Cable fitting instructions

Caution: Cable ties may have sharp edges When routing cables be sure none can contact surfaces that get hot or any moving parts such as pulleys or belts when in operation. Caution: Always disconnect the negative terminal first and reattach it last.
Read through the instructions before beginning. These are general instructions and it's not required that they be followed in exact order except as noted above about the negative terminal. All negative cables have black ends and positive cables red ends. 1. Disconnect battery negative terminal. 2. Disconnect battery to chassis earth cable at body and chassis earth points and remove. 3. Disconnect battery positive terminal. 4. Release any fixings retaining the battery to starter cable. 5. In the fuse box remove the two screws for the battery to fuse box cable and the alternator to fuse box cable. 6. At the alternator remove the nut for the alternator to fuse box cable. 7. Withdraw both cables from the fuse box and engine compartment. 8. From above, feed battery end (straight terminal) of battery to fuse box cable in to fuse box. 9. From above, feed alternator end (straight terminal) of alternator to fuse box cable in to fuse box. 10. Attach terminals inside fuse box using screws removed in step 5. 11. Route the alternator to fuse box cable and attach it to the alternator with the nut removed in step 6. If needed, secure the cable with provided wire ties. 12. From above feed new battery to starter cable and starter to chassis earth cable down towards the starter, being careful that the other ends don't contact the battery posts. (ends with heat shield go to the starter) 13. From under the vehicle remove the battery to starter positive cable and starter to chassis earth cable. 14. Attach starter to chassis earth cable to starter with starter mounting bolt removed in step 13. 15. Attach battery to starter positive cable with nut removed in step 13. 16. Route new starter to chassis cable to battery chassis earth point but don't attach yet. 17. Route new battery to starter cable to near battery positive post but don't attach yet. 18. Route battery to fuse box cable to near battery positive post but don't attach yet. 19. Feed battery to chassis earth cable (smaller terminal end) down to the chassis mounting point and attach it and the starter earth cable to the chassis at the same location (you will note this is different than OE setup but provides a more direct starter to battery earth connection). 20. Attach the battery to body earth cable to the body using the smaller terminal.

21. Attach battery positive and negative terminals to their respective posts. Note: Negative and Positive terminals are different sizes, with the Negative being smaller. Each is marked with N & - or P & + on the clamp bolt end. The markings face up when the terminal is attached. 22. Attach the battery to starter and battery to fuse box cables to the Positive terminal using the larger bolt on the terminal. When tightening the nut avoid applying leverage to the battery post. 23. Attach battery to chassis and battery to body earth cables to the Negative terminal using the larger bolt on the terminal. When tightening the nut avoid applying leverage to the battery post.

Kit contents

Kit includes: A - Battery to Chassis Earth - 1 gauge B - Battery to Body Earth - 4 gauge C - Battery To Starter - 2 gauge D - Alternator to engine compartment fuse box - 6 gauge* E - Battery to engine compartment fuse box - 6 gauge* F - Mil-spec positive terminal G - Mil-spec negative terminal Not shown, but included, starter to chassis earth (long enough to connect at battery earth point) - 2 gauge

*Made from heavy duty welding cable that allows higher amperage size for size than normal welding cable. Will support up to 200amp alternator with minimal volt drop. Other cable sizes and lengths up to 4/0 are available by special request for things such as upgrading winch wiring. Feedback is especially welcome on both the instructions and the cables themselves. Tom Rowe roveron@comcast.net