Thermo King Precedent™ Battery Charger and Supplemental Power Retrofit Kit Installation guide

Brand: Thermo King

Model: Precedent™ Battery Charger and Supplemental Power Retrofit Kit

Type: Installation guide

Rev. B

July 2023 TTKK 5555668811--1111--IIMM--EENN

Precedent™™ Battery Charger and Supplemental Power

Retrofit Kits

C-600, C-600M, S-600, S-700, S-600M and S–610M/DE

Installation Manual

Introduction

This installation manual was written to assist with the installation of the Thermo King Battery Charger and

Supplemental Power Package Retrofit Kits onto Precedent C-600, C-600M, S-600, S-700, S-600M and S-610/DE units.

Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact

your Thermo King dealer for available kits.

Due to its complexity, you should not attempt this installation unless you:

• Are an experienced mechanic

• Can safely lift 34 kilos (75 lbs.)

• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems

• Have a basic understanding of electricity and electrical wiring

• Have the necessary tools and equipment to complete the installation

This manual is published for informational purposes only. Thermo King makes no representations warranties express

or implied, with respect to the information recommendations and descriptions contained herein. Information provided

should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King

Corporation Service Department should be consulted.

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered

as, in the manufacturer’s judgment, to affect its integrity.

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct,

indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information,

recommendations or descriptions contained herein.

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TK 55681-11-IM-EN 3

AAvvaaiillaabbllee CCoonnvveerrssiioonn KKiittss ............................................................................................................................................ 44

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155 ............................................................................................ 55

SS––660000 && SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011220088 ++ AAlltteerrnnaattoorr 445522559911 .......................................................... 1111

SS––660000,, SS––661100MM//DDEE && SS––770000 MMooddeell 3300 -- AAlltteerrnnaattoorr 440011220099 ...................................................................... 1133

CC––660000,, SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100 ............................................................ 1155

SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100 ++ AAlltteerrnnaattoorr 445522559911 .............................. 2200

SS––660000,, SS––661100MM//DDEE && SS––770000 MMooddeell 5500 ((223300VV && 446600VV)) -- AAlltteerrnnaattoorr 440011334477 ...................................... 2222

SS––660000MM MMooddeell 3300 -- CChhaarrggeerr 440011226611 OOppttiioonnaall SSuupppplleemmeennttaall PPoowweerr .................................................. 2244

SS––660000MM MMooddeell 3300 -- AAlltteerrnnaattoorr 440011226622 ................................................................................................................ 3300

SS––660000MM,, SS--661100MM//DDEE MMooddeell 5500 -- ((223300VV OOnnllyy)) CChhaarrggeerr 440011226633 OOppttiioonnaall SSuupppplleemmeennttaall

PPoowweerr .. .. ............................ .. .......................... .. .............. .. ............................ .. .......................... .. .............. .. ............................ 3322

SS--661100MM MMooddeell 3300 -- CChhaarrggeerr 440011334488 .. ............ .. ............................ .. .......................... .. .............. .. ............................ 3377

CC––660000MM MMooddeell 3300 -- AAlltteerrnnaattoorr 440011334411 ................................................................................................................ 4444

CC––660000MM MMooddeell 5500 ((223300VV && 446600VV)) -- AAlltteerrnnaattoorr 440011334422 ................................................................................ 4466

SS––660000MM MMooddeell 5500 -- ((223300vv && 446600VV)) AAlltteerrnnaattoorr 440011226644 ................................................................................ 4488

RReeccoonnffiigguurriinngg tthhee SSRR44 CCoonnttrroolllleerr // TTrroouubbllee SShhoooottiinngg .............................................................................. 5500

LLiiffttggaattee CChhaarrggeerr WWiirriinngg RReeqquuiirreemmeennttss .................... .. ............................ .. ............................ .. ............................ 5511

Table of Contents

4TK 55681-11-IM-EN

Available Conversion Kits

Convert Alternator Unit to Battery Charger: Important: Liftgates or auxiliary items cannot be

wired to unit battery or any part of

transport refrigeration unit (TRU) when

battery charger is installed. You must

install the supplemental power

alternator package and wire liftgates

and auxiliary items to it.

Model BC Kit

C-600, S-600, S-700 Model 30 30A 401215*

C-600, S-600, S-700 Model 50 230V 30A 401210

S-600M Model 30 120A 401261

S-610M Model 30 120A 401348

S-600M, S-610M/DE Model 50 230V 120A 401263 Excite Harness Battery Cable Kits

C-600M 120A N/A 9 ft. 422188 45 ft. 401223

Any Model 50 460V N/A 60 ft. 422189 60 ft. 401224

Convert Alternator Unit to Battery Charger and add Supplemental Power Alternator:

Model BC and

Supp Alt

Kit + Alternator + Excite Harness + Battery cable Kit

C-600 Not

Setup**

S-600, S-700 Model 30 30A, 120A 401208 452591 & 422341 Excite Harness Battery Cable Kit

S-600, S-700 Model 50 230V 30A, 120A 01210 452591 & 422341 Excite Harness Battery Cable Kit

S-600, S-610M/DE Model 30 120A, 120A 401261 Reuse 120A from unit Excite Harness Battery Cable Kit

S-600, S-610M/DE Model 50 230V 30A, 120A 401263 Reuse 120A from unit Excite Harness

C-600M 120A, 65A

below

Standard with battery charger.

See chart below to add supplemental power

Any Model 50 460V N/A

** Kit has not been setup at this time by Aftermarket Engineering.

Add Supplemental Power Alternator to a Battery Charger Kit:

Model SPA Kit + Excite Harness + Battery cable Kit + Other

S-600, S-700, S-610M/DE Model

120A 401209 Excite Harness Battery Cable Kit *

S-600, S-700, S-610M/DE Model

50 230V or 460V 12 hp

120A 401347 Excite Harness Battery Cable Kit *

S-600, S-700, S-610M/DE Model

50 460V 19hp

120A 401347 Excite Harness Battery Cable Kit 781863 & 773085*

S-600 Model 30 120A 401262 Excite Harness Battery Cable Kit

S-600M Model 50 230V or 460V 12

120A 401264 Excite Harness Battery Cable Kit

S-600M Model 50 460V 19hp 120A 401264 Excite Harness Battery Cable Kit 781869 & 773103

C-600, C-600M Model 30 (65A

only)

65A 401341 Excite Harness Battery Cable Kit

C-600, C-600M model 50 230V

460V 12hp (65A only)

65A 401342 Excite Harness Battery Cable Kit

C-600, C-600M model 50 460V

19hp

65A 401342 Excite Harness Battery Cable Kit 781866 & 773085

* Customer selects correct belt from kit.

TK 55681-11-IM-EN 5

C–600, S–600, S–700 Model 30 - Charger 401215

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

RRiisskk ooff iinnjjuurryy iiff uunniitt ssttaarrttss wwhhiillee sseerrvviicciinngg.. TToo pprreevveenntt sseerriioouuss iinnjjuurryy oorr ddeeaatthh,, sswwiittcchh tthhee uunniitt ccoonnttrroollss ttoo tthhee

OOFFFF ppoossiittiioonn aanndd rreemmoovvee tthhee PPoossiittiivvee ((++)) bbaatttteerryy ccaabbllee ffrroomm tthhee uunniitt’’ss bbaatttteerryy.. DDiissccoonnnneecctt tthhee rreemmoottee ppoowweerr

ssuuppppllyy aatt iittss ssoouurrccee aanndd rreemmoovvee ppoowweerr ccaabbllee ffrroomm uunniitt ((iiff aapppplliiccaabbllee))..

IImmppoorrttaanntt:: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger

is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary

items to it. You may wish to also install an EON power pack wired to the supplemental alternator.

AAlltteerrnnaattoorr aanndd BBeelltt RReemmoovvaall

1. Open front curbside and roadside door panels.

2. Disconnect following alternator harness connections:

• 1-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((SSEENNSSEE,, EEXXCC))

• Terminal ring ((CCHHAA--0011))

• Terminal ring ((22AA--0011))

3. Loosen adjusting bolt for pulley tensioner.

4. Remove and discard belt.

5. Remove alternator bolts and alternator.

NNoottee:: Alternator will no longer be used.

NNeeww TTeennssiioonneerr PPuulllleeyy aanndd BBeelltt IInnssttaallllaattiioonn

6. Remove c-clip from center of tensioner.

• Slide smooth pulley off tensioner and discard.

7. Install new grooved pulley onto tensioner.

• Reinstall c-clip onto tensioner.

