FLOODED INDUSTRIAL LIFT TRUCK BATTERIES
INSTALLATION AND OPERATING INSTRUCTIONS
CAUTION-READ THE ENTIRE INSTALLATION AND OPERATING INSTRUCTIONS BEFORE PLACING BATTERIES
IN SERVICE
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. 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 during charge. Keep open flames away. Do not check electrolyte level with a cigarette lighter or match. Use a flashlight or permanent lights. Do not smoke or create sparks.
1.6 Lift batteries with a hoist, crane, lift truck, or . Move batteries on trucks, conveyors, or rollers. Be sure to place a rubber mat or similar insulating material across tops of batteries without covers 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 other material on top of a battery.
1.8 Disconnect battery from truck when performing maintenance and repair on motor or electrical system.
1.9 Open or "break" battery circuit before attempting repairs to charging plug or receptacles.
1.10 Apply a strong neutralizer, like baking soda, when acid is spilled on the floor. Check local regulations
regarding 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 battery from carrier. Wet spots on the shipping pallet may be an indication of leaking jars broken in shipment.
If there is evident 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 representative to have the battery repaired before placing it in service.
3. PLACING IN SERVICE
Verify battery weight meets or exceeds the minimum truck weight requirements. Make sure the battery charger is properly matched to the battery. Use a charger with automatic charger termination controls. GNB recommends the use of a GNB SCR or GNB FER charger.
Remove 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 vent caps and give 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 electrolyte level toward the end of charge.
Upon completion of the freshening charge/the normal, fully charged specific gravity should be 1.280 to 1.290 at 77°F. An exception to this is the 95C and 130C high capacity cell types which are 1.300 to 1.310 at 77°F.
Following the first week of service, the battery should reach its normal operating specific gravity of 1.290 to 1.300 at 77°F or 1.310 to 1.320 for the 95C and 130C high capacity cells.
—Note— If batteries are not in use, keep them charged Check specific gravities monthly and give a freshening charge (3 or 4 hours at the finish rate if the gravities have fallen 30 points (.030) or more otherwise give freshening charge every three months.
4. OPERATION
Batteries are rated in ampere hours 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 battery (to 80% or less) so that specific gravities do not go below 1,140. If truck operation results in only partial discharges (40% or less) and specrtic gravities are 1.230 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 disclose the frequency of charge intervals under these circumstances re u instances.
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.
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 restricted. Under normal! operating conditions, battery electrolyte temperature should be maintained between 60° and 100°F. Following charging, the battery should be allowed to cool approximately 8 hours prior to another discharge cycle.
6. CHARGING
When recharging a fully discharged battery, the starting charge rate may be 3 to 5 times higher than the finish charge rate indicated on the battery name plate. 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. Do not intermittently charge, "opportunity charge", or short cycle this battery. Consult your local GNB representative on specific charging problems.
7. MAINTAINING
Showing specific gravities, equalizing, charging, temperature, and voltages on a monthly basis. These records are required to maintain your warranty.
Normal a~operating conditions, the electrolyte temperature hall be between 60°F and 100°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.
Add water at end of charging period when battery is fully charged and charger has tapered to its finish rate. See Item 9.
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). discharge capacity. and voids
Do not battery below 80% of rated Over discharging shortens battery life the warranty.
Keep the top of the battery clean and dry. See Item 8.
PREVENTIVE MAINTENANCE SCHEDULE...
Check electrolyte levels
Equalize charge (heavy use application).
Record electrolyte specific gravities.
Equalize charge (light use application).
Inspect cables and charging plugs.
Clean top of cells.
Inspect charger.
Clean exterior of battery.
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 20 points or more during equalizing.
The top of the battery is always wet or one cell requires excessive water.
8. MAINTENANCE: (CLEANING)
The top of the battery should be kept clean and dry. Keep vent caps in place during use and charging. Remove only to observe levels, make water additions, lake temperatures, or take specific gravity readings with a hydrometer. The battery can be washed off with water if dusty. Keep vent caps in place. If electrolyte has accumulated on top, wash with a neutralizing solution of soda and water (one pound of baking or commercial soda ash to one gallon of water). Follow with a rinse using clear water. Check local codes before discharging cleaning water into the sewage system.
9. WATER ADDITIONS
Maintain electrolyte levels above the perforated, plastic element protector, but no higher than within 1/8" of the bottom of the cell cover vent well. Check electrolyte level weekly, or as necessary depending on battery use prior to charging. If the level is not discernable (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 within 1/8" of the bottom of the vent well. Always use distilled water or water that is known to be free of abnormally high amounts of impurities. Contact your local GNB representative U you are not sure of your water quality.
10. SERVICE
Your local GNB sales representative has more information regarding the full range of maintenance and repair service available. For more information in the U.S.A., call 1-800-872-0471.
11. RECYCLING U.S.
Federal and State Regulations require that lead acid batteries be handled and disposed of in compliance with strict guidelines. QNB offers disposal service for lead acid batteries. Call 1-888-438-5865 to arrange a pick-up or to get additional information.
FORKLIFT
OPERATION AND SERVICE.
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