Maxon TC Kit 10 Owner's manual

Owner’sManual

P/N:284550‐500

TRAIL CHARGER with EXTENDER

- Straight Truck Application

284550‐01 Version1.0406/07/2011

Owners Manual

Owners

Manual

 Operation

 Installation

 Wiring Diagram



Troubleshooting

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com



Troubleshooting

 Parts Breakdown

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

GENERAL OPERATION

GENERAL



OPERATION

PROBLEM

Onapplicationswhereliftgatebatteriesaremountedalongdistancefromtheprimaryvehicle’ selectricalsystem,

voltagedropwilloccur.Thelongerthedistanceandthesmallerthecablesthatconnectthetwobatterysystems,

thegreaterthevoltagedrop.Tochargetheseliftgate batteries,thecorrectvoltagemustbeappliedtothese

batteries.Without thenecessaryvoltage(electricalpressure)topushcurrentthroughtheliftgatebatteriesfor

recharging,norechargingcanoccur.Tochargeagroup31floodedcellbatteryat0degreesF,voltagesof15voltsare

necessary.Thesamebatterypackat80degreesFmightonlyrequire14.0volts.Theheavydutycommercialvehicle

alternatorisnormallysetat14.0voltsandflatcompensated.Thetypicalvehicle’ sbatterypackismaintainedat

approximately13.5volts.Thedifferenceoccursbecauseofthevoltagedropbetweenthebatteryandthealternator.

Withthisfactinmind,thestartingvoltagefortheliftgatebatteriesis13.5volts.

Thecircuittochargetheliftgatebatteriesincludesthecablesfromthealternatortothetruck'sbatteries,andthe

cablesfromthetruck’sbatteriestotheliftgatebatteries.Thetotallengthofthecablesandconnections(including

fuses)createvoltagedropinthesystem.Whilethetotalcircuitresistanceofthiscircuitisconstant,asthecurrent

loadincreases,thevoltagedropalsoincreases.Itisimpossibletohavethecorrectlevelofvoltageattheliftgate

batteries.Thisreducedvoltageresultsinabatterypackthatisnotmaintainedataproperstateofchargewhich

resultsinshortenedbatterylife,lessoperatingtimeandpossibledamagetotheliftgatemotor.

SOLUTION

TRAILCHARGER – Eliminatestheaboveproblembyamplifying(boosting)anyinputvoltage(9to14)tothecorrect

voltagenecessarytochargeandmaintaintheliftgatebatteries.Thisincreasedvoltagewillallowthebatteriestobe

chargedandmaintainedatahigherstateofchargesothattheyprovidetheenergynecessarytodowhateverjob

they are designed for even in the toughest environments The

Trail Charger

also will not let the liftgate batteries

they



are



designed



for

,

even



the



toughest



environments

.

The



Trail



Charger



also



will



not



let



the



liftgate



batteries



backfeedtothetruck’sbatterypack.

TheEXTENDER allowsfortheTrailChargertocontinuetooperateafterthetractoristurnedoffforupto30minutes.

Itrunsforthefirstfiveminutesandthenshutsdownforfiveseconds.Itthenmeasuresthetractorbatteriesvoltage

withnoload.Ifthetractorbatteriesarestillover12.2volts,theExtenderturnstheTrailChargerbackonforanother

fiveminutesandthenstartsthecycleoveragain.Thisallowsformorechargingtimeoftheliftgatebatterieswithout

impactingtheabilitytostartthetracto

NOTE:Ifavehicleisnotalreadyequippedwithanauxiliarybatteryboxonemustbepurchasedinorderforthis

systemtowork.Thecostoftheadditionalbatteryboxandbatteriesisnotincludedinthepriceofthiskit.

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step1:MounttheTrailChargeronthebackof

theliftgatebatteryboxusingthesuppliedself‐

drillingsheetmetalscrews.Checkthebackside

ofthemountinglocationtoensurethatnothing

willbedamagedduringinstallation.TheTrail

Chargershouldbemountedabout1½”down

fromthetopandjusttotherightofthe

grommet.Theunitmustalsobemountedwith

theplugpointeddown(6o’clock).(SeeFigure1)

Step2: Mounttheincludedinsulatedstud(C)to

theinsideoftheliftgatebatteryboxusingthe

suppliedhardware.

