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Inventory
Missing 18 bolts
Installing the Fans
Installing the Fans
Each of the fans was placed into the control box using 4 #8-32 x 1-1/2 machine screws with nylon insert nuts. We ran into an issue where we did not have the correct bolts but were able to continue by using bolts from our workshop.
Placing the Auxiliary Battery
Placing the Auxiliary Battery
The auxiliary battery was placed along the back of the control box. Using two 1/4"-20 x 4" bolts with flat washers and nylon bolts the battery is held down with a bright green bar to keep it in place.
Connecting the Fans and Relays
Connecting the Fans and Relays
We separated the orange and black wires, as well as the dual green and dual black wires, then placed them into the control box rail in blocks #11 and #23, and the dual black wire in #20.
Drive relays and DC to DC relays were connected into the control box rail in succession, with the drive relays being connected Drive Relay 85, white wire to #3, DR 86, black wire to #21, DR 87, red wire to #W with 30A fuse, and DR 30, blue wire to #A, fuse block source.
DC-DC-Relay 85, orange wire to #11, DC-DC-R 86, black wire to #21, DC-DC-R 87, green dual wire to converter, and DC-DC-R 30, red wire to #X, fuse block source.
Connecting the Auxiliary Battery
Connecting the Auxiliary Battery
The AuxBat was connected to the positive terminal using a red 10 AWG wire, and a black 10 AWG wire to connect to the negative terminal. Each terminal uses a M5 x .75 x 15mm bolt with a washer on either side and wire termination as well as a lock washer and nut to keep it together. The red wire (20") goes into fuse block Y and the black wire (16") goes into #24 on the control box rail.
It was a struggle to get some of the wires into the control box at first, but with practice it became much easier.
Connecting the Motor Cables
Connecting the Motor Cables
Our motor is the Netgain Hype 9, which uses three 1/0 AWG cables with 1/2" motor lugs. The cables were fed through the 1-1/4" fitting in the rear of the control box. Each of the terminations uses an M10 x 0.75mm x 40mm bolt, and a flat and split lock washer.
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