X043748
X043748
X043748
TECHNICAL MANUAL
7 NOVEMBER 1979
TM 11-6140-203-14-3
WARNINGS
DANGEROUS CHEMICALS ARE USED IN NICKEL-CADMIUM
BATTERIES
Hydrogen and oxygen gases are generated in explosive proportion while the
nickel-cadmium battery is being charged. Charge the nickel-cadmium battery in a
well-ventilated area to reduce concentrations of explosive gases. Turn off the
battery charger before connecting or disconnecting the nickel-cadmium battery to
prevent arcing. Do not use matches or an open flame in the charging area. Arcs,
flames, or sparks in the charging area will ignite the gases and cause an explosion.
The battery box cover must be removed and the battery case vent plug (if used)
must be open when charging.
a
TM 11-6140-203-14-3
WARNINGS
BATTERY SHOP SAFETY PRACTICES
Be extremely careful when tightening terminal screws and studs. Bodily injury and
damage to the equipment may result if the torque wrench accidentally causes a
short circuit.
c
TM 11-6140-203-14-3
REPORTING OF ERRORS
If there are no blank DA Forms 2028-2 in the back of the manual, use the
standard DA Form 2028 (Recommended Changes to Publications and Blank
Forms) and forward to Commander, US Army Communications and Electronics
Materiel Readiness Command, ATTN: DRSEL-ME-MQ, Fort Monmouth, NJ 07703.
In either case, a reply will be furnished direct to you.
Paragraph Page
CHAPTER 1. INTRODUCTION ............................................................................... 1-1 1-1
2. SPECIFIC DATA FOR EACH INDIVIDUAL BATTERY TYPE
Section I. Battery, Storage BB-422/U ................................................................. 2-1 2-1
II. Battery, Storage BB-429/U ................................................................. 2-4 2-2
III. Battery, Storage BB-501/U ................................................................. 2-7 2-5
IV. Battery, Storage BB-651/U ................................................................. 2-9 2-7
VI. Battery, Storage BB-672/U ................................................................. 2-12 2-8
VIII. Battery, Storage BB-693A/U .............................................................. 2-15 2-10
IX. Battery, Storage BB-634/U (6TNC) .................................................... 2-18 2-13
CHAPTER 3. INSTALLATION ................................................................................. 3-1 3-1
4. ORGANIZATIONAL MAINTENANCE.................................................. 4-1 4-1
5. DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE....... 5-1 5-1
APPENDIX A. REFERENCES.......................................................................................................... A-1
B. COMPONENTS OF END ITEM LIST (Not applicable)
C. ADDITIONAL AUTHORIZATION LIST (Not applicable)
D. MAINTENANCE ALLOCATION
Section I. Introduction............................................................................................................. D-1
II. Maintenance Allocation Chart.................................................................................. D-3
III. Tool and Test Equipment Requirements.................................................................. D-9
IV. Remarks ................................................................................................................. D-10
APPENDIX E. EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I. Introduction............................................................................................................. E-1
II. Expendable Supplies and Materials List .................................................................. E-3
INDEX ........................................................................................................................................................ Index-1
LIST OF ILLUSTRATIONS
Title
Number Title Page
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TM 11-6140-203-14-3
CHAPTER 1
INTRODUCTION
1-1. Scope
a. This manual is one of the series of three and it covers the specific data and maintenance allocation
for each nonaircraft nickel-cadmium battery. Refer to TM 11-6140-203-15-1, for general information pertaining
to the description, functioning, operation, and maintenance of nickel-cadmium batteries. Refer to TM 1 11-
6140-203-14-2 for the specific data and maintenance allocation for each aircraft nickel-cadmium battery.
b. TM 11-6140-203-20P-3 and TM 11-6140203-34P-3 contain the repair parts and special tools lists
for nonaircraft nickel-cadmium batteries.
c. Appendix D is current as of 8 November 1978.
1-2. Indexes of Publications
a. DA Pam 310-4. Refer to the latest issue of DA Pam 310-4 to determine whether there are new
editions, changes, or additional publications pertaining to the equipment.
b. DA Pam 310-7. Refer to DA Pam 310-7 to determine whether there are modification work orders
(MWO's) pertaining to the equipment.
1-3. Forms and Records
a. Reports of Maintenance and Unsatisfactory Equipment. Maintenance forms, records, and reports
which are to be used by maintenance personnel at all maintenance levels are listed and prescribed by TM 38-
750.
b. Report of Packaging and Handling Deficiencies. Fill out and forward DO Form 6 (Packaging
Improvement Report) as prescribed in AR 700-58/NAVSUPINST 4030.29/AFR 71-13/MCO P4030.29A, and
DLAR 4145.8.
c. Discrepancy in Shipment Report (DISREPJ (SF 361). Fill out and forward Discrepancy in Shipment
Report (DISREP) (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610.33B/AFR 75-18/MCO P4610.19C
and DLAR 4500.15.
1-4. Administrative Storage
A nonaircraft nickel-cadmium battery can be placed in administrative storage because of no immediate
operational need and the necessity to reduce the maintenance workload; or to hold it ready while the associated
end item of equipment is in the repair or overhaul process. The nickel-cadmium battery is handled differently
under each set of circumstances.
a. Normal Administrative Storage Procedures. The following procedure applies when a nickel-
cadmium battery is being placed in normal administrative storage.
(1) Remove the nickel-cadmium battery from the end item of equipment.
(2) Perform the cleaning procedures in paragraph 4-7.
(3) Place the nickel-cadmium battery in the administrative storage area making sure that the
connector terminals are not accidentally short circuited. It is not necessary to discharge the nickel-cadmium
battery since the charge will be lost through normal leakage and it will be deep-cycle discharged and recharged
prior to returning to service. Protect from freezing and excessive heat.
(4) When the nickel-cadmium battery is to be returned to service, perform the full quarterly or
every 100 cycles service procedure contained in paragraph 5-7.
b. Hold-Ready Administrative Storage Procedures. The following procedure applies when a nickel-
cadmium battery is placed in a hold-ready administrative storage while the end item of equipment is in the
repair or overhaul process.
(1) Remove the nickel-cadmium battery from the equipment.
(2) Perform those quarterly or every 100-cycle service procedures contained in paragraph 5-7
which service and deep-cycle discharge the nickel-cadmium battery. Leave the shorting device connected
across the terminals of each cell.
(3) Place the nickel-cadmium battery in the ready hold administrative storage area. Protect from
freezing and excessive heat.
(4) When the nickel-cadmium battery is required for installation in the repaired or overhauled
end item of equipment, remove it from administrative storage. Remove the shorting device from across the
terminals of each cell.
(5) Charge the nickel-cadmium battery in accordance with the instructions contained in
paragraph 5-5.
(6) Install the nickel-cadmium battery in the end item equipment.
1-5. Destruction of Army Electronics Materiel
Destruction of Army electronics materiel to prevent enemy use shall be in accordance with TM 750-244-2.
1-6. Reporting Equipment Improvement Recommendations
EIR's will be prepared using Standard Form 368. Instructions for preparing EIR's are provided in TM 38-750.
EIR's should be mailed direct to Commander, US Army Communications and Electronics Materiel Readiness
Command, AMEN: DRSEL-ME MQ, Fort Monmouth, NJ 07703. A reply will be furnished direct to you.
