Skip to content

Section 1: Power Systems - Installation Checklist

Organized by installation order for efficient build workflow. Each item is a check-off confirmation — wire gauges, lengths, torque values, and part numbers live in the linked source docs, not here.

Phase 1: Foundations

Battery Compartments

  • Install Odyssey PC1500 (START) in driver rear wheel well with access panel
  • Build enclosed AUX compartment in passenger rear wheel well with access panel
  • Install Barnes 4WD battery box in passenger rear wheel well
  • Install Dakota Lithium (AUX) in Barnes battery box

Grounding System

Ground Bus Bars:

  • Mount Engine Bay Ground Bus on firewall (engine bay side) near PMU
  • Mount Firewall Stud Bus on firewall (cabin side)
  • Mount SwitchPros Ground Bus near SwitchPros controller

Frame Rail Grounds:

  • Confirm front frame rail ground point located
  • Confirm rear frame rail ground point located
  • Confirm START battery- → Engine Bay Ground Bus
  • Confirm Engine Bay Ground Bus → engine block
  • Confirm Engine Bay Ground Bus → front frame rail
  • Confirm AUX battery- → rear frame rail
  • Confirm Firewall Stud Bus → chassis ground
  • Confirm SwitchPros Ground Bus → chassis/frame rail
  • Confirm Engine Bay Ground Bus → AUX battery- (cross-battery reference)

Ground Testing:

  • Verify ground voltage drop within spec on all battery-to-frame paths (engine @ 2000 RPM)
  • Verify cross-battery ground drop within spec under BCDC charging
  • Verify cross-battery ground drop within spec under winch load

Phase 2: Power Distribution

START Battery Circuit Breakers

  • Mount 250A circuit breaker (PMU main power) within reach of START battery
  • Mount 80A circuit breaker (BCDC input) within reach of START battery
  • Mount 150A circuit breaker (Forward Distribution Bus master) within reach of START battery
  • Confirm START battery+ → 250A CB → PMU main power
  • Confirm START battery+ → 80A CB → BCDC input
  • Confirm START battery+ → 150A CB → 2 AWG forward feed → START+ Forward Distribution Bus
  • Confirm PMU ground reference (Pin 25) → Engine Bay Ground Bus

START+ Forward Distribution Bus (engine bay):

  • Mount START+ Forward Distribution Bus (Blue Sea 2105, TBD #135) in engine bay with insulated cover
  • Mount 60A / 50A / 25A load breakers on a bracket beside the bus
  • Confirm Forward Bus → 60A CB → radiator fan power (via relay)
  • Confirm Forward Bus → 50A CB → iBooster main
  • Confirm Forward Bus → 25A CB → Turbolamik TCU power
  • Confirm iBooster enable → Ignition bus Term 5 (7.5A fuse) → firewall Pin 18
  • Install Lingenfelter VSFM-002 radiator-fan controller + coolant sensor (sensor P/N TBD #134); verify fail-to-full-speed on lost sensor

Direct Battery Connections (No Circuit Breaker):

  • Confirm ECM power/ground connected directly to START battery (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 GMRS Radio ground → START battery- (direct run for RF isolation)
  • Confirm STX Intercom ground → START battery- (direct run for RF isolation)

Testing:

  • Verify PMU main power always on
  • Verify main power cable voltage drop within spec under load

AUX Battery Inline CBs & Firewall CONSTANT Bus

  • Mount 300A circuit breaker (forward feed to firewall bus) within reach of AUX battery
  • Mount 150A circuit breaker (SafetyHub local feed) within reach of AUX battery
  • Confirm AUX battery+ ring lugs landed: Winch, BCDC output, 300A CB, 150A CB
  • Confirm AUX battery+ → 300A CB → Firewall CONSTANT Bus
  • Confirm AUX battery+ → 150A CB → SafetyHub 150

Firewall CONSTANT Bus:

