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Section 1: Power Systems - Installation Checklist

Organized by installation order for efficient build workflow.

Phase 1: Foundations

Battery Compartments

  • Install Odyssey PC1500 (START) in driver wheel well with access panel
  • Build enclosed compartment in passenger wheel well with access panel (AUX)
  • Install Barnes 4WD battery box (Group 24) in passenger wheel well - powdercoat before install
  • Install Dakota Lithium 135Ah LiFePO4 (AUX) in Barnes battery box

Grounding System

Ground Bus Bars:

  • Mount Engine Bay Ground Bus (Blue Sea 2107 PowerBar, 600A) on firewall (engine bay side) near PMU
  • Mount Firewall Stud Bus (Blue Sea 2105 MaxiBus, 250A) on firewall (cabin side)
  • Mount SwitchPros Ground Bus (Blue Sea 2105 MaxiBus, 250A) near SwitchPros controller

Frame Rail Grounds:

  • Confirm front frame rail ground point location (clean metal-to-metal)
  • Confirm rear frame rail ground point location (clean metal-to-metal)
  • Confirm 2/0 AWG: START battery- → Engine Bay Ground Bus Stud 1
  • Confirm 2/0 AWG: Engine Bay Ground Bus Stud 2 → Engine block
  • Confirm 2/0 AWG: Engine Bay Ground Bus Stud 3 → Front frame rail
  • Confirm 2/0 AWG: AUX battery- → Rear frame rail (~3 ft)
  • Confirm 4 AWG: Firewall Stud Bus Stud 1 → Chassis ground (~2 ft)
  • Confirm 1/0 AWG: SwitchPros Ground Bus Stud 1 → Chassis/frame rail

Battery Ground Reference:

  • Confirm 1/0 AWG: Engine Bay Ground Bus Stud 4 → AUX battery- (5-6 ft, 75A capacity)

Ground Testing:

  • Verify <0.1V drop: START battery- to front frame rail (engine @ 2000 RPM)
  • Verify <0.1V drop: AUX battery- to rear frame rail (engine @ 2000 RPM)
  • Verify <0.05V drop: START battery- to AUX battery- (engine @ 2000 RPM)
  • Verify <0.05V drop: START battery- to AUX battery- (BCDC charging @ 25A)
  • Verify <0.2V drop: START battery- to AUX battery- (winch operation @ 400A)
  • Verify ground bus stud torque: 100-120 in-lb (3/8"-16 studs on PowerBar)

Phase 2: Power Distribution

START Battery Circuit Breakers

Circuit Breakers (mount within 7" of battery):

  • Mount Mechanical Products 174-S2-250-2 250A CB (PMU main power)
  • Mount Mechanical Products 174-S2-080-2 80A CB (BCDC input)

START Battery Positive Wiring:

  • Confirm 2/0 AWG: START battery+ → 250A CB → PMU main power (~7 ft, temp-derated for 60°C)
  • Confirm 4 AWG: START battery+ → 80A CB → BCDC input (~6 ft)

PMU Ground Reference:

  • Confirm PMU Pin 25 connected to Engine Bay Ground Bus Stud 5 (per harness, <100mA logic/CAN reference)

Direct Battery Connections (No Circuit Breaker):

  • Confirm ECM power/ground connected directly to START battery terminals (per Cummins harness)
  • Confirm grid heater relay powered from START battery+ (via integrated fusible link)
  • Confirm grid heater ground connected directly to START battery-

Radio Grounds (RF Noise Isolation):

  • Confirm 10 AWG: GMRS Radio ground → START battery- (route through floor/frame, ~8 ft)
  • Confirm 10 AWG: Ham Radio ground → START battery- (route through floor/frame, ~8 ft)
  • Confirm 10 AWG: STX Intercom ground → START battery- (route through floor/frame, ~8 ft)

Testing:

  • Verify PMU main power always on (via 250A CB)
  • Verify voltage drop across main power cables under load (<3% at 60°C)
  • Verify ground resistance: Engine Bay Ground Bus to battery- (<0.1Ω)

AUX Battery Bus Bars & Circuit Breakers

CONSTANT Bus Bar:

  • Mount CONSTANT bus bar (Blue Sea 2107 PowerBar, 600A) in passenger wheel well
  • Confirm 1/0 AWG: AUX battery+ → CONSTANT bus (~3 ft)

Circuit Breakers (mount within 7" of battery):

  • Mount Blue Sea 187-150 150A CB (SwitchPros RCR-Force 12)
  • Mount Blue Sea 187-150 150A CB (SafetyHub 150)
  • Mount Mechanical Products 174-S2-100-2 100A CB (BODY PDU)

