Sizing Battery Cables
Battery cable size must meet the increased output capacity of your new alternator. The easiest method for determining the best cable size for your system is to compare your new alternator?s rated amperage output and the ROUND TRIP length of the cable running from the alternator to the battery being charged, and back to the alternator via ground to the chart at right. Cable length requirements may also be calculated with the formula CM=K x I x L/E (whereas CM represents the circular mil area of the conductor, K represents the mil-foot resistance of copper, I represents current, and L represents the length, in feet, of the round-trip cable run and E represents voltage drop in volts). When using this equation, a K constant of 10.75 indicates copper's mil-foot resistance and voltage drop should be calculated at 3% (0.36V for 12V, 0.72V for 24V). 94-Series Alternators
Large case 94-Series Alternators are designed to provide 165 or 210 amps at 12 volts, or 140 amps at 24 volts. Mounting is a 2"single-foot Delco-style mount. Alternators in the 94-Series feature isolated ground terminals, external regulation and 12-pole stator output.
1. Positive Output Terminal - Must be connected via properlysized cable to the battery or batteries being charged. Cable size is determined by alternator output and length of cable run. See Page 3 for wiring size chart.
2. Negative Terminal (Ground) - Must be connected to system ground via properly sized cable. Cable size is determined by alternator output and length of cable run. See Page 3 for wiring size chart.
3. Stator Output - Unrectified source of AC voltage which can be used as a signal for an electric tachometer. In 12-volt systems, stator terminal will connect to WHITE wire. In 24-volt systems, the Stator Wire will connect to the ORANGE wire in the regulator wiring harness.
4. External Field Wire (BLUE) - Connects to external voltage regulator via wiring harness.
An unsupported cable may damage the positive or negative terminals, resulting in damage to alternator, regulator and wiring. Ensure that cables are adequately supported to supply strain relief.