Service manual

2
Calibrating Comments
The text below describes our implementation, based on the Korthof design. We made a number of choices along the
way that may or may not be consistent with your personal preferences and charging needs. Most parts of our
procedure may be modified, with a few notable exceptions. Where something must be implemented exactly as specified,
it is so indicated.
While there appear to be a lot of steps below, and this document appears large, the procedure described can be
accomplished in a few hours if you have the proper tools and have collected all of the necessary parts beforehand.
Parts List
To complete the installation, you will need the following:
Manzanita Micro PFC-50 charger, available from http://www.manzanitamicro.com
RAV4Info interface, from [e-mail] (for monitoring battery temperatures and voltages).
Two GE circuit breakers part number EP100UC/EP102UCC63/673332, from http://livewiresupply.com
One Anderson SB175 connector from http://www.powerwerx.com
One 50A 240VAC weatherproof marine connector, part number 860010, from http://consumersmarine.com
One mating connector, part number 860018, from http://consumersmarine.com
One cover for mating connector, part number 860031, from http://consumersmarine.com
Your own extension cord (at least #8AWG is recommended) to connect to your power source.
30 feet of #8/0 AWG 600 volt wire with red insulator from any electrical store or Home Depot.
30 feet of #8/0 AWG 600 volt wire with black insulator
25 feet of flexible ½ inch diameter weatherproof conduit. Available at electrical supplies, Home Depot, or see
http://www.anacondasealtite.com/products.htm#Sealtite%AE%20Metallic%20Flexible%20Conduit%A0
5 conduit straps with self-tapping screws
One 14/50 surface mount range receptacle from an electrical supply or Home Depot
3 feet of #4/3 AWG 300 volt or better rated stranded cable
10 feet of quarter-inch wire protector
An exacto knife or sturdy box cutter with a sharp blade
Two #8 eye terminals for connecting #8 AWG wire to a bolt terminal
A tube of silicon seal
A dozen cable ties
5 feet of electrical solder
A roll of electrical tape
Required Tools
A torx wrench for opening the RAV4-EV’s electronics compartment, drill with metal-cutting bits, metric socket set with
socket extension, electrician’s pliers for cutting and splicing wire, small propane torch for soldering, and Phillips and
straight-head screw drivers.