Posted by Fat Boy on February 18, 03 at 10:50:35:
Hello All,
I'm in the process of swapping out all my battery cables on my '94 K2500 GMC 6.5L turbo-diesel with dual Optima Red-top batteries and a 200 amp alternator (to be installed at the same time). I have a few questions about cable length/gauge, and terminal size and I'm hoping someone here might be able to fill in some of the question marks below. Feel free to correct any measurements as well....
For the most part, I'll be running 3/0 AWG welding wire, with mil-spec top-post terminal clamps from Permier Power Welder. I'm trying to get all the measurements together so I can order the battery cables.
So far, this is what I've measured:
(LEGEND: DS = Drivers Side battery, PS = Passenger side battery, AWG = American Wire Gauge)
PS Neg to block: 36" x 3/0 AWG, 7/16" ring at block, ??" ring at terminal clamp.
DS Neg to block: 30" x 3/0 AWG, 7/16" ring at block, ??" ring at terminal clamp.
PS Neg to body: 12" x ?? AWG, 3/8" ring at body, ??" ring at terminal clamp.
DS Neg to body: 12" x ?? AWG, 3/8" ring at body, ??" ring at terminal clamp. (note: does not currently exist... this is not a factory wire)
PS Pos to starter: 48" x 3/0 AWG, ??" ring at starter, ??" ring at terminal clamp.
DS Pos to PS Pos: 66" x 3/0 AWG, ??" ring at each terminal clamp.
DS Pos to Alternator: 48" x ??" AWG, ??" ring at alternator, ??" ring at terminal clamp, 250 amp inline fuse/fusable link (the link on it now has a 12 printed on it... I assume this means it's a 120 amp fusable link).
MYSTERY WIRE:
PS Pos to ?? (starter?): 36" x ?? AWG, ??" ring at (starter?), ??" ring at terminal clamp, ?? amp inline fuse/fusable link.. This wire snakes down toward the starter with it's big prother (3/0 gauge pos to starter cable). I don't know if it's attached to the starter, solenoid, or something else. I can't see under there without dropping the starter, but somehow I think it's gotta connect to the solenoid and then to the power juncion block on the PS firewall. I can't see any direct connection between pos terminal and the power junction block... Just a bunch of wires snaking up from the area of the starter.
Basically, I need the following info:
Ring size at the terminal clamps? (Traveler?)
Ring size at the starter and alternator?
Cable/wire size for the body grounds and alternator connection? I'm thinking 8 AWG.
Length, wire size, and fusable link size of the mystery wire?
Location for the other end of the mystery wire? If terminated with another wire that connects to the power junction block, should I replace that wire, too?
Ground strap locations? I've found one (broken) from frame to body next to the down-pipe, and one (on it's last legs) from frame to block next to starter. Where are the rest?
Thank a million,
Fat Boy