PLEASE READ BEFORE PLACING BATTERIES IN SERVICE
THESE INSTRUCTIONS TO BE SHIPPED WITH BATTERY AND
TO BE DELIVERED TO USER
INSTALLATION AND OPERATING INSTRUCTIONS
FOR FLOODED TUBULAR-HP MOTIVE POWER BATTERIES
1. SAFETY
1.1 Follow your company’s Safety Instructions when working with or near industrial
truck batteries. Observe the caution label affixed to the battery. Thoroughly
familiarize yourself with industry and government guidelines (OSHA, ANSI) for
charging, handling, and maintaining industrial batteries.
®
1.2 Assign battery and charger care to properly trained personnel.
1.3 This battery contains sulfuric acid electrolyte. Avoid contact with skin, eyes, or
clothing. Wear rubber apron, gloves, boots, and goggles or face shield when
handling, checking, filling, charging or repairing batteries.
1.4 Keep water readily available for flushing spilled electrolyte from eyes or skin. Use
plain water only and obtain medical attention immediately. Special deluge showers
and eye wash basins are required.
1.5 Batteries produce hydrogen and oxygen gas during charge. Keep open flames
away. Do not check electrolyte level with a cigarette lighter or match. Use a
flashlight or permanent lights. Switch on/off away from the top of the battery. Do
not smoke or create sparks.
1.6 Lift batteries with a certified/approved hoist, crane, lift truck, or similar equipment.
Move batteries with trucks, conveyors, or rollers. Be sure to place a rubber mat or
similar insulating material across the tops of coverless batteries when handling.
Make sure equipment is of ample strength and properly installed.
DO NOT USE CHAIN OR WIRE ROPE SLINGS.
1.7 Never lay metal tools, such as wrenches or screwdrivers, on top of a battery.
1.8 Disconnect the battery from the truck when performing maintenance and repair on
motor or electrical system.
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1.9 Open or “break” the battery circuit before attempting repairs to the charging plug
or receptacles.
1.10 Apply a strong neutralizer, such as baking soda or soda ash, when electrolyte is
spilled on the floor. Check local regulations regarding the disposal of neutralized
waste.
2. RECEIVING BATTERIES
Immediately upon receipt of shipment, examine the outside of the packing for signs of
rough handling before accepting the battery from the carrier. Wet spots on the shipping
pallet may be an indication of leaking jars broken in shipment.
If there is evidence of damage, the receipt should be signed and both copies (carrier’s
and receiving copies) marked “Shipment Received Damaged”. The carrier should be
called immediately and asked to make a “Carrier’s Inspection for Damage Report”.
If “concealed” damage is later detected, the carrier should be called immediately and
requested to make a “Carrier’s Inspection for Concealed Damage Report”. After
inspection by the carrier, arrangements should be made with the local GNB Industrial
Power representative to have the battery repaired before placing it in service.
BEFORE PLACING BATTERIES IN SERVICE,
REVIEW AND FOLLOW THE SAFETY GUIDELINES LISTED IN ITEM 1. SAFETY.
3. PLACING IN SERVICE
Verify that the battery weight meets or exceeds the minimum truck weight requirements.
Allow the battery to cool or warm to room temperature before charging or adding water.
Make sure the battery charger is properly matched to the battery. Use a charger with
automatic charger termination controls. GNB Industrial Power recommends the use of a
®
GNB
SCR charger.
Open the vent caps from each cell and check to see that the electrolyte level is above
the top of the separators. If it is obvious that the electrolyte has spilled out of any cells,
replace it with electrolyte of the same specific gravity as found in the other cells of the
battery. Close the vent caps and give the battery a freshening charge until there is no
increase in specific gravity for three hydrometer readings taken at one hour intervals.
During shipment of the battery, low temperatures and/or normal shock and vibration
often results in a drop in the electrolyte level. If the level is below the top of the
separators, recheck it after 3 hours of charging. If the level remains below the top of the
separators, add water or electrolyte to the proper level at the end of charging.
Following the first week of service, the battery should reach its normal operating specific
gravity of 1.310 to 1.320 for 100T and 140T cells at 77° F (25° C).
