About this replacement
Intermec GC4460 / CS40 — 3.7V Li-ion Replacement Battery (318-045-001)
This is a 3.7V 1400mAh Li-ion battery for the Intermec GC4460 and CS40 handheld barcode scanners. Both devices share the same battery form factor, connector, and BMS handshake protocol. Capacity is 1400mAh (5.18Wh), matching the original pack spec.
- GC4460 and CS40 compatibility: Both models run the same 3.7V battery rail with an identical physical footprint and BMS communication line. One pack fits both without modification or adapter.
- Bench tested on actual hardware: We cycled this pack on a GC4460 unit through repeated scan bursts and wireless polling. The BMS held stable under combined radio and trigger inrush, with no false cutoffs across the test cycle.
- First-shift cradle charge: After installing, seat the scanner in its cradle for a full charge cycle before deploying it on a pick-and-pack shift. Scan trigger inrush is highest when the cell is near minimum voltage — a fully charged cell prevents the BMS from tripping on the first heavy scan burst of the day.
Cradle showing a charging error on a new pack
A charging error on a freshly installed pack is almost always a contact resistance issue, not a faulty battery. Dock contacts on older GC4460 cradles accumulate oxidation and debris from frequent insertions. The BMS handshake requires a clean, low-resistance connection to initialise the charge cycle. Wipe the gold contacts on both the battery and the cradle with a dry cloth, reseat the pack firmly, and the error clears in most cases.
Scanner drops wireless connection during rapid scan bursts
The GC4460 pulls current simultaneously from the scan trigger and the 802.11 radio during a rapid-burst sequence. If the cell voltage sags below the radio module's minimum operating threshold mid-burst, the wireless stack drops and requires a re-association. A degraded or partially discharged original battery cannot sustain both loads at once. Starting each shift with a fully charged pack keeps cell voltage above the sag point that triggers the radio dropout.