Toro Reelmaster 5010- H Service Manual page 224

48 VDC Battery Pack Installation (Fig. 85)
1. Make sure that the 48 VDC battery disconnect is sep-
arated to prevent unexpected 48 VDC system compo-
nent operation (see 48 VDC Battery Disconnect in the
General Information section of this chapter).
2. Make sure the battery tray is clean and repainted if
necessary. Make sure battery cables, battery terminals
and all hold down fasteners are in good condition.
3. If battery cables were removed, install cables in posi-
tions noted during disassembly. If cables were removed
from rear batteries, make sure that cables are correctly
routed through clamps and secured with removed fas-
teners.
4. Place batteries onto battery tray in machine.
5. Secure each battery with battery hold down and hex
nut.
IMPORTANT: When connecting the battery pack in
the 48 volt system, make sure that battery polarity
is carefully checked. Damage to fuses or other sys-
tem components can occur if batteries are not con-
nected correctly.
6. Install all of the battery cables except the battery
jumper cable (item 16). Make sure that cables are con-
nected to correct battery terminal noting battery polarity
as shown in Figures 86 and 87. Torque nuts on battery
cable clamps from 50 to 70 in- lb (5.7 to 7.9 N- m).
7. Carefully install battery jumper cable (item 16) to
front batteries. Do not allow tools or vehicle components
to complete the battery circuit during cable installation.
Torque nuts on battery jumper cable clamps from 50 to
70 in- lb (5.7 to 7.9 N- m).
8. Apply Toro battery terminal protector (see Special
Tools in this chapter) to all battery posts and cable con-
nectors to reduce corrosion after cable connections are
made. Make sure that terminal boots are positioned
over all cable connections.
9. Install battery covers.
10.Plug the 48 VDC battery disconnect back into the
socket before operating the machine.
Electrical System
48 VDC Battery Pack Service
Clean the battery pack with clean water and a towel. Do
not use solvents or chemicals to clean the battery pack.
When testing batteries in the battery pack of your Reel-
master, it is important to test all four (4) individual batter-
ies. Proper performance of the machine depends on all
batteries being in good condition. Testing will determine
if one (or more) of the batteries needs to be replaced.
A simple battery test can be done using a multimeter to
perform a voltage test of each of the batteries in the bat-
tery pack. Measure the battery voltage with the multime-
ter and record battery voltage. The measured voltage
can be used to determine battery state of charge. If the
voltage of any of the batteries varies by more than 10%,
it indicates a problem with the battery that has the lower
voltage.
If the battery pack system voltage drops below 50 VDC
due to storage, age or malfunction, battery inspection
and/or charging may be necessary. The batteries
should be individually charged with a 12 VDC charger
rated for operation with absorbed glass mat (AGM),
valve regulated lead acid batteries. Charge the batteries
following the battery charger manufacturer's instruc-
tions. Maximum charge voltage should be limited to 14.8
VDC. Operation of the machine will also charge the bat-
teries in the 48 VDC system.
A battery load tester can be used to test individual bat-
teries. Many locally available battery load testers do not,
however, have any adjustment on the load that is put on
the battery. Results received from using load testers
should follow the recommendations of the load tester
manufacturer.
48 VDC Battery Pack Storage
There are no special procedures or precautions for bat-
tery storage less than six (6) months. Batteries should
be disconnected from all potential load sources during
storage. Recommended storage temperatures should
be between 50
elevated temperatures will result in accelerated rates of
self discharge. Make sure that batteries are fully
charged prior to storage. If battery pack is stored in a dis-
charged state, battery performance and life will be di-
minished.
During storage, battery charging is recommended
whenever voltage of an individual battery drops below
12.7 VDC.
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F and 77 F (10 C to 25
Reelmaster 5010- H
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C). Storage at