Maxon TC Kit 8 Owner's manual

Brand: Maxon

Model: TC Kit 8

Category: Motorcycle Accessories

Type: Owner's manual

Owner’sManual

P/N:283821‐500

3 in 1 TRAIL CHARGER with LOCKOUT

283821‐01 Version2.0407/05/2011

Owners Manual

 Operation



Installation

 Wiring Diagram

 Troubleshooting

 Parts Breakdown

221N.14

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

www.purkeysfleetelectric.com

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

GENERAL OPERATION

GENERAL



OPERATION

The3in1ChargeControllersystemisthepowersourcetoaDC/DCconvertercalledaTrailChargerthatis

locatedinsideoroutsidethebatterybox.TheTrailCharger isapoweramplifierthatmaximizesthecharging

voltage sothattheliftgatebatteriesarekeptataveryfullstateofchargeandtheliftgateoperationisfaultless

andnotimpactedbydischargedbatteries.Bothofthesesystemsrequirenointeractionfromthedriver–as

thereislogicbuiltintothesystemthatallowsthemtofunctioninthemosteffectivemanner.

The3in1ChargeControllersystemisdesignedtoallowthemaximumflexibilityforfleetswithtrailersthatare

equipped with

liftgates

By utilizing the 3 in 1 system there are now three power source options to charge the

equipped



with



liftgates

.



utilizing



the



system

,

there



are



now



three



power



source



options



charge



the



liftgatebatteriesfromthetractor.Themostoptimalwayistouseadualpolestingercord.Ifthetractordoes

nothaveadualpolestingercord,the3in1ChargeControllerwilllookforthenextbestoption–asinglepole

stingercord.Whenevereitherasingleordualpolestingercordisconnectedtothe3in 1ChargeControllera

yellowLEDlightwillilluminateonthe3in1noseboxindicatingthesystemisoperationalandthatpoweris

beingdirectedtotheliftgatebatteries.Ifthetractorisnotequippedwitheitheradualorsinglepolestinger

cord,orthestingercordisnotfunctioningproperly,the3in1ChargeControllerwillutilizethe7‐wayauxiliary

circuit(Aux–bluecenterpinonsevenway)asthepowersource.WhenpowerfromtheAuxcircuitisavailable

(theAuxcircuitiskeyswitchcontrolled)agreenLEDlightwillilluminateonthe3in1noseboxindicatingthat

th A iiti il bl If th 3 i 1 Ch Ctlli ti ff f th A iit

e

uxc

rcu



sava

easapowersource.



e



n



arge

er

sopera

ngo

o



e

uxc

rcu

,

the3in1modulewillautomaticallyturnofftheTrailChargerwhenthebrakesareapplied.Thisfeaturekeeps

theABSbrakesystemonthetrailerfrombeinginte rruptedwhenthebrakesarebeingusedsothattheABS

brakesystemreceivesfullvoltage.

221N.14

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

www.purkeysfleetelectric.com

Page2

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

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

batteryboxusingthesuppliedself‐drillingsheet

metalscrews.(SeeFigure1)TheTrailChargershould

bemountedabout1½”downfromthetopandjust

INSTALLATION



INSTRUCTIONS

totherightofthegrommet.Theunitmustalsobe

mountedwiththeplugpointeddown(6o’clock).

Note:Besurethatthescrewswillnotinterferewith

thebatteriesinthebox.

Figure1

Step2: Routethemainharnessintothebatterybox

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

Note: Allwiresroutedthroughthebatteryboxshouldbe

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

Route the following wires (the Deutsch pins go to the

MAINHARNESS

Route



the



following



wires



(the



Deutsch



pins



the



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

backnexttotheTrailCharger.(SeeFigure2)

‐ Bluewire“16”,labeled“IgnitionPin#4”

‐ Blackwire“17”,labeled“12VInputPin#1”

‐ Redwire“19”,labeled“12VOutputPin#2”

‐ Whitewire“18”,labeled“GRNDPin#3”

O i “3” lbld“L k t It”

MAINHARNESSPOSITIVE,OUTPUTPOSITIVE/IGNITION,

OUTPUT GROUND BRAKE LOCKOUT WIRE

‐

rangew

re

“3”

,



“L



npu

t”

OUTPUT



GROUND

,

BRAKE



LOCKOUT



WIRE

Figure2

Step3: Mounttheincludedinsulatedstud(C)to

theinsideofthebatteryboxusingthesupplied

hardware.

