BATTERY ISOLATOR
Model 93801: 70 Amp
Model 93802: 90 Amp
Due to continuing improvements,actual product may differ slightly from the product described herein.
®
3491 Mission Oaks Blvd., Camarillo, CA 93011
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.
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PRODUCT SPECIFICATIONS
Item
Description
Electrical
Requirements
93801
: 70 Alternator Amps Maximum / 6, 12, 24, 32, 48 DC Volts Capable
Model 93802: 90 Alternator Amps Maximum / 6, 12, 24, 32, 48 DC Volts Capable
Model
Construction
Dimensions
Aluminum Extrusion / Grade 2 Steel Hardware & Fasteners
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)
Specifics
Net Weight
Features
Same Nominal Battery Voltage Required for Both Batteries / Negative Grounding Only
Model
93801
: 1.40 Lbs. / Model
93802
: 1.70 Lbs.
Multiple Battery Control (Isolates High & Low Charged Batteries)
Terminal Hardware Supplied (Fasteners Only/No Wire)
4 Slotted Mounting Holes @ 1/4” Diameter
Mounting
PRODUCT APPLICATIONS
1. Make sure 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).
Up to 1998.
Ford
GROUP
1
Chrysler
All models, all years including Nippondenso externally
regulated alternators.
Equipped with Nippondenso externally regulated
alternators.
Jeep
Japanese Imports
Motorola
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 battery posts. There are no colored
terminals.
General Motors (Delcotron)
Equipped with Delcotron CS Series (most 1985-1993) or
CS130-D Series alternators (most 1993 and newer).
Vehicles equipped with Delcotron CS Series alternator
(most 1985-1990).
Jeep
Toyota, Honda, & Some Imports
1985 and newer equipped with Nippondenso alternator
with internal regulators or alternators with an “S” (sense)
terminal.
GROUP
2
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 included).
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.
Motorola
Bosch
Other than Load Handler Series.
Requiring regulator sensing.
GROUP
3
GROUP
4
A Group 3 Isolator will have a colored fourth terminal indicating the “R” terminal.
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
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
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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. Refer to the “Recommended Wire Size/Circuit Breaker” Chart below to determine
the proper wire size and circuit breaker (not included) for your installation.
MAXIMUM
12 VOLT
RECOMMENDED
WIRE SIZE/CIRCUIT BREAKER
ALTERNATOR
RATING
Up to 15 Ft.
15 Ft. to 20 Ft.
20 Ft. to 25 Ft.
25 Ft. to 30 Ft.
70 Amps
95 Amps
130 Amps
160 Amps
240 Amps
#8 Ga./50 Amp
#8 Ga./50 Amp
#6 Ga./80 Amp
#4 Ga./120 Amp
#000 Ga./150 Amp
#8 Ga./50 Amp
#6 Ga./50 Amp
#4 Ga./80 Amp
#2 Ga./120 Amp
#000 Ga./150 Amp
#6 Ga./50 Amp
#4 Ga./50 Amp
#2 Ga./80 Amp
#2 Ga./120 Amp
#0000 Ga./150 Amp
#6 Ga./50 Amp
#4 Ga./50 Amp
#1 Ga./80 Amp
#0 Ga./120 Amp
#0000Ga./150 Amp
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.)
HEX NUT (2)
RING TERMINAL
SPLIT-LOCK WASHER
W/WIRE
(6)
(NOT INCLUDED)
HEX/SPEED NUT (3)
ISOLATOR STUD
FIGURE A
SKU 93801/93802
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PAGE 4
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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 functioning of the charging system.
(See Figure B.)
Battery Isolator
Alternator
A
“BAT”
1
2
Disconnect wires
from here
Wires
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
NewWire
A
“BAT”
1
2
FIGURE C
SKU 93801/93802
For technical questions, please call 1-800-444-3353.
PAGE 5
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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.)
A
1
2
AUX.
BATTERY
FIGURE D
11. Connect all of the auxiliary loads (phone, lights, stereo, refrigerator, winch, 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.
ALTERNATOR
EXISTING WIRE
NEW WIRE
FIGURE E
OUTPUT
REMOVE ORIGINAL WIRE(S)
FROM ALTERNATOR.
PLACE ON TERMINAL #1 OF ISOLATOR.
BATTERY #2
AUXILIARY
BATTERY #1
VEHICLE
1
2
A
ISOLATOR
CIRCUIT
BREAKER
TO VEHICLE IGNITION
SYSTEM, HEADLIGHTS, STEREO, LIGHTS, REFRIGERATOR,
HORN, ETC. WINCH, ETC.
TO AUXILIARY EQUIPMENT:
SECOND MAIN
BATTERY USED ON
MANY VEHICLES
SKU 93801/93802
For technical questions, please call 1-800-444-3353.
PAGE 6
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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 inches). 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:
WHITE/BLACK
WIRE COLORS MAY VARY
ORANGE/BLACK ORANGE/BLACK
RED/BLACK
ON DIFFERENT MODEL
FORD VEHICLES
RED/BLACK
WHITE/BLACK
ORANGE/BLACK
RED/BLACK
EXISTING WIRE
NEW WIRE
TO
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
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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 reading 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.
TESTINGTHE ISOLATORWITH 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 ohmmeter 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
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PARTS LIST AND ASSEMBLY DIAGRAM
Part #
Description
Qty.
1
2
3
4
5
6
Battery Isolator
1
3
3
4
4
3
Hex Nut (5/16” x 1-1/4” STD Thread)
Hex/Speed Nut (5/16” x 1-1/4” STD Thread)
Hex Head Sheet Metal Screw (#10)
Split-Lock Washer (1/4” I.D.)
Split-Lock Washer (5/16” I.D.)
2
3
Not
Included
6
1
4, 5
NOTE:
Some parts are listed and shown for illustration purposes 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 LICENSEDTECHNICIANS, AND NOT BYTHE 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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