1-1
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2-0
TM 11-6140-203-14-3
CHAPTER 2
SPECIFIC DATA FOR EACH INDIVIDUAL BATTERY TYPE
Type ................................ .......... Nickel cadmium (vented). Negative (charged) ................ Cadmium.
Number of Cells......................... 19. Separator material................. Plastic laminate.
Type of cell................................ B8431/U. Cell case material Molded nylon or
Electrolyte ................................ . Potassium hydroxide (KOH), 31 Acrylonitile,
percent (by weight) in distilled Butediene-
water. Styrene (ABS).
Operating- Range:
Temperature ....................... -40°C F. (-40°C.) to 125°F. 2-2. Weight and Dimensions of BB-422/U
(51.7°C.). Battery, Storage BB-422/U (NSN 6140-00-789-
2118) weighs 32 pounds. The battery is
Atmospheric pressure ......... Sea level to 10,000 feet (20.6 711/32 inches high, 53/4 inches wide and
inches of mercury 0.1). 12Yt6 inches deep. Refer to figure 2-1 for BB-
Storage: 422/U parts location.
Duration.............................. Unlimited, regardless of state of
charge. 2-3. Physical Characteristics of BB-431/U
Temperature ............................. ..-65°F. (-53.9°C.) to 165°F. (Cell)
(73.9°C.). The overall dimensions of Battery, Storage
Atmospheric pressure ................ Sea level to 50,000 feet 3.4 BB-431/U (cell) (NSN 6140-00-014-6583) are
inches 661/64 inches high, 27/" inches wide, 15/64
of mercury 0.1). inches deep, and it weighs 11/2s pounds.
Electrical Data: Refer to figures 2-2,and 2-3 for parts location
Rating................................ . 14 ampere-hous. and cell layout for the BB-422/U.
Current at rated load (2.8
amperes):
Temperatures between 0. F.
(-17.8°C.), and 125°F.
(51.7°C.) ............................ 2.8 amperes for approximately 5
hours.
2-1
TM 11-6140-203-14-3
2-4. Tabulated Data for BB-429/U (fig. 2-4) Temperatures between 0°F.
Type ................................ Nickel-cadmium (vented). (-17.8°C.) and -40°F.
Number of cells ............... 5 (40°C.) ..................... 2.8amperesfor approximately
3 hours.
Type of cell...................... B418/U
Electrolyte ....................... Potassium hydroxide (KOH), 31 Under rated load (2.8 amperes):
percent (by weight) in distilled Temperatures between 75°
water. F. (25°C.) and 85°F.
Operating range:.............. (29.4°C.)................... 6.0 volts for approximately 5
Temperature ............. -65°F. (-53.9°C.) to 125°F. hours.
(51.70 C.). Temperatures between 0°F.
Atmospheric pressure ....Sea level to 10,000 feet (20.6 (-17°C.) and -40°F.
inches of mercury 0.1). (-40°C.) .................... 5.7 volts for approximately 3
Storage: hours.
Duration.................... Unlimited, regardless of state of Intercell connector:
................................ . charge. Material .................... Nickel-Plated copper.
Temperature ............ -65°F (53.9°C.) to 165°F Number ..................... 4.
(73.9°C.). Cell plate materials:
Atmospheric pressure ....Sea level to 50,000feet (3.4 Positive (charged)......Nickel oxide.
inches of mercury 0.1). Negative (charged) ....Cadmium.
Electrical data:................. Separator material ...........Plastic laminated.
Rating ...................... 14 ampere-hours. Cell case material............. Mold nylon or Acrylonitrile-
Butadiene-Styrene.
Current at rated load (2.8 am-
peres): Voltage:
Temperatures between 0 F. Open circuit ............... Approximately 6.5 volts (fully
(-17.8°C.) and between charged, with a 24-hour
125°F. (51.7°C.)...... 2.8 amperes for approximately 5 rest period).
hours.
2-2
TM 11-6140-203-14-3
Battery, Storage BB-429/U (NSN 6140-00-996-3746) weighs approximately 7 pounds. The battery is 61/4
inches high, 229/64 inches wide, and 73/64 inches deep. Refer to figure 2-5 for BB-429/U parts location.
The overall dimensions of Battery, Storage BB-418/U (cell) (NSN 6140-00-855-7634) are 53/4 inches high, 21/4
inches wide, and 1 inch deep, and it weighs 11/8 pound. Refer to figures 2-5 and 2-6 for BB-418/U parts
location and BB-429/U cell layout respectively.
2-3
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2-4
TM 11-6140-203-14-3
EL4EC006
Figure 2-6. Battery, Storage BB-429/U, Cell Layout
2-5
TM 11-6140-203-14-3
2-6
TM 11-6140-203-14-3
Battery, Storage BB-50I/U (NSN 6140-00-134-0850) weighs approximately 32.5 pounds. The battery is 7 3/16
inches long, 6 3/4 inches wide and 7/16 inches high. Refer to figure 2-7 for parts location and BB-613/U (cell)
layout. The BB-613/U (cell) (NSN 6140-00-134-0849) is 5 3/4 inches high, 2¼ inches wide, and 1 inch deep and
weighs 1 1/8 pound.
2-7
TM 11-6140-203-14-3
Battery, Storage BB-651/U (NSN 6140-01-037-7344) weighs approximately 12 pounds. The battery is 4 3/4
inches high, 4 1/8 inches wide, and 13 inches deep. Refer to figure 2-8 for BB651/U parts location.
The overall dimensions of the five cell monoblock (NSN 6140-01-037-7343) are 3 11/16 inches high, 2 1/2
inches wide, and 3 9/16 inches deep. Refer to figure 2-8 for monoblock parts location and cell layout for the
BB-651/U.
2-8
TM 11-6140-203-14-3
0°F. (17.8°C.) and ... 850 F. (29.40 C.) .......6.0 volts for approximately 5
125°F. (51.7°C.)...... 0.94 ampere for approximately 5 hours.
hours. Temperatures between
Temperatures between 0°F. (-17.8°C.) and
0°F. (-17.80 C.) and -40°F. (-40°C.) .........5.75 volts for approximately 3
-40- F. (-400 C.).. 0.94 ampere for approximately 3 hours.
hours. Intercell connector:
Voltage: Material ..................... Nickel-Plated copper.
Open circuit .............. Approximately 6.5 volts (fully Number ..................... 4.
charged, with a 24-hour rest Cell plate materials:
period). Positive (charged) ............ Nickel oxide.
Under rated load (0.94 am- Negative (charged) ...........Cadmium.
pere) Separator material ...........Nylon cellophane sandwich or
Temperatures between double felted nylon.
75°F. (23.9°C.) and Cell Use Material ............. Nylon.
2-9
TM 11-6140-203-14-3
2-10
TM 11-6140-203-14-3
Figure 2-10. Battery, Storage BB-693A/u (Manufactured by Marathon (Sonotone) Battery Corporation), Parts Location.