  • Mount Firewall CONSTANT Bus on firewall (cabin side, near BODY PDU)
  • Confirm forward feed terminates at bus input stud
  • Mount 150A circuit breaker (SwitchPros) at Firewall CONSTANT Bus
  • Mount 100A circuit breaker (BODY PDU) at Firewall CONSTANT Bus
  • Mount 100A circuit breaker (JL Audio amp) at AUX battery bracket
  • Confirm Firewall CONSTANT Bus → 150A CB → SwitchPros power module
  • Confirm Firewall CONSTANT Bus → 100A CB → BODY PDU power studs
  • Confirm AUX battery+ → 100A CB → JL Audio amp (direct AUX feed, not via firewall bus)

Direct AUX Battery Connections (No Circuit Breaker):

  • Confirm AUX battery+ → Winch positive (direct connection per WARN spec)
  • Confirm AUX battery- → Winch negative
  • Confirm AUX battery- → JL Audio amp ground

BCDC Alpha 50 Installation

  • Mount BCDC in passenger rear wheel well (water-protected, LED visible)
  • Confirm START battery+ → 80A CB → BCDC input
  • Confirm BCDC output → AUX battery+
  • Confirm BCDC negative → AUX battery-
  • Confirm ignition signal → PMU ignition sense tap

Battery Temperature Sensor (REQUIRED for LiFePO4):

  • Install BCDC temp sensor on AUX battery positive terminal
  • Plug temp sensor into BCDC sensor port

BCDC Configuration & Testing:

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

Alternator

  • Install 270A alternator (Premier Power Welder HO-C28)
  • Confirm alternator output → START battery+
  • Confirm alternator case grounded through engine block mounting

Phase 3: Controllers - Physical Installation & Main Power

PMU24

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

SafetyHub 150

  • Mount SafetyHub 150 in passenger rear wheel well (co-located with AUX battery)
  • Confirm AUX battery+ → 150A CB → SafetyHub input
  • Confirm SafetyHub ground bus → chassis ground

BODY PDU

  • Verify all circuit breakers and relays functional in LR-2 unit
  • Replace 24V relays (K40, K42, K53) with 12V relays (Resolved in #130. #70)
  • Mount LR-2 on firewall (body side, near Firewall CONSTANT Bus)
  • Confirm Firewall CONSTANT Bus → 100A CB → BODY PDU power studs
  • Confirm BODY PDU ground → Firewall Stud Bus
  • Build harnesses to adapt J301-J306 connectors to civilian loads (TBD #69)
  • Route heated seat dash switches to LR-2 relay control inputs (K21, K22)
  • Label repurposed circuits on LR-2 enclosure

SwitchPros RCR-Force 12

  • Mount SwitchPros power module on firewall (cabin side, next to BODY PDU)
  • Mount SwitchPros Ground Bus at firewall near power module
  • Confirm Firewall CONSTANT Bus → 150A CB → SwitchPros power input
  • Confirm SwitchPros logic ground → chassis ground at firewall
  • Mount SwitchPros control panel on dash; order control cable
  • Build custom 2-pin Delphi harnesses for each output (plug-and-play lighting)

Phase 4: Integration & Wiring

Firewall Bulkhead Connector

  • Drill firewall hole for bulkhead connector
  • Mount Deutsch HDP24-24-29 receptacle (engine side)
  • Assemble Deutsch plug (cabin side)
  • Crimp contacts for all 17 wires
  • Install sealing plugs in unused cavities
  • Verify bulkhead connector seal engagement
  • Confirm Pin 1-6 assignments (Engine→Cabin): radio power, PMU lighting outputs
  • Confirm Pin 7-17 assignments (Cabin→Engine): CT4 outputs, switch signals, winch control
  • Install ferrite chokes on radio power leads (RF mitigation)

Ignition Signal Distribution

  • Confirm PBS-I PINK IGN (cabin) → ignition signal bus bar
  • Confirm ignition signal bus bar → Deutsch connector (outbound to engine bay)
  • Install inline fuse on ECM ignition feed (Cummins-mandated ECM Pin 41 protection per 5504137)
  • Confirm engine-bay junction → ECM 12V supply + PMU Pin 7
  • Confirm bus bar taps split to: CT4, SwitchPros, Fusion Radio, BCDC
  • Verify total ignition signal current within spec

