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Alternator Installation

Installation Manual
Safety tips:
-Wear eye protection
-Remove jewelry or any loose items
-Allow car to fully cool before starting installation

Steps to installing alternator:
*Batteries must be fully charged before installation.
1. Make sure vehicle is off and engine is cool.
2. Disconnect the negative cable from the battery/batteries.
3. Disconnect all other wiring from the alternator.
4. Remove the belt (note the belt routing before removing).
5. Remove the bracket bolts and original alternator.
6. Mount the new alternator. In general, the original bolts will be used.
7. Inspect he belt and replace if there are any signs of wear. We suggest you replace the belt with a .5 to 1-inch shorter belt when installing a high output alternator. Install the belt.
Make sure routing is correct and the belt is aligned to all pulley grooves.

Connections of frame/body: Clean all metal surface of any paint or rust with a wire brush or die grinder. Use a conductive corrosion inhibitor available at any electrical parts supply store.

Grounding (Uni-body frame warning): Many newer vehicles have “uni-body” or sheet metal frame structures with no traditional “full frame”. Because of seams and adhesive attached body components, additional steps may be required for proper chassis grounding. Choose the location on the sub-frame with the thickest metal possible. If there is lower than spec charging voltage at the battery, move ground connections or add additional ground cables to different frame components.

*Keep all electrical wiring at least 12” away from heat sources or the jacket of the cable could catch fire.

Alternators with one wire
Self-exciting or better known as “one wire” alternators will have NO plug on the alternator, and the OEM alternator harness plug will be left disconnected. This type of alternator requires only the positive and negative battery cables to be connected to the alternator to function. These alternators are internally regulated and will turn themselves on and off with engines rotation and regulate their own charging voltage. (May cause battery light to cut on).

Turn on – single wire alternators
If your alternator comes with a pigtail that plugs into the alternator, connect the excite wire (L) to 7v to 15v ignition power source and connect sense wire (S) directly to positive post on alternator.

Gauges
It is highly recommended you add a dash mounted volt gauge.
Connect the battery ground and confirm all other electrical connections are complete. Confirm the belt path is correct and clear of obstacles.

Before starting the vehicle, check and confirm that the battery is charged. Starting the vehicle with a discharged battery can damage the alternator.
Use a battery charger to charge the battery first if voltages are not adequate.

Ground path resistance test
If greater than 0.1V is measured improve:
Confirm all paint, anodizing, rust removed, and the connections are to bare metal.
Make certain all terminals are tight to the wire.
Make certain the ground wire is of proper size.

Charge path resistance test
If greater than 0.1V is measured improve:
Alternator charge post nut is tight.
Make sure charge wire is proper size.

Battery recommendation
2000w – upgrade main battery, 1 rear battery.
3500w – upgrade main battery, 1-2 rear batteries.
5000w – upgrade main battery, 2-3 rear batteries.
7500w – upgrade main battery, 3-4 rear batteries – 2 alternators.
10000w – upgrade main battery, 3-5 rear batteries – 2 alternators.

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