Battery Conversion Kit

For instructions to remove the Samsung batteries, center battery cover, battery cables, and battery-interface wire harness, refer to the Servicing the Lithium-Ion Batteries (Model 04590) section in the machine Service Manual.

Retain the center battery cover for later installation.

Note: Labels for wire harness and cable connections are not necessary.

1. Release tension on the brake-actuator spring by loosening the nut (Figure 2) that secures the eyebolt to the spring bracket.

   

   Figure 2

   1. Nut
   2. Spring
   3. Brake-actuator shaft

2. Remove the pins that secure the brake actuator to the side battery tray on the right side of the machine (Figure 3).

   

   Figure 3

   1. Cylinder pin
   2. Cotter pin
   3. Brake actuator

3. Remove the hardware (Figure 4) that secures the side battery trays to the machine frame.

   

   Figure 4

   1. Hardware
   2. Side battery tray

4. Remove the hardware that secures the top battery tray to the machine frame (Figure 5).

   

   Figure 5

   1. Nut
   2. Bolts
   3. Top battery tray

5. Remove the nuts that secure the TEC controller to the battery tray (Figure 6). Retain the controller for later installation.

   

   Figure 6

   1. TEC controller (retain)
   2. Nut

1. Install 5 foam strips (19 cm or 7.5 inches) to the upper mount plate (Figure 7).

   

   Figure 7

   1. Foam strips (19 cm or 7.5 inches)
   2. Upper mount plate

2. Use 4 flange bolt (1/4 x 1-1/4 inches) and 4 speed nuts (1/4 inch) to secure the TEC controller (removed from the Samsung battery tray) to the upper mount plate (Figure 8).

   

   Figure 8

   1. Speed nut (1/4 inch)
   2. TEC controller
   3. Flange bolt (1/4 x 1-1/4 inches)

1. Use 2 flange bolts (5/16 x 1 inch) and 2 flange nuts (5/16 inch) to secure the upper mount plate to the machine frame (Figure 9).

   Torque the hardware to 19 to 24 N∙m (14 to 18 ft-lb).

   

   Figure 9

   1. Flange bolts (5/16 x 1 inch)
   2. Flange nuts (5/16 inch)
   3. Upper mount plate

2. Use 2 flange bolts (3/8 x 1 inch) to secure the upper mount plate to the steering housing (Figure 10).

   Torque the bolts to 32.5 to 40.5 N∙m (24 to 30 ft-lb).

   

   Figure 10

   1. Upper mount plate
   2. Flange bolts (3/8 x 1 inch)
   3. Steering housing

1. Install 5 foam strips (19 cm or 7.5 inches) to the top strap bracket (Figure 11).

   

   Figure 11

   1. Top strap bracket
   2. Foam strips (19 cm or 7.5 inches)

2. Perform the following steps to install 3 batteries to the upper mount plate:

   1. Remove the cap (Figure 12) from the positive terminals.

      

      Figure 12

      1. Cap

   2. Align the outer batteries so that they are positioned against the left and right sides of the upper mount plate (Figure 13).

      

      Figure 13

   3. Align the center battery so that the battery terminals face rearward, and lower the center battery into the upper mount plate, between the outer batteries (Figure 13).

3. Use 6 flange bolts (3/8 x 1 inch) and 6 flange nuts (3/8 inch) to secure the top strap to the upper mount plate (Figure 14).

   Torque the hardware to 32.5 40.5 N∙m (24 to 30 ft-lb).

   

   Figure 14

   1. Flange bolt (3/8 x 1 inch)
   2. Top strap
   3. Upper mount plate
   4. Flange nut (3/8 inch)

1. Install 2 data-interface wire harnesses (19 cm or 7-1/2 inches) into the battery ports shown in Figure 15.

   

   Figure 15

   1. Data-interface wire harness (19 cm or 7-1/2 inches)
   2. Port D2
   3. Data-interface wire harness (63.5 cm or 25 inches)

2. Install an end of the data-interface wire harness (63.5 cm or 25 inches) into the battery port labeled D2 as shown in Figure 15.

