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Aircraft Battery Inspection

Aircraft battery inspection consists of the following items:

1. Inspect battery sump jar and lines for condition and security.
2. Inspect battery terminals and quickly disconnect plugs and pins for
evidence of corrosion, pitting, arcing, and burns. Clean as required.
3. Inspect battery drain and vent lines for restriction, deterioration, and
4. Routine preflight and postflight inspection procedures should include
observation for evidence of physical damage, loose connections, and electrolyte

Battery Troubleshooting
Trouble Probable Cause Corrective Action
Apparent loss of capacity Very common when recharging on Reconditioning will
a constant potential bus, as in 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 fully charged Charge. Adjust
electrolyte level. Check
aircraft voltage
regulator. If OK,
reduce maintenance

Complete failure to operate Defective connection in equipment Check and correct

circuitry in which battery is external circuitry.
installed, such as broken lead,
inoperative relay, or improper
receptacle installation

End terminal connector loose or Clean and retighten

diengaged Poor intercell hardware using proper
connections torque values.

Open circuit or dry cell

Replace defective cell.

Excessive spewage of High charge voltage Clean battery, charge,

electrolyte High temperature during charge and adjust electrolyte
Electrolyte level too high level.

Loose or damaged vent cap

Clean battery, tighten
or replace cap, charge
and adjust electrolyte
Damaged cell and seal level.

Short out all cells to 0

volts, clean battery,
replace defective cell,
charge, and adjust
electrolyte level.

Failure of one or more cells Negative electrode not fully Discharge battery and
to rise to the required 1.55 charged recharge. If the cell
volts at the end of charge Cellophane separator damage still fails to rise to 1.55
volts or if the cell’s
voltage rises to 1.55
volts or above and then
drops, remove cell and

Distortion of cell case to Overcharged, overdischarged, or Discharge battery and

cover overheated cell with internal short disassemble. Replace
defective cell.
Recondition battery.
Plugged vent cap

Overheated battery Replace vent cap.

Check voltage
regulator: treat battery
as above, replacing
battery case and cover
and all other defective
Foreign material within the Introduced into cell through Discharge battery and
cell case addition of impure water or water disassemble, remove
contaminated with acid cell and replace,
recondition battery.

Frequent addition of water Cell out of balance Recondition battery.

Damaged “O” ring, vent cap Replace damaged

Leaking cell
Discharge battery and
Replace defective cell,
recondition battery.
Charge voltage too high
Adjust voltage

Corrosion of top hardware Acid flumes or spray or other Replace parts. Battery
corrosive atmosphere should be kept clean
and kept away from
such environments.

Discolored or burned end Dirty connections Loose Clean parts: replace if

connectors or intercell connection Improper mating of necessary.
connectors parts Retighten hardware
using proper torque
values. Check to see
that parts are properly

Distortion of battery case Explosion caused by: Discharge battery and

and/or cover Dry cells disassemble.
Charger failure Replace damaged parts
High charge voltage and recondition.
Plugged vent caps
Loose intercell connectors