Introduction; Unpacking; Aftermarket Accessories Required For Installation - Maxwell ULTRA 31/1800 Manual De Instalación Y Manual De Usuario

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Introduction

The Engine Start Module (ESM) by Maxwell Technologies, Inc. is intended to provide years of reliable
starting for diesel engines up to 16 Liters in displacement. The ESM replaces one battery for starting
engines with a 12 Volt starting system. It is designed to recharge from an existing system battery(s) and
provides starting power across a broad temperature range even when batteries would not have sufficient
power. There are two products in the ESM family, the ULTRA 31/1800 for Class 7-8 Diesel Trucks with
engine displacement of 7.0 Liters to 16 Liters, and the ULTRA 31/900 for Class 3-6 Diesel Trucks with
engine displacement of 4.0 Liters to 6.9 Liters. The ESM is not recommended for gasoline engines or diesel
engines smaller than 4.0 Liters in displacement. Please make sure you install the correct ESM product for
the type and class of vehicle as shown in the specification table in Section 11.
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Unpacking

Inspect the shipping box for signs of damage prior to unpacking the ESM. Damage to the shipping box or
ESM should be reported to the carrier immediately. Retain the shipping materials until the unit has been
inspected and is determined to be operational. Remove the ESM from the shipping box by lifting the ESM
straight up. The ESM weighs only 13.5 lbs. (ULTRA 31/900) or 19 lbs. (ULTRA 31/1800) and is significantly
lighter than a similarly sized lead-acid or AGM battery. DO NOT lift the ESM from the box or carry it using the
provided jumper wire from the Starter (+) to the Battery (–) terminals. Discard jumper wire before installation.
If the unit is found to be defective or any parts are missing, contact your original Point of Purchase or
Maxwell Technologies, Inc. Technical Support toll-free at (888) 890-3337.
Authorization (RMA) number must be issued prior to returning the unit for repair or replacement.
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Aftermarket Accessories Required for Installation

Additional materials that may be needed for aftermarket installation (see Section 5.2.2, below) are shown
below. These items are not included with ESM but may be necessary to isolate other vehicle electronic non-
starting loads from the starter system. These are not required for new trucks with the ESM factory installed
from the Original Equipment Manufacturer (OEM).
 Terminal block, SS 3/8"–16 thread or equivalent. Examples are shown below:
 In place of a terminal block, a simple SS 3/8" bolt, washer and nut may be used to connect non-starter
vehicle loads to the batteries. Electrical insulation material (Heat Shrink) is also required for proper
isolation.
 2/0 AWG – 6 AWG (or appropriately size cable for the load) Cable with crimp terminals, corrugated wire
loom, and tie wraps
Tools Required: (not supplied)

Large Compound-Action Crimp Tool (or similar)

Standard Shop Tools
Installation Guide and User Manual – 12V ESM
Document No.: 1017462.7 © 2012, 2013, 2014, 2015 Maxwell Technologies, Inc.
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