Mtth Et d Mdl (D) t th iid f

Figure1

oun



e

er

e

(D)



o

e

eo



theliftgatebatteryboxusingthesupplied

hardware.

Theseshouldbemountedneartheliftgate

batteryboxgroundstud(L)asshowninthe

picturetotheright.(SeeFigure2)

Step3: ConnecttheExtenderharnesstothe

Extenderusingthe10pinplugandreceptacle.

(See Figure 3)

Figure2

(See



Figure



221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page3

Figure3

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

Step4: Routethemainharnessintotheliftgatebattery

box throughtheholeinthesideofthebatter y box.All

wiresroutedthroughthebatterybo xshouldbe

protectedwitharubbergrommetordomenut. (See

Figure4)

h fll i i (h h i h

MAINHARNESS

INSTALLATION



INSTRUCTIONS

Routet

e

ngw

res

(

eDeutsc

p

nsgotot

e

outside)outoftheliftgatebatteryboxthroughthehole 

inthebacknexttotheTrailCharger.(Thewire#’sarein

referencetothediagramonpage10.)

‐ Whitewire#5,labeled“IgnitionPin#4”

‐ Redwire#6,labeled“12VInputPin#1”

‐ Redwire#7

labeled“12VOut

utPin#2”

OUTPUTPOSITIVE,OUTPUTNEGATIVE,,

INPUT WIRE IGNITION WIRE

, p

‐ Blackwire#8,labeled“GRNDPin#3”

INPUT



WIRE

,

IGNITION



WIRE

Step5: Connectthefollowingwirestothered

insulatedjunctionstud.Thesearealllabeled

“JunctionStud”.

Red wire #3 from module

Figure4

‐

Red



wire



from



module

‐Redwire#2fromthedualpole(+)

‐Redwire#6fromTC(routedinpreviousstep)

Installthenutandtightenproperly.(SeeFigure5)

Step6: LocatetheDeutschconnectorfromthebag

kitandinsertthewiresintothecorrectpositions.

‐

Insert the input wire (12V Input Pin #1) into the #1

Figure5

‐

Insert



the



input



wire



(12V



Input



#1)



into



the



positionontheconnector.

‐ Inserttheoutputpositivewire(12VOutputPin#2)

intothe#2positionontheconnector.

‐ Inserttheoutputgroundwire(GroundPin#3)into

the#3positionontheconnector.

‐ Inserttheignitionwire(IgnitionPin#4)fromthe

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page4

extendermoduleintothe#4positiononthe

connector.(SeeFigure6)

Figure6

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

Step7: Verifythatthewiresareinsertedintothe

connectorcorrectly,inthecorrectposition,and

lockedintoplace.(SeeFigure7)

INSTALLATION



INSTRUCTIONS

Step8: Locatetheorangelockfromthebagkit

d itit th Dth t Mk

Figure7

Insert Flush,locked



nser



o

e

connec

or.

e

surethatthelockispushedinflushwiththeend

oftheconnectorandlockedintoplace.(See

Figure8)

intoplace

Step9: Slidetheincludedcleartubingoverthe

J1connector(4pin)ontheTrailCharger.Thiswill

hl d f

Figure8

ppreventwateran

contaminates

rom

enteringtheelectricalconnection.(SeeFigure9)

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page5

Figure9

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step10: ConnecttheDeutschconnectortothe

TrailCharger.Itmaybenecessarytousea

screwdrivertomakesureitisproperlyseated.

(SeeFigure10)

Step11: Installthefusecubeassemblytothe

positivepostofbatteryAintheliftgatebattery

box.(SeeFigure11)

Figure10

Step12: Attachtheoutputpositivewire(LiftGate

Battery(+))tothetopofthefusecubeusingthe

insulatedfusecubenut.

Figure11

Attachtheoutputgroundwire(LiftGateBattery(‐)),

theextendergroundwire(LiftGateBattery(‐)),and

themainharnessgroundwire(LiftGateBattery(‐))to

thenegativepostofbatteryB.

Please note:

The positive connection and the negative

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page6

Please



note:

The



positive



connection



and



the



negative



connectionshouldbedoneonoppositebatteries.

(SeeFigure12)

Figure12

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step13: Routethemainpowerharnessfrominside

theliftgatebatteryboxtothetractorbatterybox.