1. BB-693A/U (Marathon) 11. Lockwasher 21. Thermostat 31. Hexagonal head screw
2. Case Assembly 12. Phillip’s-head screw 22. Thermostat 32. shim
3. Connector receptacle J1 13. Rectangular ring 1A1 23. Phillip’s-head screw 33. Shim
4. Connector receptacle J3 14. Pressure relief valve 24. Battery terminal link 34. Manual Vent valves.
5. Connector receptacle J2 15. Threaded cap 25. Battery terminal link
6. O-ring 16. Lined Cover 26. Battery terminal link
7. O-ring 17. Cable assembly 27. Battery terminal link
8. Phillip’s-head screw 18. Thermostat assembly 28. Battery terminal link
9. Lockwasher 19. Heater Unit 29. Bellville spring
10. Phillip’s-head screw 20. Heater Unit 30. Double D washer
TM 11-6140-203-14-3
Figure 2-11. Battery, Storage BB-693a/u (Manufactured by General Electric), Parts Location.
2-12
TM 11-6140-203-14-3
1. Heater Assembly 22. Binder head screw
2. cover assembly 23. Rolled washer
3. cover gasket 24. Thermostat assembly
4. Battery terminal link 25. Valve assembly
5. Battery terminal link 26. Valve assembly
6. Battery terminal link 27. Case assembly
7. Battery terminal link 28. O-ring
8. Hexaganol head screw 29. Connector receptacle, electrical J2
9. Flat washer 30. Oval head screw
10. Belleville washer 31. Countersunk tooth lockwasher
11. Cell 32. Protective cap
12. Vent cap assembly (p/o cell (11)) 33. Protective cap
13. O-ring (p/o vent cap assembly (12)) 34. Srpring
14. Splice 35. Dust cap
15. Cable assembly 36. Warning nameplate
16. Connector assembly 37. Instruction nameplate
17. Connector gasket 39. Instruction nameplate
18. Binder head screw 40. O-ring (p/o valve assembly(25))
19. Rolled washer 41. O-ring (p/o valve assembly(26))
20. Connector receptacle J3 42. Manual Vent Valve (2)
21. Connector gasket
Figure 2-11. - Continued
The cells used in the BB-693A/U are the longer lasting separator BB-600A/A cells. The battery should then be
polypropylene separator BB-600A/A; which is also used redesigned as a BB-693A/U battery case from either
in the BB-433A/U aircraft battery. Only these cells have Marathon or General Electric. However, all 19 cells in the
been designed to meet the BB-693A/U requirements as battery must have the same stock number and manufac-
well as those of aircraft. The older BB-600/A cell with turer. Refer to figure 2-10 for the cell layout for a
cellophane separator may not meet the BB-693A/U re- Marathon built battery or figure 2-11 for the cell layout
quirements. All 19 cellophane separator cells in a BB- for one built by General Electric.
693/U battery can be replaced with 19 polypropylene
SECTION IX. BATTERY, STORAGE BB-634/U (6TNC)
2-18. Tabulated Data for BB-634/U (6TNC) inches of mercury O0.1).
Type ................................ Nickel cadmium (vented). Storage:
Number of cells ............... 10. Duration ....................Unlimited, regardless of state of
Electrolyte Potassium hydroxide (KOM), 31 charge.
percent (by weight) in distilled Temperature.....................-650 F. (53.90 C.) to 1650 F.
water. (73.90 C.).
Operating range:.............. Atmospheric pressure.......Sea level to 50,000 feet (3.4 inch-
Temperature ............. -40 F. (-40°C.) to 125°F. es of mercury +/-0.1).
(51.7°C.). Electrical data.
Atmospheric pressure ...... Sea level to 10,000 feet (20.6 Rating .......................70 ampere-hours.
2-13
TM 11-6140-203-14-3
2-14
TM 11-6140-203-14-3
The overall dimensions of the BB-634/U (6TNC) (NSN 6140-00-900-8537) are 9 inches high, 101/2 inches
wide, and 11¼ 4 inches deep. Refer to figure 2-12 for an overall view of the battery. No repair parts are
authorized for this equipment.
2-15
TM 11-6140-203-14-3
CHAPTER 3
INSTALLATION
3-1. Unpacking
a. When packed for domestic shipment, the batteries are packed several to a larger wooden case (fig. 3-
1) (each enclosed in a separate container).
b.
CAUTION
Do not attempt to pry off the wooden cover. Remove the nails for the cover and lift
off. The batteries may be damaged by the prying tool.
3-1
TM 11-6140-203-14-3
b. Check to see that the equipment is complete as listed on the packing slip. Report all discrepancies in
accordance with procedures given in TM 38-750. Shortages of a minor assembly or pan that does not affect
proper functioning of the equipment should not prevent use of the equipment.
3-2
TM 11-6140-203-14-3
NOTE
New batteries are prepared for service by direct support, general support, or depot maintenance
personnel only.
Installation of the particular nonaircraft nickel-cadmium battery will differ from ground system to ground system.
For installation procedures of each different nonaircraft nickel-cadmium battery, refer to the manual covering
the ground system. In addition, observe the following:
a. Securing Battery in Position. When installing the battery in its position to power a ground system,
see that all electrical connections are made secure. Leads to the battery should be of sufficient size to carry the
maximum current. The battery should be secured by holddowns.
b. Venting of Gases. During the charging cycle, some hydrogen and oxygen gases are evolved. When
the battery is installed in a confined location, provide some means of ventilation from this confined area to
avoid accidental ignition of the hydrogen. Always charge with cover removed.
WARNING
C02 is an acceptable fire extinguishing agent once a fire has developed. In no case should C02 be
directed into a battery compartment to effect cooling or displace explosive gases. The static electricity
generated by the discharge of the extinguisher could explode the hydrogen/oxygen gases trapped in the
battery compartment.
d. Following the visual check and the action indicated above; emergency personnel should disconnect
and remove the battery. Additional cooling may be accomplished with water fog.
3-3
TM 11-6140-203-14-3
CHAPTER 4
ORGANIZATIONAL MAINTENANCE
4-1. Scope of Organizational Maintenance
The maintenance duties assigned to the operator's of end item which are powered by nonaircraft nickel-cadmium
batteries, and organizational maintenance personnel for nonaircraft nickel-cadmium batteries are listed below,
together with a reference to table or paragraphs covering the specific maintenance functions. Test equipment, tools,
and supplies required for the performance of organizational maintenance are listed in paragraph 4-2.
a. Operator daily preventive maintenance checks and services (at the equipment site) are limited to making
sure that the battery case, cover and the top of the cells are kept clean and free of potassium carbonate deposits Sara
4-7) and, during operation of the end item of equipment, being alert for any indications which signal battery
malfunction.
b. Organizational weekly preventive maintenance checks and services for the BB-693A/U only (see para 4-
5).
c. Organizational quarterly maintenance is limited to removal of the battery from the equipment and
returning it to higher category of maintenance for reconditioning. The battery must be returned to higher category
maintenance for reconditioning if is has been through 100 cycles (discharged through normal operation (or for any
other reason intentional or accidental) and recharged) prior to 2 the scheduled quarterly maintenance date. Do not
allow the battery to remain in operation longer than the 120-day period or 100 cycles since its storage capacity will be
greatly impaired and the duration of equipment operation severely limited.
d. Visual inspection (para 4-6).
e. Touchup painting (para 4-8).
f Electrolyte level check (para 4-9).
g. Electrical leakage test (para 4-10).
h Terminal screw torque (para 4-11).
i. Organizational repair (para 4-12).
