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SOLAR BOLT
INSTALLATION GUIDE
1
SOLAR BOLT CHARGING SYSTEM
INSTALLATION GUIDE
CONTENTS
General Information ........................................................................................................................... 2
Solar Panel Installation ...................................................................................................................... 3
Solar Bolt Main Harness and Indicate Installation .............................................................................. 4
Cable Routing .................................................................................................................................... 9
Solar Bolt Controller Installation ....................................................................................................... 10
Solar Bolt Indicate Battery Connections ........................................................................................... 13
Solar Panel Configurations .............................................................................................................. 16
Parts List .......................................................................................................................................... 19
Limited Commercial Warranty Policy ............................................................................................... 22
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SOLAR BOLT
INSTALLATION GUIDE
2
GENERAL INFORMATION
The Solar Bolt™ Charging System is a Pulse Width Modulated (PWM) charge controller with
automatic temperature compensation for up to 360 watt solar application. The Solar Bolt charge
controller utilizes patent pending technology that is designed to work in conjunction with the electrical
system on a vehicle or trailer. The Solar Bolt provides three-stage charging for the batteries when the
vehicle’s primary charging system is not active. It senses when the primary charging system is active
and matches the charge voltage. This enables the solar panel to deliver up to its full output capability
to the batteries when the vehicle is running. The module’s technology allows the Solar Bolt to provide
power to the electrical system of the vehicle, which reduces the electrical load on the alternator and,
in turn, reduces the mechanical load on the engine, thereby realizing fuel savings.
The Solar Bolt Indicate™ System is automatic and easy to interpret. LED indicators assure drivers
and technicians of proper system function by monitoring the source power (in this case the stinger
cord) and the liftgate batteries. The LED for the liftgate battery gives technicians and drivers a quick
indication of whether the liftgate batteries are ready for operation or if the batteries need
maintenance.
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SOLAR BOLT
INSTALLATION GUIDE
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SOLAR PANEL INSTALLATION
90 WATT PANEL INSTALLATION
1. Start by cleaning the trailer roof so the solar panel can properly adhere to the trailer.
2. Place the solar panel four inches from the side edge of the trailer and 24 inches from the front
edge of the trailer. This will leave sufficient room so that more panels can be added in the
future (see the Solar Panel Configurations section on page 16 for instructions on mounting
more than one panel). Figure 1
3. Peel the adhesive lining off the back of the panel and press firmly on the panel to ensure it
adheres to the trailer. Applying heat to the trailer top is recommended to help the adhesive
stick.
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SOLAR BOLT
INSTALLATION GUIDE
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SOLAR BOLT MAIN HARNESS AND INDICATE INSTALLATION
1. Connect the Solar Bolt main harness to the 90 watt solar panel. The solar connectors on the
main harness are already installed and ready to attach to the solar panel positive and negative
wires. Figure 2
2. Route the main harness along the front edge of the trailer and over to the right side of the
trailer. Secure the harness by using the supplied nylon clamps and #12 x ¾” hex tek screws.
IMPORTANT: Do not screw into the roof of the trailer. Make sure to screw into the
framing of the trailer to prevent water intrusion.
Figure 3
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SOLAR BOLT
INSTALLATION GUIDE
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3. Route the main harness over the front of the trailer and use the supplied E chain to protect the
cable. Secure the harness by using the supplied rubber washers and #12 x 1” roofing screws.
IMPORTANT: Do not screw into the roof of the trailer. Make sure to screw into the
framing of the trailer to prevent water intrusion.
Figure 4
4. Route the main harness down the trailer wall and secure it using the supplied nylon clamps
and #12 x ¾” hex tek screws.
IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed main
harness every 6 inches to ensure proper support for the cable. Avoid sharp edges and
possible chaffing points. Figure 5
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SOLAR BOLT
INSTALLATION GUIDE
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5. Mount the Solar Bolt Indicate at the front of the trailer via the mounting holes on the plate that
the controller is mounted to. Figure 6
6. Route the jacketed 2 conductor input harness of the Solar Bolt Indicate over to the dual pole
receptacle on the opposite side of the trailer. Ensure that it will reach the dual pole nose box
and cut off any excess cable.
IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed input
harness every 6 inches to ensure proper support for the cable. Avoid sharp edges and
possible chaffing points. Figure 7
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SOLAR BOLT
INSTALLATION GUIDE
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7. Remove the dual pole nose box from the trailer to access the connections inside. Remove the
2 dual pole bolts connecting the positive and negative cables to the receptacle. Route the 2
conductor Solar Bolt Indicate input harness into the dual pole nose and cut off any excess.
Apply ⅜” black heat shrink to the area where the jacketing was cut off to prevent water
intrusion. Figure 8
8. Crimp the supplied ¼” eyelet onto the black wire. Solder and heat shrink this connection.
Attach it to the negative side of the dual pole receptacle.
Figure 9
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SOLAR BOLT
INSTALLATION GUIDE
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9. Attach the supplied 2 amp inline fuse holder to the positive side of the dual pole receptacle.