CONSTANT Bus Wiring:

  • Confirm 2 AWG: CONSTANT bus → 150A CB → SwitchPros RCR-Force 12 (~2 ft)
  • Confirm 2 AWG: CONSTANT bus → 150A CB → SafetyHub 150 (~2 ft)
  • Confirm 2 AWG: CONSTANT bus → 100A CB → BODY PDU (~12 ft through firewall)

Direct AUX Battery Connections (No Circuit Breaker):

  • Confirm 1/0 AWG: AUX battery+ → Winch positive (13 ft one-way, direct connection per WARN spec)
  • Confirm 1/0 AWG: AUX battery- → Winch negative (13 ft one-way, matches positive path)
  • Confirm 4 AWG: AUX battery- → Fusion Apollo amplifier ground (~8-10 ft)

BCDC Alpha 50 Installation

  • Mount BCDC in passenger wheel well (water-protected, LED visibility access)
  • Confirm 4 AWG: START battery+ → 80A CB → BCDC input (red terminal, M8, ~6 ft)
  • Confirm 4 AWG: BCDC output (brown terminal, M8) → AUX battery+
  • Confirm 4 AWG: BCDC negative (black terminal, M8) → AUX battery-
  • Confirm 18 AWG: Ignition signal (blue spade terminal) → PMU ignition sense tap

Battery Temperature Sensor (REQUIRED for LiFePO4):

  • Install BCDC temp sensor ring terminal on AUX battery positive terminal bolt
  • Route sensor cable to BCDC (short run - both in passenger wheel well)
  • Plug sensor into BCDC temperature sensor port (2-pin connector, polarity reversible)

BCDC Configuration & Testing:

  • Configure Green Power Priority via RedArc app
  • Test jump start assist function
  • Verify BCDC LED status indicates proper charging mode

Alternator

  • Install 270A alternator (Premier Power Welder HO-C28)
  • Confirm 2/0 AWG: Alternator output → START battery+ (shortest path, ~8 ft)
  • Confirm alternator case grounded through engine block mounting

Phase 3: Controllers - Physical Installation & Main Power

PMU24 Physical Installation

  • Mount PMU on firewall or inner fender (accessible for LED/USB diagnostics)
  • Confirm PMU ground reference Pin 25 connected to Engine Bay Ground Bus Stud 5

SafetyHub 150 Physical Installation

  • Mount SafetyHub 150 in passenger wheel well (co-located with AUX battery and circuit breakers)
  • Confirm 2 AWG: CONSTANT bus → 150A CB → SafetyHub input
  • Verify SafetyHub internal ground bus connected to SwitchPros Ground Bus

BODY PDU Physical Installation

  • Verify all circuit breakers and relays functional in LR-2 unit
  • Replace 24V relays (K40, K42, K53) with 12V relays (determine part numbers)
  • Mount LR-2 on firewall (body side, passenger side)
  • Confirm 2 AWG: CONSTANT bus → 100A CB → BODY PDU power studs (~12 ft)
  • Confirm 14 AWG: BODY PDU ground → Firewall Stud Bus Terminal 3 (relay coil/logic only)
  • Create custom wiring harnesses to adapt J301-J306 military connectors to civilian loads
  • Route heated seat dash switches to LR-2 relay control inputs (K21, K22)
  • Label repurposed circuits on LR-2 enclosure (match CB positions to new functions)

SwitchPros RCR-Force 12 Physical Installation

  • Mount SwitchPros controller
  • Confirm 2 AWG: CONSTANT bus → 150A CB → SwitchPros power input
  • Confirm SwitchPros ground connected to SwitchPros Ground Bus Terminal 1 (14 AWG)

SwitchPros Custom Harness Note:

Custom Delphi Harness Design

Create 12 custom 2-pin Delphi harnesses at SwitchPros:

- Each SwitchPros output → 2-pin Delphi plug (power + ground combined)
- Each light → matching 2-pin Delphi plug
- Back of SwitchPros: ~12 Delphi connectors for plug-and-play lighting
- Eliminates individual wire routing - each light is single plug connection

Phase 4: Integration & Wiring

Firewall Bulkhead Connector

Deutsch HDP20 Installation:

  • Drill 1.5" diameter hole in firewall for bulkhead connector
  • Mount HDP24-24-21PE-L015 receptacle (flange mount, engine side)
  • Assemble HDP26-24-21SE plug (cabin side)
  • Crimp size 16 contacts (0460-202-16141 pins, 0462-201-16141 sockets) for 17 wires
  • Install sealing plugs (114017/114018) in unused cavities
  • Verify IP67/IP68 seal engagement with bayonet coupling

