Energy Expansion Mounting Kit

1. Place 2 batteries in the battery tray (Figure 2).

   

   Figure 2

   1. Positive (+) terminal
   2. Negative (-) terminal

2. Use 2 hex-head bolts (1/4 inch) to loosely secure the bus bars to the batteries (Figure 3).

   

   Figure 3

   1. Bus bars
   2. Hex-head bolts (1/4 inch)

3. Use 2 hex-head bolts (1/4 inch) to connect the red and black battery cables to the bus bars that you installed in the previous step (Figure 4).

   Important: Loosely install the hex-head bolts to the cables and bus bars. You will torque the bolts in a later step.

   

   Figure 4

   Cable connections at the front

   1. Hex-head bolts (1/4 inch)
   2. Red battery cable
   3. Black battery cable

4. Verify that the bus bars are seated properly and torque the hex-head bolts (Figure 3 and Figure 4) to 11 N·m (95 in-lb).

5. Route the battery cables toward the rear battery tray as shown in Figure 4 and Figure 5.

   Important: Ensure that the cables are routed away from pinch points or sharp edges.

   

   Figure 5

   1. Red battery cable
   2. Black battery cable
   3. Rear battery tray

6. Use 2 carriage bolts (1/4 inch), washers (1/4 inch), and 2 locknuts to connect the red and black battery cables to the bus bars at the rear battery tray as shown in Figure 6.

   Torque the hardware to 10.8 N·m (8 ft-lb).

   Note: The black battery cable in the kit is installed on top of the existing black battery cable on the machine as shown in Figure 6.

   

   Figure 6

   Cable connections at the rear

   1. Black battery cable (kit part)
   2. Black battery cable (existing part)
   3. Locknut
   4. Washer (1/4 inch)
   5. Red battery cable
   6. Carriage bolt (1/4 inch)

1. Connect the wire harnesses to the batteries as shown in Figure 7.

   

   Figure 7

   1. Wire harness (data interface—7-1/2 inches)
   2. Wire harness (data interface—45-1/2 inches)

2. Route the remaining connector of the data-interface wire harness (45-1/2 inches) toward the rear battery tray (Figure 7).

3. Remove the existing wire harness (CAN) from the D2 battery port (Figure 8). Retain the wire harness.

   

   Figure 8

   1. D2 port
   2. Existing wire harness (CAN)
   3. Connector—data-interface wire harness

4. Install the remaining connector of the data-interface wire harness to the D2 battery port (Figure 8).

5. Install the wire harness (CAN) that you removed in step 3 to the D2 battery port on the top battery in the battery tray (Figure 9).

   

   Figure 9

   1. D2 port
   2. Wire harness (CAN)

6. Use a push fastener to secure the battery cables and data-interface wire harness to the battery tray (Figure 10).

   

   Figure 10

   1. Push fastener
   2. Red battery cable
   3. Wire harness
   4. Black battery cable

7. Install the foam pads to the battery cover as shown in Figure 11.

   

   Figure 11

   1. 8.3 cm (3-1/4 inches)
   2. 11 mm (7/16 inch)
   3. Battery cover
   4. Foam pad

8. Use 4 hex-head bolts (5/16 inch), 4 washers (5/16 inch), and 4 hex-flange nuts to secure the battery cover to the battery tray (Figure 12).

   

   Figure 12

   1. Hex-flange nut
   2. Hex-head bolt (5/16 inch)
   3. Washer (5/16 inch)
   4. Battery cover

Important: Before you install the cable ties, ensure that the wire harness and cables are routed away from any moving or sharp parts.

Use 2 cable ties to secure the wire harness and battery cables together in the areas shown in Figure 13.

Figure 13

1. Cable ties

You must use Toro DIAG to configure the number of equipped batteries on the machine and verify their software revision level.

1. Turn the battery-disconnect switch to the OFF position.

2. Remove the charger-cable cover (Figure 14).

   

   Figure 14

   1. Bolts
   2. Charger-cable cover

3. Remove the DC power connector from the charger (Figure 15).

   

   Figure 15

   1. DC power connector

1. Connect Toro DIAG to the machine; refer to the Toro DIAG Commercial Product User’s Guide.

2. Ensure that the software revision level for the batteries is updated by selecting the REPROGRAM button in Toro DIAG; refer to the Toro DIAG Software User’s Guide.

3. Turn the battery-disconnect switch to the ON position.

4. Within Toro DIAG, select PRIMARY CONTROLLER, navigate to the CONFIG tab, then enter number of batteries that are equipped on the machine in the NUMBER OF BATTERIES field.

5. Disconnect Toro DIAG from the machine.

1. Turn the battery-disconnect switch to the OFF position.

2. Install the DC power connector to the charger (Figure 15).

3. Install the charger-cable cover (Figure 14).

4. Turn the battery-disconnect switch to the ON position.

5. Charge the batteries; refer to your machine Operator’s Manual.

6. Perform the following steps to verify the number of active batteries on the machine:

   1. Use the machine display screen to navigate to the DIAGNOSTICS menu.

   2. Navigate to the BATTERIES menu item, select OUTPUTS, then select NUMBER OF PACKS.

   3. Verify that the number shown in the NUMBER OF PACKS screen matches the number of batteries that are equipped on the machine.