MounttheExtenderModule(D)totheinsideof

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

Theseshouldbemountednearthebatterybox

groundstudasshowninthepicturetotheright.

(SeeFigure3)

221N.14

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

www.purkeysfleetelectric.com

Page3

Figure3

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step4: ConnecttheExtenderharnesstothe

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

(SeeFigure4)

Figure4

Step5: Connectthefollowingwire stothered

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

“JunctionStud”.

‐

Purple wire (#15) from module

Purple



wire



(#15)



from



module

‐Blackwire(#7)fromthedualpole(+)

‐Blackwire(#17)fromTC(routedinstep2)

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

Figure5

Step6: LocatethefourpinDeutschconnectorfrom

thebagkitandinsertthewiresintothecorrect

positions

.

‐ Inserttheblackinputwire(#17)(12VInputPin#1)

intothe#1position(X1)ontheconnector.

‐ Inserttheredoutputpositivewire(#19)(12VOutput

Pin#2)intothe#2position(X2)ontheconnector.

‐ Insertthewhiteoutputgroundwire(#18)(Ground

Pin#3)into

the#3position(X3)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blueignitionwire

(

#16

)



(

IgnitionPin#4

)



fromtheextendermodule(R)intothe #4position

(X4)ontheconnector.(SeeFigure6)

Figure6

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step7: Verifyallthewiresareintheircorrect

positionsandlockedinplace.(SeeFigure7)

• Figure5‐1:Black10AWG12Voltinputpowerof

themainharness.

• Fi

ure5‐2:Red10AWGTrailChar

erout

ut

INSTALLATION



INSTRUCTIONS

g p

powertoliftgatebattery’spositive(+).

• Figure5‐3:White10AWGTrailChargeroutput

groundtoliftgatebattery’snegative(‐).

• Figure5‐4:Blue14AWGignitioninputofthe

mainharness.

Figure7

Ste

8: Oncebothwiresareinsertedintothe

Insert Flush,locked

into place

connectortheorangelockcanbeinserted.(See

Figure8)

into



place

gure

Step9: Insertthebrakecircuitwireintothe6way

Deutschconnectorinthe#2position.Theother

positionsshouldalreadyhaveplugsinsertedinto

theemptyholestohelppreventcorrosionand

contamination.(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

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step10: Oncethewireisinsertedintotheconnector

theorangelockcanbeinserted.Makesurethatthe

lockisproperlyseated.(SeeFigure10)

INSTALLATION



INSTRUCTIONS

Step11: Slidetheincludedcleartubingoverthe

connectorsontheTrailCharger.Thiswillhelp

preventwaterandcontaminatesfromenteringthe

ltil

(S Fi

11)

Figure10

connec

ons.

ee

gure

11)

Figure11

Step12: Theharnessplugsmaynowbeinserted

intotheTrailCharger.Pushthe4wireconnector

intothetubingandintothe appropriatesocketon

theTrailCharger.Pushthe6wireconnectorinto

thetubingandintotheappropriatesocketonthe

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

screwdrivertomakesuretheplugsareproperly

seated.(SeeFigure12)

221N.14

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

www.purkeysfleetelectric.com

Page6

Figure12

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step13: Thelastconnectionscannowbemadeat

theliftgatebatteries.Firstinstall the fusecube

assemblyononeoftheliftgatepositivebattery

terminals. (SeeFigure13)

INSTALLATION



INSTRUCTIONS

Step14: Thered10AWGTrailChargeroutput

positive wire labeled

“

liftgate

positive

”

can now

Figure13

positive



wire



labeled



liftgate



positive



can



now



connectedtothefusecubeassembly.Removethe

insulatednut,installthewireandreinstallthenut.

