Exide Technologies GB4158 User Manual

™

POST THESE INSTRUCTIONS IN THE BATTERY MAINTENANCE AREA

INSTALLATION AND OPERATING INSTRUCTIONS FOR

FP

MOTIVE POWER BATTERY AND CHARGER SYSTEM

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 washbasins 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.

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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 SECTION 1.

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.

Open the vent caps from each cell and check to see that the electrolyte level is above the plate
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 (1.280 – 1.290). 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 plate separators, recheck it after 3 hours of
charging. If the level remains below the plate separators, add water or electrolyte to the proper level
at the end of charging.

Following the first 90 days of service, the battery should reach its normal operating specific gravity of

1.285 to 1.345 at 77°F (25°C).

IF BATTERIES ARE NOT IN REGULAR USE, KEEP THEM CHARGED.

CHECK THE SPECIFIC GRAVITIES MONTHLY AND GIVE THE BATTERY 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.

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4. OPERATION

Batteries are rated in ampere-hours (Ahr) 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-LM Low Maintenance 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 60-100°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 hot to the touch, allow it to cool to room temperature before charging 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.

6. CHARGING

The battery should be charged exclusively with the charger provided with the system.

WHEN BATTERY RECHARGE IS REQUIRED, PLUG THE BATTERY CABLE CONNECTOR
INTO THE CHARGER CABLE CONNECTOR AND THEN PLUG THE 3-PRONG CHARGER
POWER CORD INTO A GROUNDED 120 VOLT 15 AMP 50 HZ OR 60 HZ POWER OUTLET.

The charger is equipped with an LED indicator to show the progress of the charging cycle.

RED LED shows that the battery is in the initial charging phase.
YELLOW LED shows that the battery has reached 80% of charge.
GREEN LED shows that the battery has reached 100% of charge.

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