Exide Technologies GB4145 User Manual

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 Fast 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 B at t e ry m a i n t e na n c e ar 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 and GNB-approved for
use with GNB Flooded Classic Platinum fast charge
batteries. Use a charger with automatic charger
termination controls.

Remove the vent caps from each cell and check to see
that the electrolyte level is above the perforated,
plastic element protector. 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 ±

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.

delivering up to 160% of their rated capacity within a 24-

our period. To achieve such high levels of usage,

h
operators must be diligent to "plug in" at all opportunities

hroughout the day, including breaks, meals, and shift

t
changes. Care must be taken to ensure specific gravity
readings in the battery cells do not go below 1.160 at any
time.

A GNB Flooded Classic Platinum fast charge battery is
designed for fast 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 motive power batteries are designed
and built to deliver 80% of their rated capacity at
77˚ F (25˚C.)

5. temperature

In the operation of fast charge lead-acid batteries, the
electrolyte temperature must not exceed a maximum of
140˚F (60˚C), and must maintain an average temperature
of 125˚F (52˚C). 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
representative for service.

6. charGinG

The start rate of a fast 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 representative on specific charging problems.

7. maintenance

• keep recorDs… Showing specific gravities,

equalizing, charging, temperature, and voltages
on a monthly basis. These records are required
to maintain your warranty.

0.005 at 77˚ F (25˚C).

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 systems are designed
to return a significant amount of ampere-hours in short
periods of time, fast charge batteries are capable of

• temperature… Under normal fast charge

operating conditions, the electrolyte temperature
shall be between 60-140˚ F (15-60˚ C). 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-approved fast
chargers have the capability for equalize charging
at specific times and days of the week (eg.

unday 08:00). Water additions can be made the

S
following 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

• Check electrolyte levels (see water additions).

• Equalize charge.

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

d
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 representative if
you are not sure of your water quality.

Batteries must Be Visually inspecteD

monthly

• Record electrolyte specific gravities.

• Visual inspection and confirmation that the

battery-mounted monitor is functioning properly.

• 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 (52˚C).

• 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.

per the aBoVe scheDule eVen with the

use oF a waterinG system.

10. serVice anD parts

Your local GNB sales representative has more
information regarding the full range of maintenance
and repair service available. GNB 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 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 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 servicing representative.
The solution used to clean and neutralize the outside of
the batteries should be disposed of in an environmentally
safe manner.

VENT WELL

COVER WATERING

1.2”

2.2”

JAR WATERING

HIGH

LEVEL

ELEMENT
PROTECTOR

LOW

LEVEL

A Division of Exide Technologies

GNB Industrial Power

USA – Tel: [phone]
Canada – Tel: [phone]

Spanish and French versions of
this document can be found at

www.gnb.com

GB4145 2013-06