PMU Input Wiring

  • Confirm ignition RUN → PMU Pin 7
  • Confirm horn button → PMU In 1
  • Confirm brake pedal switch → PMU In 2
  • Confirm reverse signal → PMU In 3 (Turbolamik aux output)
  • Confirm A/C request → PMU In 9
  • Confirm CT4 SW3 (headlight status) → PMU In 7
  • PMU In 4, 5, 6, 8 — reserved for future expansion (no wiring)

PMU Output Wiring

  • Confirm HVAC blower → OUT5
  • Confirm GMRS Radio → OUT6
  • Confirm oil cooler fan → OUT7
  • Confirm PS cooler fan → OUT8
  • Confirm Dakota Digital system → OUT9
  • Confirm wipers (WS-51C) → OUT11
  • Confirm CT4 → OUT13
  • Confirm A/C clutch → OUT17
  • Confirm horn → OUT18
  • Confirm STX Intercom → OUT20
  • Confirm brake lights → OUT21
  • Confirm reverse lights → OUT22
  • Confirm DRL/parking → OUT23
  • OUT1–4, 10, 16, 19, 24 — free (no wiring); radiator fan, iBooster, and TCU relocated to the START+ Forward Distribution Bus (see below)

PMU CAN Bus Integration

  • Confirm J1939 CAN High T-tap → PMU Pin 23/24
  • Confirm J1939 CAN Low T-tap → PMU Pin 36/37
  • Disable PMU internal CAN termination in software
  • Verify CAN bus termination resistance at ECM connector
  • Configure PMU to read J1939 SPNs: 100, 110, 175, 190

BODY PDU Circuit Wiring

  • Confirm Fusion Radio memory → CB30 (CONSTANT)
  • Confirm USB ports → CB48 (CONSTANT)
  • Confirm WolfBox camera → CB39 (CONSTANT)
  • Confirm driver heated seat → CB45 via relay K21
  • Confirm passenger heated seat → CB42 via relay K22
  • Confirm cargo lights → CB20
  • Confirm winch control → CB43

SafetyHub Circuit Wiring

  • Confirm ARB compressor motor 1 → MIDI-1
  • Confirm ARB compressor motor 2 → MIDI-2

Solar Panel Installation

  • Install Cascadia 4x4 80W panel on hood per manufacturer instructions
  • Route solar wiring: hood → firewall → BCDC
  • Confirm solar positive → BCDC solar input
  • 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
  • Configure overvoltage thresholds and trip delay
  • Test threshold settings before final installation

Solar Testing:

  • Verify solar charging via BCDC LED in daylight
  • Verify solar input voltage within range at operating temperature

Phase 5: Testing & Programming

PMU Programming

  • Program DRL auto-off when headlights active
  • Program A/C clutch engagement logic
  • Program horn activation
  • Program brake light activation
  • Program reverse light activation
  • Program oil cooler fan from SPN 175
  • Program PS cooler fan from SPN 110
  • Configure sequential load startup delays
  • Export/backup configuration to git repository

PMU Testing

  • Verify J1939 communication and data accuracy
  • Test DRL auto-off logic
  • Test A/C clutch engagement
  • Test CAN-based fan controls at threshold temps
  • Test sequential load startup timing
  • Verify LED diagnostics show correct states
  • Verify iBooster power always on

System Integration Testing

  • Verify all PMU outputs operate correctly
  • Test all BODY PDU circuits
  • Test SafetyHub circuits
  • Verify SwitchPros Delphi connectors and outputs
  • Verify Deutsch bulkhead connector seal integrity
  • Final voltage drop measurements under load (within spec)
  • Final ground resistance verification (within spec)

Reference Documentation

Power Systems:

Ground Bus Bars:

PMU:

Distribution:

External Manuals: