2nd Gen Revel 3rd Battery Install

Remove battery ground disconnect access cover to expose battery ground disconnect

Depress the red tab on the battery ground disconnect, and pull to remove from ground stud

Remove the fuse panel cover from the driver side seat base to expose fuse panel

Locate and remove fuse #32

Turn the solar disconnect knob located on the control panel to the "OFF" position.

Locate the battery compartment in the driver's side rear of the van.

Turn the locking knobs to release the battery compartment cover.

Lift and remove cover.

Locate the "ON/OFF" switch on the batteries.

Depress and hold the button for 5 seconds until the blue LED on the battery ON/OFF switch goes off. Do this for each battery.

If the LED light does not go off, depress and hold the ON/OFF button again for 5 seconds.

Ensure ALL batteries are off.

If equipped with a 3rd battery, the ON/OFF switch will be located on the front left corner of the battery. Depress for 5 seconds to turn the battery off.

Remove the screws securing the screen to the battery compartment using a #2 Phillips bit.

Once all the screws are removed, set the screen over the door hinge to keep it out of the way

Using a pick tool, remove all the screw cover caps on the bottom and sides of the battery compartment cover.

Once all the caps are removed, use a #2 Phillips bit to remove all the screws. Set the screws aside.

Locate the 3 screws on the top of the battery compartment cover.

Use a #2 Phillips bit to remove the 3 screws. Set the screws aside.

Cut the velcro for the rear screen where the battery compartment cover meets the upper wall panel.

Remove the 4 screws securing the inverter disconnect switch to the battery compartment cover using a #2 Phillips bit.

Use a 15mm socket and wrench to remove the cables on the back of the inverter disconnect switch. Mark the wires if needed.

Set the battery disconnect switch and associated hardware aside.

Remove the 120v outlet cover using a pick tool.

Using a #2 Phillips bit, loosen the two screws securing the 120v outlet to the battery compartment panel.

Fold the white tabs of the outlet flat.

With the white tabs flat, slide the outlet back into the opening as shown. This will allow the battery compartment cover to be moved further out of the way.

Locate the battery heater temp sensor. If it is secured to the battery cables, but the zip ties securing it to the battery cables.

Remove the CAN connector on each battery.

There is a lock on CAN connector. Unscrew the collar, then lift up on the connector to unseat it. Then continue unscrewing the collar until the CAN connector is free.

Remove the nuts on the battery hold down using a 13mm socket and wrench. Set the hardware and hold down aside.

Do this for both batteries.

Locate the 2 Anderson connectors for the battery cables on the back wall of the battery compartment.

Pull the connector apart to separate them.

Locate the harness and connectors for the battery heaters.

Lift up on the locking tab on the connector, and pull to separate the connector.

Lift and remove the batteries (with the cables attached) out from the compartment. Set the batteries aside.

Now is a good time to inspect the shelf the batteries rest on. We have found a lot of them to be loose. Shake the shelf to see if is loose.

If the shelf is loose, proceed to the next step on how to re-secure the shelf.

In most cases the screws securing the shelf are stripped. Mark new screw positions next to the holes already in the shelf. Do this for all the mounting points on the shelf.

Install the provided self drilling screws to secure the battery shelf to the van.

Mark the side of the storage compartment metal box for the hole location. This is the left hand side of the box, if you are facing the box.

The measurements for the hole are 4.5" from the rear of the box, and 1-3/8" down from the top of the box.

Drill the hole using a 1.5" hole saw.

Using a deburring tool, deburr the hole to remove any sharp edges.

Install the provided grommet into the hole.

Clean up any metal shavings in the van using a vacuum cleaner.

Locate the black metal shield covering the buss bars for the battery cables.

Remove the 2 screws securing the shield to the battery compartment using a stubby #2 Phillips screwdriver. There is 1 screw on each side.

Remove the shield, and set aside.

Remove the covers for both the positive and negative buss bars to expose the cables.

Remove the nut securing the positive (red) battery cables from the buss bar using a 17mm socket and wrench. Remove the 2 cables from the buss bar.

