Installation Instructions
Battery Isolators
Part Numbers: 48162, 48122, 48070, 48090, 48120, 48160, and 48161
Installation
Assemble the Battery Isolator in the following sequence:
1.
Disconnect Both Batteries - Install the isolator on a panel as close as possible to the alternator and main battery. It should be
mounted away from the engine and radiator to avoid heat and positioned in the stream of cooling air from the fan.
2.
IGN Connection - Connect a wire from the IGN terminal on the ignition switch to the IGN stud on the isolator. The IGN terminal must
be HOT in both the IGN and START positions of the ignition switch.
Note: On most GM cars and trucks a spare IGN terminal feed is provided in the main fuse block, which can be used for this
connection.
Making the connection to the "S" terminal for the Alternator For vehicles with a wire connector at the alternator location S-F-L-P
1.
Disconnect the wire connector at S-F-L-P - Insert the terminal with the yellow wire lead (supplied in poly bag) into the "S" location
in the connector (largest opening)
Connection must be made from wire side of connecter - Make sure the groove on the connector and the tab on the terminal line
2.
up. A "click" should be heard when the terminal is seated and locked into place.
3.
Reconnect connector to alternator - The other end of the yellow wire lead can now be connected to the isolator terminal battery #2
or directly to the main battery as shown in the installation diagram.
Making the connection to the "S" terminal for the Alternator For vehicles with a rubber plug covering alternator terminals S-F-L-P
1.
Remove the rubber plug from S-F-L-P - Make a hole in the plug above the "S" terminal. Feed the yellow wire through the hole and
attach the terminal on the yellow wire to the "S" terminal on the alternator (largest terminal).
2.
Replace rubber plug in the alternator -The other end of the yellow wire can now be connected to isolator terminal Battery #1 or
directly to the main battery as shown in the installation diagram.
Option: A slot can be cut half way through the plug, making sure the plug covers the yellow wire.
3.
Cut the large wire (alternator output wire) connecting the alternator to the main (#1) battery - Make sure the wire is cut at a
point before it reaches the feed to the ignition switch.
Connect the alternator end of the wire to the alternator terminal on the isolator - Check the battery end of the cut wire to the
4.
Battery #1 terminal of the isolator.
Run a wire from the Battery #2 terminal of the isolator to the second battery as shown in the installation diagram - Use wire
5.
sized to the alternator output.
6.
Insulate all wire connections where needed - Reconnect the batteries' grounds. The unit is now ready to use.
NOTE: If an ammeter is used with the alternator, it will only read in one direction.
Installation for 48070, 48090, 48120, 48160, and 48161
Assemble the Battery Isolator in the following sequence:
Disconnect Both Batteries - Install the isolator on a vertical panel (with cooling fins vertical) as near as possible to the alternator and
1.
main battery. It should be mounted away from the engine and radiator to avoid heat and positioned in the stream of cooling air from
the fan
2.
Make all connections by splicing the three wire leads assembled to the isolator - The wire leads are factory installed to assure
proper efficiency.
Note: Do not loosen or remove the wire leads as this may alter the operation of the unit. Insulate all splices properly.
3.
Disconnect the large wire (alternator output wire) connecting the alternator to the main (#1) battery - On systems using a
voltage regulator, disconnect the large wire from the regulator to the main (#1) battery.
4.
Connect this wire to the Battery #1 terminal of the isolator.
5.
Connect a wire from the ALT terminal of the isolator to the output terminal on the alternator - Use wire sized to the alternator
output.
Run a wire from the Battery #2 terminal of the isolator to the second battery as shown in the installation diagram - Use wire
6.
sized to the alternator output.
7.
Reconnect the batteries' grounds - The unit is now ready to use.
WARNING
Before beginning the installation, consult your vehicle manual for the proper method of disconnecting the main battery. This is especially
important for computer equipped vehicles.
All wiring connection are made directly at the alternator. Taking shortcuts will cause the charging system to malfunction. Do not assume
wires on solenoids, starters or terminal block are the points shown on the wiring diagram.
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