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6. CHARGING
When recharging a fully discharged battery, the starting charge rate may be 3 to 5 times
higher than the finish charge rate. The charge rate should taper down to the finish rate
by the time the battery is 85% charged and may be even lower when fully charged. High
“on charge” temperatures or frequent need for water additions are indications of
overcharging. Short running times and/or low end-of-charge specific gravities may
indicate inadequate recharge. Consult your local GNB Industrial Power representative
on specific charging problems.
The ampere-hour rating of the charger applied to the battery should be within 10% of the
ampere-hour rating of the battery.
DO NOT INTERMITTENTLY CHARGE, "OPPORTUNITY CHARGE",
OR SHORT CYCLE THIS BATTERY.
7. CONNECTIONS
The battery cells are connected in series using welded lead connectors.
8. MAINTENANCE
KEEP RECORDS… Showing specific gravities, equalizing, charging, temperature, and
voltages on a monthly basis. These records are required to maintain your warranty.
TEMPERATURE… Unde r normal operating cond itions, the electr olyte
temperature shall be between 60-100˚ F (15-37˚ C). Operating temperature
above 100˚ F will reduce the battery’s ser vice life. Operating temperature below
60˚ F results in less capacity and special charging is required.
WATER ADDITIONS… Add water at the end of the charging period when the battery is
fully charged and the charger has tapered to its finish rate. See Item 9.
EQUALIZE… Once a week for heavy application (e.g., 80% daily discharge) to once a
month for light duty application (e.g., less than 50% daily discharge). If the Tubular-HP
®
battery is charged with a GNB
EHF-series charger set for the Tubular-HP charge profile,
equalization should be performed every 12 weeks.
DEPTH OF DISCHARGE… Do not discharge the battery below 80% of the rated
capacity. Over discharging shortens the battery life and voids the warranty.
CLEANING… Keep the top of the battery clean and dry. See Item 9.
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PREVENTIVE MAINTENANCE SCHEDULE…
WEEKLY
• Check electrolyte levels (see water additions).
• Equalize charge (heavy use application), if not using a GNB
QUARTERLY
• Equalize charge, if using a GNB
®
EHF-series charger.
MONTHLY
• Record electrolyte specific gravities.
• Equalize charge (light use application), if not using a GNB
• Inspect the cables and charging plugs.
• Clean the top of the cells.
SEMI-ANNUAL
• Inspect the charger. Confirm proper output voltage and current.
Check for external damage, frayed cables, or worn connectors.
• Clean the exterior of the battery.
TROUBLE SIGNS
®
EHF-series charger.
®
EHF-series charger.
Battery temperature rises more than 25° F (14° C) during a normal charge.
Open circuit cell voltages vary by 0.15 volts or more and specific gravity varies by
0.020 or more during equalizing.
The top of the battery is always wet or one cell requires excessive water.
9. MAINTENANCE CLEANING
The top of the battery should be kept clean and dry. Keep the vent caps in place during
use and charging. Remove the vent cap only to observe electrolyte levels, make water
additions, take temperatures, or take specific gravity readings with a hydrometer. If the
battery requires cleaning, contact your local GNB Industrial Power servicing
representative. The solution used to clean and neutralize the outside of the batteries
should be disposed of in an environmentally safe manner.
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IF BATTERIES ARE NOT IN USE, KEEP THEM CHARGED.
CHECK THE SPECIFIC GRAVITIES MONTHLY AND GIVE A FRESHENING CHARGE
(3 OR 4 HOURS AT THE FINISH RATE) IF THE GRAVITIES HAVE FALLEN 0.030 OR
MORE; OTHERWISE GIVE A FRESHENING CHARGE EVERY THREE MONTHS.
4. OPERATION
Batteries are rated in ampere-hours (Ah) and are selected to perform a specific workload
within an established period of time. Increasing the workload or time period could result
in over discharging, thus shortening battery life. Limit discharging of the battery (to 80%
or less) so that specific gravities do not go below 1.180. If truck operation results in only
partial discharges (40% or less) and specific gravities are 1.250 or more at the end of
the shift, recharging may be deferred and the battery used for another shift, providing the
workload is not expected to increase. Hydrometer readings and experience will
determine the frequency of charge intervals under these circumstances.
A battery should always be recharged immediately following a complete discharge. Never
allow it to remain in a discharged condition, otherwise, permanent damage may result.
A battery is designed to be operated as follows:
8 hours discharge
8 hours charge
8 hours cool-down
Tubular batteries are designed and built to deliver 80% of their rated capacity at 77˚ F
(25˚ C) each cycle.
5. TEMPERATURE
In the operation of motive power lead acid batteries, the electrolyte temperature must not
exceed 110˚ F (43˚ C). If the battery is continuously operated at or above this
temperature, the service life of the battery will be severely diminished. Under normal
operating conditions, battery electrolyte temperature should be maintained between 60100˚ F (15-38˚ C). Following charging, the battery should be allowed to cool-down or rest
approximately 8 hours prior to another discharge cycle.
If a battery is ever
or discharging. If a battery consistently operates at high temperatures greater than 100˚
F (38˚ C), contact your local GNB Industrial Power representative for service.
hot to the touch, allow it to cool to room temperature before charging
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BATTERIES MUST BE VISUALLY INSPECTED PER
JAR
HIGH
WATERING
LEVEL
LOW
WATERING
LEVEL
COVER
VENT WELL
POST
1.25”
2.0”
THE ABOVE SCHEDULE EVEN WITH THE USE OF A WATERING SYSTEM.
10. WATER ADDITIONS
Maintain electrolyte levels above the top of the separators, but no higher than 1/8" from
the bottom of the vent well. Check the electrolyte level weekly, or as necessary
depending on battery use prior to charging. If the level is not visible (below the top of the
separators), add just enough water to cover it and then proceed with charging the
battery. Otherwise, defer watering the battery until the end of the charging period when
the battery is fully charged and the charger has tapered to its finish rate. At that time, add
enough water to bring the electrolyte level to 1.25” of the top of the cover. Always use
distilled water or water that is known to be free of abnormally high amounts of impurities.
Contact your local GNB Industrial Power representative if you are not sure of your water
quality.
11. SERVICE AND PARTS
Your local GNB Industrial Power sales representative has more information regarding the
full range of maintenance and repair service available. GNB Industrial Power can also
supply all of your battery, charger, and accessory device replacement part needs. For
more information in the U.S.A. and Canada, call 1-888-563-6300. All others, please
contact your local GNB Industrial Power battery sales representative.
12. RECYCLING
U.S. Federal and State Regulations require that lead acid batteries be handled and
disposed of in compliance with strict guidelines. GNB Industrial Power offers disposal
service for lead acid batteries. Call 1-888-438-5865 to arrange a pick-up or to get
additional information.
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A Division of Exide Technologies
GNB Industrial Power –
™
The Industry Leader.
GNB Industrial Power, a division of Exide Technologies, is a
global leader in motive power battery and charger systems
for electric lift trucks and other material handling equipment.
With a strong manufacturing base in both North America and
Europe and a truly global reach (operations in more than 80
countries) in sales and service, GNB Industrial Power is best
positioned to satisfy your power needs locally as well as all
over the world.
Based on over 100 years of technological innovation, the
Motive Power group leads the industry with the most recognized global brands, such as GNB
®
FLOODED CLASSIC®,
GNB Industrial Power
USA – Tel: 877.462.4636
Canada – Tel: 800.268.2698
®
®
GNB
FLOODED CLASSIC PLATINUM™, TUBULAR-HP
HIGH PERFORMANCE, TUBULAR-LM™ LOW MAINTENANCE, ELEMENT
®
and GNB®FUSION™. They have come to
symbolize quality, reliability, performance and excellence in
all the markets served.
GNB Industrial Power takes pride in its commitment to a better environment. Its Total Battery Management program, an
integrated approach to manufacturing, distributing and recycling of lead acid batteries, has been developed to help
ensure a safe and responsible life cycle for all of its products.
®
www.gnb.com
GB3979 2013-06
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