Makesuretheharnessissecuredwithwiretiesand

notroutedthroughanyareasthatcouldcause

chaffingordamagetotheharness.Oncetheharness

is routed cut the harness to length Be sure to leave



routed

,

cut



the



harness



length

.



sure



leave



enoughtobeabletostriptheouterjacketoffand

haveenoughwiretomakealltheelectrical

connections.(SeeFigure13)

Note: Whenroutingintothetractorbatterybox,

makesurethewiresareprotectedwitharubber

grommetordomenut.

Figure13

Step14: Installthefuse cubeassemblytothe

positivepostofbattery1inthetractorbattery

box.(SeeFigure14)

Step15: Installthe3/8”cableendtothered

wirebystrippingabout¼”oftheinsulationoffof

thewire.Nextslidethepieceofredheatshrink

Figure14

onthewire,thencrimpandsolderthe3/8”

eyeletontotheendofthewire.Slidetheheat

shrinkovertheconnectionandapplyheat.

Connectthewiretothefusecubeassemblyand

tightenthenutproperly.(SeeFigure15)

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page7

Figure15

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step:16: Installthe3/8”cableendtotheblackwire

bystrippingabout¼”oftheinsulationoffofthe

wire.Nextslidethepieceofblackheatshrinkon

thewire,thencrimpandsolderthe3/8”eyelet

ontotheendofthewire.Slide theheatshrinkover

theconnectionandapplyheat.Connectthewireto

thetractorbatterynegativepostandtightenthe

nutproperly.(SeeFigure16)

Note: Connectthegroundwiretothebattery

oppositetowherethepositivewirewasconnected.

Step17: TheTrailCharger’sgreenLEDlightshouldbe

illuminated.TheExtendermoduleshouldhaveboth

Figure16

redandgreenLEDlightsilluminated.(SeeFigure17)

Note: Tractorneedstoberunningandthesystem

voltageneedstobe approximately14.0volts.

Step18: Nowthemetalcovercanbeinstalledto

furtherpr otecttheTrailChargerfromphysical

damageandroadsplash.Usefourselfdrilling

screws (provided) to attach the cover to the batter y

Figure17

screws



(provided)



attach



the



cover



the



battery



box.Checkthebacksideofthemountinglocationto

ensurethatnothingwillbedamagedduring

installation.(SeeFigure18)

Note:Makesurethattheharnesshasadriploopfor

thewatertorundownawayfromtheTrailCharger.

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page8

Figure18

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

WIRING DIAGRAM

WIRING



DIAGRAM

IGNITIONE4

INPUTE1

OUTPUT

EXTENDER

OUTPUT



GROUNDE3

AUXILIARYBATTERYBOX

NOTE:TheTrailChargerunitchargesanauxiliary

batterypackthatissolelydedicatedtoproviding

powertotheliftgate.Itispowere dbythetrucks

primarychargingsystem.(Alternatorandbattery

pack)TheExtendermoduleallowstheTrail

Charger to have extended charge time even with

Charger



have



extended



charge



time



even



with



theengineturnedoffwithoutimpairingthe

truck’sabilitytostart.Ifavehicleisnotalready

equippedwithanauxiliarybatteryboxonemust

bepurchasedinorderforthissystemtowork.

Thecostoftheadditionalbatteryboxand

batteriesisnotincludedinthepriceofthiskit.

