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Deka G45 Service Manual

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  • Page 2: Table Of Contents

    Table of Contents Page Page INTRODUCTION ………………………………………………… 2 Operation of the Battery …………………………………… 13 SECTION III - INSTALLATION AND USE (Cont.) Specific Gravity and On-Charge OPERATION/BATTERY CONSTRUCTION …………………… 4 Cell Voltage Temperature Correction……………………… 13 SECTION I - THEORY OF Discharging/Recharging Characteristics…………………… 4 Battery Ratings ………………………………………………...
  • Page 3 Manufactured using the world’s most modern computer integrated manufacturing techniques… VENTCAP COVER Quarter-turn bayonet style Heat sealed with lead insert simplifies watering and bushing prevents leakage and inspection. voltage-to-ground. SEPARATORGUARD O-RING SEAL White color increases Accomodates positive plate growth visibility for fast electrolyte without cover distortion and leakage.

  • Page 4: Operation/Battery Construction

    SECTION I - THEORY OF OPERATION/BATTERY CONSTRUCTION OF LEAD ACID STORAGE BATTERIES Theory of Operation Discharging/Recharging Characteristics In a fully charged condition the active material in the positive plate is lead peroxide (PbO ) and the active material in the neg- ative plates is sponge lead (Pb).

  • Page 5: Ampere Hour (Ah)

    Positive plate capacity is the ampere delivery for a fixed period of time (usually six hours) for a particular size positive plate. A Deka D100 type positive plate has the capability of delivering 16.66 amperes for six hours or 100 ampere hours (16.66 x 6 = 100 AH) to a final voltage of 1.70.

  • Page 6: Grid Casting

    SECTION I - THEORY OF OPERATION/BATTERY CONSTRUCTION OF LEAD ACID STORAGE BATTERIES (cont.) Battery Construction Grid Casting - Positive and Negative Grids A plate consists of a cast lead-alloy grid structure into which lead oxide pastes are applied. Since lead by itself would be too soft and flexible to make a grid, a certain amount of antimony is added to the grid to prevent it from sagging or warping.

  • Page 7: Assembling An Element

    SECTION I - THEORY OF OPERATION/BATTERY CONSTRUCTION OF LEAD ACID STORAGE BATTERIES (cont.) plate, to the desired cell size. Both outside plates are negative, therefore the number of plates per cell is always an odd num- ber, with each cell having one more negative then positive plate.

  • Page 8: Assembling Into Trays

    SECTION I - THEORY OF OPERATION/BATTERY CONSTRUCTION OF LEAD ACID STORAGE BATTERIES (cont.) Assembling into Trays To create a battery, a specific amount of completed cells (ele- ment, jar and cover) are inserted into a steel tray. Spacer material may be added between the cells and tray to assure a tight assembly.

  • Page 9: Section Ii - Battery Safety

    Irritating to eyes, respiratory system, and skin. surfaces. No smoking. Dispose of contents/container in accordance Battery 102 Deka Road, May form explosive air/gas mixture during charging. IF SWALLOWED OR CONSUMED: rinse mouth. with local and national regulation. a non-metallic container or bucket to prevent the chains from...

  • Page 10: Charging Batteries Charging Areas - Proper Equipment

    SECTION II — BATTERY SAFETY (cont.) CHARGING BATTERIES HANDLING ACID Charging Areas — Proper Equipment Pouring Acid All plants should have designated charging areas, especially if they Use a carboy tinter or safety siphon when removing acid from a change batteries at the end of each shift.These areas should have carboy container.

  • Page 11: Eye Wash And Emergency Shower Facilities

    SECTION II — BATTERY SAFETY (cont.) Eye Wash and Emergency Shower Facilities 2. A deluge shower (Fig. II-3) should be used where high spe- cific gravity acid (above 1.400) is handled. The shower uses a handle or foot treadle to turn on a powerful water stream Emergency eye wash and acid neutralization facilities should that can wash acid from skin and clothes.

  • Page 12: Repairing Batteries

    SECTION II — BATTERY SAFETY (cont.) Repairing Batteries Keep in mind several safety points when repairing batteries: 5. To prevent possible short circuits, use insulated tools 1. Never work on a battery while on charge or discharge. whenever you are working on a battery. If possible, Always disconnect it from the charger or truck first.

  • Page 13: Placing A Dry Charged Battery In Service

    SECTION III — INSTALLATION AND USE (cont.) Operation of the Battery There are several factors that effect the operation of the battery concerning its ability to deliver capacity and life expectancy. Many chemical reactions are effected by temperature, and this is true of the reaction that occurs in a storage battery.