8. Install new belt and adjust to proper tension.

781875 — Belt S-600

781856 — Belt S-700

781858 — Belt C-600

6TK 55681-11-IM-EN

NEW TENSIONER PULLEY

& BELT

RCS1913

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155

TK 55681-11-IM-EN 7

AAlltteerrnnaattoorr HHaarrnneessss RReemmoovvaall

9. Open Control Box door and disconnect following alternator harness wires:

• Power wire ((22AA--0011)) from the 22AA stud on the SR-4 controller board.

• Alternator ground wire ((CCHHAA--0011)) from the ground stud on frame.

• 3-pin connector ((22YY--0022,, EEXXCC--0022)) from main harness.

• Carefully remove complete alternator harness from unit and discard.

CCuurrrreenntt SSeennssoorr RReemmoovvaall ((iiff eexxiissttss))

10. Open Blower and Fans Control Box door and disconnect 2- pin connector from current sensor.

• Remove sensor.

NNoottee:: The empty connector and sensor will no longer be needed.

RCS1916

2A-01

CHA-01

2Y-02, EXC-02

EVAPORATOR

FAN HIGH SPEED

EVAPORATOR

FAN LOW SPEED

CONDENSER

FAN CURB

CONDENSER

FAN ROAD

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155

8TK 55681-11-IM-EN

AAcccceessss ttoo BBaatttteerryy CChhaarrggeerr MMoouunnttiinngg SSttuuddss

11. Remove roadside door panel.

12. Remove 5 bolts securing door hinge bracket.

13. Remove 3 bolts holding battery charger box cover.

14. Remove cover to expose four studs on panel.

RCS1915

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155

TK 55681-11-IM-EN 9

LLooww VVoollttaaggee HHaarrnneessss IInnssttaallllaattiioonn

15. Inside the Control Box, connect the battery charger harness:

• 4-pin connector ((JJCCAANNHH--0011,, JJCCAANNLL--0011,, JJSSHH--0022,, JJCCHH--0011)) to JJ3333 on SR-4 controller board.

• Single power wire ((22LL--0011)) to 22AA stud on SR-4 controller board.

• 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) to mating connector ((22YY--0022,, EECCXX-- 0022)) from the main harness.

16. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on BBaatttteerryy

CChhaarrggeerr.

17. Remove the two screws from the charger cover, loosen connectors and install the following wires:

• Single wire ((CCHHBBAATT--0011)) along with ECU Power Harness (supplied loose in kit) wire ((BBAATT--GGNNDD--0011)) to

connection AA.

• ECU Power Harness single wire ((BBAATT--LLOOAADD--0011)) to connection BB.

• Single wire ((22BBCC--0022)) to connection CC.

• Reinstall cover, tighten screws and connectors.

BBaatttteerryy CChhaarrggeerr IInnssttaallllaattiioonn

18. Attach nameplate onto battery charger box cover.

19. Install a nylon washer onto each stud.

20. Install battery charger onto studs.

21. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely.

22. Connect the 2-pin connector ((BBAATT--LLOOAADD--0011,BBAATT--GGNNDD--0011)) to mating connector ((EECCUU//AALLTT)) from battery cable to

ECU unit.

23. Route the two ground wires to the unit ground plate located behind the control box and connect as follows:

• Single wire ((CCHHBBAATT--0011)) to ground plate 66 GGNNDD PPLLTT.

• Single wire ((CCHHBBCC--0011)) to ground plate 66 GGNNDD PPLLTT--0011.

24. Secure temperature sensor on frame member with a clamp.

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155

10 TK 55681-11-IM-EN

HHiigghh VVoollttaaggee BBaatttteerryy CChhaarrggeerr HHaarrnneessss IInnssttaallllaattiioonn

25. Route high voltage harness attached to battery charger to the BBlloowweerr aanndd FFaannss CCoonnttrrooll BBooxx.

26. Open cover and remove the blind grommet inside box. Install harness conduit fitting and nut securely.

27. Route and attach wires to the EEvvaappoorraattoorr FFaann HHiigghh SSppeeeedd contactor high voltage terminals on the bus bar:

• Attach one wire to LL11,LL22 and LL33.

NNoottee:: TThhee wwiirreess ccaann bbee ppuutt iinn aannyy oorrddeerr oonnttoo tthhee ccoonnttaaccttoorr ssiinnccee tthhee bbaatttteerryy cchhaarrggeerr rreeccttiiffiieess tthhee 33 pphhaassee,,

hhoowweevveerr tthhee ggrroouunndd wwiirree mmuusstt oonnllyy bbee aattttaacchheedd ttoo tthhee ggrroouunndd ssttuudd..

28. Attach ground wire (GGNNDD)) to ground stud inside box.

29. Close and secure the Control box and Blower and Fans Control box covers.

30. Reinstall door hinge brackets.

31. Reinstall roadside door panel.

32. Close and secure roadside and curbside doors.

PPrrooggrraammmmiinngg tthhee SSRR44 CCoonnttrroolllleerr

NNoottee:: See“RReeccoonnffiigguurriinngg tthhee SSRR44 CCoonnttrroolllleerr // TTrroouubbllee SShhoooottiinngg ,” p. 50 to complete the installation.

ABA877-1

EVAPORATOR

FAN HIGH SPEED

EVAPORATOR

FAN LOW SPEED

CONDENSER

FAN CURB

CONDENSER

FAN ROAD

GND

EVAPORATOR

FAN HIGH SPEED

EVAPORATOR

FAN LOW SPEED

CONDENSER

FAN CURB

CONDENSER

FAN ROAD

CC––660000,, SS––660000,, SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011221155

TK 55681-11-IM-EN 11

S–600 & S–700 Model 30 - Charger 401208 + Alternator

452591

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

ssuuppppllyy aatt iittss ssoouurrccee aanndd rreemmoovvee ppoowweerr ccaabbllee ffrroomm uunniitt ((iiff aapppplliiccaabbllee))..

IImmppoorrttaanntt:: DDiissccoonnnneecctt aannyy lliiffttggaattee oorr aauuxxiilliiaarryy iitteemmss ffrroomm tthhee uunniitt bbaatttteerryy oorr cchhaarrggiinngg ssyysstteemm aanndd rreewwiirree tthheemm

ttoo tthhee ssuupppplleemmeennttaall aalltteerrnnaattoorr.. FFaaiilluurree ttoo rreewwiirree wwiillll rreessuulltt iinn bbaatttteerryy cchhaarrggeerr ffaauulltt..

IMPORTANT Sense Harness (422188 or 422189) is required and must be ordered separately.

3377 oorr 6655 AAmmpp AAlltteerrnnaattoorr RReemmoovvaall

1. Open front curbside and roadside door panels.

2. Disconnect following alternator harness connections:

• 1-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((SSEENNSSEE,, EEXXCC))

• Terminal ring ((CCHHAA--0011))

• Terminal ring ((22AA--0011))

3. Loosen adjusting bolt for pulley tensioner.

4. Remove alternator bolts and alternator.

112200 AAmmpp AAlltteerrnnaattoorr IInnssttaallllaattiioonn

5. Remove pulley from existing alternator and reinstall onto 120 amp alternator.

• Tighten M16 nut to 61 N•m (45 ft-lb).

6. Install 120 amp alternator using the same mounting hardware:

• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).

• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).

• Reinstall belt and adjust to proper tension.

SSeennssee HHaarrnneessss IInnssttaallllaattiioonn

7. Attach 2-pin connector ((SSEENNSSEE,, EEXXCC)) onto alternator.

8. Route single ((EEXXCC)) wire into control box:

• Insert ((EEXXCC)) wire firmly into pin CC of 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) located on the battery charger harness installed

earlier.

• Attach 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) to the mating connector ((22YY--0022,, EEXXCC--0022)) located inside the control box.

9. Route single ((SSEENNSSEE) wire to accessory positive (+) battery power. DDOO NNOOTT ccoonnnneecctt tthhiiss ttoo uunniitt’’ss bbaatttteerryy..

IImmppoorrttaanntt:: CCoonnnneecctt SSEENNSSEE wwiirree ttoo tthhee cclloosseesstt aacccceessssoorryy bbaatttteerryy iiff uussiinngg mmuullttiippllee bbaatttteerriieess..

NNoottee:: AAddddiittiioonnaall kkiittss oorr iinnddiivviidduuaall ccoommppoonneennttss ((nnoott ssuupppplliieedd)) aarree rreeqquuiirreedd ttoo ccoommpplleettee lliiffttggaattee cchhaarrggeerr

aapppplliiccaattiioonnss.. CCoonnttaacctt yyoouurr TThheerrmmoo KKiinngg ddeeaalleerr ffoorr aavvaaiillaabbllee kkiittss.. SSeeee““LLiiffttggaattee CChhaarrggeerr WWiirriinngg

RReeqquuiirreemmeennttss ,,”” pp.. 5511 ..

