Components and Assembly
8
BATTERY OPERATION AND REPLACEMENT
Blue plug - Front, 48V hook-up to motor.
Gray plug - Top, 24V series hook-up to create a 48V pack.
Red plugs - Rear/Right/Left, 24V access for recharging batteries either inside or outside.
Blue port - 48V terminal to connect power to motor. When charging at this port, use only
approved 48V DC charging unit.
Breaking in the Power Packs
The power packs will not produce the full amperage per hour until it has been fully dis-
charged and recharged 12-13 times.
Removing Power Packs
Note:
Each pack weighs 185 lbs (84 kg). For safe removal, additional help may be
needed.
1.
Open and secure hood (Figure 1).
2.
Remove all three plug connections (red, blue and gray). Never try to remove packs
out of machine before completely disconnecting the blue plug in front and the gray
plug on top.
3.
After plugs are free, connect the battery cart to the machine. Slide batteries from
the machine onto the cart (Figure 1.1).
4.
Secure batteries onto the cart; disconnect the cart from the machine.
Replacing Power Packs
1.
To replace the power packs, reverse the above steps.
2.
Slide power pack straight into machine; not at an angle. It should be nested prop-
erly in between the guards.
3.
Once power packs are properly installed, connect gray plug at top, blue plug at
front. Failure to connect all the plugs will not allow machine to operate. Make sure
plugs are connected firmly and securely together. Plug connectors are stiff.
4.
Close hood; secure latch. Machine is now ready to operate.
Note:
There is a right and left to each power pack as well as a front and back. From a
seated position, the power pack with a blue plug is the right hand pack. Blue plug to the
front, red plug to the rear. Power pack with no plug in the front is the left pack. No plug
to front, red plug to rear. Failure to properly install power packs correctly will not allow
power hook up.
Pairing Power Packs
Power packs should be kept in their original pairs. Mixing the power packs can throw
them out of balance and shorten the battery life. Mark power pack cases to easily know
which ones are paired.
Charging the Battery
Charging can be done in or out of the machine. Take advantage of charging during
downtime.
1.
Turn the e-stop to the off position; unplug the blue 48V plug.
2.
Open and secure the rear hood (keep open for ventilation).
3.
Power packs must be connected (hooked in series, gray plugs on top of the packs).
FIG. 1
FIG. 1.1
402228_5200QL_RevE
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