  • Page 14: Specific Gravity Temperature Correction

    SECTION III — INSTALLATION AND USE (cont.) Typical Recharging Characteristics Specific Gravity Electrolyte Specific On-Charge Temperature Corrections DISCHARGE CHARGE Temperature Gravity Cell Voltage 2.80 1.360 Correction Correction Fahrenheit Celsius 1.340 2.60 VOLTS PER CELL 1.320 +.022 +.18 1.300 2.40 +.020 +.17 SPECIFIC TEMPERATURE...
  • Page 15 SECTION III — INSTALLATION AND USE (cont.) D and M Series MAX POWR Series ELECTROLYTE SPECIFIC GRAVITY ELECTROLYTE SPECIFIC GRAVITY VS. PERCENT DISCHARGE GRAVITY VS. PERCENT DISCHARGE 1.325 1.320 GRAVITY 1.310 1.300 1.300 1.290 1.290 1.280 1.280 1.270 1.270 1.260 1.260 1.250 1.250...

  • Page 16: Improper Charging

    Contact your charger. Use a multiple digit-system if you have several authorized Deka Service Representative. different sizes or types of batteries. Prefixes or suffixes 4. Remember to accurately record the number of cycles, can be used to identify batteries by size, voltage, shift, specific gravity, temperature and voltage readings;...

  • Page 17: Section Iv - Battery Maintenance

    SECTION IV — BATTERY MAINTENANCE AND TROUBLESHOOTING (cont.) The correct hydrometer reading corresponds to an imaginary line drawn across the side of the barrel at the lowest level of the electrolyte. If the hydrometer has to be removed from the vent DAILY BATTERY RECORD hole, pinch the nozzle tightly or place a gloved finger against the opening to prevent dripping.

  • Page 18: Adding Water/Adjust Electrolyte Levels

    Tap water in certain areas of the country is unsuitable at any time, while in other areas it may be satisfacto- The Deka Battery Cleaning System, is a state-of-the-art pro- ry only during certain seasons. If the water in your area isn’t cess that completely cleans and neutralizes batteries, while suitable, use distilled or de-ionized water.

  • Page 19: Performing A Test Discharge

    WHEN CLEANING OR WASHING BATTERIES. Check the gas escape holes in the vent plugs for dirt clogs. For more detailed information on capacity testing, contact East Penn Manufacturing Company or your local authorized Deka For maximum effectiveness, the solution should be applied with Representative.

  • Page 20: Procedure For Adjusting The Specific Gravity Of The Electrolyte Of A Battery

    8. As it is necessary to add acid to the cell in order to raise 2. The recommended specific gravity for some of the Deka the specific gravity of the electrolyte, sulfuric acid of 1.400 industrial battery styles is shown in Table 1. For example, specific gravity shall be used.

  • Page 21: Storage Battery Troubleshooting Chart

    SECTION IV — BATTERY MAINTENANCE AND TROUBLESHOOTING (cont.) Table 4-2 STORAGE BATTERY TROUBLESHOOTING CHART Symptoms POSSIBLE CAUSE POSSIBLE REMEDY Battery overheats 1. Malfunctioning Charging Equipment 1. Replace or repair defective charger parts during charge (timer, voltage sensitive relay, control board, etc.) 2.
  • Page 22 SECTION IV — BATTERY MAINTENANCE AND TROUBLESHOOTING (cont.) Table 4-2 – Cont. Symptoms POSSIBLE CAUSE POSSIBLE REMEDY Low electrolyte 1. Cracked or broken Jar(s) (Look for 1. Replace jar(s) and adjust gravity electrolyte puddles on floor) 2. Cell missed when watered 2.

  • Page 23: Basic Rules For Battery Care And Maintenance

    East Penn Manufacturing Co. Irritating to eyes, respiratory system, and skin. surfaces. No smoking. Dispose of contents/container in accordance Battery 102 Deka Road, May form explosive air/gas mixture during charging. IF SWALLOWED OR CONSUMED: rinse mouth. with local and national regulation. Electrolyte Lyon Station, PA 19536 Extremely flammable gas (hydrogen).

  • Page 24: Lead-Acid Batteries

    V-2). The gelled electrolyte requires a separator to prevent short-cir- Ultra Charge Deka Dominator Battery Curve cuits between the electrodes. This additional separator causes additional resistance. Therefore, the internal resistance of com-...

  • Page 25: Operating Instructions

    SECTION V – VALVE REGULATED LEAD-ACID BATTERIES (cont.) OPERATING INSTRUCTIONS SEALED VALVE REGULATED LEAD ACID (SVRLA) WARNING: Charging shall be performed by using only the supplied on-board charger for GELLED ELECTROLYTE BATTERIES Gelmate, or the Ultra Charge Charger with the D.S.G. Sealed Lead-Acid Battery charge curve profile, or any other EPM-approved motive power gel electrolyte charger.

