Pre-Installation Checks - Maxwell ULTRA 31/1800 Manual De Instalación Y Manual De Usuario

a. 125°C Rated Cross-linked polyethylene — SAE J1127 Type SGX.
b. 125°C Rated Thermoset Elastomer — SAE J1127 Type SGR where flexibility is required.
Selection of the correct size American Wire Gauge (AWG) of cable depends upon the length of the
Positive and Negative cables required to connect the ESM to the Starter. Add both the Positive and
Negative cable lengths from the ESM to the Starter for total length and select the cable size from the
table below:
RECOMMENDED ESM TO STARTER SOLENOID POSITIVE AND NEGATIVE CABLE SIZE
Total Cable Length Feet
(Length in Meters)
Use AWG Cable Size
(Metric Cable Size)
Select the proper gauge cable for the total length of the positive and negative cables from the ESM to the
Starter Motor. Note: Cable gauges in the table above may seem small. They are correct and must be
followed to achieve the maximum life of the starter motor.
5.2.3

Pre-Installation Checks

1. Prior to installing the ESM test the starting and charging system to isolate any pre-existing problems.
Refer to the Technology and Maintenance Council (TMC) of the American Trucking Associations
(ATA) Recommended Practice 129A (RP 129A) for procedures to test the cable interconnects
between all the starting and charging system components for maximum voltage drop. Repair any
issues found before proceeding.
2. Remove all cables from the vehicle batteries, noting where they were originally connected.
3. All cable lug terminations and battery terminals should be thoroughly cleaned to remove grease and
oxidation.
4. Test the vehicle batteries individually and ensure they are properly charged to avoid issues later.
Remove and replace any batteries that are discharged below their specified voltage or failed to test
to their Cold Crank Amp (CCA) rating.
5. Place the ESM in the desired location being careful to align the (+) and (-) terminals in line with the
existing Vehicle Battery(s) (+) and (-) terminals; remove a Battery if needed to install the ESM.
NOT CONNECT THE ESM UNTIL INSTRUCTED.
Wiring Instructions (refer to the "before and after" installation diagrams below)
5.2.4
1. For aftermarket installations remove all the cables from the Starter Solenoid Positive terminal. Note:
If the Starter includes an Integrated Magnetic Switch the short cable from the Magnetic Switch to the
Starter Solenoid Positive Terminal can remain connected. All other connections to Starter Solenoid
Positive Terminal must be isolated from the ESM.
2. Most heavy duty truck manufacturers connect the Alternator and other vehicle power cables to the
Starter Solenoid Positive Terminal. Remove the Alternator, any vehicle power cables and Battery (+)
cables from the Starter Solenoid Positive Terminal. Connect these together using a terminal block or
a nut and bolt so that they are isolated from the Starter Solenoid Positive Terminal but remain
connected to any Battery (+) terminal.
3. Mount the Terminal Block or other junction point to a secure location and make sure it is properly
isolated from all vehicle grounds. Securely insulate, tie wrap and/or bundle all loose cables to
minimize damage from vibration, potential grounds, abrasion and corrosion.
4. Remove the Alternator cable connection and other vehicle ground cables from the Starter Negative
Terminal. Connect these together using a terminal block or a nut and bolt so that they are isolated
from the Starter Negative Terminal but remain connected to any Battery (-) terminal. If there is
another cable from the Starter Negative Terminal to the frame remove and discard that cable.
5. Mount the Terminal Block or other junction point to a secure location and make sure it is properly
isolated from all vehicle grounds. Securely insulate, tie wrap and/or bundle all loose cables to
minimize damage from vibration, potential grounds, abrasion and corrosion.
Installation Guide and User Manual – 12V ESM
Document No.: 1017462.7 © 2012, 2013, 2014, 2015 Maxwell Technologies, Inc.
SELECTION TABLE
15 - 20 Feet 20 - 25 Feet
(4.5 - 6.1 m) (6.1 - 7.6 m)
2 AWG 1 AWG
2
(35 mm ) (50 mm
25 - 30 Feet 30 - 40 Feet
(7.6 - 9.1 m) (9.1 - 12.2 m)
1/0 AWG
2 2
) (50 mm )
2/0 AWG
2
(70 mm )
DO
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