4-2. Test Equipment, Tools, and Supplies
The following test equipment, tools, and supplies are required for organizational maintenance.
a. Test Equipment. Multimeter AN/USM-223.
b. Tools. Tool Kit, Battery Service TK-90/G.
c. Supplies. Lint-free cloth (item 1, app E).
4-3. Preventive Maintenance
Preventive maintenance is the systematic care, servicing, and inspection of nickel-cadmium batteries to prevent
occurrence of trouble, reduction of downtime, and insurance that the equipment is serviceable.
a. Systematic Care. Procedures given in paragraphs 4-6 through 4-11 cover routine systematic care and
cleaning essential to the proper upkeep of the equipment.
b. Preventive Maintenance Checks and Services. The preventive maintenance checks and services instructions. contained
in paragraph 4-la and 4-1c, and paragraph 4-5 outline functions to be performed at specific intervals. These checks
and services are to maintain nickel-cadmium batteries in a combat-serviceable condition; that is, in good general
(physical) condition and in good operating condition. To assist operator and maintenance personnel in maintaining
combat serviceability, the maintenance guidance indicates what to check, how to check, and the normal indications.
The procedure information, where applicable, lists the paragraphs or manuals that contain detailed repair or
replacement procedures. If the defect cannot be remedied by performing the corrective actions listed, a higher
category of maintenance or repair is required. Records and reports of these checks and services must be made in
accordance with requirements given in
4-4. Organizational Preventive Maintenance Checks and Services
Organizational preventive maintenance checks and services of the nickel-cadmium batteries are required daily, and
in addition to daily, quarterly (or every 100 discharge-charge cycles) whichever shall occur first.
a. Paragraph 4-la specifies checks and services that must be accomplished daily.
b. Paragraph 4-5 specifies checks and services that must be accomplished weekly for the BB-693/U only.
c. Paragraph 4-1c specifies additional checks and services that must be performed quarterly (or every 100
discharge-charge cycles) whichever shall occur first.
4-5. Weekly Preventive Maintenance Checks and Services for BB-693A/U ONLY
Perform the following preventive maintenance checks and services for the BB-693A/U only on a weekly basis.
Performance of this procedure does not exempt the battery from the required quarterly (or 100 discharge-charge
cycle) maintenance.
NOTE
Weekly Preventive Maintenance Checks and Services for BB-693A/U is only required if battery power has
been used during the previous week.
a. With the BB-693A/U mounted in the vehicle, use the APU or vehicle generator system to charge the
battery and monitor charging current until the charging current remains steady for one hour. Set charging
voltage using 1% meter to the following values at the ambient temperatures given:
(1) Above 800 F.-28V.
(2) Between 32-F.-80F.-28.5V.
(3) Below 320 F.-29V.
b. Allow the battery to rest (stand) for not less than
4-1
TM 11-6140-203-14-3
one-half hour or more than 2 hours. Remove the filler caps and check the electrolyte level following the instructions
contained in paragraph 4-9. If the electrolyte level requires adjustment refer to higher category of maintenance.
c. Perform the electrical leakage test following the instructions contained in paragraph 4-10. If the leakage cur-
rent indication is less than 30 milliamperes (ma), the battery passes the electrical leakage test. If the indication is more than
30 ma, remove the battery from the vehicle and clean it as specified in paragraph 4-7. Repeat the electrical leakage test. If
the battery still fails to pass the test, refer the problem to higher category of maintenance.
d. A battery which passes the electrical leakage test after cleaning, should be placed on charge until the charging
current is 5 amperes or less.
4-6. Visual Inspection
Many causes of battery failure may be detected by visual inspection. Because the battery cannot be disassembled by
organizational maintenance personnel, visual inspection is limited to observing the assembled battery. Visual inspection is
accomplished as follows:
a. Damage. Release the snap fasteners, remove the cover, and check the battery as indicated in (1) through (7) below.
(1) Battery case or cover scratched or dented.
(2) Battery case liners or cover gasket loose or damaged.
(3) Cell terminal or terminal screws bent or broken.
(4) Cell cases cracked.
(5) Filler cap warped or cracked.
(6) Connector bent or broken.
NOTE
If electrolyte appears on tops of cells, check setting of charging voltage, paragraph 4-5a, and perform leakage test,
paragraph 4-Sc. Proceed as directed in paragraph 4-7.
(7) Tops of cell cases and caps for presence of electrolyte.
b. Improper Installation. Check the battery for improper installation as indicated in (1) and (2) below.
(1) Filler cap improperly seated.
(2) Loose terminal screws, battery terminal links, or connector.
c. Loose Connections. Check for loose connections as listed below.
(1) Battery terminal links between cells.
(2) Battery terminal links between cells and receptacle.
d. Electrolyte Leakage. If electrolyte leakage is present in the battery and is not the result of an improperly
installed filler cap or spillage, a cell case is probably cracked check for cracked cell cases (tops). In any case of electrolyte
leakage, higher maintenance category repair is required.
e. Corrosion or Deposits. Corrosion or white potassium carbonate deposits are caused by gassing and
bubbling of electrolyte through the vent valves on the fillercaps. Check for either as follows:
(1) Check the top of the cell cases, cell terminals, battery terminal links, and fillercaps.
(2) Check the battery case and cover.
4-7. Cleaning
CAUTION
Do not attempt to clean the nickel-cadmium battery with solvents, adds or any chemical cleaner; damage
to the cells, gaskets, and the liner may result. DO NOT disassemble the battery; clean only those parts
that can be reached without disassembly.
Potassium carbonate deposits in the dry state are nonconductive and when in contact with nickel- or nickel-
plated material is noncorrosive. When moisture is added to the powder, which occurs with drastic humidity
changes, an electrical leakage path is established. Also, if the potassium carbonate comes in contact with
copper, which could occur if the nickel-plating is scratched, corrosion will set in. For these reasons, the battery
must be carefully cleaned and kept free of potassium carbonate deposits.
a. Release the snap fasteners, as necessary, and remove the cover from the battery case.
b. Brush any deposits from the cell tops and intercell connectors with a nylon brush. DO NOT use a
wire brush. Wipe off the loosened deposits.
c. Wipe the battery case with a clean lint-free cloth (use item 1, app E).
d. If electrolyte is spilled on the cells or in the battery (between the cells), clean the battery without disassembly as follows:
(1) Secure the fillercaps on the cells.
(2) Set the battery on a clean surface, remote from any contaminants.
(3) Thoroughly wash the tops of the cells with distilled water. (if distilled water is not available, use drinking water.)
(4) After washing the tops of the cells, lay the battery on its side and raise the bottom of the
battery a few inches to allow drainage of the excess water from between the cells.
WARNING
To be usable for cleaning, the compressed air source must limit the nozzle pressure to no more than 29
pounds per square inch gauge (PSIG). Goggles must be worn at all times while cleaning with
compressed air.
(5) Allow the battery to remain in this position until dry. Compressed air may be used to speed the
drying process, if available.
e. Clean the fillercaps as follows:
(1) Use the fillercap wrench to turn each fillercap one-fourth turn counterclockwise and remove
each fillercap from its cell.
