SHEET 1 OF 9 TITLE: INSTALLATION INSTRUCTIONS FOR FAST CHARGE SYSTEM 1. EFFECTIVITY CHARLATTE T135 with POWER PAC CONTROLLERS 2. REASON TO INSTALL FAST CHARGE SYSTEM 3. DESCRIPTION FAST CHARGE AUXILLARY COMPONENTS INSTALLED IN VEHICLE 4. COMPLIANCE CHARLATTE T135 with POWER PAC CONTROLLERS 5. MANPOWER AS NECESSARY 6. TOOLING HANDTOOLS, DRILL WITH 5/32, 3/16, 3/8, AND 1/2 BITS 7. REFERENCE SEE ATTACHED PAGES 8. MATERIAL AVAILABILITY ALL INCLUDED IN THE RETROFIT KIT 9. ACCOMPLISHMENTS FOLLOW THE INSTRUCTIONS INCLUDED
SHEET 2 OF 9 SAFETY! 1. DRIVE THE T135 TO A PROPER MAINTENANCE AREA. SHUT DOWN THE UNIT AND SET THE PARKING BRAKE BEFORE MAINTENANCE IS PERFORMED. NOTICE BE SURE TO DISCONNECT THE BATTERY PLUGS LOCATED UNDER THE HOOD OF THE TRACTOR BEFORE PROCEEDING. CUTTING THE HOLE FOR BURTON BOX HOUSING 2. THE HOLE CAN NOW BE CUT AT THE BACK OF THE TRACTOR TO ACCOMMODATE THE NEW FAST CHARGE BURTON PLUG. THE HOLE NEEDS TO BE APPROX. 3.75 INCHES BY 1.75 INCHES. CUT THE HOLE AS SHOWN IN THE ATTACHED ENGINEERING DRAWING WITH AN AN OXY-ACETYLENE TORCH. THIS WILL MAKE SURE THE CABLES WILL RUN SMOOTHLY FROM THE BURTON RECEPTACLE TO THE BATTERY CONNECTOR. GRIND OFF THE EDGE OF THE CUT ALL THE WAY AROUND SO THAT THE HOLE IS SMOOTH. THIS WILL ALLOW YOU TO PASS THE SBX PLUG THROUGHT THE PANEL. 3. FIT THE PIECE OF SHEATHING AROUND THE INSIDE OF THE 3.75x1.75 HOLE TO COVER ITS EDGES.
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SHEET 4 OF 9 BURTON BOX INSTALLATION 4. NOW INSTALLATION CAN BEGIN FOR THE YELLOW BURTON BOX (SUPPLIED IN RETROFIT KIT) THAT WILL HOUSE THE BURTON RECEPTACLE. TAKE THE EMPTY BOX IN HAND AND PLACE AS SHOWN BELOW, BEING CAREFUL TO MAKE THE SHIELD EDGE FLUSH WITH THE OUTSIDE OF THE REAR TRACTOR PLATE (MAKE SURE THERE IS AN EASY PATH FOR THE CABLES THROUGH THE NEWLY CUT HOLE). MARK THE FOUR (4) HOLE CENTERS WITH THE EMPTY BOX AND DRILL OUT THE HOLES WITH 3/8 DRILL. CONNECTING THE BURTON RECEPTACLE TO YELLOW BOX 5. PROVIDED IN THE KIT IS A SMALL HARNESS OF 4 COLORED WIRES. ON ONE END OF EACH WIRE IS A RING TERMINAL. ATTACH THESE WIRES VIA THE RING TERMINALS TO THE CORRECT TERMINALS ON THE BURTON RECEPTACLE (AEROVIROMENT WILL ASSIST WITH CORRECT WIRE PLACEMENT). 6. TIGHTEN DOWN THE TWO 2/0 CABLES ON THE BURTON RECEPTACLE IN THE ORIENTATION TO PASS THESE CABLES THROUGH THE REAR WALL OF THE TRUCK.
SHEET 5 OF 9 7. GET THE YELLOW BOX SUPPLIED IN RETROFIT KIT AND USING THE 4 SCREWS PROVIDED ATTACH THE BURTON RECEPTACLE WITH ATTACHED CABLING IN POSITION. SEE PICTURE BELOW. 8. RUN THE SBX PLUG AND ATTACHED BLACK CABLES AND FOUR (4) COLORED WIRES THROUGH THE NEWLY MADE 3.75x1.75 HOLE, LEAVING THEM LAYING ON THE MOTOR AND SET BOX OVER THE FOUR 3/8 DRILLED HOLES TO BOLT BOX DOWN WITH THE PROVIDED 5/16 1 BOLTS AND SPLIT WASHERS: CONNECTING THE RECEPTACLE TO BMID CONTROLLER 9. TAKE THE 4 #16 GAUGE WIRES AND PLUG THEM INTO THE 4-PIN FEMALE WEATHERPACK PLUG (PROVIDED IN THE KIT) IN THE ORDER AEROVIROMENT REQUIRES. CONNECT THIS PLUG TO THE 4-PIN MALE PLUG FROM THE BMID CONTROLLER (AEROVIROMENT TO SUPPLY).
