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POWERLINE

HEAVY DUTY ISOLATORS

MODELS: 22-15, 22-18, 22-21, 22-63, 33-94, 33-115

CONGRATULATIONS!

...for choosing this high quality POWERLINE PRODUCT. The latest state of the art engineering plus years of experience have gone into each POWERLINE product. The attached instructions are provided to assist you with step by step installation. Test procedures are also provided to be kept with your equipment should future reference be desired. Every effort has been made to use the finest materials and workmanship. In the event that service is ever needed or you have questions regarding the product, installation or performance please give us a call. Your Friends at the factory

AN ISO 9001 COMPANY

R

A DIVISION OF HEHR INTERNATIONAL INC. 4616 Fairlane Avenue, Ft. Worth, TX 76119 817.535.0284 · fax: 817.531.2755 · Canada: 905.852.5417 E-Mail: [email protected]

HEHR POWER SYSTEMS

FORM 05080 MBJ 06/99

TEST INSTRUCTIONS POWERLINE C.S. TYPE ISOLATOR USING OHM METER

I. 2. 3.

Remove all wires from the isolator Using a needle movement ohmmeter on RX-1 scale or digital ohmmeter on diode scale. Hold red probe on terminal A, with black probe touch terminals Bl and B2. A good isolator will show current flow. With red probe on A touch E terminal with black probe. A good isolator will not show any current flow. Place black probe on a terminal and touch terminal Bl and B2 terminal with the red probe. A good isolator will not show any current flow. With black probe on terminal A touch E with red probe. A good isolator will show current flow.

4.

Note: on some import ohm meters the red and black leads are reversed for above tests.

ELECTRICAL TEST 1. Engine not running, terminal B2 should read system battery voltage. Terminal B2 should read auxiliary battery voltage. The A terminal may read 0 to 10 volts if using a digital ohmmeter. This may be due to the capacitor in the alternator. Ground out terminal A momentarily and retest, voltage reading should be 0. The E terminal should have 0 volt reading. Key on engine not running, terminal E should read system battery voltage, terminal A should read system battery voltage or may be as much as .6 volts less battery but no more. Battery post of alternator should read battery system voltage or as much as .6 volts less than battery but no more. For 12 volt systems the A terminal should read approximately 15 volts. The B1 and B2 terminal should read 13.8 to 14.2 volts. If the A terminal reads 13.8 to 14.2 volts the regulator is sensing the alternator output rather than the main battery. This situation needs to be corrected. for proper charging.

2.

3. 4.

5.

6.

Isolator Installation Instructions Delco "CS" series alternators

The POWERLINE solid State Multi-Battery Isolator is a product of extensive heat-chamber engineering and testing. POWERLINE isolators are designed to handle the total current rating through either leg. All POWERLINE isolators designed to be used with Delco "CS" type alternators are negative ground, multi-battery systems with an excitation terminal. The isolator comes with a #22-50 alternator control plug and harness. (A #22-598 adaptor is required for Delco "CS"-D type alternators)

CAUTION: Isolator rating must be equal or greater than alternator amperage rating.

Prior to starting isolator installation, start engine and run at fast idle. Measure voltage at the battery terminal, it should be about 14 volts. After installation, re-check above to confirm the same voltage.

1. Disconnect Negative cable from battery. 2. Mount isolator in a location away from maximum engine heat, in a location that will allow the isolator to receive maximum air flow. 3. Remove all original wires connected to the alternator output post (battery connection). A. Attach all original wires removed from output post of alternator together and tape up. 4. Install a new wire from the alternator output post to the "A" terminal of the isolator. 5. Install a new wire from "B1" terminal of isolator to main engine battery. 6. Install a new wire from the "B2" terminal of isolator to auxiliary battery. 7. On a 3-battery system connect a new wire from "B3" to second auxiliary battery. 8. Connect good grounds from auxiliary batteries to engine. NOTE: See cable chart for correct cable size. 9. "E" terminal connection: (yellow wire) Connect one end to "E" terminal on isolator. Connect to 10 amp Self Reset Breaker, and from breaker connect to a 20 amp on / off ignition source. See drawing C88-5 for use with relay to remove overload on late model vehicles. The clear connector fits all Chevrolet and GMC trucks from 1985 thru 1994. The blue 1/8" connector is used on all 1995 and up Chevrolet and GMC trucks. 10. Remove the control plug from the alternator (plug can be removed by using a small screwdriver, prying up under locking tab). 11. Install new control plug #22-50 (provided with isolator). NOTE: The 22-50 control plug is used with the standard Delco "CS" type alternator. If you have a Delco "CS" type D alternator, it will also require a #22-598 adaptor harness to allow the #22-50 to connect to the alternator. 12. Cut the original control plug wire (wires) approximately 6" from plug. Strip the wires approximately 3/16" to ¼" from the end on the harness side. Using the supplied butt connectors, splice new plug to harness wire's matching colors.