Remove the nut securing the negative (black) battery cables from the buss bar using a 17mm socket and wrench. Remove the 2 cables from the buss bar.

The battery cables that are referenced above are the 2 gauge wires that run to the Anderson connectors to which the batteries themselves connect to.

Remove the screws securing the Anderson cables to the rear tray wall.

Discard the Anderson cables as we will not be reusing them.

Use a 3/16" Hex Security Bit to remove the bolts securing the wires to the two stock batteries.

Take care to not strip the head of the bolts. The factory uses red loctite to secure the bolts. If the head of the bolt strips, you may have to use vice grips to remove, or use a grinder to cut a slot into the bolt head and use a flat head screw driver to remove.

Once you have the bolts removed, you slide off the battery terminal protection boots. We will reuse them.

Discard the battery cables as we will not be reusing them.

Locate the the 3 positive wires provided in the kit. One side of the cables will have a larger diameter hole in the lug than the others. That is the side of the cable we will be attaching to the positive bus bar.

Note the orientation of the cable lug end in the video. The offset side of the lug will face the rear of the compartment. This will ensure the cables seat properly on the bus bar.

Install the 3 new cables onto the bus bar, and install the lock washer and the nut. Tighten the nut until snug. Check the other nuts on the bus bar to ensure they are secure as well.

Check to make sure the lugs are flat against each other and the bus bar. You may have to slightly rotate the lug ends to get them to seat flush each other.

Locate the the 3 negative wires provided in the kit. One side of the cables will have a larger diameter hole in the lug than the others. That is the side of the cable we will be attaching to the positive bus bar.

Note the orientation of the cable lug end in the video. The offset side of the lug will face the rear of the compartment. This will ensure the cables seat properly on the bus bar.

Install the 3 new cables onto the bus bar, and install the lock washer and the nut. Tighten the nut until snug. Check the other nuts on the bus bar to ensure they are secure as well.

Check to make sure the lugs are flat against each other and the bus bar. You may have to slightly rotate the lug ends to get them to seat flush each other.

After you have the cables secure, and you have checked the other nuts on both bus bars, reinstall the plastic bus bar covers.

You can then reinstall the metal cover plate that goes over the bus bars that we previously removed

Route the cables for the lower battery down to the compartment. We like to use the first set of cables installed onto the bus bar for the lower battery.

Feed the wires into the hole with the grommet previously drilled into the lower storage box.

It is very important you make sure the grommet did not get pulled or pushed out of the hole when you are feeding the wires. The grommet MUST be in properly installed, otherwise chaffing could happen.

Use two of the small P Clamps to secure the lower battery cables as shown. We want the one on the shelf to be upside down so it will have the wires make a nice sweep into the grommet. We do not want a tight bend on the cables going into the grommet.

Route the remaining upper battery cables as shown, and use the provided clamps to secure the wires to the rear wall of the compartment.

Note how the front battery (towards the front of the van) NEGATIVE cable is left out of the most rearward clamp. This is to allow enough room for the cable to reach the negative terminal of the front battery.

We want the cables to be neatly routed and well secured, higher up in the compartment like is shown in the video. We want to ensure the cables will not interfere with the batteries, hold downs, or any other item the cables can chafe on.

Note how the single larger P Clamp is used at the top of the loop of cables, to secure all 4. (the two positive cables, and the two negative cables.)

Take your time routing the cables to ensure the cables are routed properly and are neatly routed.

Locate the provided 3rd battery tray, strap, battery lug boots (red and black), and hardware in the kit.

Position the battery tie down strap as shown. The buckle end should be approx. 3" from the cut out on the tray.

With the tray placed in the compartment and centered, secure the rear tab of the battery tray to the back wall wall of the compartment using the 2 small self drilling screws provided using a #2 Phillips bit. Ensure the strap is not pierced by the screws.

After the rear two screws are secured, ensure the buckle is 3" out form the cut out. This will ensure the battery strap secures the battery properly.

Use the 6 provided screws to secure the base of the battery tray to the floor using a #2 Phillips bit.