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page9

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

WIRING DIAGRAM

Components

A. TruckBatter

Positive

WIRING



DIAGRAM

B. FuseCube,30Amp

C. JunctionStud

D. ExtenderModule

E. TrailCharger

1. Input

2. Output

Ground

4. Ignition

F. FuseCube,30Amp

G. LiftgateBatteryPositive

H. LiftgateBatteryNegative

J. TruckBatteryNegative

Wire

Connection 1

Connection 2

Color

Wire

Connection



Connection



Color

1. GroundWire(MainHarness) TruckBatter yNegative LiftgateBatteryNegative Black

2. PositiveWire(MainHarness) TruckBatter yPositive InsulatedJunctionStud Red

3. ExtenderPositiveSenseWire ExtenderModule InsulatedJunctionStud Red

4. ExtenderGroundWire ExtenderModule LiftgateBatteryNegative Black

5. ExtenderIgnitionWire ExtenderModule TrailChargerIgnition#4 White

6. InputWiretoTrailCharger InsulatedJunctionStud TrailChargerInput#1 Red

7. OutputPositiveWire TrailChargerOutput#3 LiftgateBatteryPositive Red

8. OutputNegativeWire TrailChargerGround#4 LiftgateBatteryNegative Black

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page10

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

1. Disconnect andtesttheliftgatebatteries.

Battery1Battery2Battery3Battery4

RtdCCA



CCA

__________ ______________________________

RatedRC __________ ______________________________

OpenCircuitVoltage __________ ______________________________

TestResults __________ ______________________________

TesterUsed __________ ______________________________

Note:Allbatteriesmustpassloadtestorbereplacedbeforeproceeding.

Note: Forsteps2through11refertothewiringdiagramonpage15.

2.TurninputpowerontotheTrailCharger.Thetruckneedstoberunningandthetruckbatteryvoltagemustbein

the13.8to14.2voltrange.

h h l h ll d ( )

3.Ist

egreenLEDont

eTrai

C

argeri

uminate

?

(

yesorno

)

_________

Ifyesmovetostep9.Ifnogotostep4.

Note: IftheliftgatebatteriesarecompletelychargedtheTrailChargermightnotturnon.Toensurethisisnot

thecaseruntheliftonecompletecycle.

Didthe

reenli

htturnon?

esorno

)

g g (y

)

_________

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

TROUBLESHOOTING GUIDE

4. RemovetheharnessplugfromtheTrailCharger. (SeeFigure1) Checkthevoltagereadingattheinputpin(E1)

andtheliftgatebatterynegative(H).Thisshouldbethesameasthetruckbatteryvoltage.(i.e.voltagebetween

positive(A)andnegative(J))

TractorBatter yVoltage:________ (E1)PinVoltage:__________

TROUBLESHOOTING



GUIDE

Ifthetractorbatteryvoltageandthevoltageat(E1)arenotthesame,checkforthefollowing:

A. Checkthefusecube(B)atthetruckbatteries.Ifthefuseisblown,repairthecircuitandreplacethefuse.

Recheckthevoltagebetween(E1)and(H)asinstep4.Thisshouldbethesameasthebatteryvoltage.If

yes,skiptostep5.Ifno,continuetostepB.

B. CheckVoltagebetween(C)and(H).Thisshouldbethesameasthebatteryvoltage. Ifyes,continuetostep

C.Ifno,repairthewirebetweentheredinsulatedstud(C)andthefuse(B)andcontinuetostepC.

C. CheckVoltagebetween(E1)and(H).Thisshouldbethesameasthebatteryvoltage. Ifyes,skiptostep5.If

no,repairthewirebetweentheredinsulatedstud(C)and(E1)andcontinuetostepD.

Ch k th d iitb hki th lt bt (H) d (J) Thi hldb lt If



egroun

c

rcu



yc

ng

evo

age

ween

(H)

an



(J)

.

Thi

ss



ezerovo

s.

yes,

continuetostep5.Ifno,repairthewirebetween(H)and(J)thencontinuetostep5.

5. Verifythatthevoltagereadingbetweentheinsulatedjunctionstud(C)andtheliftgatebatterynegative(H)is

greaterthan13.3volts(enginemustberunning)beforecontinuingtothenextstep.

A. Theredlightonthemoduleshouldbeon.Ifyes,continuetostepB.Ifno,verifythattheredwire

betweenthemodule (D)andtheinsulatedjunctionstud(C)isnotdamaged,broken,orpinched.Also

verifythattheblackwirebetweenthemodule(D)andtheliftgatebatterynegative(H)isnotdamaged,

broken,orpinched.Iftherearenodamagedwires,replacethemoduleandthenstartoveratthe

beginningofstep5.

