Energy Expansion Kit

1. Park the machine on a level surface.

2. Ensure that the parking brake is engaged.

3. Shut off the machine and remove the key.

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

5. Raise the hood.

6. Use a digital multimeter to measure the voltage across the positive and negative bus bars.

   The voltage should be less than 1 VDC. If the voltage is above 1 VDC, ensure that the key switch is in the OFF position and the battery-disconnect switch is in the OFF position, then check the voltage again. If the voltage is still above 1 VDC, there may be a battery fault; refer to the traction unit Service Manual or your authorized Toro distributor.

Retain all removed parts for later installation.

1. Remove the channel support and foam pad from the battery compartment that contains 4 batteries (Figure 1).

   

   Video 1

   

   Figure 1

   1. Foam pad
   2. Nut
   3. Channel support

2. Remove the wire harness from the battery spacers and the batteries (Figure 2).

   

   Figure 2

   1. Wire-harness connection—batteries
   2. Wire-harness connection—spacers
   3. Battery spacers

3. Remove the battery spacers (Figure 2) from the battery compartment.

   If you are installing 2 batteries (13 total batteries installed on the machine), retain a battery spacer for later installation.

4. Remove the bus bars (Figure 3) from the battery compartment.

   

   Figure 3

   1. Black battery cable
   2. Upper bus bar
   3. Bolt
   4. Lower bus bar
   5. Red battery cable

Parts needed for this procedure:

1. Insert your desired amount of new batteries into the battery compartment.

   • Figure 4 shows 2 installed batteries (13 total):

     

     Figure 4

     1. 2 installed batteries

   • Figure 5 shows 4 installed batteries (15 total):

     

     Figure 5

     1. 4 installed batteries

2. Connect the new wire harnesses to the battery ports labeled D2 (Figure 6).

   

   Figure 6

   Machine with 13 installed batteries shown

   1. Battery ports (labeled D2)
   2. Wire harnesses

3. Remove the appropriate amount of caps from the bus bars (Figure 7).

   

   Figure 7

   1. Caps (removed for machine with 13 batteries)
   2. Caps (removed for machines with 15 batteries)

4. Perform the following steps to install the bus bars:

   1. Use the previously removed bolts to loosely secure the bus bars to the batteries (Figure 3).

   2. Use the previously removed hardware to install the battery cables to the bus bars (Figure 3).

   3. Use the bolts included in the kit to loosely secure the bus bars to the new batteries (Figure 8).

      

      Figure 8

      Machine with 13 installed batteries shown

      1. Bolt
      2. Upper bus bar
      3. Lower bus bar

5. If your machine has 13 installed batteries:

   1. Use the previously removed bolts to install a battery spacer to the battery-compartment gap (Figure 9).

      

      Figure 9

      1. Bolt
      2. Battery spacer

   2. Install the wire harness (shown in Figure 2) that you removed in the previous procedure to the battery ports labeled D1; refer to Figure 10.

      

      Figure 10

      1. Wire harness (previously removed)
      2. Battery ports (labeled D1)

6. Verify that the bus bars are seated properly and torque the bolts that you used to secure the bus bars to the batteries (Figure 3 and Figure 8) to 11 N·m (95 in-lb).

7. Install the channel support and foam pad; refer to Figure 1.

Machines with 15 total batteries should be equipped with 1 weight on the bumper. If you installed 4 additional batteries to the machine, remove 1 of the existing weights from the bumper.

Note: Machines with 13 total batteries should be equipped with 2 weights on the bumper; no weight adjustments are needed.

1. Loosen the hardware that secures the weight-lock rod to the bumper.

2. Remove a weight and position the remaining weight at the center of the bumper as shown in Figure 11

   

   Figure 11

   1. Weight-lock rod
   2. Nut
   3. Weight

3. Tighten the weight-lock-rod hardware to secure the weight to the bumper.

1. Verify that the battery-disconnect switch is in the ON position.

2. Verify that there are no fault codes displayed on the machine display.

   • If the display shows a U1311 fault code, the battery software does not match the machine software and the software needs to be reprogrammed using the current release of Toro DIAG.

   • If the display shows a U1151 fault code, the number of batteries on the machine does not match the amount of batteries that were configured in Toro DIAG. Connect the machine to Toro DIAG and ensure that the number of batteries on the machine matches the amount of batteries listed in Toro DIAG.

   Refer to your authorized Toro distributor for any needed assistance.