4-2
TM 11-6140-203-14-3
(2) Wash each fillercap thoroughly in tap water. Completely dry each filercap with a clean, dry, lint-
free cloth and compressed air as necessary.
(3) Use the fiflercap wrench to replace each fillercap to each cell, and tighten by turning the fillercap
one-fourth turn clockwise.
f. Foreign matter should not normally collect in the fillercap seat on the cell. To remove foreign matter
from the fillercap seat; use either of the following methods:
(1) Remove the fillercap, e above. Use a clean, dry, lint-free cloth and very carefully remove any
foreign matter which has accumulated in the fillercap seat. Make certain that none of the foreign matter falls into the cell.
(2) Cut the lugs off a fillercap which is going to be thrown away. Remove the fillercap from the cell (e
above). Place a clean, dry, lint-free cloth over the base of the fillercap without lugs. Place it over the fillercap seat to
be cleaned and turn the fillercap and cloth with a fillercap wrench.
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.
NOTE
Refer to paragraph 2-3, TM 11-6140-203-15-1 for detailed information concerning the electro-chemical
action when charging a nickel-cadmium battery.
WARNING
Explosive gases may be released during charging. Check to be sure that the charging area is. well
ventilated. Do not use matches or an open flame in the charging area. Guard against short circuits;
resulting arcs may cause an explosion. Do not disconnect the charging cable from the battery until the
battery charger has been turned off. Explosions or serious burns may result.
f. Charging. Charge the battery using the constant- voltage method or the constant-current charging
method as given in (1) or (2) below. At the end of charge, before
the current has been shut off, the individual cell voltages should be checked for uniformity. Cell voltages
should be within 0.1 volts of each other. Low cell voltage (under 1.2 volts) may indicate a shorted cell, while
high voltage (over 1.9 volts) indicate either a dry cell or bad connec- tion.
(1) Constant-Voltage Method. Table 5-1 provides the constant-voltage charging rate required for
temperature, number of cells, and time to accomplish the charge cycle. For example, for a temperature of 800
F and a battery containing 19 cells, charge for 2 hours at 30 volts. Periodically monitor the constant-voltage
charging rate by placing the test prods of a voltmeter across the battery terminals and adjust the output of the
battery charger, as necessary).
(2) Constant-Current Method. Table 5-2 provides the constant-current charging value required for
the specific ampere-hour rating of a battery and the amount of time it normally takes to accomplish the charge
cycle. For example, for a fully discharged battery, charge a 34-ampere-hour battery at 21.3 amperes for 2
hours, 10.6 amperes for 4 hours, or 6.8 amperes for 7 hours. If the battery does not meet the minimum end-of-
charge voltage, check individual cells for low voltage .If no low cells are present then charge must be continued
until the minimum voltages are reached. A new battery may re- quire 20-30% more charge than normal on its
very first charge
.
Table 5-1.Constant-Voltage Charging Rate
Table 5-2. Constant-Current Charging Rate and End- Table 5-2. Constant-Current Charging Rate and End-
of-Charge Voltage of-Charge Voltage-Continued
5-2
TM 11-6140-203-14-3
g. Performance Test. Performance testing for a new battery, before placing it into service, consists of
discharge capacity and electrical leakage tests. A battery which passes both of these tests is considered to be
serviceable.
(1) Discharge Capacity Test.
(a) After charging (f above), allow the battery to rest (para 5-4) and check the electrolyte level (para 5-5).
(b) Refer to table 5-3 for the discharge time, current rate, and variable resistor value for the battery to
be tested.
(c) Connect the switch (item 7, app E), variable resistor (item 8) and test equipment as shown in figure
5-1. Two multimeters (AN/USM-223) are required. Charger/Analyzers as indicated in 5-3i, may be used in
place of resistors. Check Charger/Analyzer literature to determine if the particular battery to be tested can be
operated on the specific Charger/Analyzer.
(d) Begin the discharge capacity test
(e) When the battery has been discharged for the specific time, at the rate indicated in table 5-3,
measure the closed circuit battery terminal voltage and then as quickly as possible, the individual cell voltage.
(f) The battery terminal voltage should be as specified in table 5-3. If any cell is less than 1 volt, stop
discharging and mark the cell(s) which measure less than 1 volt for replacement.
(g) If batteries are discharged at a higher rate then specified in table 5-3, refer to section 2 for
applicable capacity at the specific rate.
(h) If all cells are 1 volt or greater, stop discharging and recharge the battery (f above). Allow the
battery to rest and adjust the electrolyte level (para 5-6). Proceed to 2 below.
electrolyte resulting in damage to the battery. Do not adjust electrolyte level after a battery has discharged.
The correct electrolyte level cannot be determined when the battery has been discharged. Conversely, never
allow electrolyte to fall below the cell level indicators when the battery is in a charged condition. Low
electrolyte level in the charged condition will cause the cells to heat up, resulting in their destruction.
NOTE
An inherent characteristic of nickel-cadmium battery cells is that the electrolyte is absorbed within the
plates and separators to a point where it is not visible from the top of the cells when at a low state of
charge or in a discharged condition. When the battery is recharged, the electrolyte level rises and
reaches its maximum height at full charge. Ideally the electrolyte level should be checked on a fully
charged battery that has been at rest for 30 minutes. The correct level of electrolyte is 1/4 inch above
the top of the plates of a fully charged cell that has been at rest for the time specified in paragraph 5-4.
The procedure for checking the electrolyte level is exactly the opposite of that for lead-acid batteries in
which the electrolyte level is adjusted by adding water before placing the battery on charge, or whenever
the electrolyte level is low.
The maximum electrolyte level for a nickel cadmium battery is one-fourth inch above the top of the places.
Perform the following procedures for electrolyte adjustments:
a. Before using the syringe, if necessary, modify it as follows:
(1) Use a sharp pin that has been heated with a flame from a match to pierce the stem of the
syringe one-fourth inch from the bottom of the stem (A, fig. 5-2).
(2) Let the pin remain in the stem for 2 or 3 minutes and then withdraw the pin slowly from the
stem.
b. Remove the fillercaps with the nylon wrench.
CAUTION
Do not spill electrolyte on the battery. Spilled electrolyte may cause corrosion of connectors and short-
circuiting between cells, resulting in damage to the battery.
c. Use the stem-pierced syringe, filled with distilled water item 9, app E), insert the syringe into the
cell until it rests on the top of the plates (B, fig. 5-2). Slowly squeeze the contents of the bulb until the bulb is
empty or the electrolyte is just below the mouth of the cell. Avoid overfilling.
d. Release the bulb to withdraw all liquid that is one- fourth inch above the top of the plates. if no
liquid is withdrawn, repeat c above.
e. Repeat c and d above for all cells.
f. Replace the fillercaps after the electrolyte level of all cells has been adjusted.
g. Thoroughly wash out the syringe.
5-4
TM 11-6140-203-14-3
EL4EC019
Figure 5-2. Electrolyte Level Adjustment
5-5
TM 11-6140-203-14-3
(spring metal strip) across the positive and negative terminals of that cell. DO NOT USE ANY OTHER
METHOD TO DETERMINE WHEN A SHORTING DEVICE SHOULD BE PLACED ACROSS THE CELL
TERMNALS.
