Maxon TC Kit 7 Owner's manual

TRAIL CHARGER with EXTENDER and

COMBO NOSE BOX

284424‐01 Version1.0203/14/2011

wners

anua

 Operation

 Installation

 Wiring Diagram

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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

batteries

.

Without



the



necessary



voltage



(electrical



pressure)



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vehicle'sbatteryboxtothedualpole

receptacleatthebackofthetractor,thedualpolecablefromthetractortothetrailer,thereceptacleatthefrontof

thetrailer,andthecablethatconnectstotheliftgate batteries.Thetotallengthofthiscanbewellover60feet.All

ofthislength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



proper



state



charge



which



results



shortened



battery



life

,

less



operating



time



and



possible



damage



the



liftgate motor.

SOLUTION

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

voltage



necessary



charge



and



maintain



the



liftgate



batteries.



This



increased



voltage



will



allow



the



batteries



voltage



necessary



charge



and



maintain



the



liftgate



batteries.



This



increased



voltage



will



allow



the



batteries



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

backfeedtothetractor’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

with



load

.



the



tractor



batteries



are



still



over



volts

,

the



Extender



turns



the



Trail



Charger



back



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tractor.

Thesystemallowsthefleettoutilizeeitheradualorsinglepole“stinger”cordtoprovidepowertotheTrailCharger

withExtender.Thisredundantgroundingsystemprovidestwocircuitstocarrythechargingcurrent:thecopper

circuitfromthedualpolegroundtotheliftgatebatteriesortheframeofthetrailer.

221N.14

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

www.purkeysfleetelectric.com

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

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

the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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batteryboxusingthesuppliedhardware.

Theseshouldbemountednearthe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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

INSTALLATION INSTRUCTIONS

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

box throughtheholeinthesideofthebattery

box.Allwiresroutedthroughthebatterybox

shouldbeprotectedwitharubbergrommetor

domenut. (SeeFigure4)

Route the following wires (the Deutsch pins go to

MAINHARNESS

INSTALLATION



INSTRUCTIONS

Route



the



following



wires



(the



Deutsch



pins



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

holeinthebacknexttowheretheTrailCharger

waspreviouslymounted.(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”

Rd i #7 lbld“12V O Pi #2”

OUTPUTPOSITIVE,OUTPUTNEGATIVE,,

INPUTWIRE,IGNITIONWIRE

‐

w

re

,



“12V



utput

n

#2”

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

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

Figure5

positions

.

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

#1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.

( )

221N.14

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

www.purkeysfleetelectric.com

Page4

‐ Inserttheignitionwire

(

IgnitionPin#4

)

from

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

connector.(SeeFigure6)

Figure6

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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

)

ontheTrailChar

er.Thiswill

Figure8

( p) g

helppreventwaterandcontaminatesfrom

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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.(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thatthe

positiveconnectionandthenegativeconnection

should be done on opposite batteries (See Figure 12)

221N.14

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

www.purkeysfleetelectric.com

Page6

should



done



opposite



batteries

.

(See



Figure



12)

Figure12

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step13: Atthefrontofthetrailer,locateand

markthelocationwherethecombinationsingle

anddualpolenoseboxwillbemounted.Consult

thetrailermanufacturerforproperlocationand

h b d

mountinginstructions.T

isstepmust

e

one

toensurethatthewiringharnessisnotcuttoo

shortinthefollowingsteps.(SeeFigure13)

Step14: Routethemainpowerharnessfrominside

thebatteryboxtothefrontofthetrailer.Utilizethe

factorychannelsuptothefifthwheelplateandthen

throu

htheelectrical

airlinetubestherestofthe

Figure13

g /

waytothefrontofthetrailertothedualpole

receptacle.Oncetheharnessisrouted,andithas

beendeterminedthatthereisenoughcable,cutthe

harnesstolength.Besuretoleaveenoughtobe

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

wiretomakealltheelectricalconnections.Make

sure to secure the harness with wire

ties (See

sure



secure



the



harness



with



wire

‐

ties

.

(See



Figure14)

Step15: Installthe¼”cableendtotheblack

groundwirebystrippingabout¼”ofthe

insulationoffofthewire,slideapieceofthe

Figure14

includedblackheatshrinkonthewire,then

crimpandsolderthe¼”eyeletontothe endof

thewire.Slidetheheatshrinkoverthe

connectionandapplyheat.Connecttheground

wiretothenegativesideofthedualpole

receptacleandtightenthebolttospecification.

