-cadmium cells.
charge or discharge current flowing.
Rated Capacity
Overcharging The number of Ah that a battery is capable of
Continuing the charge after replacing the Ah delivering when fully charged and under
of capacity that had been removed previously. specified conditions of rate of discharge,
Overcharging is required in order to make up temperature and end-point voltage.
for the inefficiency of charge. It is sometimes Sometimes also expressed in watt-hours.
used to keep a battery in a “ready” condition.
During overcharge, the vented nickel- Rechargeable Battery
cadmium cell will evolve hydrogen and A battery that chemically stores electrical
oxygen resulting from the decomposition of energy and is capable of cyclic delivery and
the water in the electrolyte. The evolved gas restoration of the energy through the
is proportional to the overcharge current. utilization of reversible chemical reactions.
Oxidation Reconditioning
The release of electrons by the cell’s active A procedure consisting of a deep discharge
material—as by the cadmium at the negative and a constant current charge that is used to
plate—to the external circuit during a correct a cell imbalance that may occur during
discharge. continual use of a rechargeable battery.
Plate Reversal
One of the two-cell components at which the In a rechargeable battery, this refers to a
electrochemical reactions take place and in change in the normal polarity of the cell or
which chemical energy is stored. See Positive battery to the opposite polarity as when a cell
Plate and Negative Plate. is driven into reverse during a deep discharge,
or, when a cell or battery is inadvertently
Plateau Voltage charged in reverse.
The closed circuit voltage observed on the
relatively flat portion of a discharge curve. Separator
A material that is used to prevent metallic
Positive Electrode—See Positive Plate contact between the positive and negative
plates in a cell. Vented nickel-cadmium cells
Positive Plate also contain a gas barrier to prevent the gas
The plate to which electrons flow through the (oxygen) produced at the positive plate during
external circuit when the battery is overcharging from reaching the negative plate
discharging. In the nickel-cadmium battery, it which it would tend to discharge.
is the plate that contains nickel oxide which is
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Shorting Clip
A short length of wire (with or without a low
value resistor), or a metal spring, used to
“short” a cell to zero volts.
State of Charge
The amount of stored energy (capacity)
available in a rechargeable battery. Usually
expressed as a percentage of its full capacity.
Terminals
The positive and negative parts of a cell
through which external connections are made
to the plates.
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.
Vent Plug
A normally sealed device which allows the
controlled venting of gases from a cell while
preventing electrolyte leakage. The vent plug
is removed when electrolyte level adjustments
must be made.
Vented Cell
A rechargeable cell which employs a vent
plug to permit gases to be expelled during
overcharge; sometimes also called a “flooded
cell” because of the volume of electrolyte used
in the cell.
Voltage
The difference in potential measured between
the two electrodes of a cell or battery and
expressed in units of volts.
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DESCRIPTION AND OPERATION
DESCRIPTION
The SP-138 battery consists of eleven nickel-cadmium cells, type 38SP100, enclosed in a cold-rolled
steel fluidized bed epoxy coated container.
The battery is designed to be used for standby/busbar support and auxiliary power starting. Two
Battery units are required for aircraft operation.
NOTE: The cell assembly contains a vent/filler cap which incorporates a visual liquid level
indicator for checking the low level limit of the electrolyte.
Nominal Voltage: 14 Volts

Rated Capacity: 38 Ampere Hours at One Hour Rate
Electrical Receptacle: Type BR-8 (MS-3509)
Electrolyte: KOH S.G. 1.30
Overall Dimensions: 10.75 x 9.25 x 12 High
Weight: 46 lbs.
GENERAL
The nickel-cadmium battery cell is an electrochemical system in which the active materials
contained in the plates undergo changes in oxidation state with little or no change in physical state.
These active materials do not dissolve in the alkaline (potassium hydroxide) electrolyte while going
through the changes in oxidation state. As a result the electrodes are very long-lived.
In common with many of the other battery systems, some of the electrochemical mechanisms
involved in the charge, discharge, and storage of the nickel-cadmium battery cell are rather complex.
This is especially true of the positive (nickel hydroxide) plate. However, a brief, simplified account
of the essential reactions is offered here in order to help initiate the reader into the theory and
principles of this system and thus further his understanding of the operation of the battery and the
role played by its main components.
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OPERATION
VOLTAGE AND CAPACITY
The open circuit voltage of a vented nickel-cadmium battery cell is generally accepted as 1.28
volts. (The open circuit voltage of a battery would be 1.28 volts times the number of cells in the
battery.) This value is the same regardless of the size or shape of the cell although it does depend
upon such factors as the temperature of the cell and the elapsed time since its last charge.
Immediately after removal from a charger, the voltage is higher (above 1.40 volts) but slowly settles
and maintains a value of about 1.35 to 1.28 volts per cell. The open circuit voltage does not indicate
the state of charge.
The nominal voltage of a vented nickel-cadmium battery cell is usually accepted as 1.20 volts. This
voltage or greater is normally maintained throughout the discharge period until about 80% of the 2-
hour rated capacity has been removed from the cell. When discharged at significantly higher rates or
temperatures other than normal room temperature, the cell’s voltage will fall below 1.20 volts more
rapidly.
The closed circuit voltage of a vented nickel-cadmium battery cell is that voltage read immediately
after a load is connected and is something less than its open circuit voltage. It is highly dependent
upon such factors as length of stand time subsequent to charging, the magnitude of the discharge
current, and battery temperature. Typically, it would be about 1.25 volts when measured at the 1-
hour rate at 750-800F; at the 5-hour rate it would be about 1.28 volts.
The working voltage or plateau voltage is that voltage observed on the level plateau of the
discharge curve of a nickel-cadmium battery cell when the cells’ voltage is plotted against time.
This value generally averages 1.22 volts and ranges from 1.15 to 1.25 volts again depending upon
the stand time, discharge current, and battery temperature.
The end-of-charge voltage, measured while the cell is on charge, depends upon its temperature and
the method used for charging it. As an example, a cell in a 22-cell battery being charged at room
temperature at 33.0 volt constant voltage would read about 1.5 volts at the end of charge; at a 31.9
volt constant voltage condition, the cell would read about 1.45 volts. Under constant current
charging conditions, this value would depend upon temperature and charge current.
Capacity is a measure of the stored electrical energy, generally expressed in ampere-hours, that is
available for use from a fully charged battery.
CHARGE
Charging results in the conversion of electrical energy to stored chemical energy.
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OVERCHARGE
Continued charging after full chemical conversion. Overcharge beyond nameplate capacity is
required to obtain maximum battery capacity.
DISCHARGE
Discharging results in the conversion of the chemical energy stored in the cell to electrical energy.
OVERDISCHARGE
A cell which has been driven into a region where its voltage has become negative is said to have
been over-discharged (also known as cell reversal). In such a cell, the positive plate assumes a
negative polarity and the negative plate assumes a positive polarity.
Under extreme discharge conditions, negative voltages have been observed. The effect of such
reversal is the occurrence of vigorous gassing. Long term high rate overdischarges may cause
particles to break away from the plates. This could result in a permanent loss of capacity or cause an
internal short. There appears to be no long-term effects of occasional cell reversal at low-to-medium
rates.
Factors Affecting Capacity
Capacity is measured quantitatively in ampere-hours at a specified discharge rate to a specified cut-

