loading

I have been working on Bongo's/Freda's since 2007.
I fell in love with them and over the next 5 years or so, I had owned 3. Sadly I had to sell my last one due to personal reasons, but this has not stopped me helping many people.

I make up the split charge and circuit swap loom kits here at home. They are specifically made to measure and fit with the utmost ease to save you money. Lots of people buy the kits and don't have mechanical or electrical skills, but have fitted the kits themselves.
The kits are supplied with a hard copy of the instructions if required, but normally, I email the instructions so you always have them to hand. Also, this helps you to understand what you will be required to do to fit the kits.

Please don't hesitate to ask me any questions. I can be found at
www.bongoforum.co.uk , look for Rooster and send me a pm.
Your questions don't only need to be about SC or circuit swap loom kits, I have helped a lot of people with other electrical and some mechanical issues too.

Here are the fitting instructions to the Split Charge Kit.

Fitting of VSR Intelligent SC Kit

Before you commence, ensure the main battery negative is disconnected from the battery terminal for safety. Wrap it in a polythene bag to stop it accidentally reattaching while you work.

Remove the front part of the air scoop by unclipping the two mushroom clips in the front cross panel. Position the SCU (Split Charge Unit) onto the side of the air-box at the side of the LB (Leisure Battery) and fix in place with the two supplied screws. Ensure you do not foul any internal moving parts inside the air scoop.

You will need to remove the SCU now you have the correct position and fixing holes while you wire up the unit. It is easier to get the position with no cables attached.

See fig

If fitting a battery tray, fit the battery tray into position and at the same time fit the negative cable to a cleaned surface (wire brush)under a 6mm bolt (10mm head) on the n/s inner wing. Use the supplied 6mm bolt and look for an existing free thread in the panel. Coat in grease/Vaseline after fitting

See fig which is the circuit guide to the following instruction.

Position a midi fuse onto one of the midi fuse holders. Fit Cable ‘A’ to one terminal of the fuse holder and Cable ‘B’ to the other terminal. Nip up the nuts(8mm socket).

Fit the other end of cable ‘B’ to the SCU (MAIN-Red Dot -Terminal) you will require a 13mm spanner for this.

Fit one end of cable ‘C’ to the SCU. (Aux Terminal, 13mm)

Position the other midi fuse onto the remaining holder and fit Cable ‘C’ and fit Cable ‘D’ using the same method as you have fitted the first fuse holder.

Now refit the SCU onto the side of the air box. Fit the end of Cable ‘D’ to the Leisure battery Positive Terminal, If fitting a circuit swap loom, now is a good time to fit the feed cable to the small fuse box

Note! Do not over tighten the post bolts when fitting the main cables to the battery. Nip gently until there is no movement from side to side of the cables. Use the 8mm star washers (4 supplied) one on the terminal bolt, then one before fitting the nut.

Affix the thin black wire from the SCU to a clean earth point and coat in grease/Vaseline to protect from damp. There are some 10mm headed bolts on the bulk head that can be used (extend the wire if necessary using a good crimp or solder method)

You can now fit the remaining eyelet on cable ‘A’ to the Main Battery Positive Terminal.

Cable tie the fuse holders to the battery clamp on the Main Battery and either the battery clamp or battery carrying handle on the Leisure Battery

After making sure all connections are tight, close the lids on the fuse holders and tie up the Main Cable that runs from the Main Battery to the SCU with cable ties.

Once you have completed the installation. Re-attach the negative terminals to both batteries. Grease/Vaseline all battery terminals.

TESTING

To test the SCU is working correctly, check the voltage on the LB. This should be around 12v if it is charged.

Start the engine and you should be able to see the voltage on the LB is now around 13.8v, this is nominal charging voltage, it may go up to around 14.7v if the LB is low on charge, this is normal.

1 x Intelligent (VSR) Durite Split Charge Unit

4 x 110a Battery Cables

2 x 80amp midi fuses

2 x midi fuse holders

2 x battery terminal post clamps - positive & negative (Note: The positive clamp diameter is larger than the negative, do not mix these up)

Cable ties

Please note, photographs and drawings are not to scale and are a guide only.

Step 1:

About This Instructable

600views

2favorites

License:

More by rooster_uk:Mazda Bongo Ford Freda Split Charge & circuit swap looms 
Add instructable to: