BACKGROUND
The post is in two parts. Part 1 talks about the Littelfuse busbars in general terms. Part 2 does a deep dive into how INEOS has used the busbars in a 2023 AU Spec Trialmaster fitted with the High Load Auxiliary Switch Panel option and front winch.
PART 1 - LITTELFUSE BUSBARS OVERVIEW
Information about the 7 stud (main battery) and 5 stud (aux battery) busbars used in the INEOS is spread all over the forum. I will centralise a summary here. Feel free to add your own information.
All IG models have the 7 stud busbar. Models with the aux power option also have a 5 stud version. The busbars look like this (the first image has no fuses installed):
DETAILED INSTRUCTION MANUAL FROM LITTELFUSE ON THE FHZ
Littelfuse Manuals can be found here, here and especially here. The third link is to the very informative instruction sheet.
In summary some of the main features are: Max Main Input of the busbar is 400 amps. Maximum amps 600 amps, but only 400 amps continuous. Available fuses are 40 to 600 amps, but maximum fuse rating used by the Grenadier is 350 amps.
STUDS USED IN FHZ HOLDER
The FHZ busbars can have an M6, M8 or M10 stud in a slot.
A busbar can have only one size stud or all three (M6, M8 and M10) at the same time. The stud size used depends on the rated circuit needed. You must check what studs are used in any busbar fitted to your Grenadier.
TORQUES SETTINGS FOR FHZ STUDS
Tip: I would torque to the specific figure given, and then the range helps cover any variation in the accuracy of your torque wrench. For example, 14Nm for the M8 stud.
SOURCE OF FHZ BUSBARS
Australia
If you wish to buy a spare 5 stud FHZ busbar for remote travel, you can buy them from Swe-Check here. It only comes with M8 studs in the spare slots.
Europe
Try Mouser here, you need to searc more you go to that link. Mouser also has M6 studs, but not M8 or M10 studs for sale (Source @Tinki here.)
Other countries
Start your search here.
MOUNTING HOLES ON THE FHZ FUSE HOLDER
The mounting holes on the four corners of the FHZ busbar are for M8 bolts (Source: Point 3 on page 2 of the FHZ Instruction Sheet.
ZCASE MEGA FUSES USED IN FHZ BUSBAR
The FHZ busbars use a fuse known as a ZCASE MEGA fuse, or MEGA ZCASE fuse or even sometimes called a battery fuse.
See the fuse thread for a further discussion of ZCASE MEGA fuses.
SOURCE OF ZCASE MAGE FUSES
Australia
Australian owners can buy ZCASE MEGA fuses from Swe-Check here. You need to select the fuse rating for a given circuit by looking at what is in your INEOS. ZCASE MEGA fuses are expensive.
Europe
Try Mouser here.
Other countries
Start your search here.
The post is in two parts. Part 1 talks about the Littelfuse busbars in general terms. Part 2 does a deep dive into how INEOS has used the busbars in a 2023 AU Spec Trialmaster fitted with the High Load Auxiliary Switch Panel option and front winch.
PART 1 - LITTELFUSE BUSBARS OVERVIEW
Information about the 7 stud (main battery) and 5 stud (aux battery) busbars used in the INEOS is spread all over the forum. I will centralise a summary here. Feel free to add your own information.
All IG models have the 7 stud busbar. Models with the aux power option also have a 5 stud version. The busbars look like this (the first image has no fuses installed):
DETAILED INSTRUCTION MANUAL FROM LITTELFUSE ON THE FHZ
Littelfuse Manuals can be found here, here and especially here. The third link is to the very informative instruction sheet.
In summary some of the main features are: Max Main Input of the busbar is 400 amps. Maximum amps 600 amps, but only 400 amps continuous. Available fuses are 40 to 600 amps, but maximum fuse rating used by the Grenadier is 350 amps.
STUDS USED IN FHZ HOLDER
The FHZ busbars can have an M6, M8 or M10 stud in a slot.
A busbar can have only one size stud or all three (M6, M8 and M10) at the same time. The stud size used depends on the rated circuit needed. You must check what studs are used in any busbar fitted to your Grenadier.
TORQUES SETTINGS FOR FHZ STUDS
Tip: I would torque to the specific figure given, and then the range helps cover any variation in the accuracy of your torque wrench. For example, 14Nm for the M8 stud.
SOURCE OF FHZ BUSBARS
Australia
If you wish to buy a spare 5 stud FHZ busbar for remote travel, you can buy them from Swe-Check here. It only comes with M8 studs in the spare slots.
Europe
Try Mouser here, you need to searc more you go to that link. Mouser also has M6 studs, but not M8 or M10 studs for sale (Source @Tinki here.)
Other countries
Start your search here.
MOUNTING HOLES ON THE FHZ FUSE HOLDER
The mounting holes on the four corners of the FHZ busbar are for M8 bolts (Source: Point 3 on page 2 of the FHZ Instruction Sheet.
ZCASE MEGA FUSES USED IN FHZ BUSBAR
The FHZ busbars use a fuse known as a ZCASE MEGA fuse, or MEGA ZCASE fuse or even sometimes called a battery fuse.
See the fuse thread for a further discussion of ZCASE MEGA fuses.
SOURCE OF ZCASE MAGE FUSES
Australia
Australian owners can buy ZCASE MEGA fuses from Swe-Check here. You need to select the fuse rating for a given circuit by looking at what is in your INEOS. ZCASE MEGA fuses are expensive.
Europe
Try Mouser here.
Other countries
Start your search here.
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