  • Page 26: Maintenance Instructions

    SECTION V – VALVE REGULATED LEAD-ACID BATTERIES (cont.) MAINTENANCE INSTRUCTIONS SEALED VALVE REGULATED LEAD ACID (SVRLA) WARNING: Always wear safety glasses when working around batteries! GELLED ELECTROLYTE BATTERIES Keep sparks and flames away! The valve regulated pressure relief valve should never be removed or loosened! 1.

  • Page 27: Section Vi - Battery Repair Repair Or Replace

    SECTION VI — BATTERY REPAIR Repair or Replace? Removing Connectors It can be difficult to decide if a battery is worth repairing or if it To remove a complete cell (jar, element and cover) from a bat- should be replaced. When you have to make this decision, the tery or to remove an element from a jar, you first have to take most important things to consider are the battery’s age, cycle off the intercell connector shrouds from the cell(s) being...

  • Page 28: Removing An Element

    SECTION VI — BATTERY REPAIR (cont.) Removing an Element If the jar is known to be serviceable, it may not be necessary to remove the complete cell. Usually only the element, complete with cover, has to be pulled. This can only be done however, on those batteries containing a compound type cover-to-jar seal.

  • Page 29: Reassembling The Battery

    SECTION VI — BATTERY REPAIR (cont.) Before installing an element in a previously used jar, wash out any sediment which may have accumulated in the bottom of the jar and clean all compound from around the inside of the top edge (if the battery has a compound seal).

  • Page 30: Using Sealing Compound

    SECTION VI — BATTERY REPAIR (cont.) Cells from which elements were pulled, or which had damaged jars or covers replaced, should be given an equalizing charge and acid should be adjusted immediately following repair and before they are returned to service. When installing repaired cells or new cells back into the battery, use post lifters, attached to the negative posts, and a block and tackle or lifting beam to lower the cell into the tray (Fig.

  • Page 31: Section Vii - Safety Data Sheets

    SECTION VII — SAFETY DATA SHEETS...
  • Page 32 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 33 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 34 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 35 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 36 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 37 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 38 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 39 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 40 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 41 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 42 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 43 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 44 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 45 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 46 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 47 SECTION VII — SAFETY DATA SHEETS (cont.)
  • Page 48 SECTION VII — SAFETY DATA SHEETS (cont.)

  • Page 49: Glossary Of Battery Terminology

    GLOSSARY Acid In the lead acid storage battery Battery (Storage) A storage battery is a con- Carboy A large cylindrical container or bottle industry, “acid” implies “sulfuric acid”, and is nected group of two or more storage cells of plastic or glass used to ship acid. used to describe the electrolyte or liquid in (common usage permits this term to be the cell.
  • Page 50 GLOSSARY (cont.) Cover The lid or cover of an enclosed cell Electromotive Force (EMF) Electrical pres- Gang Vent Vents for usually three adjacent generally made of the same material as the sure or potential, expressed in terms of volts. cells which are connected to a common man- jar or container and through which extend ifold.
  • Page 51 GLOSSARY (cont.) Internal Resistance The resistance within Litharge (PbO) A yellowish-red oxide of lead Moss Dendritic crystals of lead (Pb) which the cell or battery to the flow of an electric (monoxide), sometimes used in making sometimes grow at high-current density current, and is measured by the ratio of the active material.
  • Page 52 GLOSSARY (cont.) PbO Chemical symbol for litharge. Rated Capacity The ampere hours of dis- SLl Battery Battery for automotive use in charge that can be removed from a fully starting, lighting, and ignition. Chemical symbol for lead peroxide charged secondary cell or battery, at a spe- (dioxide).
  • Page 53 GLOSSARY (cont.) Temperature Correction In storage cells, Vacuum Cell Filler A device used to fill cells Watthour Meter A watthour meter is an elec- the specific gravity and charging voltage vary in the charging room in which a vacuum is tric motor that measures and registers inversely with temperature, while the open used to withdraw the air displaced by the fill-...
  • Page 54 NOTES...
  • Page 55 NOTES...
  • Page 56 Lyon Station complex. satisfaction, above and beyond the industry standard, to our partners and customers worldwide. e-mail: epmmotve@eastpenn-deka.com www.dekabatteries.com East Penn Manufacturing Co. Lyon Station, PA 19536-0147 Phone: 610-682-6361 Fax: 610-682-4781 Order Hotline: 610-682-3260 All data subject to change without notice.

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