Pin Assignment Verification:

  • Confirm Pin 1-6 (Engine→Cabin): Radio power (3), PMU lighting outputs (3)
  • Confirm Pin 7-17 (Cabin→Engine): CT4 outputs (4), switch signals (5), winch control (2)
  • Install ferrite chokes on radio power leads at radio end (RF mitigation)

Ignition Signal Distribution

  • Confirm 18 AWG: Ignition RUN → Deutsch connector Pin 12 → PMU Pin 7
  • Confirm ignition signal bus bar splits to: CT4, SwitchPros, Fusion Radio, BCDC
  • Verify total ignition signal current <500mA for all taps

PMU Input Wiring

  • Confirm 18 AWG: Ignition RUN → PMU Pin 7 (dedicated wire, not from bus bar)
  • Confirm horn button → PMU In 1 (via Deutsch connector Pin 11)
  • Confirm brake pedal switch → PMU In 2 (via Deutsch connector Pin 13)
  • Confirm reverse signal → PMU In 3 (Turbolamik aux output, Reverse gear)
  • Confirm Boomerang fob present → PMU In 4 (via firewall pin TBD)
  • Confirm push-button → PMU In 5 (via Deutsch connector Pin 15)
  • Confirm Turbolamik P/N → PMU In 6 (engine bay, direct from TCU)
  • Confirm A/C request → PMU In 9 (via Deutsch connector Pin 14)
  • Confirm CT4 SW3 (headlight status) → PMU In 7 (tap on engine bay side of connector)

PMU Output Wiring

High-Current Outputs (Combined):

  • Confirm iBooster main power → OUT1+10 combined (46A @ 40°C capacity, non-adjacent)
  • Confirm radiator fan → OUT2+3+4 combined (75A total capacity)

25A Outputs:

  • Confirm HVAC blower → OUT5 (20A max) - ground: factory HVAC ground
  • Confirm GMRS Radio → OUT6 (15A) - ground: direct to START battery-
  • Confirm oil cooler fan → OUT7 (15A) - ground: Engine Bay Bus Stud 8
  • Confirm PS cooler fan → OUT8 (15A) - ground: Engine Bay Bus Stud 8
  • Confirm Dakota Digital system → OUT9 (25A) - ground: Firewall Stud Bus T4-5

15A Outputs:

  • Confirm wipers (WS-51C) → OUT11 (15A) - ground: Firewall Stud Bus T2
  • Confirm Ham Radio → OUT12 (13A) - ground: direct to START battery-
  • Confirm CT4 → OUT13 (9A, CONSTANT) - ground: Firewall Stud Bus T1
  • Confirm ADU7 Display → OUT14 (2A) - ground: A-pillar
  • Confirm winch contactor trigger → OUT15 (1A) - control signal only

7A Outputs:

  • Confirm A/C clutch → OUT17 (5A) - ground: factory A/C ground
  • Confirm horn → OUT18 (5.4A) - ground: Engine Bay Bus Stud 6
  • Confirm iBooster ignition signal → OUT19 (5A) - ground: Engine Bay Bus Stud 7
  • Confirm STX Intercom → OUT20 (5A) - ground: direct to START battery-
  • Confirm brake lights → OUT21 (3A) - ground: SwitchPros Ground Bus T4
  • Confirm reverse lights → OUT22 (5A) - ground: SwitchPros Ground Bus T4
  • Confirm DRL/parking → OUT23 (2A) - ground: SwitchPros Ground Bus T5
  • Confirm Ignition Authorize → OUT24 (5A) - drives ECM ignition relay + keyless crank chain

PMU CAN Bus Integration

  • Confirm J1939 CAN High T-tap → PMU Pin 23/24 (18-20 AWG twisted pair, <12" stub)
  • Confirm J1939 CAN Low T-tap → PMU Pin 36/37 (18-20 AWG twisted pair, <12" stub)
  • Disable PMU internal CAN termination in software (bus already terminated at ECM + harness end)
  • Verify 60Ω resistance across CAN High/Low at ECM connector (harness disconnected, ignition off)
  • Configure PMU to read J1939 SPNs: 100 (oil pressure), 110 (coolant temp), 175 (oil temp), 190 (RPM)

