Thermo King 42-2499 Reference guide

60 Amp In-Line Fuse Assembly Kit

Installation Procedures

KIT 42-2499

Recommended Best Practices

• The in-line fuse must be located in an accessible location as close to the battery as possible while keeping

it from directly touching or laying on the battery.

• The distance from the battery positive (+) terminal to the in-line fuse should be kept to a minimum and

not exceed 12.00 in. (305 mm).

• Depending on the application, the wire from the in-line fuse to the unit’s power wire may need to be

shortened to eliminate excess or coiled wire.

• The in-line fuse should be positioned vertically to help promote water drainage.

• Fuses mounted horizontally must have the slit in the sleeving pointing downwards.

• If the vehicle is equipped with a battery disconnect switch, always connect the unit’s power wire after the

switch. This allows power to the unit to be turned off by the battery disconnect switch.

• The ring terminals used must be sized to match the battery power stud or lug bolt. Oversized ring

terminals can contribute to high resistance resulting in the fuse overheating and failure. Various size

terminal rings are provided in the kit - choose the correct size for your specific battery requirement.

• All hand crimped terminals must be securely crimped, soldered and covered with heat shrink tubing.

• The in-line fuse must be secured to the vehicle or alongside the positive battery cable with the supplied

cable ties.

• Use harness routing that provides adequate protection against possibility of short circuit.

• All battery/electrical connections must be clean and tight.

KIT COMPONENTS

Item P/N Description Qty.

1. NSS 60 Amp In-Line Fuse Assembly 1

2. 413408 Butt Splice Connector 1

3. 418311 Ring Terminal, 3/8'' 6 AWG 1

4. 419797 Ring Terminal, 5/16'' 6 AWG 1

5. 419580 Ring Terminal, 1/4'' 6 AWG 1

6. 552332 Cable Ties 2

7. NSS Heat Shrink Tubing, 1-1/2'' long 2

8. TK 56239 Installation Procedures 1

In-Line Fuse Installation - Self-Powered and Direct-Drive Truck Units

IMPORTANT: You must read and follow the Recommended Best Practices on page 1.

1. Cut one in-line fuse wire to a maximum length of 12.00 in. (305 mm) and strip 0.50 in. (12 mm) from the

end.

2. Slide the heat shrink tubing onto the wire and position it away from the connection.

3. Securely crimp and solder the correct size ring terminal onto the wire.

4. Position the heat shrink tubing over the body of the terminal and the wire and then apply heat.

5. Cut the other end of the in-line fuse wire and the unit’s power (2) wire to appropriate lengths and strip

0.50 in. (12 mm) from the ends of each wire.

6. Slide the heat shrink tubing onto one wire and position it away from the connection.

7. Using the supplied butt splice connector, securely crimp and solder the two wires together.

8. Position the heat shrink tubing over the entire connection and then apply heat.

9. Attach the ring terminal onto the positive (+) battery lug and tighten securely.

10. Route and secure the in-line fuse to the vehicle or alongside the positive battery cable with the supplied

cable ties.

• The in-line fuse should be positioned vertically to help promote water drainage.

• Fuses mounted horizontally must have the slit in the sleeving pointing downwards.

IMPORTANT: Cable ties should be positioned within 5.00 in. (127 mm) on each side of fuse as shown and

no further than 10.00 in. (254 mm) apart.

Typical Self-Powered and Direct-Drive Truck Installations

Heat Shrink Tubing Butt Splice

Unit Power Wire

Alternative Battery Lug

Installation

In-Line Fuse Retro-Fit Installation - Heat King Units

IMPORTANT: Turn the unit power switch off and disconnect the positive (+) battery cable from the battery.

1. Locate and remove the existing maxi-fuse going from the alternator to the starter.

2. Lay the new in-line fuse assembly next to the maxi-fuse assembly. Cut the new in-line fuse wires so the

overall length of the new fuse assembly is the same as the maxi-fuse.

3. Strip 0.50 in. (12 mm) from each wire end.

IMPORTANT: The ring terminals used must be sized to match the battery power stud or lug bolt. Oversized

ring terminals can contribute to high resistance resulting in the fuse overheating and failure. Various size

ring terminals are provided in the kit - choose the correct size for your specific requirement.

4. Slide heat shrink tubing onto each wire positioning them away from the wire ends.

5. Securely crimp and solder a 1/4'' ring terminal onto one wire and a 5/16'' ring terminal onto the other wire.

6. Position the heat shrink tubing over the body of each terminal and wire and then apply heat.

7. Install the new in-line fuse assembly and tighten hardware securely. Use the supplied cable ties to secure

fuse assembly.

• The in-line fuse should be positioned vertically to help promote water drainage.

• Fuses mounted horizontally must have the slit in the sleeving pointing downwards.

8. Discard the maxi-fuse.

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