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EAST PENN Deka Ready Power Lithium Service Manual

Lithium battery
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LITHIUM BATTERY SERVICE MANUAL
Supporting All Generation One Lithium Batteries

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Summary of Contents for EAST PENN Deka Ready Power Lithium

  • Page 1 LITHIUM BATTERY SERVICE MANUAL Supporting All Generation One Lithium Batteries...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction ............3 Troubleshooting ..........11 Training ..............3 Overview ..............11 How to Use This Manual .......... 3 Troubleshooting Methodology ........11 Troubleshooting Chart ..........11 Safety ..............3 Pack Advisor Service Tool ........14 General ..............3 Specific Troubleshooting Tasks ......15 Elements of Concern ..........3 Proper PPE, Tool, and Equipment ......

  • Page 3: Introduction

    1: INTRODUCTION 4. Arc Flash: The light and heat produced as part of an arc fault, a type of electrical explosion or discharge that results from a connec- tion through air to ground or another voltage phase in an electrical 1:1 Training system.

  • Page 4: Electrolyte Exposure

    Fully read and understand the process before conducting any trouble- shooting or service on a Deka Ready Power lithium battery or accessory. Contact a member of the Navitas service team if you have any questions about any of the processes listed below.
  • Page 5 3.3.2 Internal Torque Values – All Batteries (except 48v 1050ah) 2 Contractor Battery 24v Battery 3 Contractor Battery...

  • Page 6: External Components & Accessories - Removal / Replacement

    3.3.3 Internal / External Torque Values – 48v 1050ah 48v 1050ah Battery 3.4 External Components & Accessories – Removal / Replacement 3.4.1 External Component Overview...
  • Page 7 3.4.2 Counterweight Lid CAUTION: DO NOT pull the connector by the wires as this may damage the cable. The battery’s counterweight may have been shipped with a lid to protect 3. Remove the opposite end from the UIM by unscrewing the connector the external cables from damage.

  • Page 8: Internal Components Replacement

    3.4.7 Battery Monitor Identification (BMID) Reinstallation of the Battery Cables: Harness 1. Follow removal instructions in reverse. The BMID cable is used to aid in the communication between the 2. Torque all terminal nuts to spec. battery and charger. 3. Reinstall all terminal covers and torque hardware to spec. (if using Removal of BMID harness: metal covers).
  • Page 9 3.5.2 Fuse Installation of the new fuse: 1. Follow removal steps in reverse. The Deka Ready Power Battery is current protected by an internal fuse. On most battery models, the fuse is accessible through the fuse access 2. Install fuse over the two exposed studs. door on top of the battery lid.
  • Page 10 Installation of BMS: 5. While continue to hold the lid up, route the loose communication harness ring terminals up through the access holes in the lid. These 1. Follow removal steps in reverse will be installed in a future step. 2.

  • Page 11: Troubleshooting

    3.5.6 Contactors 6. Disconnect the contactor control cables by squeezing the tabs on either narrow end of the connector and lifting it up and away from the Deka Ready Power batteries are equipped with two or more contactors contactor. Make note of which connector goes to each contactor for which are controlled by the BMS.

  • Page 12: Troubleshooting Chart

    4.3 Troubleshooting Chart UIM/BDI Cable Disconnected or Damaged 1. Inspect/Reinstall/Replace cable. 2. Swap cable with Known good cable to test. UIM/BDI Damaged/Not functional 1. Inspect/Replace Unit. 2. Isolate the UIM/BDI by jumping the wake pins on CAN 1 with a jumper across pins 7&8. 3.
  • Page 13 4.3 Troubleshooting Chart continued Battery is powered off 1. Verify DC voltage at cable ends 2. Power Battery on through UIM/BDI, or CAN 1 cable 3. Refer to troubleshooting chart about battery won’t power on Truck Will Not Power On Truck power cable disconnected/damaged 1.

  • Page 14: Pack Advisor Service Tool

    4.4 Pack Advisor Service Tool 4.4.2 Pack Advisor Dashboard Pack Advisor is a PC based service tool that when connected to a Deka Ready Power battery, can provide performance, operation, and diagnostic information. Pack Advisor also provides the ability to update battery software and configuration.

  • Page 15: Specific Troubleshooting Tasks

    Historical DTCs will only be available after pressing the scan button at 4. Place a jumper between these pins, being carefully not to touch any the bottom right corner of Pack Advisor. You will need to do this every other pins. time a Pack Advisor is opened or connected to a new battery.
  • Page 16 When contactors are open (battery off): • BMID Y Harness (if equipped) • BMID to CAN Harness (if equipped) On the CAN 1 (black) communication receptacle located on the battery lid, measure across pins 7 & 8 to see battery voltage. •...
  • Page 17 4.5.7 Verifying CAN Transmission Functionality Verify proper CAN transmission out from the battery is helpful when troubleshooting charging or integrated truck communication issues. The first test requires the battery to be powered off, wile the second requires the battery to be on. When contactors are open –...

  • Page 18: Appendix

    5: APPENDIX 5.1 Supporting Documents 1. “Deka Ready Power User Manual” 2. “Pack Advisor User Manual” 3. “DTC Troubleshooting Guide”...
  • Page 20 Sales Hotline: 610-682-3260 e-mail: motivepowersales@dekabatteries.com www.dekabatteries.com East Penn Manufacturing Co. Lyon Station, PA 19536-0147 Phone: 610-682-6361 Fax: 610-682-4781 All data subject to change without notice. No part of this document may be copied or E.P.M. Form No. 2708 08/23 © 2023 by EPM Printed in U.S.A.

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