(See Figure 15)

221N.14

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

www.purkeysfleetelectric.com

Page7

(See



Figure



15)

Figure15

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step:16: Connecttheredpositivewireofthe

mainharnesstothefuseassemblywithorange

leads.Thefuseassemblyalreadyhasabutt

connectorat tached.Justslideapieceofthe

includedredheatshrinkonthewire

thencrim



, p

andsoldertheconnection.Slidetheheatshrink

overtheconnectionandapplyhead.Connectthe

otherendofthefuseassemblytothepositive

sideofthedualpolereceptacleandtightenthe

bolttospecification.(SeeFigure16)

Step17: Mountthecombinationsingleanddual

polereceptacleonthefrontofthetrailerwhere

youhadpreviouslymarkedinstep#14.(See

)

Figure16

Figure17

)

Step18: Connecttheblackgroundwire#11that

comesoutofthe bottomofthenoseboxtothe

hi(d)ith lf d illi (S

Figure17

ass

s

(

groun

w

ith

ase



illi

ngscrew.

ee

Figure18)

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step19: Installationisnowcomplete,connecta

tractortothetrailerviathedualpolereceptacleand

checkoperationofTrailCharger.TheTrailCharger’s

green LED light should be illuminated The extender

green



LED



light



should



illuminated

.

The



extender



moduleshouldhavebothredandgreenLEDlights

illuminated.

Step20: 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battery

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

ensure that nothing will be damaged during

ensure



that



nothing



will



damaged



during



installation.(SeeFigure19)

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

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

Figure19

221N.14

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

www.purkeysfleetelectric.com

Page9

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

WIRING DIAGRAM

WIRING



DIAGRAM

IGNITIONE4

INPUTE1

OUTPUT

EXTENDER

A. DualPolePositive

B. 30AmpInlineFuse

C. Junction Stud

D. ExtenderModule

Trail



Charger

OUTPUT



GROUNDE3

Trail Charger

1. Input

2. Output

3. Ground

4. Ignition

F. 30AmpFuseCube

G. LiftgateBatteryPositive

Liftgate Battery Negative

Liftgate



Battery



Negative

J. DualPoleNegative

K. SinglePole(Positive)

L. SinglePoleChassisGround

M. FrontofTrailerChassisGround

Wire

Connection 1

Connection 2

Color

Wire

Connection



Connection



Color

1. GroundWire(MainHarness) DualPoleNegative LiftgateBatteryNegative Black

2. PositiveWire(MainHarness) DualPole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Ex tender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

CbB Piti Wi

DlPl Piti

Si l Pl (P iti )

221N.14

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

www.purkeysfleetelectric.com

o

ox

iti

ve



e

iti

e

iti

)

10. ComboBoxNegativeWire DualPoleNegative SinglePoleChassisGround Black

11. NoseBoxChassisGroundWire DualPoleNegative FrontofTrailerChassisGround Black

Page10

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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

Teste r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dualpolecordmustbeconnectedfromthetractortothe dual pole

receptacleonthetrailerorhaveadualpolecordconnectedtoabatteryonamobilecart.Thetractorneedsto

berunningorthemobilecartneedstohaveachargerconnectedandturnedonandthevoltagemustbeinthe

13.8to14.2vo

trange.

3.IsthegreenLEDontheTrailChargerilluminated?(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com

letec

cle.

Didthegreenlightturnon?(yesorno) _________

221N.14

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

www.purkeysfleetelectric.com

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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sourcevoltage.(i.e.batterysourceatfront

oftrailer,positive(A),negative(J))

SourceVoltage:________ (E1)PinVoltage:__________

TROUBLESHOOTING



GUIDE

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

A. Checkthefuse(B)belowthenosebox.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 batter y voltage.Ifyes,skipto

step5.Ifno,continuetostepB.

Check Voltage

between (C)

and

(H).

This should be the same as the

battery

voltage.

If yes, continue to step

Check



Voltage



between



(C)



and



(H).



This



should



the



same



the



battery



voltage.



yes,



continue



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)to(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.