BODY PDU Circuit Wiring

  • Confirm Fusion Radio memory → CB30 (15A, 14 AWG, CONSTANT)
  • Confirm USB ports → CB48 (20A, 14 AWG, CONSTANT) - 2× Powerwerx PanelUSB-75W (7.5A fuse ea)
  • Confirm WolfBox camera → CB39 (10A, 16 AWG, CONSTANT)
  • Confirm driver heated seat → CB45 (15A, 14 AWG) via relay K21 - 5A peak, 2A sustained
  • Confirm passenger heated seat → CB42 (20A, 14 AWG) via relay K22 - 5A peak, 2A sustained
  • Confirm cargo lights → CB20 (10A, 16 AWG) - switch on wheel well top
  • Confirm winch control → CB43 (10A, 18 AWG) - dash rocker + remote parallel control

Verification:

  • Verify Fusion radio current draw matches fuse ratings
  • Verify WolfBox model and 10A fuse adequate
  • Verify all BODY PDU load grounds route to individual load ground points (high-side switching)

SafetyHub Circuit Wiring

  • Confirm ARB compressor motor 1 → MIDI-1 (60A, 6 AWG, ~12 ft to under passenger seat)
  • Confirm ARB compressor motor 2 → MIDI-2 (60A, 6 AWG, ~12 ft to under passenger seat)
  • Confirm winch contactor trigger → ATC-1 (15A, 14 AWG, ~13 ft to front bumper)

Solar Panel Installation

  • Install Cascadia 4x4 80W panel on hood per manufacturer instructions (SolarClasp adhesive)
  • Route wiring: Hood → Firewall → BCDC (~10-12 ft, MC4 connectors)
  • Confirm solar positive → BCDC solar input (yellow terminal)
  • Confirm solar negative → Chassis ground (NOT BCDC negative)
  • CRITICAL: Verify polarity before connection - reverse polarity damages BCDC

Optional Overvoltage Protection (cold weather):

  • Mount overvoltage relay module near BCDC (weatherproof location)
  • Configure overvoltage threshold: 47V disconnect, 44V reconnect
  • Configure trip delay: 1-2 seconds (ignore brief spikes)
  • Test threshold settings before final installation

Solar Testing:

  • Monitor BCDC LED in daylight to verify solar charging
  • Verify solar input voltage within range (9-48V) at operating temperature

Phase 5: Testing & Programming

PMU Programming

Output Combining:

  • Configure iBooster combining (OUT1+10, non-adjacent terminals)
  • Configure radiator fan combining (OUT2+3+4, PWM variable speed)

Logic Programming:

  • Program DRL auto-off when headlights active (In 7 CT4 SW3 → OUT23 disable)
  • Program A/C clutch engagement logic (In 9 → OUT17)
  • Program horn activation (In 1 → OUT18)
  • Program brake light activation (In 2 → OUT21)
  • Program reverse light activation (In 3 → OUT22)
  • Program oil cooler fan based on SPN 175 (220-230°F hysteresis) → OUT7
  • Program PS cooler fan based on SPN 110 (210-220°F hysteresis) → OUT8
  • Configure sequential load startup delays (0.5s, 1.0s, 1.5s)

Backup:

  • Export/backup configuration (.pmu format) to git repository
  • Print critical logic (DRL, fan control) for emergency recovery

PMU Testing

  • Verify J1939 communication and data accuracy (SPNs 100, 110, 175, 190)
  • Test DRL auto-off logic (verify OUT23 disables when headlights active)
  • Test A/C clutch engagement (verify OUT17 activates with In 9)
  • Test CAN-based fan controls at threshold temps (OUT7, OUT8)
  • Test sequential load startup timing
  • Verify LED diagnostics show correct states
  • Verify iBooster CONSTANT power (OUT1+10 always on)

Ground Bus Testing

  • Verify Engine Bay Ground Bus stud torque: 100-120 in-lb
  • Verify Firewall Stud Bus terminal torque per Blue Sea spec
  • Verify SwitchPros Ground Bus terminal torque per Blue Sea spec
  • Verify all ground bus connections have clean metal-to-metal contact

System Integration Testing

  • Verify all PMU outputs operate correctly (test each output individually)
  • Test all BODY PDU circuits (CB30, CB48, CB39, CB45, CB42, CB20, CB43)
  • Test SafetyHub circuits (MIDI-1/2 ARB, ATC-1 winch trigger)
  • Verify SwitchPros Delphi connectors and outputs
  • Verify Deutsch bulkhead connector seal integrity
  • Final voltage drop measurements under load (<3% at operating temp)
  • Final ground resistance verification (<0.1Ω all paths)

Reference Documentation

Power Systems:

Ground Bus Bars:

PMU:

Distribution:

External Manuals: