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Photo 2/16 | 001 High Output Alternators Amps Snow Plowing Pickups | Diesel pickups equipped with high-amp draw accessories—such as snowplows, HVAC systems, inverters, emergency lights, business and CB radios, and winches—are prime candidates for high-output alternators. (Photo by Larry D. Walton)
Photo 3/16 | 002 High Output Alternators Amps Ford Snow Winching 311a3300b | Heavy-duty electric winches put the biggest hit on batteries. The larger winches used on heavy-duty pickups, such as Warn Industries’ 16.5ti Thermometric Self-Recovery unit, draw more than 500 amps under full pull. Even smaller-capacity winches will easily outpace the rate at which a single alternator can feed the batteries.
Photo 4/16 | 003 High Output Alternators Mechman Wiring Kit | One of Mechman Alternators’ “Big 3” wiring kits includes no-crimp cable ends and fine-strand, flexible cable. This type of end uses a set-screw to secure the cable. A slick setup, but we still prefer soldering or crimping.
Photo 5/16 | 004 High Output Alternators Wire Gauge | The charge wire is very important, and its length and gauge must be scrutinized. Powermaster Motorsports’ Todd Ryden says, “As current requirements to support the demands of accessories and added electrical components grow, the gauge of the charge wire needs to fatten up to support the output of a larger alternator.” “One-aught,” or 1/0 wire (far left), is ideal for the charge wire on alternators producing more than 250 amps.
Photo 6/16 | 005 High Output Alternators Dual Battery Tray Wiring | Running a high-output alternator (or dual alternators) does little good if the cabling and connections between the alternator and the batteries is improperly done. New batteries and fine-strand cables of the correct gauge are critical to maximizing alternator performance.
Photo 7/16 | 006 High Output Alternators Alternator Charge Path Test | After installing a high-output alternator, Mechman techs recommend doing a “charge-path test” of both the ground and power circuits. Voltage measurements on both tests should show less than 0.1 volt. If the reading is higher, there’s a problem with the integrity of ground and/or power connections. (Illustration courtesy of Mechman Alternators)
Photo 8/16 | 007 High Output Alternatorsgm Duramax Alternator Wiring | GM uses special inductive load sensors attached to the ground cables between the alternator and batteries. The ring-type sensors must be reinstalled on the heavier-gauge battery cable when upgrading to a higher-output alternator, as this Mechman illustration shows.
Photo 9/16 | 008 High Output Alternators American Power Solutions | American Power Systems (APS) builds a wide range of high-output alternators and brackets for ’10-and-newer Ford, Ram, and GM diesels. One example is the 360HPI-EF67-12WV, which makes 360 amps, for the ’17-to-present Ford Super Duty with single or dual alternators.
Photo 10/16 | 009 High Output Alternators Powermaster 48787 | Powermaster’s 48787 alternator is a direct bolt-in upgrade for Ford’s older 7.3L Power Stroke engine. It produces 130 amps at idle and 200 at the top end. Powermaster, which offers high-output alternators for a wide range of vehicles, dyno-tests every alternator at its West Chicago, Illinois, manufacturing plant.
Photo 11/16 | 010 High Output Alternators Mean Green Alternators Group | Mean Green’s custom high-output alternators, which the company says produce more than 300 amps at 6,000 rpm alternator-shaft speed, are direct bolt-on replacements for stock single- and dual-alternator setups. From left to right: MG1398HD (Ram 6.7L), MG8247HD (GM 6.6L), and MG8306HD (Ford 6.7L).
Photo 12/16 | 011 High Output Alternators Powerbastards Ford 6 711627 1 | This exact-fit, high-output alternator from PowerBastards is designed specifically for ’11-to-’16 Ford diesels. It is said to deliver 150 amps at idle and 300-plus amps at full output. The brand-new unit uses the same mounts and electrical connections as the stock alternator.
Photo 13/16 | 012 High Output Alternators Mechman Group | Mechman Alternators offers custom-built, high-output alternators that can deliver up to 370 amps in some applications. Their 300-plus–amp Elite and S Series Billet-Tech units for Ford, Ram, Chevrolet, and GMC fullsize diesels are manufactured using the latest technology and components.
Photo 14/16 | 013 High Output Alternators Sinister Diesel Ho Alternator | Sinister Diesel high-output alternators for late-model Ford Power Stroke, Cummins, and Duramax engines are available with up to 250 amps of output in some applications, featuring an upgraded high-amperage regulator, stator, and high-temp bearings (select models). All are available with either a powdercoated or anodized Sinister Blue billet cover.
Photo 15/16 | 014 High Output Alternators Nations Dual Alternator Kit | If your late-model Ram, Ford, or GM diesel needs an upgrade to dual alternators, Nation’s Starter Alternator offers kits for all three. Packages include a waterjet-cut, powdercoated, 3/8-inch steel plate and 280XP High-Amp Alternator (200 amps at idle), a GM idler pulley, Gates Green Stripe serpentine belt, and all wiring and mounting hardware for clean and trouble-free installation.