nifty TM Series Operating And Safety Instructions Manual page 34

TM Series
Operating & Safety Instructions
2) Some Niftylifts are fitted with a Battery Management System, which permanently monitors the
condition of the batteries. When the batteries become discharged to 20% of their capacity the
management system will begin to "shut down" the hydraulic power packs. This causes the
drive/boom operating system to alternately stop and start, signalling to the operator that re-
charging is necessary. However, there is sufficient power remaining to enable the operator to
drive slowly to the nearest charging point.
Should the operator ignore the onset of the battery discharge warning the "shut down" of the motors
will continue, until the machine is rendered in-operative. Immediate charging will then be required.
CHARGING LIMITATIONS
Battery charging times will increase slightly if using an 110V supply as opposed to a 240V supply. This
is due to the connection of the primary coils being in parallel, which in effect only allows the
transformer to see 220V. Similarly, the capacity of the 110V supply will decide the input current
available; hence a small hand-tool transformer will not operate the battery charger efficiently, therefore:
- charging times will increase further due to input limitations.
Attention should also be given to the use of extension cables as power leads. Excessive cable lengths
from the supply point to the battery charger will result in significant voltage drop, leading to a reduction
in the chargers efficiency. In addition, inadequate sized cable cores will have a limiting effect on its
current carrying capacity, which will again lead to a reduction in the chargers efficiency. Both of these
can result in over-heating of the cable with the attendant risk of fire, short circuits or damage to the
components themselves.
The charger requires a minimum battery voltage of 4.5 volts per battery (overall for two batteries 9
volts, for 4 batteries 19 volts for 8 batteries 38 volts). If the voltage is below these values then the
charger will not function (Charger will not detect batteries to begin charge.) If the batteries have fallen
to such a poor state they will have to be removed from the machine and charged individually with an
independent charger until the optimum voltage has been reached. This is best performed at very low
currents to 'recover' the batteries if sulphation has already started i.e. a 'trickle' charger. This can take
several hours, possibly days. Careful monitoring of the rise of battery voltage will indicate when
recovery has been achieved.
TOPPING UP
During the course of normal operation, the batteries should be inspected at least once a fortnight to
check the level of electrolyte. During the end of charge, gassing takes place, which will cause a slight
reduction in the volume of acid in the battery. This can be topped up with de-ionised water as required.
During this inspection, it is useful to note any imbalance in the fluid levels. One indication of a faulty
cell would be an increase in the loss of battery acid, which would then require more frequent topping
up on that cell, or cells. Faulty cells can liberate excess hydrogen, even during normal operation, with
the resulting risk of explosion if ignited. Any faulty batteries should be replaced as soon as
possible with an equivalent sized and rated unit.
Note: BATTERIES CONTAIN ACID, therefore: - protective safety glasses and gloves
(Appropriate PPE) MUST be worn whilst performing these checks.
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English/USA – 01/10
Issue 06