Connect the opposite end of the 2 amp inline fuse holder to the red positive wire from the Solar
Bolt Indicate harness. Solder and heat shrink this connection. Secure the dual pole nose box
back onto the trailer when this step is complete.
Figure 10
10. Secure the Solar Bolt Indicate battery harness to the front of the trailer using the supplied
nylon clamps and #12 x ¾” hex tek screws.
IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed battery
harness every 6 inches to ensure proper support for the cable. Avoid sharp edges and
possible chaffing points. Figure 11
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SOLAR BOLT
INSTALLATION GUIDE
9
CABLE ROUTING
1. Route both the Solar Bolt Indicate and main harness back toward the liftgate batteries. Secure
with wire ties or cable clamps as you go.
IMPORTANT: Place the supplied cable clamps along the 2 conductor jacketed cables
every 18 inches to ensure proper support for the cable. Avoid sharp edges and possible
chaffing points. Figure 12
2. Once the cable is routed to the battery box, feed both the Solar Bolt main harness and the
Solar Indicate battery harness into the battery box through a dome nut or a grommet. DO NOT
cut the two harnesses until the mounting location for the Solar Bolt controller is determined.
Figure 13
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SOLAR BOLT
INSTALLATION GUIDE
10
SOLAR BOLT CONTROLLER INSTALLATION
1. Mount the Solar Bolt controller to the liftgate battery box by using the supplied #12 ¾” hex tek
screws. Figure 14
2. Determine the appropriate amount of cable needed to make the connections to the Solar Bolt
controller, then cut excess cable. Strip off jacketed insulation from the Solar Bolt main harness
to approximately 2 inches. Strip the insulation on both wires.
Figure 15
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SOLAR BOLT
INSTALLATION GUIDE
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3. Connect the blue wire from the Solar Bolt main harness to the wire on the Solar Bolt controller
labeled SOLAR POSITIVE. Solder and heat shrink.
Figure 16
4. Connect the white wire from the Solar Bolt main harness to the white wire located on the Solar
Bolt controller. Solder and heat shrink. Figure 17
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SOLAR BOLT
INSTALLATION GUIDE
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5. Connect the ground wire from the Solar Bolt controller to the liftgate battery negative terminal.
Figure 18
6. Connect the positive wire from the Solar Bolt controller to the liftgate battery positive terminal.
Figure 19
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SOLAR BOLT
INSTALLATION GUIDE
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SOLAR BOLT INDICATE BATTERY CONNECTIONS
1. Determine the appropriate amount of cable needed to reach the liftgate batteries, and cut off
the excess cable. Strip the outer jacket of the Solar Bolt Indicate battery harness to the
appropriate length so each wire can reach the liftgate batteries.
Figure 20
2. Apply the supplied ⅜ inch black heat shrink where the jacket was stripped off.
Figure 21
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SOLAR BOLT
INSTALLATION GUIDE
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5. Cut 4 inches off the red wire from the Indicate battery harness (the fuse holder adds length, so
if the red wire is not cut it will be longer than needed). Crimp supplied fuse holder to the red
wire of the Indicate harness. Solder and heat shrink.
Figure 24
6. Connect the fuse holder to the positive terminal of one of the liftgate batteries.
Figure 25
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SOLAR BOLT
INSTALLATION GUIDE
16
SOLAR PANEL CONFIGURATIONS
When adding additional panels, follow the following configuration instructions:
IMPORTANT: The first Solar Panel (90 Watt) should have been placed four inches from the
edge of the trailer (see the Solar Panel Installation section on page 3 for details on installing
the first panel).
180 Watt (2 Solar Panels)
1. Place the second solar panel no more than four inches away from the first solar panel.
2. Connect the supplied Solar Bolt Y Splitter input side to the Solar Bolt main harness (Positive-
Positive, Negative-Negative).
3. Connect the Solar Bolt Y Splitter outputs to the two solar panels (Positive-Positive, Negative-
Negative).
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.
Figure 26
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SOLAR BOLT
INSTALLATION GUIDE
17
270 Watt (3 Solar Panels)
1. Place the third panel no more than four inches away from the second solar panel.
2. Connect the second Solar Bolt Y Splitter input side to the longest output from the first Solar
Bolt Y Splitter (Positive-Positive, Negative-Negative).
3. Connect the outputs of the second Solar Bolt Y Splitter to the second and third solar panels.
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.
Figure 27
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SOLAR BOLT
INSTALLATION GUIDE
18
360 Watt (4 Solar Panels)
1. Place the fourth panel no more than four inches away from the third solar panel.
2. Connect the third Solar Bolt Y Splitter input side to the longest output of the second splitter
(Positive-Positive, Negative-Negative).
3. Connect the outputs of the third Solar Bolt Y Splitter to the third and fourth solar panels.
4. Clamp the Solar Bolt Y Splitter to the edge of the trailer.
Figure 28
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