3. Use 6 bolts (1/4 x 3/4 inch) to secure the following items to the battery terminals (Figure 16).

   • 4 bus bars

   • Red (+) battery cable

   • Black (-) battery cable

   • Red (+) battery cable on the red/black battery-cable assembly

   

   Figure 16

   1. Red (+) battery cable (red/black battery-cable assembly)
   2. Battery terminal
   3. Red (+) battery cable
   4. Bus bar
   5. Bolt (1/4 x 3/4 inch)
   6. Black (-) battery cable

4. Torque the bolts (1/4 x 3/4 inch) to 10.7 to 11.8 N∙m (95 to 105 in-lb).

1. Remove the cap (Figure 17) from the positive terminals of the remaining 2 batteries.

   

   Figure 17

   1. Cap

2. Assemble the 2 batteries on the bottom base plate as shown in Figure 18.

   

   Figure 18

   1. Bottom base plate

3. Install 2 foam strips (37 cm or 14.5 inches) to the lower mount plate (Figure 19).

   

   Figure 19

   1. Lower mount plate
   2. Foam strips (37 cm or 14.5 inches)

4. Install the Model 04593 decal to the lower mount plate as shown in Figure 20.

   

   Figure 20

   1. Model 04593 decal

5. Use 6 flange bolts (3/8 x 1 inch) and 6 flange nuts (3/8 inch) to loosely secure the lower mount plate to the bottom base plate (Figure 21)

   

   Figure 21

   1. Flange nuts (3/8 inch)
   2. Lower mount plate
   3. Flange bolts (3/8 x 1 inch)

6. Ensure that the batteries are centered in the base plate and torque the hardware to 32.5 to 40.5 N∙m (24 to 30 ft-lb).

7. Use a floor jack to install the assembly that contains the bottom base plate, batteries, and lower mount plate as follows:

   1. Place the assembly on a floor jack.

      Important: The batteries and base plate weigh approximately 34 kg (75 lb). Have an assistant help you to ensure that the batteries and base plate are centered on the floor jack. Keep the center of the batteries and base plate aligned to the jack to prevent the batteries from falling.

   2. Use 4 carriage bolts (3/8 x 1 inch) and 4 flange nuts (3/8 inch) to secure the battery assembly to the machine frame (Figure 22).

      Torque the hardware to 32.5 to 40.5 N∙m (24 to 30 ft-lb).

      

      Figure 22

      1. Flange nuts (3/8 inch)
      2. Machine frame
      3. Carriage bolts (3/8 x 1 inch)
      4. Battery assembly

1. Use the previously removed cylinder pin and cotter pins to secure the brake actuator to the lower mount plate (Figure 23).

   

   Figure 23

   1. Cylinder pin
   2. Cotter pin
   3. Brake actuator

2. Tighten the eyebolt nut for the brake-actuator spring so that the spring length is 11.4 cm (4.5 inches); refer to Figure 24.

   

   Figure 24

   1. Eyebolt nut
   2. Spring
   3. Spring length—11.4 cm (4.5 inches)
   4. Arm-bracket hole
   5. Actuator shaft

1. Use 4 bolts (1/4 x 3/4 inch) to secure the following items to the battery terminals (Figure 25):

   • 2 bus bars

   • Red (+) battery cable

   • Black (-) battery cable

   • Black (-) battery cable on the red/black battery-cable assembly

   

   Figure 25

   1. Bus bar
   2. Black (-) battery cable (from upper batteries)
   3. Data-interface wire harness (19 cm or 7-1/2 inches)
   4. Red (+) battery cable (from upper batteries)
   5. Bolt (1/4 x 3/4 inch)
   6. Black (-) battery cable (red/black battery-cable assembly)

2. Install a data-interface wire harness (19 cm or 7-1/2 inches) to the battery ports shown in Figure 25.

3. Install the remaining end of the data-interface wire harness (63.5 cm or 25 inches) to the upper-battery port shown in Figure 26.

   

   Figure 26

   1. Data-interface wire harness (63.5 cm or 25 inches)

4. Torque the bolts (1/4 x 3/4 inch) to 10.7 to 11.8 N∙m (95 to 105 in-lb).

1. Remove the left side cover from the machine (Figure 34).

   

   Figure 34

   1. Screw
   2. Left side cover

2. Remove and retain the fuse assemblies (fuses and cables) from the fuse bracket (Figure 35).

   

   Figure 35

   1. Fuse assemblies

3. Remove the existing fuse bracket from the frame (Figure 36). Retain the hardware.

   

   Figure 36

   1. Flange bolt (1/4 inch)
   2. Fuse bracket
   3. Flange nut (1/4 inch)

4. Remove the existing charging connector from the frame (Figure 37). Retain the connector and hardware.

   

   Figure 37

   1. Bolt (#6)
   2. Charging connector
   3. Locknut (#6)

1. Use the previously removed flange bolt (1/4 inch) and flange nut (1/4 inch) to secure the connector bracket and fuse bracket to the frame (Figure 38).

   

   Figure 38

   1. Flange bolt (1/4 inch)
   2. Connector bracket
   3. Fuse bracket
   4. Flange nut (1/4 inch)

2. Secure the new charging connectors to the existing charging connectors (Figure 39).

   

   Figure 39

   1. Charging connectors
   2. Bolt (#6)
   3. Locknut (#6)
   4. Existing charging connector

3. Use the new bolts (#6) and locknuts (#6) and previously removed bolts (#6) and locknuts (#6) to secure the charging connectors to the frame and the connector bracket (Figure 39).

4. Install the fuse assemblies to the new fuse bracket (Figure 35).

5. Install the left side cover (Figure 34).

1. Unplug the wire-harness connector from the existing DC-DC converter (Figure 40) and remove the converter from the machine frame.

   Retain the hardware (i.e., the 2 bolts and 2 nuts) that secured the converter to the frame.

   

   Figure 40

   1. Wire-harness connector
   2. Bolts and nuts
   3. DC-DC converter

2. Use the existing hardware to secure the new DC-DC converter to the machine frame (Figure 41).

   

   Figure 41

   1. New DC-DC converter
   2. Bolts and nuts

3. Install the CAN-wire-harness connectors as follows (Figure 42):

   • Connector for the CAN wire harness labeled P04: Connect to the DC-DC converter connector.

   • Connector for the CAN wire harness labeled P03: Connect to the machine-wire-harness connector labeled P07 (the connector that you disconnected from the existing DC-DC converter).

   

   Figure 42

   1. DC-DC converter connector
   2. P07—machine-wire-harness connector
   3. P03—CAN wire harness
   4. P04—CAN wire harness

1. Locate the wire-harness connector labeled P09 near the center cutting unit, charging connectors, and fuse holders (Figure 43).

   

   Figure 43

   1. Diode
   2. Wire-harness connector—P09

2. Remove the diode from the wire-harness connector labeled P09 (Figure 43) and install the tethered cap to the connector (Figure 44).

   

   Figure 44

   1. Tethered cap
   2. Wire-harness connector—P09

3. Remove the CAN bus isolation module from the wire-harness connector labeled P50 (Figure 45) and remove the isolation module from the machine.

   

   Figure 45

   1. CAN bus isolation module (remove)
   2. Wire-harness connector—P50

4. Install the 6-socket cap to the wire-harness connector labeled P50 (Figure 46).

   

   Figure 46

   1. 6-socket cap
   2. Wire-harness connector—P50

5. Install the cover to the right side of the machine (Figure 47).

   

   Figure 47

   1. Cover
   2. Bolt