With

the harness plug removed check the voltage reading

between the ignition pin (E4) and the liftgate

With



the



harness



plug



removed

,

check



the



voltage



reading



between



the



ignition



(E4)



and



the



liftgate



batteryground(H).Thisshouldreadwithinonevoltofthebatteryvoltagebetween(C)and(H).Ifyes,

moduleisoperatingandthegreenandredLEDlightsshouldbeon.IftheLEDlightsarenotonandthere

isnovoltagebetween(E4)and(H),removethe

redleadfromthemodulethatat tachedtothebattery

positive(G)andthenreattach.BothLEDlightsshouldturnonforonesecondandthenturnoff.This

meansthemodulehaspower.Ensuretheredandblackleadsareonthecorrectbatteryterminal.Ifyes

andtheLEDlightsdonotcomeon,replacethemoduleandthenstartoveratthebeginningofstep5.

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

6.Withtheharnessplugremoved,checkthevoltagereadingbetweenthegroundpin(E3)andtheliftgatebattery

positive(G).Thisshouldbethesameasbatteryvoltage.Ifyes,continuetostep7.Ifno,repairtheleadfrompin

(E3)toliftgatebatterynegative(H).

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

TROUBLESHOOTING GUIDE

7. Withtheharnessplugremoved,checkthevoltagereadingbetweentheoutputpin(E2)andtheliftgatebattery

negative(H).Thisshouldbethesameasbatteryvoltage.Ifyes,continuetostep8.Ifno,checkthe30ampfuse

cube(F).Ifthefuseisblown,repairthecircuitandreplacethefusecube(F).Ifthevoltagereadingbetweenthe

outputpin(E2)andtheliftgatebatterynegative(H)isstillnotthesameasbatteryvoltage,repairtheleadfrom

theoutputpin(E2)totheliftgatebatterypositive(G).

TROUBLESHOOTING



GUIDE

8. Checkthevoltagebetweentheliftgatebatterynegative(H)andthetruckbatterynegative(J).Themetershould

readzero.Ifnotzero,repairthegroundwirebetween(H)and(J).

9. ReconnecttheharnessplugbackintotheTrailCharger.

10.

Hook

a clip

‐

on ammeter around the output cable

between

the

output pin (E2)

on the Trail Charger plug

and

the

10.

Hook



clip



ammeter



around



the



output



cable



between



the



output



(E2)



the



Trail



Charger



plug



and



the



liftgatebatterypositive(G)thencheckthevoltagewithavoltmeterbetween(G)and(H).Seefigure3.

Recordthereadings __________volts__________amps__________temp

Allowtheunittooperateforfivetotenminutesandretest.

th di

lt t

ecor



erea

ngs __________vo

s__________amps__________

emp

11. Whatistheambienttemperatureoftheliftgatebatteries? __________F

Note:Incoldweather,thevoltagemayincreaseupto15.0volts.Seechartbelowforrecommendedcharging

voltagesvs.temperature.

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

TrailChargerplugE

GreenLED

Figure1

Toliftgatebattery

i (H)

Toliftgatebattery

i (H)

E1 E4

negat

ve

(H)

negat

ve

(H)

Volt

Meter

Volt

Meter

Volt

Meter

Toliftgatebattery

negative(H)

Toliftgatebattery

positive(G)

Volt

Meter

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Figure2

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

IGNITIONE4

INPUTE1

OUTPUT

EXTENDER

OUTPUT



GROUNDE3

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

EXTENDER MODULE INFORMATION

EXTENDER



MODULE



INFORMATION

Toliftgatebatterynegative(H)

ToTrailChargerignitionpin(E4)

10PinConnector

Toredjunctionstud(C)

STARTUPState

BothLED’sturnonfor1secondandthenturnoff,thenitgoestotheOFFState.

OFF State

OFF



State

GreenLEDoff.

RedLEDoff.

Outputisoff.

Inthisstatethemoduleisinlowpowermodeanddrawslessthan1mAofcurrent.

Ifthedualpolevoltagerisestoover13.3voltsthenitgoestotheRUNNINGState.

RUNNINGState

GreenLEDon.

RedLEDon.

Outputison.

Ifthedualpolevoltagedropsbelow13.3voltsthenitgoestotheTIMINGState.

TIMINGState

GreenLEDoff.

RedLEDon.

Outputison.

Ifthedualpolevoltagedropsbelow11.0voltsthenitgoestotheOFFState.

Ifthedualpolevoltagerisestoover13.3voltsthenitgoestotheRUNNINGState.

IfithasbeenintheTIMINGStatefor30minutesthenitgoestotheOFFState.