13. Connect the red sense lead in the #22-50 control plug to the "B1" terminal of the isolator using 5/16 terminal (supplied). NOTE: any wires in the #22-50 control plug that do not have a matching wire in the original harness must be taped up. 14. Re-connect the NEGATIVE battery cable to the battery NEGATIVE POST. 15. Start engine test charging system. 16. See page C88-1 thru C88-6 for your wiring requirements. Page C88-7 is for alternator identification and plug requirements.

WIRING DIAGRAM

DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

(NOT USED)

WHITE BROWN PINK/BLACK RED

FACTORY HARNESS

BROWN

4/0 2/0

B1 B2 A

E

+

4/0

12 VOLT MAIN BATTERY

4/0

2/0

FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER

+

-

12 VOLT AUX BATTERY

HEHR POWER SYSTEMS

C88-1 03-23-99

WIRING DIAGRAM

DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

WHITE

WHITE BROWN PINK/BLACK RED

FACTORY HARNESS

BROWN (NOT USED)

4/0 2/0

B1 B2 A

E

+

12 VOLT

4/0

4/0

MAIN BATTERY

2/0

FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER

+

-

12 VOLT AUX BATTERY

HEHR POWER SYSTEMS

C88-2 03-23-99

WIRING DIAGRAM

DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

(NOT USED)

WHITE BROWN PINK/BLACK RED

FACTORY HARNESS

PINK/BLACK

(NOT USED)

4/0 2/0

B1 B2 A

E

+

4/0

12 VOLT MAIN BATTERY

4/0

2/0

FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER

+

-

12 VOLT AUX BATTERY

HEHR POWER SYSTEMS

C88-3 03-23-99

WIRING DIAGRAM

DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

WHITE

WHITE BROWN PINK/BLACK RED

FACTORY HARNESS

PINK/BLACK

(NOT USED)

4/0 2/0

B1 B2 A

E

+

4/0

12 VOLT MAIN BATTERY

4/0

2/0

FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER

+

-

12 VOLT AUX BATTERY

HEHR POWER SYSTEMS

C88-4 03-23-99

WIRING DIAGRAM

DELCO CS TYPE ALTERNATOR/ISOLATOR INSTALLATION

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

(NOT USED)

WHITE BROWN PINK/BLACK RED

FACTORY HARNESS

BROWN

4/0 2/0

B2 A

+

B1

E

12 VOLT MAIN BATTERY

4/0

10 AMP BREAKER 87 87A 30

4/0

2/0

86 85

FUSE PANEL 86 CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 87A 87

+

-

12 VOLT AUX BATTERY

OPTIONAL IGNITION CONNECTION FOR "E" TERMINAL

85

30

BOSH RELAY 12 VOLT 0332-204-101

HEHR POWER SYSTEMS

C88-5 05-03-99

WIRING DIAGRAM

ISOLATOR CONVERSION KIT FOR STANDARD ISOLATOR - TO USE WITH CS TYPE DELCO ALTERNATOR

ORIGINAL CHARGE CABLE (TAPE & DO NOT USE)

(NOT USED)

WHITE BROWN

FACTORY HARNESS

BROWN

PLUG ADAPTOR KIT #22-50 PINK/BLACK RED

(NOT USED) FIELD SUPPLIED WIRE

4/0 2/0

B1 A B2

ALSO REQUIRES #22-598 ADAPTOR FOR CS-D TPPE ALTERNATOR

+

12 VOLT

RED SPOT

4/0 #22-175

ALTERNATOR EXCITING KIT

BLOCKING DIODE BLACK SPOT

MAIN BATTERY

4/0 2/0

FUSE PANEL CONNECT TO 20 AMP ON/OFF KEY CIRCUIT 10 AMP BREAKER

+

-

12 VOLT AUX BATTERY

NOTE: 22-50 ADAPTOR

CONNECT ONLY MATCHING COLORED WIRES IN FACTORY HARNESS. ALL OTHERS EXCEPT RED, TAPE UP AND DO NOT USE.

C88-6 03-23-99

HEHR POWER SYSTEMS

RED

ACK / BL NK PI WN BRO ITE WH

ITE WH WN BRO

DELCO CS 130 ALTERNATOR CONNECTOR

K LAC K/B PIN RED

DELCO CS 130D ALTERNATOR CONNECTOR

CS 130 CONVERSION HARNESS

CS 130 TO CS 130D CONVERSION HARNESS

#22-50

INCLUDED WITH CS ISOLATOR

#22-598

SPECIAL NOTE:

POWERLINE PART #22-598

THIS MUST BE ORDERED SEPERATELY WHEN CONNECTING A CS130D TO A POWERLINE ISOLATOR.

C88-7 10/99

RECOMMENDED BATTERY CABLE SIZE (AS A FUNCTION OF CURRENT AND LENGTH)

MINIMUM SIZE CABLE TO USE (AWG) RATED OUTPUT (AMPS) UP TO 5 FT. 5-10 FT. 10-15 FT. 15-20 FT. 8 AWG 4 AWG 2 AWG 2 AWG 0-60

SYSTEM VOLTAGE

20-25 FT. 1 AWG 0 AWG 00 AWG

25-30 FT. 0 AWG 00 AWG 000 AWG 4/0 AWG 4/0 AWG 4/0 AWG 6 AWG 4 AWG 2 AWG 1 AWG 1 AWG 0 AWG

12 VOLTS

60-100 100-150 150-190 190-250 250-300 0-30 30-50 50-75 75-100 100- 25 125-150

6 AWG 4 AWG 4 AWG 2 AWG 0 AWG 14 AWG 12 AWG 10 AWG 6 AWG 4 AWG 2 AWG

4 AWG 2 AWG 1 AWG 0 AWG

1 AWG 0 AWG 00 AWG

0 AWG 00 AWG

00 AWG 000 AWG 4/0 AWG 4/0 AWG 4/0 AWG

00 AWG 000 AWG 4/0 AWG 4/0 AWG 14 AWG 10 AWG 8 AWG 6 AWG 4 AWG 2 AWG 10 AWG 8 AWG 6 AWG 4 AWG 4 AWG 1 AWG 8 AWG 6 AWG 4 AWG 4 AWG 2 AWG 1 AWG 8 AWG 6 AWG 4 AWG 2 AWG 2 AWG 0 AWG

24 VOLTS

Length of cable shown is for either POS. lead or GND. lead, not total length. Maximum acceptable voltage drop = 0.5 volts in a 12 volt system, 1.0 volts in a 24 volt system.

LIMITED WARRANTY

HEHR POWER SYSTEMS warrants each new product against factory defects in material and workmanship for a period of time as outlined in the Warranty Period schedule (Form W 1OOOA-4/95). Exclusions from this warranty for damage or failure due to accident, misuse, negligence or improper installation. Material required for repair or replacement of defective part is to be supplied at no charge on delivery of the defective part to HEHR POWER SYSTEMS, 4616 Fairlane Avenue, Fort Worth, Texas, 76119 or an authorized service center. The customer is responsible for all freight on returned parts. There are no warranties, expressed or implied (including any implied warranties merchantability or fitness), which extend beyond this warranty period. The loss of use of the product, loss of time, inconvenience, commercial loss or consequential damages are not covered. HEHR POWER SYSTEMS reserves the right to change the design or any product without assuming any obligation to modify any product previously manufactured. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. Some states do not allow limitations on how long an implied warranty lasts. Some states do not allow the exclusion or limitations of incidental or consequential damages. Therefore, the above limitation(s) or exclusion(s) may not apply to you.

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