NOTE: Follow the procedures on pages 7–10 to complete this installations.

12 TK 55681-11-IM-EN

SS––660000 && SS––770000 MMooddeell 3300 -- CChhaarrggeerr 440011220088 ++ AAlltteerrnnaattoorr 445522559911

TK 55681-11-IM-EN 13

S–600, S–610M/DE & S–700 Model 30 - Alternator

401209

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

ssuuppppllyy aatt iittss ssoouurrccee aanndd rreemmoovvee ppoowweerr ccaabbllee ffrroomm uunniitt ((iiff aapppplliiccaabbllee))..

ttoo tthhee ssuupppplleemmeennttaall aalltteerrnnaattoorr.. FFaaiilluurree ttoo rreewwiirree wwiillll rreessuulltt iinn bbaatttteerryy cchhaarrggeerr ffaauulltt..

IMPORTANT: Your unit must already be equipped with a Battery Charger to install the supplemental power package.

Sense Harness (422188 or 422189) is required and must be ordered separately.

112200 AAmmpp AAlltteerrnnaattoorr IInnssttaallllaattiioonn

1. Open front curbside and roadside door panels.

2. Loosen adjusting bolt for pulley tensioner.

3. Remove and discard belt.

4. Remove c-clip from center of tensioner.

• Slide ggrroooovveedd pulley off tensioner and discard.

5. Install new ssmmooootthh pulley onto tensioner.

• Reinstall c-clip onto tensioner.

6. Install supplied pulley from kit onto alternator.

• Tighten M16 nut to 61 N m (45 ft-lb).

7. Install alternator onto bracket with supplied hardware.

• Tighten M8 alternator bolts to 23 N m (17 ft-lb).

• Tighten M10 alternator bolts to 30 N m (22 ft-lb).

8. Install new belt and adjust to proper tension.

781876 — Belt S-600 / S-610M/DE

781857 — Belt S-700

SSeennssee HHaarrnneessss IInnssttaallllaattiioonn

9. Attach sense harness 2-pin connector ((SSEENNSSEE,, EEXXCC)) onto alternator.

10. Route single ((EEXXCC)) wire into control box:

• Insert ((EEXXCC)) wire firmly into pin CC of 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) located on the battery charger harness installed

earlier.

• Attach 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) to the mating connector ((22YY--0022,, EEXXCC--0022)) located inside the control box.

11. Route single ((SSEENNSSEE) wire to accessory positive (+) battery power. DDOO NNOOTT ccoonnnneecctt tthhiiss ttoo uunniitt’’ss bbaatttteerryy..

IImmppoorrttaanntt:: CCoonnnneecctt SSEENNSSEE wwiirree ttoo tthhee cclloosseesstt aacccceessssoorryy bbaatttteerryy iiff uussiinngg mmuullttiippllee bbaatttteerriieess..

NNoottee:: AAddddiittiioonnaall kkiittss oorr iinnddiivviidduuaall ccoommppoonneennttss ((nnoott ssuupppplliieedd)) aarree rreeqquuiirreedd ttoo ccoommpplleettee lliiffttggaattee cchhaarrggeerr

aapppplliiccaattiioonnss.. CCoonnttaacctt yyoouurr TThheerrmmoo KKiinngg ddeeaalleerr ffoorr aavvaaiillaabbllee kkiittss.. SSeeee““LLiiffttggaattee CChhaarrggeerr WWiirriinngg

RReeqquuiirreemmeennttss ,,”” pp.. 5511 ..

12. Secure all wiring with band wraps.

13. Close and secure all doors.

PPrrooggrraammmmiinngg tthhee SSRR44 CCoonnttrroolllleerr

See “RReeccoonnffiigguurriinngg tthhee SSRR44 CCoonnttrroolllleerr // TTrroouubbllee SShhoooottiinngg ,” p. 50 to complete the installation.

14 TK 55681-11-IM-EN

RCS1914

EXISTING TENSIONER

PULLEY & BELT

EXC

ALT. CONNECTOR

2Y-02,EXC-02

SS––660000,, SS––661100MM//DDEE && SS––770000 MMooddeell 3300 -- AAlltteerrnnaattoorr 440011220099

TK 55681-11-IM-EN 15

C–600, S–600 & S–700 Model 50 (230V Only) - Charger

401210

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

ssuuppppllyy aatt iittss ssoouurrccee aanndd rreemmoovvee ppoowweerr ccaabbllee ffrroomm uunniitt ((iiff aapppplliiccaabbllee))..

IImmppoorrttaanntt:: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger

is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary

items to it. You may wish to also install an EON power pack wired to the supplemental alternator.

AAlltteerrnnaattoorr aanndd BBeelltt RReemmoovvaall

1. Open front curbside and roadside door panels.

2. Disconnect following alternator harness connections:

• 1-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((SSEENNSSEE,, EEXXCC))

• Terminal ring ((CCHHAA--0011))

• Terminal ring ((22AA--0011))

3. Remove alternator belt.

4. Remove alternator bolts and alternator.

NNoottee:: Alternator will no longer be used.

RCS1917

16 TK 55681-11-IM-EN

AAlltteerrnnaattoorr HHaarrnneessss RReemmoovvaall

5. Open Control Box door and disconnect following alternator harness wires:

• Power wire ((22AA--0011)) from the 22AA stud on the SR-4 controller board.

• Alternator ground wire ((CCHHAA--0011)) from the ground stud on frame.

• 3-pin connector ((22YY--0022,, EEXXCC--0022)) from main harness.

• Carefully remove complete alternator harness from unit and discard.

CCuurrrreenntt SSeennssoorr RReemmoovvaall ((iiff eexxiissttss))

6. Open BBlloowweerr aanndd FFaannss CCoonnttrrooll BBooxx door and disconnect 2-pin connector from current sensor.

• Remove sensor.

NNoottee:: The empty connector and sensor will no longer be needed.

CC––660000,, SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100

TK 55681-11-IM-EN 17

AAcccceessss ttoo BBaatttteerryy CChhaarrggeerr MMoouunnttiinngg SSttuuddss

7. Remove roadside door panel.

8. Remove 5 bolts securing door hinge bracket.

9. Remove 3 bolts holding battery charger box cover.

10. Remove cover to expose four studs on panel.

LLooww VVoollttaaggee HHaarrnneessss IInnssttaallllaattiioonn

11. Inside the CCoonnttrrooll BBooxx, connect the battery charger harness:

• 4-pin connector ((JJCCAANNHH--0011,, JJCCAANNLL--0011,, JJSSHH--0022,, JJCCHH--0011)) to JJ3333 on SR-4 controller board.

• Single power wire ((22LL--0011)) to 22AA stud on controller board.

• 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) to mating connector ((22YY--0022,, EECCXX-- 0022)) from the main harness.

12. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on BBaatttteerryy

CChhaarrggeerr.

13. Remove the two screws from the charger cover, loosen connectors and install the following wires:

• Single wire ((CCHHBBAATT--0011)) along with ECU Power Harness (supplied loose in kit) wire ((BBAATT--GGNNDD--0011) to

connection AA.

• ECU Power Harness single wire ((BBAATT--LLOOAADD--0011) to connection BB.

• Single wire ((22BBCC--0022)) to connection CC.

• Reinstall cover, tighten screws and connectors.

BBaatttteerryy CChhaarrggeerr IInnssttaallllaattiioonn

14. Attach nameplate onto battery charger box cover.

15. Install a nylon washer onto each stud.

16. Install battery charger onto studs.

17. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely.

18. Connect the 2-pin connector ((BBAATT--LLOOAADD--0011,, BBAATT--GGNNDD--0011) to mating connector ((EECCUU//AALLTT)) from battery cable to

ECU unit.

19. Route the two ground wires to the unit ground plate located behind the control box and connect as follows:

• Single wire ((CCHHBBAATT--0011)) to ground plate 66 GGNNDD PPLLTT

• Single wire ((CCHHBBCC--0011) to ground plate 66 GGNNDD PPLLTT--0011

CC––660000,, SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100

18 TK 55681-11-IM-EN

20. Secure temperature sensor on frame member with a clamp.

HHiigghh VVoollttaaggee BBaatttteerryy CChhaarrggeerr HHaarrnneessss IInnssttaallllaattiioonn

21. Route high voltage harness attached to battery charger into the BBlloowweerr aanndd FFaannss CCoonnttrrooll BBooxx..

22. Open cover and remove the blind grommet inside box and install harness conduit fitting and nut securely.

23. Route and attach wires to the EEvvaappoorraattoorr FFaann HHiigghh SSppeeeedd contactor high voltage terminals on the bus bar:

• Attach one wire to LL11,LL22 and LL33.

