™
PLEASE READ BEFORE PLACING BATTERIES IN SERVICE
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THESE INSTRUCTIONS TO BE SHIPPED WITH
BATTERY AND TO BE DELIVERED TO USER
FLOODED FLAT-PLATE AND TUBULAR-PLATE FAST CHARGE
AND OPPORTUNITY CHARGE MOTIVE POWER BATTERIES
INSTALLATION AND OPERATING INSTRUCTIONS
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.
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.
P O S T T H E S E I N S T R U C T I O N S I N
TH E BATT E RY MA I N T E N A N CE A R E A .
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 requires the use of a GNB Fusion
with GNB FusionTMbatteries.
Remove the vent caps from each cell and check to see
that the electrolyte level is above the plates. 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. Replace 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
element protector, recheck it after 3 hours of charging.
If the level remains below the element protector, add
water or electrolyte to the proper level at the end of
charging.
Following the first month of service, the battery should
reach its normal operating specific gravity of 1.305 ±
0.005 at 77°F.
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;
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charger
diligent to "plug in" at all opportunities throughout the
ay, including breaks, meals, and shift changes. Care
d
must be taken to ensure specific gravity readings in
he battery cells do not go below 1.160 at any time.
t
GNB Fusion, Tubular-HP, Tubular-LM, and
NB Flooded Classic Platinum Batteries are designed
G
for opportunity charging during breaks, meal times,
and shift changes. When not being used, the battery
should always be connected to the Charger.
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.
Flooded flat-plate and tubular-plate motive power
batteries are designed and built to deliver 80% of their
rated capacity at 77°F.
5. TEMPERATURE
In the operation of fast and opportunity charge leadacid batteries, the electrolyte temperature must never
exceed a maximum of 140°F, with a maximum
average temperature of 125°F when measured over
one week of operation. Following the end of the day
full charge, the battery should be allowed to cool to
ambient temperature prior to the next discharge.
If a battery consistently operates at temperatures
close to the allowable maximums, contact your local
GNB Industrial Power representative for service.
6. CHARGING
The start rate of a fast or opportunity charge battery
can be as high as 40% of the batteries rated capacity
at the 6 hour rate. During the end of the day full
charge, the charge rate should taper down to the finish
rate (approximately 5% of the rated capacity) by the
time the battery is 85% charged and may be even
lower when the battery is fully charged.
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.
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. Because fast charge and
opportunity charge systems are designed to return a
significant amount of ampere-hours in short periods of
time, these batteries are capable of delivering 160% of
their rated capacity within a 24-hour period. To
achieve such high levels of usage, operators must be
7. MAINTENANCE
• KEEP RECORDS… Showing specific gravities,
equalizing, charging, temperature, and voltages
on a monthly basis. These records are required
to maintain your warranty.
• TEMPERATURE… Under normal fast charge and
opportunity charge operating conditions, the
electrolyte temperature shall be between 60140°F. Operating temperature above 100° F will
reduce the battery’s service life. Operating
temperature below 60°F results in less capacity
and special charging is required.
• WATER ADDITIONS… GNB Fusion chargers
have the capability for equalize charging at
specific times and days of the week (eg. Sunday
8:00). Water additions can be made the following
0
day prior to use, provided an equalization charge
is confirmed to have been performed.
• EQUALIZE… Once a week.
• 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 8.
• PREVENTIVE MAINTENANCE SCHEDULE…
WEEKLY
9. WATER ADDITIONS
Maintain electrolyte levels above the bottom of the
perforated, plastic element protector, but no higher
than 1/8" from the bottom of the cell cover vent well.
Check the electrolyte level weekly, or as necessary
epending on battery use prior to charging. If the level
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is not visible (below the element protector) 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 between 1.2-2.2” 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.
• Check electrolyte levels (see water additions).
• Equalize charge.
MONTHLY
• Record electrolyte specific gravities.
• Visual inspection and confirm that the Power
Trac unit LED is illuminated.
• 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
• Battery temperature averages more than
125°F.
• 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.
10. SERVICE AND PARTS
BATTERIES MUST BE VISUALLY INSPECTED
PER THE ABOVE SCHEDULE EVEN WITH THE
USE OF A WATERING SYSTEM.
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.
11. 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.
8. MAINTENANCE CLEANING
The top of the battery should be kept clean and dry.
Keep the vent caps in place during use and charging.
Remove them 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.
A Division of Exide Technologies
GNB Industrial Power –
A Division of Exide Technologies
™
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
GB4103 2013-06
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