NOTE
For the BB-634/U (6TNC) the individual cell terminals are not accessible.
Therefore, dis- charge at the 6-hour rate until the total battery voltage reaches 10.0
volts.
(a) Position the appropriate discharge fixture (5-4 for BB-422/U) over an uncovered battery. Push
down firmly on the discharge fixture unto it uniformly covers the battery case.
(b) Clamp the battery case catches on the strikes of the discharge fixture bottom plate.
(c) Leave the discharge fixture on the battery for 16 to 18 hours. After 16 to 18 hours of discharge,
remove the discharge fixture
5-6
TM 11-6140-203-14-3
5-9. Disassembly
A complete disassembly of the battery is required for any of the following defects: Defective cell or cells,
electrolyte leakage, electrical leakage, cell installed in reverse polarity, or defective battery case.
Disassemble the battery, as given in a through e below:
a. Discharge the battery as given in paragraph 5-7c
b. After completely discharging the battery, remove all terminal links by removing their screws and
associated washers
c. Remove all cells from the battery case as follows:
(1) Loosen all fillercaps to relieve any internal pressure.
(2) Fabricate a cell puller by using two terminal links bent at right angles and appropriate
nonconductive heavy cord or flat web material as shown in figure 5-5.
NOTE
Do not use wire or other conductive material. Use the cell terminal screws and
washers to secure the cell puller to the cell terminals and
5-8
TM 11-6140-203-14-3
carefully work each cell out of the battery case starting with the cell that is approximately in the center position.
NOTE
If a cell puller cannot be fabricated as shown in figure 5-5, screw a stud of the appropriate size into
each cell terminal. Grasp these studs with pliers and lift the cell straight up.
d. Remove liners from the battery case and inspect the interior of the case for peeling or chipping
of paint or corrosion. Return defective cases to the depot for repair.
(1) Remove screws and washers that hold the connector or receptacle to the battery case.
(2) Remove the battery terminal connector or receptacle.
CAUTION
Be careful when removing the gaskets from the battery case. Do not allow the scraper to gouge the
battery case.
(3) For connectors or receptacles having damaged gaskets, remove the gaskets by scraping or
peeling the gasket from the battery case. For batteries having liners or cover gaskets, remove liners
and cover gaskets by scraping or peeling.
5-9
TM 11-6140-203-14-3
(1) Remove, clean (para 4-7), and replace fillercaps on all cells. Be sure fillercaps are on
tight.
CAUTION
Do not allow tapwater to enter cell; the electrolyte will be diluted or contaminated and will require replacement.
(2) Wash each cell with tapwater. Remove potassium carbonate deposits by brushing with
the nylon brush. Rewash the cell with tapwater.
5-10
TM 11-6140-203-14-3
WARNING
To be used for cleaning, the compressed air source must limit the nozzle pressure to no more than 29 pounds per square
inch gauge (PSIG). Goggles must be worn at all times while cleaning with compressed air.
(3) Air hose until dry.
(4) Lightly buff each cell terminal with fine sandpaper or emery cloth.
(5) Examine each cell for cracks, distorted case, discoloration, and electrolyte contamination. If a cell has a
crack or distorted case, the cell is beyond repair and should not be used. If the exterior of a cell is discolored with burn
spots or contains electrolyte contamination (contamination is evident if foreign substances are in electrolyte), the cell is
unserviceable and should be dis- carded. For cells that visually appear to be free of cracks, discoloration, distortion, and
electrolyte contamination, proceed as follows to test the cell for electrolyte leakage:
(a) Invert cell for 2 minutes.
(b) After the cell has been inverted for 2 minutes, lay cell on each of its sides either on a blotter or a
paper towel for 30 seconds per side. Any wetting of the blotter or the paper towel is cause to consider the cell repairable, if
the leakage is from the cell terminal only. This repair can be accomplished by the depot. Coordinate the shipment of
these defective cells with Commander, US Army Communications and Electronics Materiel Readiness Command, ATTN:
DRSEL-MMG-B, Fort Monmouth, NJ 07703.
b. Installing Cover Gasket.
(1) Check to be sure that the cover is clean and dry.
(2) Lay the cover on a clean, flat surface and thoroughly clean the side of the cover to be cemented.
(3) Apply a layer of cement (item 10, app E) to the cleaned area of the cover.
(4) Apply a layer of cement to the cleaned side of the cover gasket.
(5) Position the cover gasket on the cover, with the cemented areas of both cover and cover gasket mating.
(6) Firmly press (by hand) the cover gasket in place on the cover.
(7) Allow at least 2 hours for the cement to dry before installing the cover on the battery.
c. Installing Battery Terminal Connector or Receptacle.
Check to be sure that the terminal connector or receptacle is clean and dry. (2) Install the terminal connector or
receptacle, using screws, washers, and gaskets as required.
d. Installing Battery Case Liner.
NOTE
If necessary to replace any liner, use polyamnide
plastic sheet (item 11, app E).
(1) Check to see that the battery case is clean and dry.
(2) Cut the battery case liner or insulator (polyamide plastic sheet, (NSN 9330-00-877-2872)) to the same size as the
one removed and install the replacement battery case liner in the battery case.
e. Installing Cells in Battery Case.
NOTE
Each battery must be constructed of cells made by the same manufacturer and carry the
same stock number. DO NOT mix cells made by different manufacturers or different stock
numbers from the same manufacturer, to retrofit a battery. Use cells with or as close to the
same date code or length of service as possible.
(1) Replace liners. Using appropriate cell layout diagram shown in chapter 2 for the specific battery, replace
all cells in the battery case. If a cell is difficult to insert, apply a light coat of petroleum jelly or teflon spray to the sides of
the cell case and press firmly into place with the polarity symbols in the correct direction. Cells are connected in series
(positive to negative). Using polyamide plastic sheets (item 11, app E), shim cells as necessary for a tight fit.
(2) Replace all terminal hardware in the following sequence:
(a) Intercell connectors.
(b) Belleville washer.
(c) Flatwasher.
(a) Stud (finger tight).
NOTE
Torque hardware before applying corrosion pre- ventive compound. Be sure all cell
terminals and intercell connectors are clean and smooth before assembling.
(3) Torque all connections as specified in paragraph 4-11. After reassembly, coat all hardware with
corrosion preventive compound item 12 app E).
f. Charging. Charge the battery, using constant-potential or constant-current method (para 5-f). Allow the
battery to rest (Para 5-4). Remove the fillercaps. Use dis- tilled water to adjust the electrolyte level to one-fourth inch
above the top of the plates Sara 5-6).
g. Testing. Perform the procedures given in paragraph 5-Sg to test the battery.
5-11. Vent Valve (metal) Test
a. Fabricate the metal vent valve tester as shown in figure 5-6.
b. Install 24 metal vent valves to be tested into the 24 holes. Tighten each metal vent valve sufficiently to prevent
leakage when air pressure is applied.
c. Connect air pressure pump with a 0- to 25-pound per square inch (psi) gauge to the Shrader valve mounted on the
metal vent valve tester
d. Submerge the metal vent valves into a tank of water. Slowly apply air pressure until 2 psi is reached. Observe for
leakage. If any metal vent valves leak with the 2 psi of air pressure applied, the metal vent valve is defective and
5-11
TM 11-6140-203-14-3
should be discarded. Continue slowly increasing the applied air pressure until 10 psi of air pressure is reached.
