[vidyanand]

DIY Quick Connector for Bosch C7 (and C3) Car Battery Charger

I needed an extra quick connector to charge my TVS Wego, which has limited use for local errands and would often get discharged by sitting idle. The battery is difficult to reach compared to a car. You need to unscrew 4 bolts to remove a panel and then pull out the battery to access the terminals to clamp. The quick connect harness for Bosch C7 would take care in avoiding this easily.



Although searching with the part did result in Amazon listing but was never available Bosch C75AC0 Quick Connect Cable Harness for C7 Battery Charger with Built-in Cable Fuse. I shot an email to Bosch customer service which was of no help. They redirected to check with local Bosch Car service center who never had this product. So eventually decided to go the DIY way as earlier suggested in the thread.

Items needed:

• XT60 connector pair - 1
  
  
• Electrical Wire Crimp Terminals Connectors 4-6 sqmm (this is same size as in the C7 charger) - 4
  
  
• 1.5 sqmm wires - needed length in pair
• Shrink Wrap
• Soldering Kit

I had all items available at home except the connectors. XT60 was ordered on amazon while the battery terminal was sourced from local electrical shop.

Task is simple, make two sets of the XT60 -to- Battery Terminal Connector. One with Male one and the other with Female XT60 connector. Pics to clarify.







One set needs to be attached to the C7 clamps.







Fix the other set to your car (or scooter ) battery terminals. I fixed in scooter and routed to the storage compartment for easy access. Shrink wrap/zip tie the cables together along the length as needed so that they do not move around. I made a small hole to let the cable in the compartment. Missed taking the battery terminal connected pic (will request mods to attach later when I access the battery in the future).





That is it. Just pop up the seat (hood in your car) and connect it to charge multiple vehicles as needed. Just add one set for each vehicle, making sure that the all vehicles must use the same connector end (Male or Female) while the C7 attached is opposite end. XT60 can be bought individually of all Male or all Female as needed.

Significant Pointers

• Can use any such easily available connector pairs, e.g. XT90 or other.
• The connector has +ve and -ve marking to make it easier. I used blue wire for negative and red for positive.
• Connector already soldered with wire are also available in case you want to skip soldering. Simple connect or crimp will ease the job.
• Battery Terminal ring that I used was perfect for the 12V battery in Wego. Do check for size if you car battery has bigger terminal bolts. I went with the ring size in C7 kit assuming this would work.
  
• This is not water proof at the connectors without a cap. One can choose a water proof connector set, if available.

To reduce risk, I kept the the connector with the cavity attached to C7 clamps while the one in scooter would not accumulate water. Additionally, I used a USB-A Terminal cap to mold as a cap in the scooter.


That's all folks, hope it helps since Bosch did not make this part available to buy for users with multiple vehicles to charge.

[Aditya]

DIY: Quick Connector for Bosch C7 (and C3) Car Battery Charger - Post copied to a new thread.

[Redex]

Like it. I have a bike smart charger and replaced the existing plug/socket connection with a feely available standard connector. This allowed me to make fly leads that are connected to the bike battery permanently with a socket as you have. I made up a lead for each bike and my boat. Now I can easily move the charger to any vehicle I have.
Most bike trickle chargers have a similar option for wired and clip connections. They differ in having a socket on the lead from the charger into which you can plug a pair of battery clips or a fly lead bolted to the bike battery. It removes the risk of shorting between the battery clips while using the plug/socket lead. The only problem is matching the manufacturers plug/socket if you want to make your own "adaptors/extensions" so I just replaced them with standard plug/sockets.

[jagdish_ker]

I was facing the same challenge last year and at last, ended up buying 2 additional cables from amazon.de as I am living in Europe. It wasn't the best solution as each additional cable cost me approx. 1/3 the cost of the whole charging kit back in India.

[Sedate]

Originally Posted by vidyanand

DIY Quick Connector for Bosch C7 (and C3) Car Battery Charger

Although searching with the part did result in Amazon listing but was never available Bosch C75AC0 Quick Connect Cable Harness for C7 Battery Charger with Built-in Cable Fuse. I shot an email to Bosch customer service which was of no help......

Items needed:

• XT60 connector pair - 1

I was planning to do the exact same thing for Suzuki swish that my father rarely uses. Once battery is down, getting the vehicle on to main stand requires a lot of effort and strength. One can only kick start when the vehicle is on main stand. It looks like a security feature, but the effort needed is high.

Is there an advantage in using XT60 connector? I was planning to use Anderson powerpole.

[vidyanand]

Originally Posted by Sedate

Is there an advantage in using XT60 connector? I was planning to use Anderson powerpole.

Any connector can be used. I did not have anything lying around in my house and XT60 or XT90 were the common ones used in Battery projects so I ordered XT60. Can be easily sourced if I decide to make multiple harnesses. I did see the 'Anderson Powerpole' connectors during the search but was not aware what is it called, now I know . I think this is better suitable without the worry to source Male or Female connector while creating new harness.

[Pferdestarke]

Originally Posted by vidyanand

The quick connect harness for Bosch C7 would take care in avoiding this easily.

Brilliant DIY! Just in time for someone like me who is trying to charge multiple vehicles.

I have few queries though:

1. The connectors need to be waterproof as we are leaving them open to elements. Is XT60 waterproof?

2. We need to cover the connector on vehicle end with a proper dust cap to avoid accidental shorting. I've searched for a dust cap for XT60 but couldn't find one. Help me find one if you come across any.

[bravo6]

You should really add a fuse close to one of the battery ring terminals.

I did a similar mod around the same time! The difference being I cut the stock cable between the charger and the connector, added a water proof connector, which then connects to a "bike harness" or a "car harness" for ease of use.



Here's the wiring scheme:

Top left: Bosch C3 charger ----> Water proof (WP) connector Female

Top Right (Car): WP connector Male ----> Fuse ----> Bosch Ring terminals ----> (not in picture) Bosch Crocodile Clips

Centre (Bike): WP connector Male ----> Stock Bosch connector ----> (not in picture) Stock Bosch connector w/ dust cap ----> Fuse ----> Ring terminals ----> Bike battery
The Bosch dust proof connector sits under my bike seat, permanently attached to the battery. No need to worry about corrosion, and more importantly no need to remove both seats to access the battery.

Originally Posted by Pferdestarke

1. The connectors need to be waterproof as we are leaving them open to elements. Is XT60 waterproof?

No. It will corrode over time.

I've searched for a dust cap for XT60 but couldn't find one. Help me find one if you come across any.

Just search for "waterproof automotive connector" on amazon and you'll find both uncrimped:


...and those with pigtails that you can solder directly to:


I had bought a 10 pack of the former to make a 12V cigarette port for bike to connect phone charger. I sealed off one half of the connector with M-seal, and used that as a dust/water proof cap. A slightly expensive and overkill solution, but total peace of mind. Absolutely no issues riding in rain/dust/mud and getting pressure washed.