off voltage usually at room temperature. The cut-off voltage is generally figured as 1.0 volt per cell,
but varies with the discharge rate and temperature. At higher rates and low temperatures, the cut-off
voltage is sometimes calculated as 0.6 volt per cell while at lower rates and/or higher temperatures a
cut-off voltage of about 1.1 volts is used.
Battery capacity depends upon several factors including such items as:
1. Cell design (cell geometry, plate thickness, hardware, and thermal design govern performance
under specific usage conditions of temperature, discharge rate, etc.).
2. Discharge rate (high current rates yield less capacity than low rates.).
3. Temperature.
4. Charge rate (higher charge rates generally yield greater capacity).
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Before Charging
Perform necessary inspection, cleaning, repair, and torque check on intercell connector hardware
before charging.
Charging Precautions and Notes
CAUTION: REMOVE ALL SHORTING DEVICES FROM THE BATTERY TERMINALS

AND CELLS BEFORE CONNECTING THE CHARGER CABLE.
Charge Batteries in an Upright Position
Inversion of batteries during the final stages of charge may cause excessive loss of electrolyte.
Use Correct Polarity
Reverse charging at high rates may damage the battery. Before starting the charge, make sure that
the battery is connected correctly to the charging source—the positive terminal of the charger output
to the positive terminal of the battery; the negative terminal of the charger to the negative terminal of
the battery. Generally the red lead on the charging source is positive; the positive terminal of the
battery is indicated by a plus sign.
Charge Method
It will be necessary to charge the battery prior to putting it into service. Marathon recommends a
two step constant current charging profile or charging with an RF-80K Reflex Charger. (See Battery
Charging section of this manual.)
Adjust Charge Controls
The charge voltage or charge current on the charging source should be set at zero before throwing
the switch. Then slowly adjust the voltage or current level to the required value. Otherwise, too
high a current may cause a partially charged battery to gas violently and spew electrolyte.
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Avoid Short Circuits
A Nickel-cadmium battery can produce tremendous surges of power on being short circuited. This
should be avoided especially on charged or partially charged batteries. In any event, care should be
exercised when working with the battery. Do not drop tools or other metallic objects onto the
intercell connectors, severe arcing will result with possible injury to personnel and damage to the
battery. Only insulated tools should be used for servicing nickel-cadmium batteries.
Rings, metal watch bands or other metallic jewelry should be removed before working around
the battery. Should such metallic objects contact intercell connectors of opposing polarity, they
may fuse themselves to the connectors and cause severe skin burns.
CHARGING INFORMATION
Charging Individual Cells
Exercise care when charging individual cells outside of the battery can. Gas pressure developed
during the charge and overcharge of an unsupported cell may crack the cell case and cause injury to
personnel; always support the wide faces of the cell. To simulate battery assembly, a special frame
may be fabricated to fit the cell, or two plates may be placed on each wide face of the cell (or several
cells connected in series) and held together by a C-Clamp.
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BATTERY CHARGING
Constant Current
Constant current charging refers to a method in which the charger maintains a predetermined and
constant current throughout the charge and overcharge intervals. It is the preferred method of
charging and is very effective in maintaining cell balance and full capacity.
The constant current charging method is generally used in battery maintenance shops because of its
simple current design, its relatively low current carrying, low cost components, and ease of operation
and regulation.
Reflex Mode
Reflex charging refers to charging with a Christie RF80K battery charger. This device applies a
negative current pulse (discharge) to the battery as it approaches full charge. The effect is to
minimize gas bubble formation and to improve charge acceptance for the battery.
Marathon recommends a two step charge profile consisting of one hour of Reflex charging at the 2C
rate plus 2 hours of constant current charging at one C/5rate.
WATER LOSS
As the battery approaches the end of charge and during overcharge, gassing occurs. The gassing
results chiefly from the electrolysis of the water component of the electrolyte and makes necessary
the periodic inspection of the electrolyte level in cells and the addition of water when it falls below a
certain recommended level.
Adjustment of Electrolyte
Water additions to adjust the liquid level are made within the last 15 minutes of the topping charge
using the green leveling tool supplied in Marathon Kit 32480-001.
NOTES: Make electrolyte adjustments with distilled, deionized, or demineralized water only. Do
not use tap water.
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TESTING AND FAULT ISOLATION
Maintenance and Reconditioning Schedules
At no time should a battery be allowed to deteriorate to a point where its performance affects the
mission or the operation of the aircraft. A proper maintenance program is required to prevent battery
failures. Such a program requires trained, knowledgeable personnel familiar with proper battery
maintenance and reconditioning procedures and the keeping of accurate records.
Depending upon: a) type of starting service; b) battery duty cycle; c) operating temperature; and d)
charger voltage regulator setting, flight hours are the main factor in determining the frequency of
water additions and reconditioning cycles.
Because of the widely varied flight profiles encountered in individual aircraft use, no fixed
maintenance and reconditioning period can be specified. These periods can only be approximated.
The user must eventually apply his experience and the information gained during the first few
maintenance and reconditioning periods to determine the schedule that is best suited to his particular
type of battery usage.
Reconditioning Nickel-Cadmium Batteries
Importance of Reconditioning
Under certain conditions of use, nickel-cadmium batteries may show a temporary loss of capacity.
Usually this loss is due to an imbalance in individual cell capacities as may result from differences in
self discharge rates, charge efficiency, etc. Reconditioning is recommended to restore a battery to its
full capacity and to prevent premature damage and failure.
The data obtained during the reconditioning of a battery is invaluable for determining the maximum
flight hours between reconditioning services.
In aircraft where more than one battery is used, either in series or parallel starting. Perform the
conditioning service on both batteries during the same inspection period.
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Reconditioning Procedure
A battery may be received in the service shop in an unknown state of charge. The cells may look as
if they are dry and need water. It may be a discharged battery or one that has been allowed to run
dry. In any case, proceed as follows:
1. Inspect the battery per instructions on Page 501. If necessary, clean the battery (refer to Page
401).
2. Perform an electrical leak check. This refers to the external electrical leakage between a cell
terminal or connector and the battery can caused by electrolyte collecting around the cells
usually as a result of spewing from the vent caps. It may also be caused by a damaged cell case-
to-cover seal. A leakage path greater than about 50 milliamperes between the battery can and
either positive or negative terminals of the battery is considered to be excessive.
NOTE: Do not use the voltage reading between the terminals and the battery as a criteria for
rejection; current flow is the determining factor.
CAUTION: DEPENDING UPON CONDITIONS, A POTENTIAL SHOCK HAZARD MAY

EXIST ACROSS EITHER BATTERY TERMINAL AND THE CAN ON A
BATTERY ASSEMBLY HAVING A VOLTAGE OF 50 VOLTS OR GREATER
AND A LEAKAGE CURRENT GREATER THAN 2 MILLIAMPERES. KEEPING
THE LEAKAGE CURRENT BELOW 2 MILLIAMPERES BY THOROUGH
CLEANING AND INCREASED MAINTENANCE WILL REDUCE OR
ELIMINATE THIS POTENTIAL SHOCK HAZARD.
Procedure
A. To determine if external leakage is of such a magnitude as to require a complete battery

cleaning, set the range selector of a multimeter to the 500 milliampere range or higher.
B. Place the positive lead of the meter on the positive terminal of the battery receptacle and
momentarily touch the negative lead of the meter to any exposed metal on the battery can.
NOTE: Most Marathon batteries are supplied with epoxy coated battery cans and covers - in
order to completely insulate the cells from the can. Where epoxy cans are used, current
flow may be measured between the battery terminals and the screws that are used to
mount the main connector.
C. If the needle deflection is within the meter limits, connect the negative lead of the meter to
the battery can. Now, decrease the meter current range until the current, if any current flow
exists, is readable. Record this current value.
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D. Repeat the above, connecting the negative lead of the meter on the negative terminal of the
battery receptacle and the positive meter lead to any exposed metal on the battery can.
E. If either of the above current measurements exceed 50 milliamperes, flush the tops of the
cells and dry as on Page 401.
F. Repeat the above current test on both positive and negative terminals. If the tops of the cells
are cleaned properly and the current measurement is still greater than 50 milliamperes, one or
more of the cells may be leaking. To isolate this cell or cells, proceed as follows:
(1) Using a voltmeter of 1000 ohms-per-volt or greater, place one of the meter leads on
either the negative or positive terminals of the battery and the other lead on any
exposed metal of the battery can; note the meter reading. If the meter reads left of zero,
reverse the positions of the meter leads.
(2) Keep one meter lead on the exposed metal surface of the can and move the other lead
systematically from one cell terminal to another, noting the voltage readings. Voltage
readings will decrease and finally go negative indicating the location of the path and
possibly a leaky cell.
(3) If the cell is leaking, replace the cell or cells following the procedure described on Page
301. If no leaking cells are found, the leakage path may be due to electrolyte along the
outside of the cells and at the bottom of the battery can: proceed as on Page 401.
3. Charge: Charge the two batteries connected in series on a constant current charger at 21 amps for
2 ½ hours. Reduce the rate to 7.6 amps and continue to charge for 2 hours. During the last 15
minutes of the 7.6 amp charge, adjust the electrolyte level using deionized water and the green
syringe tip in Marathon kit 32480-001
Alternately, the Christie RF80K may be used for the main charge. Set the charger to 22 cells and
80 amps (2C). Charge for 1 hour, and then complete the charge at 7.6 amps per step 3.
4. Discharge: The battery is now ready for discharge. Discharge it at 38 amps (1 hour rate) to an
average voltage of 1.0 volt per cell (22 volts for a 22 cell battery) and record the time.
A. If the discharge capacity is more than 85% of the 1 hour rate (i.e., 51 minutes, or 32.3 amp
hours), the battery has passed the capacity test and may be prepared for return to service.
Recharge as in Step 6 below.
B. If the discharge capacity is less than 51 minutes, the battery has failed the capacity test and a
supplemental (deep cycle) discharge must be performed as in Step 5 below, followed by
another cycle of charge and discharge as in Steps 3 & 4, and another charge as in Step 6.
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5. Deep Cycling: Continue the above discharge. As each individual cell reaches 0.5 volts or less,
place a metal shorting clip (Figure 903) across its terminal while the load is still applied.
Continue until all cells are shorted.
Allow the battery to remain shorted for at least 4 hours, preferably overnight.
6. Recharge: Recharge the battery per step 3, above.
A. During the final 5 minutes of charge, read the voltage of each individual cell. For automatic
chargers that have terminated, reset the charge 10 additional minutes and read the voltage of
each cell at the end of this time (with current flowing). The minimum voltage should be 1.55
volts per cell and the maximum 1.75 volts per cell at room temperature (70 0F-800F). If any
cell fails to rise to the minimum voltage specified, the charge should be continued for an
additional hour. At this time, with current flowing, read the voltage of each cell again.
B. Any cell that fails to rise to 1.55 volts or peaks above these voltages, then decreases below
1.50 volts must be removed from the battery. Any cell whose voltage rises above 1.75 volts
should also be removed.
C. If three or more cells are found to be defective, either at one time or over a period of time, it
is recommended that all the cells in the battery be replaced because the probability is great
that the remaining cells have also been damaged and will shortly have to be replaced.
D. If the battery has passed all of the requirements of Steps 1 through 6 above, the battery is
ready for installation or storage.
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

1. APPARENT LOSS OF Very common when recharging across PERIODIC RECONDITIONING WILL HELP
CAPACITY constant potential bus, as in aircraft – ALLEVIATE THIS CONDITION.
usually indicates imbalance between cells
because of difference in temperature,
charge efficiency, self-discharge rate,
etc., in the cells.
Electrolyte level too low. Battery not CHARGE AS IN STEP 3. ADJUST

fully charged. ELECTROLYTE LEVEL AND CHECK
CAPACITY AS IN STEP 4. CHECK
CHARGING SYSTEM.
2. COMPLETE FAILURE Defective connection in equipment CHECK AND CORRECT EXTERNAL

TO OPERATE circuitry in which battery is installed – CIRCUITRY.
such as broken lead, inoperative relay or
improper receptacle installation.
End terminal connector loose or CLEAN AND RETIGHTEN HARDWARE

disengaged. Poor intercell connections. USING PROPER TORQUE VALUES.
Open circuited or dry cell. REPLACE DEFECTIVE CELL.
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3.EXCESSIVE SPEWAGE High charge voltage. CLEAN BATTERY, CHARGE AND ADJUST
OF ELECTROLYTE High temperature during charge. ELECTROLYTE LEVEL.
Electrolyte level too high.
Loose or damaged vent cap. CLEAN BATTERY, TIGHTEN OR REPLACE

CAP, CHARGE AND ADJUST
ELECTROLYTE LEVEL.
Damaged cell and seal. SHORT OUT ALL CELLS TO 0 VOLTS,

CLEAN BATTERY, REPLACE DEFECTIVE
CELL, CHARGE AND ADJUST
ELECTROLYTE LEVEL.
4. FAILURE OF ONE OR Negative Electrode not fully charged. CHARGE BATTERY AS IN STEP 3. IF THE
MORE CELLS TO RISE CELL STILL FAILS TO RISE TO 1.55 VOLTS
TO THE REQUIRED OR IF THE CELLS’ VOLTAGE RISES TO
1.55 VOLTS AT THE 1.55 VOLTS OR ABOVE AND THEN DROPS
END OF CHARGE. BY 0.05 VOLTS MORE, REMOVE CELL
AND REPLACE.
5. DISTORTION OF Overcharged, overdischarged, or DISCHARGE BATTERY AND

CELL CASE AND overheated cell with internal short. DISASSEMBLE, REPLACE DEFECTIVE
COVER CELL. RECONDITION BATTERY.
Plugged vent cap. REPLACE VENT CAP

Overheated battery. CHECK CHARGER VOLTAGE, TREAT
BATTERY AS ABOVE, REPLACING
BATTERY CASE AND COVER AND ALL
OTHER DEFECTIVE PARTS.
6. FOREIGN MATERIAL Introduced into cell through addition of DISCHARGE BATTERY AND
WITHIN THE CELL impure water or water contaminated with DISASSEMBLE, REMOVE CELL AND
CASE acid. REPLACE, RECONDITION BATTERY.
7. PARTICLES OF Too high a concentration of electrolyte PROCEED AS IN 6.

PLATE MATERIAL caused by adding potassium hydroxide
raising the specific gravity.
8. FREQUENT Cell out of balance. RECONDITION BATTERY.

ADDITION OF WATER
Damaged “O” ring, vent cap. REPLACE DAMAGED PARTS.
Leaking cell. DISCHARGE BATTERY AND
DISASSEMBLE, REPLACE DEFECTIVE
CELL, RECONDITION BATTERY.
Charge voltage too high. ADJUST CHARGING VOLTAGE.
9. CORROSION OF TOP Acid fumes or spray or other corrosive REPLACE PARTS. BATTERY SHOULD BE
HARDWARE atmosphere. KEPT CLEAN AND KEPT AWAY FROM
SUCH ENVIRONMENTS.
10. DISCOLORED OR Dirty connections. CLEAN PARTS AND REPLACE IF
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BURNED END Loose connection. NECESSARY, RETIGHTEN HARDWARE
CONNECTORS OR Improper mating of parts. USING PROPER TORQUE VALUES.
INTERCELL CHECK TO SEE THAT PARTS ARE
CONNECTORS PROPERLY MATED.
11. DISTORTION OF Explosion caused by: DISCHARGE BATTERY AND

BATTERY CASE Dry cells DISASSEMBLE, REPLACE DAMAGED
AND/OR COVER Charger failure PARTS AND RECONDITION.
High charge voltage
Plugged vent caps
Loose intercell connectors
12. CELL TO BATTERY Excessive spewage. CLEAN BATTERY, CHARGE AS IN STEP 3,

CAN LEAKAGE TO AND ADJUST ELECTROLYTE LEVEL.
GROUND DETECTED RECHECK FOR ELECTRICAL LEAKAGE.
BY TESTING AS ON
PAGE 102. Damaged cell case to cover seal. DISCHARGE BATTERY AND
DISASSEMBLE, REPLACE DEFECTIVE
CELL, RECONDITION BATTERY.
13. FOAMING OF Contaminant in electrolyte. DISCHARGE BATTERY AND REPLACE

ELECTROLYTE DEFECTIVE CELL.
DURING CHARGE
Apparent low electrolyte concentration RECONDITION BATTERY, REPLACE CELL

following addition of water. THAT CONTINUES TO FOAM.
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BATTERY SERVICE DATA SHEET File

Page of
Work Order Aircraft Type

Date Aircraft No.
Battery S/N Hours in Service
Battery Type Service Performed by
Specifications Main Chg. Amps Top Chg. Amps

Torque in Lbs. Cap. Test Amps
Sensor
Inspections ()
Initial Visual Torque Deep Cycle No

Elect. Leakage Vents
Connector(s) Sensor Final Inspection
TESTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 1 2 2 2
8 9 0 1 2
Main Chg. Volts
30 Minutes
Time to 1.55V
Initial H2O CCs
Top Chg. Volts

15 Minutes
30 Minutes
60 Minutes
90 Minutes
120 Minutes
Total H2O CCs
Capacity Volts
15/30 Minutes
30/60 Minutes
45/90 Minutes
51/120 Minutes
Approved for service Date
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BATTERY DISASSEMBLY
Before disassembling the battery assembly, make sure that all cell assemblies are completely
discharged. This may be accomplished as follows:
1. Deep discharge the battery at the one-hour rate per steps 4 & 5, as shown on page 103.
2. After the battery assembly has been discharged as above and cooled to room ambient
temperature, remove the shorting clips. Remove the socket head cap screws, the lockwashers,
and the flat washer. Remove all intercell connectors. Loosen the vent and filler cap assemblies,
using the vent wrench (Figure 904).
The cell assemblies may now be removed by using a cell puller (Figure 906) as necessary. When
removing cell assemblies from a battery, always tighten the puller to the cells and use an even
straight-up pull. After removing the cell assemblies, re-tighten the vent and filler cap assemblies
using the vent wrench.
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24-34-01 NOV 30/03
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CLEANING
Cleaning Procedures
The battery should be kept in a clean, dry state for optimum performance. The extent of the cleaning
process depends upon the condition of the battery. Several procedures are described in the following
paragraphs.
If heavy overcharging has occurred, gassing and spewing of electrolyte may cause a white powdery
substance, potassium carbonate, to form on top of the cells. This may be removed by brushing the
cells with a stiff bristle brush or a clean cloth.
If necessary, the tops of the cells may be flushed with ordinary tap water. Make certain that all of
the cell vent plugs are properly seated. Tip the battery at about a 45° angle with its receptacle (or
power connector) facing upward. Flush with water from the top of the battery in a downward
direction so as to prevent, as much as possible, any water from entering the battery can. It is
permissible to use a non-conductive bristle brush to clean away stubborn dirt particles. Any excess
liquid should be drained off and the battery permitted to dry. Drying may be accelerated by the use
of oil-free compressed air.
WARNING: USE OF COMPRESSED AIR FOR CLEANING CAN CREATE AN

ENVIRONMENT OF PROPELLED FOREIGN PARTICLES WHICH MAY
ENTER THE EYES AND CAUSE SERIOUS INJURY. AIR PRESSURE FOR
CLEANING SHALL NOT EXCEED 30 PSI. EFFECTIVE CHIP GUARDING
INCLUDING EYE PROTECTION IS REQUIRED.
CAUTION: THE WATER USED TO WASH THE CELLS OR BATTERY WILL BECOME
CAUSTIC; AVOID CONTACT WITH IT. DO NOT USE A METAL BRUSH:
THIS MAY RESULT IN A SHORT CIRCUIT WHICH MAY CAUSE SKIN
BURNS OR DAMAGE TO THE BATTERY. DO NOT CLEAN THE TOP
CELLS WITH SOLVENTS, ACIDS OR ANY CHEMICAL SOLUTION.
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If the battery has free electrolyte on the top of the cells, drain off as much as possible, wash with
water, and air dry. If the electrolyte has overflowed to an extent that it has run down between the
cells, the battery should be completely discharged, disassembled, and completely cleaned before
reassembling.
1. Disassembly—Disassemble the battery as described on page 301.
2. Wash the cells under running water. Do not allow the wash water to enter the cells’ interior.
3. Dry the cells with clean absorbent toweling or with an air hose.
4. Inspect each cell for cracks, holes or other defective condition. If any defects are found; replace
with new cells.
5. Wash and clean all hardware to remove accumulated dirt and carbonate deposits. Heavy
deposits may be removed by scrubbing with a stiff bristle brush. Corrosion preventive greases
may be removed from connectors, screws, nuts, and washers by washing in alcohol or by
degreasing after they are removed from the cells.
6. Allow all parts to dry thoroughly before reassembling.
7. Inspect all parts and replace those that are damaged or heavily corroded. Replace connecting
straps that are burned, bent or have defective nickel plating. Polish tarnished connecting straps
with a fine emery cloth being careful not to remove the plating.
8. Check the battery power receptacle for burns, cracks and bent or pitted terminals. Replace
defective receptacles. They can overheat, arc, depress battery voltage and cause premature
battery failure.
9. Repair or replace bent battery cases and covers, loose or damaged cover gaskets and cell hold-
down bars.
10. Reassemble battery.
11. Clean vent caps (vent plugs). Use hot water to thoroughly wash vent assemblies.
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CHECK / INSPECTION
Inspection Prior to Installation
When the battery is unpacked, a thorough inspection should be made to ensure that no damage
occurred during shipment. Inspect the shipping container as well as the battery. Before putting the
battery in service, check the following points carefully.
1. Damage - See if any liquid has spilled into the shipping container. This may be a sign of a
damaged cell. Check for dented battery container. Check for cracked cell cases or covers. Do
not place a damaged battery into service. Report any signs of improper handling to the
shipping company.
2. Shorting Straps - Some batteries are shipped with shorting devices across the main power
receptacle outlet terminals. Before subjecting battery to electrical service this device must be
removed.
3. Electrical Connections - Poor electrical contact between mating surfaces may reduce discharge
voltage, cause local overheating and damage the battery. See that all electrical contacting areas
are clean. Test all terminal hardware to ensure tightness. If necessary, re-torque them to the
proper value. See Table 601.
4. Liquid Level - Marathon batteries are shipped with the proper amount of electrolyte. When a
battery has been discharged or allowed to stand for a long period of time, the electrolyte becomes
absorbed into the plates. Since the battery has been shipped in a discharged (or partially
discharged) condition, the liquid level of the cells may appear to be low. Do not add water to
discharged cells. Spewing of electrolyte may take place during the subsequent charge.
Charging the battery will cause the liquid level of the individual cells to rise to the proper
operating level. If this does not happen, add sufficient distilled or demineralized water to the
charged cells until the correct liquid level is reached.
WARNING: THE ELECTROLYTE USED IN NICKEL-CADMIUM BATTERIES IS A

CAUSTIC SOLUTION OF POTASSIUM HYDROXIDE. USE RUBBER
GLOVES, AN APRON AND A FACE SHIELD WHEN HANDLING THE
SOLUTION. IF ANY IS SPILLED ON CLOTHING OR OTHER MATERIALS,
IT SHOULD BE BATHED IMMEDIATELY WITH LARGE QUANTITIES OF
WATER. IF THE ELECTROLYTE GETS ON THE SKIN BATHE THE
AFFECTED PARTS WITH LARGE QUANTITIES OF WATER AND
NEUTRALIZE WITH A 3% BORIC ACID SOLUTION OR VINEGAR. IF
ELECTROLYTE GETS INTO THE EYES, FLUSH WITH WATER AND GET
MEDICAL ATTENTION IMMEDIATELY.
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5. Cell Vents - Marathon batteries are equipped with special type vents that permit the gases to
escape from the cells and prevent foreign material from entering. Do not obstruct these vents in
any manner.
Charging New Batteries and Cells
Your Marathon battery is normally shipped in a discharged (and shorted) state. It will therefore need
charging before installation (see Page 6 for charging rate and time). If by special order the battery is
shipped in a charged state, it is advisable to top charge the battery at the 5-hour rate until cell
voltages reach 1.55 volts per cell and check the electrolyte level.
When individual cells are to be charged, refer to the caution note on Page 5 before starting charge.
Installation of the Battery
Ventilation
Batteries evolve some hydrogen and oxygen during overcharge. It is therefore necessary to provide
some means of ventilation to remove these gases from confined areas in order to prevent accidental
ignition of the hydrogen. The battery cans contain vent tubes to vent the gases. The air flow should
be a minimum of 5 cubic feet per hour or sufficient to keep the hydrogen concentration below 4
percent.
Securing the Battery in Position
When installing the battery in its permanent location, care should be taken to see that all locking
devices are tight and that all electrical connections are made secure. Secure it with the proper hold-
downs.
Poor battery connections can reduce discharge voltages and create “hot spots” that may lead to
battery degradation. Make certain that the electrical contact areas are clean and that the connections
are wired correctly.
Checking Cell Polarities
Check the polarity of each cell or group of cells to be sure that they are connected properly. The
polarity of each cell is indicated by a “plus” sign molded into the cell cover adjacent to the positive
cell terminal.
Charger
For systems having a battery charger, check the chargers’ electrical settings to ensure proper
charging of the battery.
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P/N 30475-002
Quick Disconnect Devices
Periodically inspect the battery quick disconnect receptacle for burns, arcing, discoloration,
corrosion or powdering at rear of receptacle at terminal post risers, marbleizing of the plastic,
excessive wear of plating on male pins.
If any marbleizing or white powder shows, remove the connector from the battery. When using a
Simpson 260, or equivalent meter, set on the lowest resistance scale. Place one probe on each pin of
the Elcon/Rebling receptacle. If there is any meter deflection, or excessive wear is evident, replace
the receptacle.
Inspection In the Aircraft
A visual inspection of the battery in the aircraft should normally be made at least once every 50
flight hours during the first few months of service. After that, experience should indicate a proper
and more meaningful schedule. The following items should be inspected and the indicated
corrective measures taken if necessary.
CAUTION: EXERCISE EXTREME CARE WHEN WORKING AROUND THE BATTERY.

DO NOT USE METAL BRUSHES OR METAL BRUSH SUPPORTS. REMOVE
RINGS AND OTHER METAL JEWELRY FROM THE HANDS. ANY OF THESE
MAY CAUSE AN ELECTRICAL SHORT WHICH MAY RESULT IN SKIN
BURNS AND DAMAGE TO THE BATTERY.
Check the battery can, cover and external battery receptacle and connections for evidence of
distortion or damage. Check external connections for proper contact. Repair or replace as
necessary.
Check the battery for excessive heat (uncomfortable to the touch) or evidence of overheating. If
present, remove battery and service in battery shop.
Check the vent lines for obstructions, leaks or damage of any kind and repair or replace. Check
battery box vents for obstructions or cracks and repair or replace.
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P/N 30475-002
Remove the battery cover and inspect for the following:
1. Cleanliness - Under normal conditions the battery will usually remain clean except for possible
dust and a light powdery deposit (potassium carbonate) on the intercell connectors and upper
surfaces of the cells. These deposits may be removed by wiping with a cloth or brushing with a
plastic brush. If an excessive deposit is seen, the battery should be removed and cleaned.
2. Cell Hardware - If the intercell connectors and terminals are excessively corroded, the battery
should be removed from the aircraft and discharged prior to cleaning or replacing the indicated
hardware. If overheated or damaged parts (cracked cell tops, etc.) are evident, the battery should
be removed from the aircraft, discharged and rebuilt. If the hardware is clean, re-torque all
screws or nuts as per Table 601.
3. Vent Assemblies - Inspect vent caps, “0” rings and vent sleeves for obstructions, cracks or
damaged seals. Wash and dry assemblies and remove carbonate accumulation if present.
Replace if defective.
4. Excess Electrolyte - If an excessive amount of electrolyte is seen on the tops of the cells and/or a
pool of electrolyte in the battery can, the battery should be removed and serviced in the battery
shop.
5. Cell Electrolyte Level - Check the electrolyte level in each cell. If it is below the minimum
requirement, the battery should be removed from the aircraft and water added as per Page 6. Do
not add water to a battery in an aircraft because of the uncertainty concerning its state of charge.
Pre-Electrical Inspection
Following battery assembly and before capacity testing, the following checks are recommended:
1. Voltmeter Check
Check the cells with a voltmeter following the battery circuit, making sure the cells are in proper
order and the cell polarities are correct (see illustrated parts list). CHARGING A CELL IN
REVERSE MAY RESULT IN PERMANENT DAMAGE.
2. Check Terminal Torque

Be sure that all terminal screws or nuts are correctly torqued (see Table 601).
3. Inspect Vent Caps

Check vent caps for correct seating and correct assembly. Replace damaged vents.
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P/N 30475-002
4. Reconditioning
After the above checking procedure has been completed, the battery should be reconditioned per
Page 101.
Inspection and Mechanical Check
When a battery is received in the shop for routine servicing, it should first be inspected visually for
damage to the can, cover, and external battery connectors. Repair or replace these as necessary.
(Discharge battery as on Page 103, before repairing can or connectors.) Check the inside of the
battery for such things as cleanliness, loose or corroded connections, leaking cells and damaged
hardware. Inspect the cell vent assemblies. Retighten loose vent plugs and replace damaged or
missing vent plugs or vent “0” rings to prevent contamination of the electrolyte.
CAUTION: EXERCISE CARE WHEN WORKING AROUND THE BATTERY. AVOID THE
USE OF UNINSULATED TOOLS—SEVERE ARCING MAY RESULT WITH
POSSIBLE HARM TO PERSONNEL AND DAMAGE TO THE TOOLS AND A
CELL OR CELLS IN THE BATTERY.
RINGS, METAL WATCH BANDS 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 FLAME AWAY
FROM THE BATTERY.
Battery Disconnect And Receptacle Inspection