Observe for leakage. Metal vent valves that do not leak with 10 psi of air pressure applied are defective and
should be discarded.
5-12
TM 11-6140-203-14-3
NOTE:
HOLES DRILLED AT 90 TO FACILLIATE INSTALLATION OF VENT VALUVES BY PLACING VENT
VAULVE TESTER ON EITHER SIDE. EACH SIDE ACCOMIDATES 12 VENT VALVES.
5-13
TM 11-6140-203-14-3
The battery blanket electrical test consists of measuring for a low resistance, through the heating element, at
the battery blanket terminal board. An infinite or very high
5-14
TM 11-6140-203-14-3
resistance indicates that the battery blanket is defective and should be replaced. As a guide the following
specifications are provided:
a. General Electric Battery Blanket
(1) Resistance. 4. 4- to 4. 8-ohms.
(2) Power Consumption. 175 watts plus or minus 9 watts at 29 volts dc.
5-15
TM 11-6140-203-14-3
APPENDIX A
REFERENCES
The following publications are available to maintenance personnel of nonaircraft nickel-cadmium batteries:
DA Pam 310-4 Index of Technical Manuals, Technical Bulletins, Supply Manuals
(Types 7, 8, and 9), Supply Bulletins, and Lubrication Orders.
DA Pam 310-7 US Army Index of Modification Work Orders.
SB 11-573 Painting and Preservation Supplies Available for Field Use for
Electronics Command Equipment.
TB 43-0118 Field Instructions for Painting and Preserving Electronics
Command Equipment Including Camouflage Pattern Painting
of Electrical Equipment Shelters.
TM 11-6130-236-12 Operator and Organizational Maintenance Manual; Charger,
Battery PP- 1451/G (NSN 6130-00-985-8157).
TM 11-6130-238-14 Operator's, Organizational, Direct Support, and General
Support Maintenance Manual for Charger, Battery PP-1659/G,
and PP-1659A/G (NSN 6130-00-985-8185).
TM 11-6130-246-12 Operator's and Organizational Maintenance Manual: Power Supply
PP-1104C/G (NSN 6130-00-542-6385) (With Instructions for
Use as Battery Charger).
TM 11-6140-203-15-1 Operator, Organizational, Direct Support, General Support, and
Depot Maintenance
Manual: Aircraft and Nonaircraft Nickel-Cadmium Batteries
(General).
TM 11-6140-203-14-2 Operator's, Organizational, Direct Support, and General Support
Maintenance Manual for Aircraft Nickel-Cadmium Batteries.
TM 11-6140-203-20P-3 Organizational Maintenance Repair Parts and Special Tools Lists for Nonaircraft
Nickel-Cadmium Batteries BB-422/U (NSN 6140-00-789-
2118), BB-651/UIH6(V) (NSN 6140-00-935-5265), BB-429/U
(NSN 6140-00-996-3746), BB-501/U (NSN 6140-00-134-0850),
BB-693/U (NSN 6140-00-862-2979), and BB-651/U (NSN
6140-00-037-7344).
TM 11-6140-203-34P-3 Direct Support and General Support Maintenance Repair Parts and
Special Tools Lists (Including Depot Maintenance Repair Parts
and Special Tools) for Nonaircraft
Nickel-Cadmium Batteries BB-422/U (NSN 6140-00-789-
2118), BB-651/UIH6(V) (NSN 6140-00-935-5265), BB-429/U
(NSN 6140-00-996-3746), BB-501/U (NSN 6140-00-134-0850),
BB-693/U (NSN 6140-00-862-2979), and BB-651/U (NSN
6140-00-037-7344).
TM 11-6625-654-14 Operator's, Organizational, Direct Support, and General Support
Maintenance Repair Parts and Special Tools Lists (Including
Depot Repair Parts and Special Tools) for Multimeter
AN/USM-223.
TM 38-750 The Army Maintenance Management System (TAMMS).
TM 750-244-2 Procedures for Destruction of Electronics Material to Prevent
Enemy Use Electronics Command).
A-1
TM 11-6140-203-14-3
APPENDIX D
MAINTENANCE ALLOCATION
SECTION I. INTRODUCTION
D-1. General
This appendix provides a summary of the maintenance operations for Nonaircraft Nickel-Cadmium Batteries. It authorizes
categories of maintenance for specific maintenance functions on repairable items and components and the tools and equipment
required to perform each function. This appendix may be used as an aid in planning maintenance operations.
D-2. Maintenance Function
Maintenance functions will be limited to and defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination.
b. Test. To verify serviceability and to detect incipient failure by measuring the mechanical or electrical characteristics
of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition, i. e. , to clean
(decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air sup- plies.
d. Adjust. To maintain, within prescribed limits, by brining into proper or exact position, or by setting the operating
characteristics to the specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test measuring and
diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified
standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
g. Install. The act of emplacing, seating, or fixing into position an item, part, module (component or assembly) in a
manner to allow the proper functioning of the equipment or system.
h. Replace. The act of substituting a serviceable like type part, subassembly, or module (component or assembly) for
an unserviceable counterpart.
i. Repair. The application of maintenance services (inspect, test, service, adjust, align, calibrate, replace) or other
maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or resurfacing) to restore serviceability to an
item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly),
end item, or system.
j. Overhaul That maintenance effort (service/action) necessary to restore an item to a completely
serviceable/operational condition as prescribed by maintenance standards (. e. , DMWR) in appropriate technical
publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not
normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like
new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours,
miles, etc. ) considered in classifying Army equipments/components.
D-3. Column Entries
a. Column 1, Group Number. Column 1 lists group numbers, the purpose of which is to identify components,
assemblies, subassemblies, and modules with the next higher assembly.
b. Column 2, Component/Assembly. Column 2 contains the noun names of components, assemblies, sub-
assemblies, and modules for which maintenance is authorized.
c. Column 3, Maintenance Functions. Column 3 lists the functions to be performed on the item listed in column
2. When items are listed without maintenance functions, it is solely for purpose of having the group numbers in the MAC
and RPSTL coincide.
d. Column 4, Maintenance Category. Column 4 species, by the listing of a "work time" figure in the appropriate
subcolumn(s), the lowest level of maintenance authorized to perform the function listed in column 3. This figure represents
the active time required to perform that maintenance function at the indicated category of maintenance. If the number or
complexity of the tasks within the listed maintenance function vary at different maintenance categories, appropriate "work
time" figures will be shown for each category. The number of task- hours specified by the "work time" figure represents the
average time required to restore an item (assembly, sub- assembly, component, module, end item or system) to a
serviceable condition under typical field operating conditions. This time includes preparation time, troubleshoot- ing time,
and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the
maintenance functions authorized in the maintenance allocation chart. Subcolumns of column 4 are as follows:
C Operator/Crew
O Organizational
D-1
TM 11-6140-203-14-3
F Direct Support
H General Support
D Depot
e. Column 5, Tools and Equipment. Column 5 specifies by code, those common tool sets (not
individual tools) and special tools, test, and support equipment required to perform the designated function.
f. Column 6, Remarks. Column 6 contains an alphabetic code which leads to the remark in section
IV, Remarks, which is pertinent to the item opposite the particular code.
a. Tool or Test Equipment Reference Code. The numbers in this column coincide with the numbers
used in the tools and equipment column of the MAC. The numbers indicate the applicable tool or test
equipment for the maintenance functions
b. Maintenance Category. The codes in this column indicate the maintenance category allocated the
tool or test equipment.
c. Nomenclature. This column lists the noun name and nomenclature of the tools and test equipment
required to perform the maintenance functions.
d. National/NATO Stock Number. This column lists the National/NATO stock number of the specific
tool or test equipment.
e. Tool Number. This column lists the manufacturer's part number of the tool followed by the Federal
Supply Code for manufacturers (5-digit) in parentheses.
D-2
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
Adjust .4 3
Adjust .2 4
Repair .5 4 A
Repair .5 4
Overhaul 2.0 1-11,
15-18
D-3
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE CATEGORY TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,15-18
Rebuild 5.0 1-18
D-4
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,
15-18
D-5
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
D-6
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
Adjust .4 3
Adjust .2 4
Repair .5 4
Repair .5 4
Overhaul 2.0 1-11,
15-18
D-7
TM 11-6140-203-14-3
SECTION II MAINTENANCE ALLOCATION CHART FOR
BATTERIES, STORAGE - BB-422/U, BB-429/U, BB-501/U, BB-693/U, BB-651/U BB-2HNC, BB-672/U, BB-6TNC
(1) (2) (3) (4) (5) (6)
GROUP COMPONENT/ MAINTENANCE MAINTENANCE LEVEL TOOLS AND
NUMBER ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
00 BATTERY,STORAGEBB-672/U,BB-2Hmc,BB-6TNC Inspect .2 4
Inspect .7 4
Test .8 1-4
Service .2 4,5,6,
8-12
Replace .1 4
D-8
TM 11-6140-203-14-3
1 F,H,D FIXTURE, BATTERY DISCHARGE AND CELL VOLTAGE BALANCING FOR 6110-00-179-8273
BB-422/u BATTERY. (SEE NOTE 1:)
2 F,N,D BATTERY DISCHARGE PLATE AE-IDP-1582 FOR BB-651/uIN-6(V) 5830-O0-637-0937
BATTYERY. (SEE NOTE 1. )
3 O,F,H,D MULTIMETER AN/uJSM-223.
NOTES:
1. Use appropriate and available, discharge fixtures,
chargers, charging cables and analyzers when servicing batteries.
D-9
TM 11-6140-203-14-3
SECTION IV. REMARKS
REFERENCE REMARKS
CODE
D-10
TM 11-6140-203-14-3
APPENDIX E
EXPENDABLE SUPPLIES AND MATERIALS LIST
SECTION I. INTRODUCTION
E-1. Scope
This appendix lists expendable supplies and materials you will need to operate and maintain Nonaircraft Nickel-
Cadmium Batteries. These items are authorized to you by CTA 50-970, Expendable Items (Except Medical,
Class V, Repair Parts, and Heraldic Items).
d. Column 4-Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item indicates the part number followed by the Federal Supply Code for
Manufacturer (FSCM) in parentheses, if applicable.
e. Column 5-Unit of Measure (UIM). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e. g. , ea, in,
pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your
requirements.
E-1
TM 11-6140-203-14-3
E-3
TM 11-6140-203-14-3
INDEX
Paragraph Page
Administrative Storage ........................................................................................................... 1-4 1-1
Adjusting Electrolyte Level...................................................................................................... 5-6 5-3
Battery-Charger Equipment for Direct Support and General Storage Maintenance.................. 5-3 5-1
Battery Service Record-Format .............................................................................................. 3-3 3-1
Battery Blanket Electrical Test ................................................................................................ 5-14 5-14
Charging Procedures (Direct Support and General Support) ................................................... 5-f 5-2
Checking Unpacked Equipment .............................................................................................. 3-2 3-1
Cleaning ................................................................................................................................. 4-7 4-2
Cleaning Fillercaps ................................................................................................................. 4-7c 4-2
General Instructions for Direct Support and General Support.................................................. 5-1 5-1
Performance Test of Nickel-Cadmium Batteries (Direct Support and General Support)......................... 5-5g 5-3
Periodic Service Procedures (Direct Support and General Support)........................................ 5-7 5-5
Physical Characteristics:
Battery, Storage BB-43 1/U (Cell)..................................................................................... 2-3 2-1
Battery, Storage BB-418/U (Cell)...................................................................................... 2-6 2-3
Battery, Storage BB-547/U (Cell)...................................................................................... 2-11 2-8
Battery, Storage BB-634/U (6TNC)................................................................................... 2-19 2-15
Battery, Storage BB-671I/U (Cell)..................................................................................... 2-14 2-10
Battery, Storage BB-693/U (Cell)...................................................................................... 2-17 2-13
Preparing New Battery for Service (Direct Support and General Support)............................... 5-5 5-1
Preventive Maintenance ......................................................................................................... 4-3 4-1
Reconditioning Battery Components (Direct Support and General Support) ............................ 5-10 5-10
Record Format ....................................................................................................................... 3-3a 3-1
Recording Procedure .............................................................................................................. 3-3b 3-1
Repair (Organizational)........................................................................................................... 4-12 4-4
Rest Period After Charging ..................................................................................................... 5 -4 5-1
Technical Characteristics:
Battery, Storage BB422/U ................................................................................................ 2-1 2-1
Battery, Storage BB-429/U ............................................................................................... 2-4 2-2
Index-1
TM 11-6140-203-14-3
Paragraph Page
Battery, Storage BB-501/U ............................................................................................... 2-7 2-5
Battery, Storage BB-634/U (6TNC)................................................................................... 2-18 2-13
Battery, Storage BB-651/U ............................................................................................... 2-9 2-7
Battery, Storage BB-672/U ............................................................................................... 2-12 2-8
Battery, Storage BB-693/U ............................................................................................... 2-17 2-13
Batter, Storage 6TNC (MB-634/U) .................................................................................... 2-18 2-13
Test Equipment, Tools, Additional Equipment and Supplies.................................................... 5-2 5-1
Test Equipment, Tools, Additional Equipment and Supplies (Organizational).......................... 4-2 4-1
Tightening Terminal Screws ................................................................................................... 4-11 4-4
Touchup Painting lnstructions ................................................................................................. 4-8 4-3
Troubleshooting (Direct Support and General Support)........................................................... 5-8 5-8
Vent Valve Test (Direct Support and General Support) ........................................................... 5-11 5-1
Visual Inspection .................................................................................................................... 4-6 4-2
Index-2
By Order of the Secretary of the Army:
E. C. MEYER
General, United States Army
Chief of Staff
Official:
J. C. PENNINGTON
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-28, Operator maintenance requirements for Direction
and Warning Systems, Alarm and DA Form 12-36A, Requirements for Aircraft and Nonaircraft Nickel Cadmium
Batteries.
THE METRIC SYSTEM AND EQUIVALENTS
PIN: 043748-000