NNoottee:: TThhee wwiirreess ccaann bbee ppuutt iinn aannyy oorrddeerr oonnttoo tthhee ccoonnttaaccttoorr ssiinnccee tthhee bbaatttteerryy cchhaarrggeerr rreeccttiiffiieess tthhee 33 pphhaassee,,

hhoowweevveerr tthhee ggrroouunndd wwiirree mmuusstt oonnllyy bbee aattttaacchheedd ttoo tthhee ggrroouunndd ssttuudd..

24. Attach ground wire (GGNNDD)) to ground stud inside box.

25. EEaarrllyy PPrroodduuccttiioonn UUnniittss OOnnllyy - Check fuse size and change if needed.

• Replace the 10 amp fuses with the 15 Amp fuses supplied.

26. Close and secure the Control box and Blower and Fans Control box covers.

27. Reinstall door hinge bracket.

28. Close and secure roadside and curbside doors.

PPrrooggrraammmmiinngg tthhee SSRR44 CCoonnttrroolllleerr..

See “RReeccoonnffiigguurriinngg tthhee SSRR44 CCoonnttrroolllleerr // TTrroouubbllee SShhoooottiinngg ,” p. 50 to complete the installation.

CC––660000,, SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100

TK 55681-11-IM-EN 19

ABA684-1

GND

New Fuses

230V UNITS

CC––660000,, SS––660000 && SS––770000 MMooddeell 5500 ((223300VV OOnnllyy)) -- CChhaarrggeerr 440011221100

20 TK 55681-11-IM-EN

S–600 & S–700 Model 50 (230V Only) - Charger 401210 +

Alternator 452591

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

ssuuppppllyy aatt iittss ssoouurrccee aanndd rreemmoovvee ppoowweerr ccaabbllee ffrroomm uunniitt ((iiff aapppplliiccaabbllee))..

ttoo tthhee ssuupppplleemmeennttaall aalltteerrnnaattoorr.. FFaaiilluurree ttoo rreewwiirree wwiillll rreessuulltt iinn bbaatttteerryy cchhaarrggeerr ffaauulltt..

3377 oorr 6655 AAmmpp AAlltteerrnnaattoorr RReemmoovvaall

1. Open front curbside and roadside door panels.

2. Disconnect following alternator harness connections:

• 1-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((WWRRPPMM--0022))

• 2-pin connector ((SSEENNSSEE,, EEXXCC))

• Terminal ring ((CCHHAA--0011))

• Terminal ring ((22AA--0011))

3. Remove alternator bolts and alternator.

112200 AAmmpp AAlltteerrnnaattoorr IInnssttaallllaattiioonn

4. Remove pulley from existing alternator and reinstall onto 120 amp alternator.

• Tighten M16 nut to 61 N•m (45 ft-lb)

5. Install 120 amp alternator using the same mounting hardware.

• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).

• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).

• Reinstall belt, adjust tension and tighten alternator bolts.

SSeennssee HHaarrnneessss IInnssttaallllaattiioonn

6. Attach 2-pin connector ((SSEENNSSEE,, EEXXCC)) onto alternator.

7. Route single ((EEXXCC)) wire into control box:

• Insert ((EEXXCC)) wire firmly into pin CC of 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) located on the battery charger harness installed

earlier.

• Attach 3-pin ((AALLTT.. CCOONNNNEECCTTOORR)) to the mating connector ((22YY--0022,, EEXXCC--0022)) located inside the control box.

8. Route single ((SSEENNSSEE) wire to accessory positive (+) battery power. DDOO NNOOTT ccoonnnneecctt tthhiiss ttoo uunniitt’’ss bbaatttteerryy.

IImmppoorrttaanntt:: CCoonnnneecctt SSEENNSSEE wwiirree ttoo tthhee cclloosseesstt aacccceessssoorryy bbaatttteerryy iiff uussiinngg mmuullttiippllee bbaatttteerriieess..

NNoottee:: AAddddiittiioonnaall kkiittss oorr iinnddiivviidduuaall ccoommppoonneennttss ((nnoott ssuupppplliieedd)) aarree rreeqquuiirreedd ttoo ccoommpplleettee lliiffttggaattee cchhaarrggeerr

aapppplliiccaattiioonnss.. CCoonnttaacctt yyoouurr TThheerrmmoo KKiinngg ddeeaalleerr ffoorr aavvaaiillaabbllee kkiittss.. SSeeee““LLiiffttggaattee CChhaarrggeerr WWiirriinngg