Toro Groundsmaster e3200 User manual

Form No. 3464-198 Rev A

Energy Expansion Kit

Groundsmaster

e3200 T raction Unit

Model No. 161-0859

Installation Instructions

Safety

Refer to your traction unit Operator ’ s Manual for electrical system safety information.

Installation

Loose Parts

Use the chart below to verify that all parts have been shipped.

Procedure Description

Qty .

Use

No parts required

–

Prepare the machine.

No parts required

–

Remove the battery spacers and bus

bars.

HyperCell® battery (sold separately;

refer to your authorized T oro distributor)

2 or 4

Wire harness 23

Bolt 4

Install the batteries.

No parts required

–

Adjust the rear weight (for machines

with 15 batteries only).

No parts required

–

Complete the installation.

81 1 1 L yndale A venue South

Bloomington, MN 55420

Original Instructions (EN)

Printed in the USA

*3464-198*

Preparing the Machine

No Parts Required

Procedure

1. Park the machine on a level surface.

2. Ensure that the parking brake is engaged.

3. Shut of f the machine and remove the key .

4. T urn the battery-disconnect switch to the O FF

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 Of f position and the

battery-disconnect switch is in the Of f 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 T oro distributor .

Removing the Battery

Spacers and Bus Bars

No Parts Required

Procedure

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 ).

g448862

Figure 1

1. Foam pad

3. Channel support

2. Nut

2. Remove the wire harness from the battery

spacers and the batteries ( Figure 2 ).

g448873

Figure 2

1. Wire-harness

connection—batteries

3. Battery spacers

2. Wire-harness

connection—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.

g459391

Figure 3

1. Black battery cable 4. Lower bus bar

2. Upper bus bar 5. Red battery cable

3. Bolt

Installing the Batteries

Parts needed for this procedure:

2 or 4

HyperCell

battery (sold separately; refer to your

authorized T oro distributor)

2 Wire harness

4 Bolt

Procedure

1. Insert your desired amount of new batteries into

the battery compartment.

•Figure 4 shows 2 installed batteries (13

total):

g448876

Figure 4

1. 2 installed batteries

•Figure 5 shows 4 installed batteries (15

total):

g448877

Figure 5

1. 4 installed batteries

2. Connect the new wire harnesses to the battery

ports labeled D2 ( Figure 6 ).

g452835

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 ).

g455916

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:

A. Use the previously removed bolts to loosely

secure the bus bars to the batteries ( Figure

3).

B. Use the previously removed hardware to

install the battery cables to the bus bars

(Figure 3 )

C. Use the bolts included in the kit to loosely

secure the bus bars to the new batteries

(Figure 8 ).

g452847

Figure 8

Machine with 13 installed batteries shown

1. Bolt 3. Lower bus bar

2. Upper bus bar

5. If your machine has 13 installed batteries:

A. Use the previously removed bolts to install

a battery spacer to the battery-compartment

gap ( Figure 9 ).

g456289

Figure 9

1. Bolt 2. Battery spacer

B. 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 .

g459386

Figure 10

1. Wire harness (previously

removed)

2. Battery ports (labeled D1 )

6. V erify 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

1 1 N·m (95 in-lb).

7. Install the channel support and foam pad; refer

to Figure 1 .

Adjusting the Rear W eight

For Machines with 15 Batteries

Only

No Parts Required

Procedure

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 1 1

g450219

Figure 1 1

1. W eight-lock rod 3. W eight

2. Nut

3. T ighten the weight-lock-rod hardware to secure

the weight to the bumper .

Completing the Installation

No Parts Required

Procedure

T urn the battery-disconnect switch to the O Nposition.

There should be no fault codes showing on the

machine. If the display shows a U131 1 fault code, the

battery software does not match the machine software

and the battery will need to be reprogrammed.

Notes:

This manual suits for next models

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