With the
transformation of Project Tahoe into our chase vehicle and off-road
play vehicle, we were in need of an electrical system upgrade. We
had already plugged in one set of lights and plan on a full set of
additional electrical accessories. We are even looking at
installing a receiver-mounted winch.
We have used Wrangler NW Power Products in
the past and know they are of excellent quality.
W
e decided to install a dual battery
system with Wranglers trick battery manager and a high output
alternator. Wrangler makes a dual battery kit for just about any
vehicle, including most late models. Each kit can be customized to
your needs and your application.
The dual
battery kit for the Tahoe was the Chevy - GMC 1996-1999 kit. Our
Project Tahoe already had a tray mounted opposite from the main
battery on the drivers side - most won't have this, but it depends
on the option packages from the factory.
Our vehicle also has the 105amp alternator, which is larger
than most. Most will have the 70amp alternator. We chose to upgrade
to the Wrangler Powermate 155 amp alternator which is mounted in
the same size case as our original but it will use an external
regulator. The Powermate alternators are constructed with premium
components. The Power Boss external voltage regulators feature
visible LED's for diagnostics. The regulator will show red when
battery power is on, green when ignition is on, and amber when
field voltage is on.
The regulators are compatible with the OEM
computer systems and come with a large finned heat sink to keep
them cool. The regulator also features a secondary main battery
sensing circuit so that the system will provide more accurate
charge rate to the batteries for longer battery life.
This is the new Powermate on the left and our old
alternator on the right.
All terminals on the new Powermate are VERY clearly
labeled.
At the core of the dual battery system is the
battery isolation relay. You can use the relay alone or with the
optional battery manager kit. We chose to add the battery manager
kit which includes a dash mounted mode switch. The battery manager
definitely qualifies as "cool". With the battery manager you have
three modes of operation that can be controlled from inside the
cab.
DUAL - ON _ MODE
This is the normal position and the led is green.
Switch is to the left. The vehicle starts using main battery only.
Both batteries charge while motor is running. The batteries are
totally isolated when ignition switch is off, start, or accessory
position.
AUX - OFF - MODE
The switch is in the center position and the LED
is clear. Only the main battery is charged. Circuits connected to
the AUX battery still function. If the aux battery fails then the
alternator is protected as the aux battery is totally
disconnected.
DUAL EMERGENCY - ON - MODE The
switch is to the right and the red LED is lit. This connects both
batteries when the ignition is off or on. You can jump start
yourself if the main battery is too low to start the engine. Both
batteries are joined.
This is the Power Boss external regulator with LED
diagnostics.
Optional Battery Manager kit with dash mounted
switch.
What else is in the
kit?
You will find heavy duty
premium grade fine strand welding cable. All ends are pneumatically
crimped and have polarity marked heat shrink tubing installed.
Special side post battery hardware is included. These are also good
just to replace the crummy OE side posts. The stud is machined out
of brass and can be stacked to add a second power tap. Large 150
amp fused link is included.
What else is
needed?
You will need a second battery.
Bad batteries can cause alternator problems. We are big fans of the
Optima Batteries. They are sealed and can be mounted at any angle.
They are rated for 800 cold cranking amps, stand up to the abuse in
an off-road vehicle, recharge quickly and require no maintenance.
We used a red top but Optima also builds a yellow top deep cycle
unit if that fits your needs better. The Optima's are UPS shippable
and available from Wrangler NW right along with the rest of your
order.
You will need a good belt to turn
the new alternator. It is important to use a premium quality belt
such as the Dayco, Goodyear Hi-Miler or Gates Green Stripe.Installation
We started by installing the new Optima Red Top
battery in the driver side tray.You will probably have to install a
second tray also. Ours already had two.
Next we removed the serpentine belt and the stock
alternator. The same brackets will be used for the new
alternator.
The new Powermate alternator installed in the
original location. You will want to install a NEW belt sized for
the large alternator.
We mounted the new isolation relay and external
voltage regulator on the supplied bracket. NOTE:We put a
slight angle on the bracket so that it would fit in closer to the
firewall.
It is difficult to see but the relay and regulator
are mounted underneath the ABS brake module.
Next we attached the regulator harness and then
routed that across the top of the motor to the alternator. It is
protected by split loom covering.
We attached the new wires to the relay then routed
one to the auxiliary battery and the other over the fan shroud and
to the 175 amp fuse.
We attached the new 175 amp fuse then on one side
the cable from the isolation relay, the main battery, and the OE
cable feeding the main fuse panel. On the other side we connected
the main charge cable to the new alternator and used one of the OE
cables to connect to the utility stud on the alternator.
This shows the new charge wire from the Powermate
alternator to the fuse.
You can see the cable coming from the relay over
the fan shroud and the other new cable feeding from the fuse to the
main battery.
The Battery Manager harness is connected to the
Isolation relay.
The other end of the Battery Manager needs to be
routed through the firewall. You will need a 1/2" hole to fit the
end through. The red connector hooks to an ignition source that is
ON in RUN position only.
The Battery Manager switch connects to the harness
you passed through the firewall then can be mounted to your
dash.
131 amps at idle! NICE
Summary
All the
components are top notch. Wrangler NW Power Products has Dual
Battery kits and high output alternators to fit just about any
vehicle. Each kit is then customized to fit YOUR application. Take
your time and the installation is not that difficult. The Wrangler
NW tech support should be able to help you through any snags that
you run in to. If you plan on upgrading your charging system we
think Wrangler should be at the top of your list.
Contact Information
Wrangler Northwest Power Products
1-800-962-2616 | 503-235-4110 www.wranglernw.com
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With the
transformation of Project Tahoe into our chase vehicle and off-road
play vehicle, we were in need of an electrical system upgrade. We
had already plugged in one set of lights and plan on a full set of
additional electrical accessories. We are even looking at
installing a receiver-mounted winch.