SHEET 6 OF 9 REMOVAL OF OLD CHARGING SYSTEM 10. OPEN THE CONTROLLER PANEL BOX BY REMOVING BLACK PLASTIC COVER WITH SPECIAL TRIANGULAR KEY OR 11/32 SOCKET. 15 13 14 12 11 11. DISCONNECT THE BLUE CABLE (FROM THE CHARGING PLUG) FROM THE B- POST OF THE POWER PAK CONTROLLER. (SEE POINT 11 ABOVE) 12. DISCONNECT THE RED CABLE (FROM THE CHARGING PLUG) FROM THE CHARGING CONTACTOR + POST. (SEE POINT 12 ABOVE) 13. DISCONNECT THE BLACK/WHITE WIRE (FROM THE CHARGING SWITCH) FROM THE CHARGING CONTACTOR + POST. (SEE POINT 13 ABOVE) 14. DISCONNECT THE BLACK WIRE (FROM THE CHARGING SWITCH) FROM THE CHARGING CONTACTOR COIL TERMINAL. (SEE POINT 14 ABOVE)
SHEET 7 OF 9 15. MOVE THE RED CABLE, FROM THE BATTERY SIDE (+ MARKED SIDE) OF THE CHARGING CONTACTOR, TO THE OTHER SIDE OF THE CONTACTOR. THEREFORE THERE ARE NOW TWO CABLES ON ONE SIDE OF THE CHARGING CONTACTOR (SEE POINT 15 BELOW). 15 16 16. MOVE THE #001 MARKED WIRE FROM THE OUTSIDE TERMINAL OF THE MICRO SWITCH ON THE CHARGING CONTACTOR TO THE TERMINAL INSIDE IT. MOVE THE #119 MARKED WIRE FROM THE OUTSIDE TERMINAL ON THE SAME MICRO SWITCH TO THE TERMINAL JUST INSIDE IT. THESE WIRES ARE NOW ON THE NORMALLY CLOSED SIDE OF THE MICRO SWITCH. (SEE POINT 16 ABOVE).
SHEET 8 OF 9 17. REMOVE THE FOUR (4) SCREWS FROM THE CHARGING PLUG LOCATED AT THE REAR OF THE TRACTOR. INSTALL THE FOUR (4) SHORTER SCREWS INCLUDED IN THE KIT TO PLUG THE HOLES. CHARGING PLUG AND HARDWARE 18. REMOVE THE TWO (2) SCREWS FROM THE INTERLOCK SWITCH LOCATED AT THE REAR OF THE TRACTOR. INSTALL THE TWO (2) SCREWS REMOVED BACK INTO THE HOLES TO PLUG THEM. INTERLOCK SWITCH AND HARDWARE 19. REMOVE THE CHARGING PLUG / WIRES AND CHARGING SWITCH / WIRES FROM THE TRUCK. 20. BLOCK THE HOLE UP THAT THE WIRES PASSED THROUGH TO PREVENT WATER GETTING INTO THE CONTROL PANEL. 21. CHECK ALL CONNECTIONS IN THE CONTROLLER BOX TO MAKE SURE TIGHT. 22. CONNECT THE CONTROLLER SBX PLUG TO THE SBX PLUG THAT GOES TO THE BURTON PLUG
SHEET 9 OF 9 23. CLAMP CABLE (FROM THE SBX PLUG TO THE BURTON PLUG) TO REAR OF TRUCK USING THE CLAMP PROVIDED IN THE KIT. THIS SHOULD BE CLAMPED TO ALLOW BURTON PLUG TO BE PLUGGED INTO BURTON RECEPTACLE AND WHEN UNPLUGGED NOT HIT THE GROUND. THE CLAMP SHOULD ALSO ALLOW THE TRUCK S REAR LID TO SHUT CORRECTLY. 24. CONNECT THE BATTERY SBX PLUG TO THE SBX PLUG ATTACHED TO THE BURTON RECEPTACLE 25. FINALLY CONNECT THE BURTON PLUG TO RECEPTACLE. WARNING NOTE :- POWER IS NOW GOING TO THE CONTROL PANEL.