Every five minutes it turns off the output for 5 seconds and then measures the dual pole voltage if the dual pole

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page16

Every



five



minutes



turns



off



the



output



for



seconds



and



then



measures



the



dual



pole



voltage

,



the



dual



pole



voltageisunder12.2voltsthenitgoestotheOFFState.

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

PARTS BREAKDOWN

PARTS



BREAKDOWN

284550‐01 COMPLETEKIT(TC,Extender,Harness,BagKit,Cover)

CompleteKitContents: Qty

906484‐01 TRAILCHARGER 1

284552‐01 TCEXTENDERCOMPLETEMODULEWITHHARNESS 1

906871‐01 25FTMOD5TRAILCHARGERSTRAIGHTTRUCKHARNESS 1

267522‐01 TRAILCHARGERCOVER 1

284554‐01 25FTMOD5TRAILCHARGERSTRAIGHTTRUCKBAGKIT 1

BagKitContents: Qty

906874‐01 10GA30"TRAILCHARGEROUTPUTWIRE 1

906875‐01 10GA30"TRAILCHARGERGROUNDWIRE 1

906876‐01 10GA24"TRAILCHARGERJUNCTIONSTUDTOINPUTWIRE 1

906873

SECONDARY LOCK

906873

‐

SECONDARY



LOCK

907015‐01 DEUTSCHPLUG 1

906877‐01 1‐1/4"CLEARIDTUBING,0.17ft. 1

906878‐01 SINGLEFUSECUBEBRACKET 2

906879‐01 CFNUTFORFUSECUBEBRACKET 2

906880‐01 FUSECUBE,30AMP 2

906881‐01 RED3/8JUNCTIONSTUD 1

906882‐01 REDRUBBERBOOT 1

*1/4"REDHEATSHRINK,1inchlong 1

*1/4"BLACKHEATSHRINK,1inchlong 1

*12‐10GA3/8"EYELET 2

*323/32"SMALLZIPTIES 12

*3/4"BLACKHEATSHRINK,3incheslong 1

284556

TRAIL CHARGER HARDWARE BAG KIT

284556

‐

TRAIL



CHARGER



HARDWARE



BAG



KIT

HardwareBagKitContents: Qty

** 5/8”NylonClamps 12

** ¼X20Nylonlocknut 8

** ¼”Flatwashers 8

** ¼X20¾”bolts 8

** #12X1½”Hextekscrews 1

** #12X¾”Hextekscrews 10

** #10X1”Hextek screws 5

** 3/8X16jamnut 1

REPLACEMENTITEMS Qty

907095 30AMPATCFUSE 1

907096

2 AMP ATC FUSE

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page17

*Itemsnotavailableseparately,mustorder25ftTrailChargerStraightTruckBagKit(284554‐01).

**Itemsnotavailableseparately,mustorderTrailChargerHardwareBagKit(284556‐01).

907096



AMP



ATC



FUSE



T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

284552‐01906484‐01284550‐01

906871

267522

284554

906871

‐

267522

‐

284554

‐

906874‐01 906875‐01 906876‐01

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page18

906873‐01 907015‐01

906877‐01

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

906878‐01(Qty:2) 906879‐01(Qty:2) 906880‐01(Qty:2)

906881

¼” RdHtSh i k

906882

906881

‐

¼”



906882

‐

12‐10Ga.3/8”Eyelet(Qty:2)

¼”BlackHeatShrink

SmallZip‐Ties(Qty:12)

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page19

¾”BlackHeatShrink

284556‐01 5/8”NylonClamps(Qty:12)

T.C.WITHEXTENDER– STRAIGHTTRUCKAPP.

VERSION1.04

06/07/2011

¼”FlatWasher(Qty:8)¼”x20NylonLockNut(Qty:8) ¼”x20x¾”Bolts(Qty:8)

#12 1 ½” H

#12 ¾” H

S (Qt 10)

#10 1” H

S (Qt 5)

#12

x



½”



ex

crews

#12

x

¾”



ex

crews

(Qt

y:

10)

#10

x

1”



ex

crews

(Qt

y:

3/8”x16JamNut

907095

907096

221N.14

Street,Rogers,AR72756P: 479.621.8282F: 479.621.9595

www.purkeysfleetelectric.com

Page20

Maxon TC Kit 10 Owner's manual

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