1. All high performance alternators require an upgraded output charge cable if replacing an existing lower output alternaor. At a minimum, use 2GA for 120 to l40 amp units - use l/0GA for 140 to 220 amp units. We recommend 2/0 cable as the minum output charge cable when using our ZCCJE1222 alternator. Personally, we use 4/0 cable to reduce resistance and gain additional useable output. The charge cable is the large cable connected to the output stud on the alternator & the other end attached to the POS post on the battery or bus bar. The large wire size ensures a minimum of voltage drop or attenuation, especially considering the cable will be running through engine spaces.

2. Check for worn out or undersized batteries. Load test batteries to determine condition. Bad batteries wreak havoc on a charging system. Poor batteries shorten an alternator's life.

3. Replace frayed wires & undersized battery cables. Remove alt clamp on battery cable repair ends. Replace with Heavy Duty, high quality parts. Upgraded cables will give the electrical system a giant boost in performance & reliability.

4.BELTS - BELTS - BELTS.
The importance of installing PREMIUM quality belts can not be over emphasized. Loose, Worn Out, or Glazed belts will not handle a high performance charging system. We recommend GATES Green stripe "MOULDED NOTCH" OR GOODYEAR HI-MILLER belts for replacement of V type belts.

5. IMPORTANT BELT TIGHTENING TIPS
Install NEW belts, adjust tension (1/4 inch depression), and run the motor for at least 15 minutes. Then re-tighten (adjust tension) to take up the initial belt stretch. Do not put off this critical step! Check belt tension often. When cruising, check the belts visually every hour. When you are at a dock or achored for the evening, press to check the depression after engine shutdown. Slipping belts generate excessive heat at the pulley. Heat is then transferred to the bearing and breaks down the lubricant, causing early bearing failure. When belts become glazed replace them immediately. The alternator output voltage will decrease when belts slip. Slipping belts are the #1 cause of low voltage charging conditions.

6. Do Not Do - Ill Advised:   Not to mention Cost vs Gain
A common question we receive is regarding how to modify the water pump pulley to allow for dual belts. Simply, the answer is NO. The water pump/pulley is not designed for the side loading that will be impacted by a device that requires two belts. A developing situation that then arises is that they then want to have a double sheeve crankshaft pulley with split loading. First, they want to place one belt around the first sheeve, water pump/pulley, and then on to the pulley of the device requiring 2 belts. Next, they then want to place the second belt around the crankshaft second sheeve and then on to the device that requires the second sheeve without going around the water pump/pulley. Simply, the answer is NO, again. You can not have belts of two different sizes to drive a device. Belt tensioning will never be equal on the two belts. All the devices will have uneven stress, belt wear, ... The two situations discussed above are to be avoided. We have received numerous emails from various sources that describe this scenario over and over. Normally, it is the result of someone attempting to be cute, lack of space, lack of $, .... Ultimately, a lack of understanding engineering principles will eventually cause failure regardless of personal requirements or resources. Do it right the first time or don't do it at all. One does not always get the chance to pull over to nearest dock (and fix it).

7. Common Question and Answer putting the above (4,5, and 6) in perspective

I have a model _______ (fill in the blank) Engine and I am tired of loose alternator belts and black belt dust all over the place. Do you have a pulley and belt kit to upgrade standard equipment alternator belt to serpentine? If so, how much does it cost? Does it replace the old pulley or mount to the old pulley?

Usually this situation comes about from one of three scenarios - Improper installation (alternator & pulley alignments), improper or lack of tensioning, or constant overload. Refer to 4 and 5 above regarding belts and tensioning. Regarding item 6 - Based on your engine size, you may be in a situation that you are overtaxing your existing alternator (battery bank size in excess of 500AH and using a single alternator of limited output). If your battery bank exceeds 500ah, certainly by 600-700ah, you probably need our second High Output Alternator (ZCCJE1222, 220+ amps). Also, the cost to do the mods you were considering are as expensive as adding a second High Output Alternator in the first place. Again, the mod you were considering is a no go item. Contact us via a phone call for full details regarding your specific situation.