The following procedure defines an inspection program to field check the battery disconnects and
receptacles.
BATTERY DISCONNECT BD6-3 (MS25182-2)
BATTERY QUICK DISCONNECT BD13-1
BATTERY RECEPTACLE BR8-1 (MS3509)
Equipment Required
Quick Disconnect Inspection Gauge (Reference Special Tools) Figure 901, Dial Calipers, capable of
reading to .001 inch.
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P/N 30475-002
Procedure
1. Inspection of Battery Quick Disconnect - Disengage the battery disconnect from the mating
receptacle and inspect for the following: (NOTE: Do not connect or disconnect if the battery is
under load.)
A. Evidence of corrosion or pitting of the helix.
B. Excessive free-play in the handwheel - worm assembly.
C. Evidence of arcing or burn marks on the helix. This is caused when the disconnect is
removed under electrical load.
D. Insert the .385 inch diameter end of the inspection gauge into each helix to a depth of .437
inches. The fit shall be snug with a force to remove greater than one pound. This is to test
the resiliency of the helix to an oversized pin.
E. Insert the .370 inch diameter end of the inspection gauge into each helix to a depth of .437
inches. The fit shall also be snug with a nominal force to remove of one pound. This will
ensure proper contact to a worn or undersized contact pin.
2. Inspection of Battery Receptacle - With the mating disconnect removed, the receptacle shall be
inspected for the following:
A. Evidence of corrosion or pitting on the contact pins.
B. Evidence of arcing or burn marks on the contact pins. This is caused when the disconnect is
removed under electrical load.
C. Evidence of battery electrolyte leakage through the receptacle body and/or the contact pins.
NOTE: Electrolyte leakage can be noticed by a discoloration of the receptacle body with the
glass fibers exposed.
D. Gauge each contact pin diameter using the dial calipers. The diameter shall be .375 ± .005
inches.
3. Replace defective parts.
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REPAIR
Replacement of Damaged Cells
If three or more cells are found to be defective, either at one time or over a period of time, it is
recommended that all the cells in the entire battery be replaced because the probability is great that
the remaining cells have also been damaged and will shortly have to be replaced.
If a cell becomes contaminated or physically damaged and must be replaced, proceed as follows:
1. Discharge the battery (Page 301), remove the shorting clips.
2. Clean the battery (Page 401).
3. Remove the end terminal connections. Save all of the hardware.
4. Loosen all vent plugs using the vent wrench.
5. Remove enough intercell connectors to permit the cell to be withdrawn from the battery can.
6. Do not withdraw a cell from the battery unless a discharged or shorted replacement cell is
immediately available.
7. Withdraw the cell, using the cell puller tool shown in Figure 906. Always tighten the puller
to the cell and pull in a straight-up direction.
8. Insert the new (discharged) cell, making certain to insert the cell with the polarity symbols in
the right direction. (Cells are connected plus to minus.) If the cell is difficult to insert, apply
a light coat of petroleum jelly or silicone grease to the sides of the cell case before inserting.
9. Replace the intercell connectors, assemble the hardware finger tight.
CAUTION: DO NOT SUBSTITUTE “HOME-MADE” HARDWARE. CARE MUST BE

TAKEN THAT THE POLARITY OF THE POWER RECEPTACLE IS
CAREFULLY OBSERVED SO THAT, WHEN THE BATTERY IS INSTALLED
IN THE AIRCRAFT, THE SYSTEM WILL FUNCTION PROPERLY.
10. Torque the terminal connection to the values indicated in Table 601 using a calibrated torque
wrench.
11. Charge the battery per page 103.
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P/N 30475-002
12. Adjust the electrolyte level (see Page 103) and tighten all vent plugs. The battery is now
ready to put into service.
Replacement of Damaged Power Connectors
The battery is provided with a special quick disconnect receptacle. Should one of these become
damaged, it will be necessary to replace it with a replacement part obtained from your local
Marathon Aircraft Battery Distributor. Care should be taken in the removal of this connector to
preserve all the hardware and gasketing, if possible, so that the new part may be installed properly.
To remove the receptacle, first remove those connections which go to the end cells in the battery,
thus reducing the possibility of a short circuit when the connector body is removed from the battery
can. All Marathon batteries have the same hardware arrangement attaching the power receptacle to
the battery as is used on the intercell connectors. When installing the replacement part, it is
necessary to consult Table 601 for the torque values.
CAUTION: DO NOT SUBSTITUTE “HOME-MADE” HARDWARE. CARE MUST BE

TAKEN THAT THE POLARITY OF THE POWER RECEPTACLE IS
CAREFULLY OBSERVED SO THAT, WHEN THE BATTERY IS INSTALLED
IN THE AIRCRAFT, THE SYSTEM WILL FUNCTION PROPERLY.
TORQUE VALUES
THREAD SOCKET HEAD TORQUE

SIZE CAP SCREW INCH-POUNDS
CELL TERMINAL ¼ - 28 3/16” 100 – 125
RECEPTACLE
8 – 32 20
SCREWS
Table 601
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P/N 30475-002
ASSEMBLY (INCLUDING STORAGE)
Battery Assembly
Reassemble the cell assemblies into the battery can assembly. If a cell assembly must be replaced,
USE ONLY NEW CELLS MANUFACTURED BY MARATHON POWER TECHNOLOGIES.
Position the cell assemblies correctly with respect to polarity as shown on the Illustrated Parts List
(IPL). 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 ASSEMBLIES AT THE MIDDLE OF A ROW SHOULD BE INSERTED LAST.
Lightly polish the cell terminal surfaces with 3M Scotchbrite and wipe clean.
Place intercell connectors in their correct position as shown on the IPL.
Install all hardware finger-tight.
Tighten each socket head cap screw to the torque specified in Table 601.
CARE SHOULD BE TAKEN TO INSURE THAT THE SOCKET HEAD CAP SCREW IS NOT
BINDING, DUE TO THREAD DAMAGE, OR BOTTOMING, BUT IS ACTUALLY
TIGHTENING THE INTERCELL CONNECTORS. IMPROPER TORQUE MAY RESULT IN
DAMAGE TO THE BATTERY.
It is good practice to follow the battery assembly IPL during final tightening 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 assembly once it is started. Forgetting
where the tightening job was stopped is a good way to miss tightening a screw. One loose
connection can permanently damage a battery and may cause an explosion.
Battery Storage
The active materials of the sintered-plate in a Nickel-Cadmium battery do not react significantly
with the electrolyte during use or storage. Thus, this type of battery may be stored up to five years in
a discharged state without damage.
Charge Retention
If full capacity is required immediately after long storage, a trickle charge of 2 milliamperes per
ampere hour of capacity is recommended during the storage period. Batteries on continuous trickle
charge should be checked periodically to ensure adequate electrolyte levels.
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Storage Maintenance
The following procedures are recommended:
Before placing a battery in storage, the battery should be cleaned. Where operation is required
immediately after removal from storage, proper cleaning is even more important to avoid the
possibility of contaminants creating conductive paths within the battery case and increasing the self-
discharge rate.
If battery is to be stored in a rundown shorted-out condition (ensures equalization of cells),

discharge the battery at the 1-hour rate. As each cell reaches 0.5 volts or less, place a metal shorting
clip across its terminals while the load is still applied. Allow cells to remain shorted in this manner
for 24 hours, then place a spring (Part #25908-001) across the receptacle positive and negative pins
and remove the shorting clips from the cells. Apply grease to the intercell hardware.
Nickel-Cadmium batteries may be stored in a non-corrosive atmosphere up to five years at

temperatures ranging from — 650F to +1200F; the upper limit may be extended to +1600F for short-
term storage.
Batteries stored for long periods (3 months or more) in a charged condition should be top charged
at the 5-hour rate (8 amps) upon removal from storage until individual cell voltages reach 1.55 or
greater. After cleaning the vent plugs and adjusting the electrolyte level, the batteries may be placed
into service.
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT
The following tools and equipment are necessary to perform maintenance on the SP-138 battery,
Part Number 30475-002.
Figure
Part No. Description
No.
901 MS25182-2 Battery Quick Disconnect Inspection
902 31379-001 Shorting Clips
903 25624-001 Vent Cap Wrench
904 32515-001 Cell Puller
Nickel-Cadmium Battery Charger
Marathon Christie RF-80K series is recommended
905 32415-001 Syringe

905 32479-001 Syringe Tip - Green
Calibrated Voltmeter
Torque Wrench 0-150 IN-LB
On Page 902 “SPECIAL TOOLS, FIXTURES AND EQUIPMENT”, Battery Charger part number
and description not included. All special tools referenced above, with the exception of the
MS25182-2 inspection gauge, multimeter, and torque wrench are available in Marathon Kit 32480-
001.
Page 901
24-34-01 MAR 27/08
P/N 30475-002
Battery Quick Disconnect Inspection Gauge for MS25182-2

Figure 901
Shorting Clips
Figure 902 Vent Cap Wrench
Figure 903
Cell Puller Syringe and Tips

Figure 904 Figure 905
Page 902
24-34-01 NOV 30/03
P/N 30475-002
ILLUSTRATED PARTS LIST
Introduction
The purpose of this illustrated parts list (IPL) is to serve as a guide for identifying the assemblies and
parts of the battery.
Exploded View of Battery
The exploded view identifies all the part numbers appearing in the Illustrated Parts List by means of
index numbers. This allows to locate all the removable parts of the component. It is prepared
according to a functional breakdown and accompanied with parts list arranged in a logical order of
disassembly.
Illustrated Parts List
In this list is shown the part number, the nomenclature, and quantity of items required in each
component. The appropriate index number identifies the items and their position in the component.
Page 1001
24-34-01 NOV 30/03
P/N 30475-002
100
90
81
80
70
30
50
111
11
110
112
(RBF) 114
(RBF) 113
(RBF) 11
10
(RBF) REMOVE BEFORE FLIGHT
Battery Assembly
IPL Figure 1
Page 1002
24-34-01 MAR 27/08
P/N 30475-002
51 74 51
73 73
51 51
71(7)
32
72 72
31
Details
IPL Figure 2
Page 1003
24-34-01 MAR 27/08
P/N 30475-002
1 30475-002 ASSY, BATTERY TSP-138 11-38SP100 (NI-CD) (30476-002) 1

10 40132-001 CAN ASSY, MARKED 1
11 15766-002 DUST CAP 2
30 30181-02C CELL ASSEMBLY, 38SP100 (30180-04C) 11
31 29078-001 FILLER CAP, OPTICAL 11
32 16979-001 VENT WRENCH 1
-40 LINERS
-50 SHIMS
51 9988-174 SHIM, 3.0 x 7.5 x .032 4
-60 BARRIERS
-70 CONNECTORS
71 16102-135 CONNECTOR 7
72 16102-136 CONNECTOR 2
73 16102-142 CONNECTOR 2
74 16167-006 CONNECTOR 1
80 18100-022 WASHER, CRES. .265 x .563 x .032 24
81 6560-017 WASHER, LOCK 1/4 SS 24
90 10488-011 SCREW, SOCKET HD. CAP 1/4-28 x 5/8 24
100 30478-002 COVER ASSEMBLY, LINED 1
110 16163-026 ASSEMBLY RECEPTACLE 1
111 24583-001 RING, RECTANGULAR 1
112 23084-001 SCREW, FL.HD. SEMS 8-32 x 3/8 4
113 26916-004 COVER, INSULATOR 1
114 25908-001 SPRING, SHORTOUT 1
Page 1004
24-34-01 MAR 27/08

24 34 01 (30475 002) MD

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Component Maintenance Manual

MarathonNorco Aerospace, Inc.

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Rev Issue Date Rev Issue Date Rev Issue Dated

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RECORD OF TEMPORARY REVISIONS

Temporary Page Issue Date

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SERVICE BULLETIN LIST

Number Revision Date

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Introduction INTRO-1 NOV 30/03

Description and Page 1 NOV 30/03

Testing and Fault Page 101 NOV 30/03

Disassembly Page 301 NOV 30/03

Cleaning Page 401 NOV 30/03

Check / Inspection Page 501 NOV 30/03

THIS PAGE IS INTENTIONALLY BLANK

Description and Operation 1

Testing and Fault Isolation 101

Check / Inspection 501

Assembly (Including Storage) 701

Special Tools, Fixtures and Equipment 901

Illustrated Parts List 1001

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WARNING: SERIOUS INJURY CAN RESULT FROM CARELESSNESS WHILE HANDLING

1. Remove all metal articles such as bracelets and rings.

2. Metal tools must be insulated.

5. Do not mix lead-acid and nickel-cadmium battery servicing.

6. Do not use petroleum spirits, trichloroethylene or other solvents.

DEFINITIONS OF COMMONLY USED BATTERY TERMS

Cadmium Electrode—See Negative Plate Closed Circuit Voltage

“C” Rate End-of-Charge Voltage

Nominal Voltage chemically reduced to a lower oxidation state

THIS PAGE IS INTENTIONALLY BLANK

DESCRIPTION AND OPERATION

Nominal Voltage: 14 Volts

VOLTAGE AND CAPACITY

Charging results in the conversion of electrical energy to stored chemical energy.

Factors Affecting Capacity

Capacity is measured quantitatively in ampere-hours at a specified discharge rate to a specified cut-

Charging Precautions and Notes

CAUTION: REMOVE ALL SHORTING DEVICES FROM THE BATTERY TERMINALS

Charge Batteries in an Upright Position

Use Correct Polarity

Adjust Charge Controls

Avoid Short Circuits

Charging Individual Cells

TESTING AND FAULT ISOLATION

Maintenance and Reconditioning Schedules

Reconditioning Nickel-Cadmium Batteries

CAUTION: DEPENDING UPON CONDITIONS, A POTENTIAL SHOCK HAZARD MAY

A. To determine if external leakage is of such a magnitude as to require a complete battery

6. Recharge: Recharge the battery per step 3, above.

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Electrolyte level too low. Battery not CHARGE AS IN STEP 3. ADJUST

2. COMPLETE FAILURE Defective connection in equipment CHECK AND CORRECT EXTERNAL

End terminal connector loose or CLEAN AND RETIGHTEN HARDWARE

Open circuited or dry cell. REPLACE DEFECTIVE CELL.

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Loose or damaged vent cap. CLEAN BATTERY, TIGHTEN OR REPLACE