Re: Wiring Suggestions: LN 230amp
Yes, make sure your batteries are fully charged before running the new alt. As for wiring, it's quite simple, but you can get very complicated if you want to. lol I have a 250 amp alt, so I know what I did works great.
As for size of wire, you could definitely go with 1/0 cable without a problem, but I would recommend 2/0 just for that extra peace of mind. Either way works. Now, for the simple way. Connect one lead from battery negative to the alternator case. If it didn't come with a ground post on the side of the alt, just use a bolt in the small hole which sits between the two bolts on the passenger side. Connect another lead from battery positive to the alternator ouput, but make sure you have a AGL fuse in-line rated at 230 amps, or as close to it as possible. I would think a 250 amp fuse would be fine, and think it's the closest they make to 230. That's it! Leave your stock wiring in place and drive.
And now, the complicated way. lol Really, it's not bad, but does take some time and more wire. Instead of running the ground straight to the alternator, you replace the existing grounds with more wire in the new gauge. Not really needed if you ask me, though I do recommend making sure existing grounds are clean.
One other addition I DO recommend, though, is either replacing or supplementing the wiring between batteries. I didn't replace, I just added. Make a run of your gauge of choice from battery to battery...pos to pos, neg to neg. That way you are ensuring maximum current flow between batteries as well.
Oh, for your cable ends, use tinned copper to prevent corrosion. And for your cables, use pure copper. No CCA! I use Excelene welding cable and have had it there for almost three years without a single problem.
2004 Excursion 6.0
New HPOP/HPO system o-rings; Updated standpipes and dummy plugs
EGR delete; Rebuilt oil cooler; CCV collection mod
VR Black Diamond head gaskets and ARP studs
Oil and coolant bypass filters; Shell EC-1 coolant
Rebuilt turbo; 250 amp alt; 6000 watts of brain scrambling
One giant 240 pound English Mastiff riding shotgun!