D. Checkthegroundcircuitbycheckingthevoltagebetween(H)and(J).Thisshouldbezerovolts.Ifyes,

ti t t 5 If i th i bt (H) d (J) th ti t t 5

con

nue

os

ep

.

no,repa

r

ew

re

ween

(H)

an



(J)



encon

nue

os

ep

E. With the power source at the dual pole, check to see that you have the same voltage reading at the

single pole. If not, repair or replace wire #9 that connects the single pole (positive) to the dual pole

positive inside the combo nose box. Note: this could be checked the opposite way if the power

source is plugged in to the single pole.

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Extender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

damaged

,

broken

,



pinched

.



there



are



damaged



wires

,

replace



the



module



and



then



start



over



thebeginningofstep5.

B. Withtheharnessplugremoved,checkthevoltagereadingbetweentheignitionpin(E4)andbattery

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

operatingandgreenandredLEDlightsshouldbeon.

IftheLEDlightsarenotonandthereisnovoltage

at(4)and(H),removetheredleadfromthemodulethatattachedtothebatterypositive(G)andthen

221N.14

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

www.purkeysfleetelectric.com

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.

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

TROUBLESHOOTING GUIDE

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).

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

TROUBLESHOOTING



GUIDE

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).

8. Checkthevoltagebetweentheliftgatebatterynegative(H)andthedualpolereceptacle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

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.

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

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

TROUBLEHSOOTING GUIDE

TROUBLEHSOOTING



GUIDE

IGNITIONE4

EXTENDER

INPUTE1

OUTPUTE2

GROUNDE3

A. DualPolePositive

B. 30AmpInlineFuse

C. Junction Stud

Extender Module

Figure3

Clip‐OnAmmeter

Extender



Module

E. TrailCharger

1. Input

2. Output

3. Ground

4. Ignition

F. 30AmpFuseCube

G. Liftgate BatteryPositive

H. Liftgate BatteryNegative

J. DualPoleNegative

K. SinglePole(Positive)

L. SinglePoleChassisGround

M. FrontofTrailerChassisGround

221N.14

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

www.purkeysfleetelectric.com

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

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ANDCOMBONOSEBOX

VERSION1.02

03/14/2011

PARTS BREAKDOWN

PARTS



BREAKDOWN

284424‐01 COMPLETEKIT(TC,Extender,Harness,BagKit,Cover,ComboNoseBox)

CompleteKitContents: Qty

906484‐01 TRAILCHARGER 1

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

284431‐01 53FTMOD5TRAILCHARGERD.P.POWEREDHARNESS 1

267522‐01 TRAILCHARGERCOVER 1

284403‐01 DUALPOLE/SINGLEPOLENOSEKIT 1

284584‐01 MOD7TRAILCHARGERDUALPOLEPOWERED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

907107‐01 30AMPFUSEHOLDERASSEMBLYFORDUALPOLEAPPLICATIONS 1

906873‐01 SECONDARYLOCK 1

907015‐01 DEUTSCHPLUG 1

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

906878‐01 SINGLEFUSECUBEBRACKET 1

906879‐01 CFNUTFORFUSECUBEBRACKET 1

906880‐01 FUSECUBE,30AMP 1

906881‐01 RED3/8JUNCTIONSTUD 1

906882‐01 REDRUBBERBOOT 1

*1/4"REDHEATSHRINK,2inches 2

*1/4"BLACKHEATSHRINK,1inch 1

*12‐10GA1/4"EYELET 1

*323/32"SMALLZIPTIES 12

*3/4"BLACKHEATSHRINK,3inches 1

284556‐01 TRAILCHARGERHARDWAREBAGKIT 1

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

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53ftTrailChargerMod7BagKit(284584‐01).

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

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

906484‐01284424‐01

284431‐01284552‐01

26722‐01 284433‐01

221N.14

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

www.purkeysfleetelectric.com

Page18

284584‐01 906874‐01

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

906876‐01906875‐01

907107‐01(Includes30AmpFuse) 906873‐01

907015‐01

906877‐01

221N.14

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

www.purkeysfleetelectric.com

Page19

906878‐01 906879‐01

T.C.WITHEXTENDERANDCOMBONOSEBOX

VERSION1.02

03/14/2011

906880‐01 906881‐01

¼”RedHeatShrink

906882‐01

12‐10Ga.¼”Eyelet¼”BlackHeatShrink

221N.14

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

www.purkeysfleetelectric.com

Page20

SmallZip‐Ties ¾”BlackHeatShrink

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