Chicago Electric 93801 User's Manual
Contents
1. a colorless odorless toxic fume that when inhaled can cause serious personal injury or death 3 Prior to installation make sure to read and understand all instructions and safety precautions as outlined in the engine manufacturer s diagnostic repair manual 4 Prior to installation make sure the vehicle s transmission is placed in PARK or NEUTRAL and the emergency brake is applied 5 Always keep hands fingers and body away from the moving parts and hot parts of the engine 6 Dress properly Do not wear loose clothing or jewelry as they can be caught up in moving parts Wear restrictive hair covering to contain long hair 7 Do not use this product if under the influence of alcohol or drugs Read warning labels if taking prescription medicine to determine if your judgement or reflexes are impaired while taking drugs If there is any doubt do not use this product 8 Replacement parts and accessories This product must be repaired and serviced by a qualified service technician only When this product is serviced only identical replacement parts should be used Use of any other parts will void the warranty Only use accessories intended for use with this product impact eye goggles when installing this product and when working with tools 9 WARNING Avoid eye injury Make sure to wear ANSI approved safety and equipment 10 LA WARNING The warnings and cautions discussed in this instruction manual can2. etc to the positive post of the auxiliary battery ies Reconnect the ground cables removed in Step 5 Also make sure the negative terminal of the auxiliary battery ies are properly grounded with a conventional ground strap Protect with circuit breakers as needed See Figure E 12 Perform the electrical tests page 8 to assure proper operation FIGURE E ALTERNATOR EXISTING WIRE gt NEW WIRE REMOVE ORIGINAL WIRE S OUTPUT FROM ALTERNATOR PLACE ON TERMINAL 1 OF ISOLATOR BATTERY 1 BATTERY 2 VEHICLE AUXILIARY BREAKER EO JA TO VEHICLE IGNITION TO AUXILIARY EQUIPMENT BATTERY USED ON SYSTEM HEADLIGHTS STEREO LIGHTS REFRIGERATOR MANY VEHICLES i HORN ETC WINCH ETC 9 G a a a 8 Q a a R f 4 lt SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 6 SPECIAL INSTRUCTIONS FOR FORD INSTALLATIONS 1985 AND LATER 1 NOTE This section applies to Ford alternators with 2 plug in connections If your alternator has an output bolt return to Step 10 of the General Installa tion Instructions page 6 2 CAUTION Disconnect the battery before proceeding with modification and installa tion 3 Locate the connector on the side of the alternator that has one light wire and two heavy black wires with orange or red trace See Figure F 4 Cut both black orange wires close to the alternator allowing enough length to attach a splice approximately 2 3 inch
3. CHICAGO BATTERY ISOLATOR Model 93801 70 Amp Model 93802 90 Amp 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 2006 by Harbor Freight Tools All rights reserved No portion of this instruction sheet or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools For technical questions please call 1 800 444 3353 SAVE THIS MANUAL You will need this instruction manual for the safety warnings and precautions assembly operating parts list and assembly diagram Keep your invoice with this instruction manual Write the invoice number on this instruction manual Keep this instruction manual and invoice in a safe and dry place for future reference UNPACKING When unpacking check to make sure all the parts shown in the Parts List page 9 are included If any parts are missing or broken please call Harbor Freight Tools at the number shown on this instruction manual as soon as possible SAFETY WARNINGS AND PRECAUTIONS 4 WARNING Avoid risk of fire Prior to installation remove the cables from the negative terminals of all the batteries on your vehicle 2 Inhalation Hazard Do not operate an engine in a closed area or in a poorly ventilated area When running an engine produces carbon monoxide
4. ctioning of the charging system See Figure B Battery Isolator Alternator BAT Disconnect wires Wi re S from here FIGURE B 9 Connect one end of a new wire of the proper size See Recommended Wire Size Circuit Breaker Chart to the battery BAT terminal of the alternator and the other end to the A terminal of the Isolator This should now be the only wire connected to either of these terminals See Figure C NOTE 1985 1990 Ford or 1998 and newer Ford vehicles may require special instruc tions see page 7 for specific instructions Battery Isolator Alternator BAT FIGURE C SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 5 10 Mount a circuit breaker not included as near to the auxiliary battery as possible but away from engine or exhaust heat See Recommended Wire Size Circuit Breaker Chart for proper size Connect one end of a new wire of the proper size to the 2 terminal of the Isolator Run the wire to the circuit breaker and connect it to the AUX terminal or its equivalent Run another wire from the circuit breaker to the auxiliary battery connecting one end to the BAT terminal of the circuit breaker and the other to the positive terminal of the auxiliary battery Repeat for three and four battery isolators See Figure D FIGURE D 11 Connect all of the auxiliary loads phone lights stereo refrigerator winch
5. e to thoroughly review the Applications Chart below prior to installing the Isolator These Group designations are pertinent when reading all subse quent instructions in this manual 2 NOTE All vehicle part makes and models listed in this manual are registered trademarks of the vehicle part manufacturers General Motors Delcotron Except Delcotron CS series alternators CS series used on most 1985 and newer GM vehicles Ford Up to 1998 regulated alternators alternators Japanese Imports With alternators using external voltage regulated or external sensing Load Handler Series or 8EM Remote Sensing Series A Group 1 Isolator will have an alternator post and up to four ee eee eee posts There are no colored ee see a ee Equipped with Delcotron CS Series most 1985 or CS130 D Series alternators most 1993 and newer most 1985 1990 Toyota Honda amp Some Imports 1985 and newer equipped with Nippondenso alternator with internal regulators or alternators with an S sense terminal Ford Many 1998 and newer Unplugging the plug in connector from the alternator and counting the number of holes in the connector can identify the CS Series alternator The CS Series will have three small holes and one large hole The CS130 D alternator has four pin terminals all the same size The SI Series will have two slotted holes in the connector Delco CS Series alternators require a separate sense wire not inc
6. efer to the Recommended Wire Size Circuit Breaker Chart below to determine the proper wire size and circuit breaker not included for your installation ALTERNATOR RATING 70 Amps 8 Ga 50 Amp 8 Ga 50 Amp 6 Ga 50 Amp 6 Ga 50 Amp MAXIMUM RECOMMENDED 12 VOLT WIRE SIZE CIRCUIT BREAKER 5 Remove the cables from the negative terminals of all the batteries on your vehicle 6 Mount the Isolator in a convenient location as near to the alternator as possible and away from the exhaust manifold Allow for proper ventilation Do not mount on the engine Drill 1 8 holes and mount with the Screws 4 and Split Lock Washers 5 provided See Assy Diagram 7 Install the Hex Speed Nuts 3 Ring Terminal with Wire not included Split Lock Washers 6 and Hex Nuts 2 to the three Isolator Studs as shown in the illustration See Figure A RING TERMINAL SPLIT sear WASHER W WIRE 6 pn NOT INCLUDED CEH EX SPEED NUT 3 ISOLATOR STUD FIGURE A SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 4 8 Locate the BAT terminal at the rear of the alternator Disconnect ALL the wires including the voltage regulator sensing wire if present from the BAT terminal of the alternator Reconnect these same wires to the 1 terminal of the Isolator Lengthen the wires if necessary NOTE Disconnecting or cutting these wires in a location other than at the alternator may result in improper fun
7. es Do not cut the smaller wire Damage to the vehicle may occur if the wires are cut beyond the factory cabling splice approximately 6 inches from the alternator See Figure F 5 Splice an extension wire to both wires extending from the vehicle wire harness and connect the other end to the A terminal of the Isolator See Figure F 6 Splice an extension wire to both wires extending from the vehicle wiring harness and connect the other end to the 1 terminal of the Isolator See Figure F 7 Return to Step 11 of the General Installation Instructions page 6 NOTE WIRE COLORS MAY VARY ON DIFFERENT MODEL FORD VEHICLES RANGE BLACK RED BLACK w EXISTING WIRE NEW WIRE AUXILIARY BATTERY GROUP 1 ALTERNATORS FORD INSTALLATIONS ISOLATOR WITH 2 PLUG IN CONNECTORS FIGURE F SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 7 ELECTRICALTEST PROCEDURES 1 NOTE Connect the negative test lead to the negative terminal on the battery Testing With The Engine Not Running The 1 terminal of the Isolator should read vehicle battery voltage The 2 terminal should read auxiliary battery voltage The A terminal may read from zero to 13 volts Testing With The Engine Running And Alternator Charging The 1 and 2 should read regulator setting or less typically from 13 8 to 14 5 volts The A terminal voltage should read 0 8 to 1 volt higher than the read
8. ing of the 1 and 2 terminals Testing For 12 Volt Systems The A post should read approximately 14 8 to 15 5 volts The 1 and 2 terminal should read 13 8 to 14 5 volts If the A terminal reads 13 8 to 14 2 volts the regulator may be sensing the alternator output rather than the main battery This situation needs to be corrected for proper charging of batteries TESTING THE ISOLATOR WITH AN OHMMETER If using a digital ohmmeter a diode scale MUST be used 1 Remove all wires from the Isolator 2 Using a needle movement ohmmeter Rx 1 scale or a digital onmmeter diode scale hold the RED probe on terminal A and with the BLACK probe touch terminal 1 and 2 A good Isolator will show a current flow from A to 1 and 2 3 Next hold the BLACK probe on terminal A and with the RED probe touch terminal 1 and 2 A good Isolator will allow no current flow from A to 1 and 2 4 Hold one probe on the aluminum heatsink making sure there is contact by scratching through the protective coating Then touch with the other probe terminals A 1 and 2 A good Isolator will show no current flow NOTE On some import ohmmeters the RED and BLACK probes are reversed for these tests SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 8 PARTS LIST AND ASSEMBLY DIAGRAM Split Lock Washer 1 4 D NOTE Some parts are listed and shown for illustration purp
9. luded All Group 2 Isolators may be used in Group 1 applications Simply disregard the additional excitation E terminal A Group 2 Isolator will have a colored fourth terminal indicating the E terminal Bosch Requiring regulator sensing A Group 3 Isolator will have a colored fourth terminal indicating the R terminal GROU P Battery Isolators are not compatible with these alternators A Battery Separator is recommended for these applications Alternators with internal voltage sensing i e some Mitsubishi and GROUP Other than Load Handler Series Hitachi or single wire self exciting Delco alternators Isolators may be used if the alternator is modified SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 3 GENERAL INSTALLATION INSTRUCTIONS PRODUCT USAGE The Battery Isolator allows maintenance free and deep cycle batteries to be properly charged and also offers dual battery control 1 IMPORTANT If you are installing the Isolator on a Toyota Alternator Group 2 or a Motorola Bosch Aternator Group 3 refer to the special instructions in this manual before disconnecting any part of the existing system 2 For optimum system performance use a battery labeled Deep Cycle in the auxiliary position 3 Multi Battery Isolators are designed for alternator systems with negative ground and batteries of the same nominal voltage Batteries of differing voltages cannot be used 4 R
10. not cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator REQUIRED TOOLS AND HARDWARE 1 Prior to installation make sure you have the following tools and hardware all not included to complete the installation A Phillips screwdriver F Automotive Grade Wire B Drill with 1 8 bit G Ring Terminals C Wire crimper H Butt Connectors D Open end wrench set I Appropriately sized circuit breaker E Nut driver set J Terminal boot covers SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 2 PRODUCT SPECIFICATIONS lem Ci escription Model 93801 70 Alternator Amps Maximum 6 12 24 32 48 DC Volts Capable Requirements Model 93802 90 Alternator Amps Maximum 6 12 24 32 48 DC Volts Capable Dimensions Model 93801 4 1 2 Wide x 4 Deep At Base x 2 1 2 High 3 1 4 High At Terminals Model 93802 4 1 2 Wide x 4 15 16 At Base x 2 1 2 High 3 1 4 High At Terminals Same Nominal Battery Voltage Required for Both Batteries Negative Grounding Only Net Weight Model 93801 1 40 Lbs Model 93802 1 70 Lbs Features Multiple Battery Control Isolates High amp Low Charged Batteries Terminal Hardware Supplied Fasteners Only No Wire 4 Slotted Mounting Holes 1 4 Diameter PRODUCT APPLICATIONS 1 Make sur
11. oses only and are not available individually as replacement parts PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO SKU 93801 93802 For technical questions please call 1 800 444 3353 PAGE 9
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