Dual battery system
- plus -
Redarc DC-DC Charger
Step 1: Remove the original batteries and parallel wiring
- Remove the trim cover by pushing down on the centre of each retaining clip, then lifting the clips out.
- Disconnect the negative/earth terminal clamp from each battery and secure the cables to prevent them touching the battery terminals.
- Disconnect the positive terminal clamp from each battery
- Disconnect the heavy cable joining the positive terminal clamp of each battery, and remove the cable. It won't be reused.
- Remove the battery retaining clamps and remove each battery from the vehicle.
- If you break/lose any of the clips, the correct ones are here.
Step 2: Wire the DC-DC charger
Cut and attach the following cables to wire the charger:
- 8mm2 (8AWG) cable to run from the charger's RED wire to the starting battery (left side of the vehicle). Join to the charger with a heavy crimp & solder joiner. Crimp/solder one of the 6mm eye terminals included with the FK40 fuse kit to the other end.
- 8mm2 (8AWG) cable to run from the charger's BROWN wire to the auxiliary battery (right side of the vehicle). Join to the charger with a heavy crimp & solder joiner. Crimp/solder one of the 6mm eye terminals included with the FK40 fuse kit to the other end.
- Crimp & solder a heavy 6mm eye terminal to the charger's BLACK wire.
- If you have solar panels, connect the YELLOW wire from the Redarc charger to the positive output from the panel(s). If you don't have solar panels, secure the yellow cable and tape the end of it. I'm attaching mine to a 50A Anderson plug (along with another earth cable) for ease of future use. WARNING: Solar panels produce DC power even in shade and can cause electrocution. Cover panels from light and use extreme caution when wiring solar panels.
- The BLUE, GREEN and ORANGE wires are not required for my installation, so I am cutting them off to slightly different lengths, then encasing them in heat-shrink tube. Check the Redarc manual to verify if you need to use these wires for your vehicle and/or auxiliary battery type.
- Create two small loops of 8mm2 cable (around 100mm in length). On one end of each, crimp/solder one of the 6mm eye terminals included in the FK40 kit. On the other end of each, crimp/solder an 8mm eye terminal.
- Cover all joins and terminal points with heat shrink tubing. 10mm is the size you'll need.
- Cover all cables with split tubing. You'll need 7mm to run the single cables over to the batteries, and 10mm for multiple cables, such as for the solar anderson plug.
Step 3: Install the DC-DC charger
- Install the charger into the Long Ranger bracket using the supplied 4x screws and nyloc nuts supplied.See photo for correct orientation.
- Remove the factory bolt adjacent to the bonnet latch (10mm head), and the bolt retaining the horn (12mm head). See photo to identify the correct bolts.
- Sit the charger on top of the radiator support panel, and run the cables over to the starting and auxiliary batteries.
- Lower the charger down into the gap between the grille and radiator.
- Using the M6x20mm bolt and washer supplied with the bracket, loosely attach the lower mounting point of the charger bracket to the captive nut in the vertical support. I am also using this bolt to attach the earth terminals for the charger and the solar anderson plug.
- Attach the top two mounting points using the two bolts removed earlier. Don't forget to reattach the horn! When all the bolts are loosely fitted, you can tighten all of them.
- Secure the cabling with cable ties to prevent chafing/shorts.
Step 4: Install the new batteries and complete the wiring
- Place the new accessory/deep cycle battery on the right (driver) side of the vehicle.
- Place the new starting battery on the left (passenger) side of the vehicle.
- Fit and tighten the factory retaining brackets for each battery,
- Attach the wires from the charger to one side of the each fuse holder, and run one of the small loops from the other side of each fuse holder to the positive terminals of each battery. Attach the rest of the positive battery connections.
- Make all the negative battery terminal connections.
- Start the vehicle and verify the operation of accessories and the Redarc DC-DC charger.
Step 5: Cut and refit the trim panel
- Cut and attach the template supplied with the charger bracket to the trim panel.
- Drill out two 12mm holes as shown on the template. I drilled two smaller pilot holes first.
- Join the two holes to create the viewing window.
- Refit the trim panel to the vehicle and secure with 7 factory clips.
- If you break or lose any of the trim clips, you can find the correct ones here.