If the battery strap buckle is too close to the tray, you can pull it out at this time. If the strap is tight, you may need to loosen the screws to allow the strap to be adjusted.

The provided hardware may be slightly different than what is shown in the image.

Gently pull the plastic battery compartment panel away and secure using a bungee cord or strap. This will help provided the necessary room to slide the 3rd battery in place.

Take great care moving the plastic panel. It is extremely fragile and easily damaged!

Slide the battery between the battery compartment and the plastic panel, in the orientation shown. The ON/OFF switch should be in the front left corner of the battery, if you are facing the battery.

Once the battery is slid in front of the battery compartment, install the provided battery terminal protector boots onto the wires.

Do not slide the battery into the compartment at this time. It is much easier to connect the battery cables with the battery outside of the compartment.

Ensure the battery is off, and was not accidentally powered on when sliding the battery into place. If the battery was accidentally turned on during handling, depress the ON/OFF button for 5 seconds until the blue LED light shuts off.

Before sliding the battery into the battery compartment, connect the battery cables to their respective terminals on the battery.

Connect the red wire to the positive terminal on the battery. Tighten the bolt using a 13mm socket and wrench.

Connect the black wire to the negative terminal on the battery. Tighten the bolt using a 13mm socket and wrench.

Slide the protective boots onto the battery terminals.

With the cables secured to the battery terminals and the protective boots installed, install one of the provided zip ties on each protective boot. This will prevent the boot from sliding off, and exposing the battery terminal. Cut the tails off the zip ties once secured.

Take the Velcro strap and route it over the top of the battery. Slide the battery into the compartment.

With the battery slid all the way into the back of the cabinet, take the Velcro strap and secure the battery to the battery tray. Ensure the Velcro strap is pulled tight, and the battery is secured.

Place the two original batteries back into place, and secure using the hardware previously removed. Take care as to not over tighten the clamping bar that goes over the top of the batteries, as we do not want to crush the battery. The clamping bar needs to be secure, but not so much they are damaging the battery,

Slide the protective boots previously removed from the original cables, and slide them onto their respective cables. (red to red, black to black)

Install one set of wires onto the rear battery, and one set onto the front battery. Install the provided hardware to secure the cable lugs to the battery terminals. The order of the hardware is as follows: Bolt, Lock Washer, Flat Washer.

Tighten the bolt using a 13mm socket and wrench. Make sure the bolts are snug, but not over tightened.

For the rear most battery, ensure the battery heater wires run behind the battery hold down bolts.

Make sure the batteries are OFF and did not get accidentally powered on during handling.

Reconnect the battery heater harness, and tuck the excess along the side of the front battery.

Reinstall the battery heater temp. sensor onto the battery cable.

Reconnect the CAN connector on the two original batteries. The CAN connector needs to be lined up and oriented correctly to seat properly into the battery. Once seated, tighten the collar on the CAN connector to secure to the battery.

Connection showed with the battery on a bench for clarity purposes.

There is not a CAN connection for the 3rd battery. Only the 2 original upper batteries.

Reinstall the inverter disconnect wires back onto the disconnect switch. Tighten using a 15mm socket and wrench.

Reinstall the inverter disconnect switch back into the panel using the 4 screws previously removed.

Slide the 120v out back through the opening in the plastic battery compartment cover.

Tighten the screws to secure the outlet in the opening.

Reinstall the outlet cover by snapping it into place.

Place the plastic battery compartment panel back into place.

Secure the panel using the screws previously removed, and reinstall the plastic screw cap covers.

Reinstall the 3 screws removed previously on the top of the panel.

Reinstall the screen into place, an secure using the screws removed previously.

Press the ON/OFF button on each battery to turn them on. The blue LED should illuminate when the battery is powered on.

If equipped with a 3rd battery, ensure to power on that battery as well.

Reinstall the battery compartment cover.

Turn the solar disconnect knob to the "ON" position on the control panel.

Place the battery disconnect terminal back onto the ground stud.

Push the battery disconnect terminal onto the stud until it clicks. Give the terminal a tug to ensure it is fully seated.

Reinstall fuse #32

Reinstall the battery disconnect access cover.