TM 11-6140-203-14-3
i.
If the meter pointer does not move close to midscale, turn the range switch one range at a time,
until a midscale indication is obtained.
j.
Record the meter indication.
k.
Repeat the procedures described in d through j above with the black test probe of the AN/USM-223
connected to the negative terminal of the battery and the red test probe to a paint-free surface as described in e
above.
l.
If any of the milliampere (ma) indications recorded in j above is greater than the ampere-hour
rating of the battery being tested, remove the battery from service and send it to direct support maintenance for
repair on a direct exchange basis. Remove the battery from service if the leakage current is more than 5.5 ma
when testing a 5.5 ampere-hour battery or more than 30 ma when testing a 30 ampere-hour battery, etc.
4-11. Terminal Screw Torque
WARNING
Be extremely careful when tightening the ter- minal screws. Bodily injury and equipment damage may
result if the torque wrench accidentally causes a short circuit.
The terminal screws are tightened with the aid of the torque wrench and a socket or screwdriver adapter (p/o
TK-90/G).
NOTE
For batteries that have Allen-head terminal screws, an Allen-head adapter is needed for the torque
wrench.
a.
Place the socket, screwdriver adapter, or Allen-head adapter on the torque wrench.
b.
Insert the torque wrench into the loose terminal screw.
c.
Rotate the torque wrench clockwise until the given number, in inch pounds as listed below, is
indicated on the torque wrench.
Screw or stud diameter
Inch-pounds to tighten
8-32 (screw)
Between 20 and 25
10-32 (screw)
Between 35 and 50
10-32 (stud)
Between 15 and 20
5/16-24 (stud)
Between 20 and 25
d.
Carefully remove the torque wrench.
4-12. Organizational Repair
Organizational repair of nonaircraft nickel-cadmium batteries is limited to replacement of fillercaps, tightening
ter- minal screws, replacement of 0-ring seals, replacement of connector dust caps, and replacement of the
pressure relief valve on the BB-693/U. Instructions for each of these functions are given below:
WARNING
The storage battery is charged and will cause bodily injury and equipment damage if the cell terminals or
connectors terminals are short circuited. Be extremely careful when repairing the storage battery.
a.
Removal and Replacement of Fillercaps.
WARNING
Electrolyte on the filercap will cause serious burns if allowed to come in contact with the flesh.
To remove the fillercap use the vent cap wrench. Place the vent cap wrench over the fillercap and turn
counter-clockwise one-quarter turn until loose and remove the fillercap from the cell. To replace the fillercap
turn the vent cap wrench one-quarter turn clockwise until the filtercap is tight. Remove the vent cap wrench.
b.
Tightening Terminal Screws. Tighten loose terminal screws by following the directions given in
c.
Removal and Replacement of O-Ring Seals.
(1)
Remove the fillercap by following the directions given in a above.
(2)
Carefully wash the fillercap to remove any trace of electrolyte before replacing the O-ring seal.
(3)
Grasp the fillercap firmly with one hand.
(4)
With the other hand, remove the 0-ring seal on the bayonet end of the fillercap.
(5)
Replace with a new 0-ring seal by holding one side of the new seal in place and stretching the other side over
the tangs, sliding the 0-ring seal against the shoulder of the fillercap. Make certain the 0-ring seal is seated firmly.
(6) Place the fillercap on the cell by following the instructions given in a above.
d.
Removal and Replacement of Connector Dust Cap (BB-422 Only).
(1)
Remove the screw that holds the connector dust cap keeper chain to the battery box.
(2)
Unscrew the connector dust cap from the battery connector.
(3)
Place the new connector dust cap of the battery connector. Hand tighten the connector dust cap.
(4)
Secure the connector dust cap by inserting the screw through the connector dust cap keeper chain and secure
it to the battery box.
e. Removal and Replacement of Pressure Relief Valve (BB-6931U Only). Remove the BB-693/U pressure relief
valve by unscrewing it from the battery case. Screw a replacement pressure relief valve into the same location.
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