ThewhiteTrailChargeroutputgroundwireand

thewhitewirefromthemainharnessshouldbe

connectedtothenegativepostoftheopposite

batteryasshown.(SeeFigure14)

Figure14

O th TilCh i tdth

ep

nce

e



arger

smoun



e

mainharnesscanberoutedtothefrontofthe

trailerutilizingthefactorychannelsuptothefifth

wheelplate andthenthroughtheelectrical/airline

tubestherestofthewaytothefrontofthetrailer.

(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

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step16: 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mounting

h b d h

instructions.T

isstepmust

e

onetoensuret

at

thewiringharnessisnotcuttooshortinthe

followingsteps.(SeeFigure16)

Step17: Routethemainharnesstothe frontofthe

trailerutilizingthefactorychannelsuptothefifth

hllt d th th h th ltil/ili

Figure16

p

ean



en

roug



ee

r

ne

tubestherestofthewaytothefrontofthetrailer.

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

Figure17

securetheharnesswithwire‐ties.(SeeFigure17)

Step18:.Routetheharnessintothe3in1nosebox

throughtheholeinthebottom.(SeeFigure18)

221N.14

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

www.purkeysfleetelectric.com

Page8

Figure18

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step19: Connecttheblackwire(7)fromthemain

harnesstothefuseassembly(K)thatisalready

connectedtothedualpolepositive(L).Stripthe

endoftheblackwire(7)approximately¼”.Slidea

f h ¼” d h hk h

pieceo

t

e

¼”

re



eats

rin

overt

ewire.

Insertthestrippedwireintothebuttconnectorof

thefuseassembly(K),crimpandsolder.Placeheat

shrinkoverconnectionandapplyheat.(SeeFigure

19)

Step20: Connecttheyellowwire(6)fromthemain

harnesstothefuseassembly(J)thatisalready

connectedtotherelay(H)86terminal.Striptheend

of the yellow wire (6) approximately ¼

”

Slide a piece

Figure19



the



yellow



wire



(6)



approximately



.

Slide



piece



ofthe¼”redheatshrinkoverthewire.Insertthe

strippedwireintothebuttconnectorofthefuse

assembly(J),crimpandsolder.Placeheatshrinkover

connectionandapplyheat.(SeeFigure20)

Figure20

Step21:.Connectthewhitewire(8)fromthemain

harnesstothedualpolenegative(M).Striptheendof

th hit i (8) itl¼” Slid i f

ew

hit

ew

re

(8)

approx

y

¼”

.

Slid

eap

eceo



theblackheatshrinkoverthewire.Insertthe

strippedwireintothe¼”eyeletfromthebagkit,crimp

andsolder.Placetheheatshrinkovertheconnection

andapplyheat.Connecttheeyelettothedualpole

negative(M).Tightenproperly.(SeeFigure21)

221N.14

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

www.purkeysfleetelectric.com

Page9

Figure21

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step22: Routethewhitewire(2)fromthe3in1nose

boxtothe7‐waynosebox,cuttolength.Striptheend

ofthewhitewire(2)approximately¼”.Slideapiece

oftheblackheatshrinkoverthewire.Insertthe

stri

edwireintothe#10e

eletfr omtheba

kit



pp y g ,

crimpandsolder.Placetheheatshrinkoverthe

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

groundpin(D)ofthe7‐way.Tightenproperly.(See

Figure22)

Figure22

Step23:.Connecttheblue fuseassembly((E)

11020FH‐2)fromthebagkittothe7‐wayauxpin(B).

Tightenproperly.(SeeFigure23)

Figure23

Step24: Routethebluewire(1)fromthe3in1

noseboxthatisconnectedtotherelay(H)87

terminal to the 7

way nose box Cut the blue wire

terminal



the



‐

way



nose



box

.

Cut



the



blue



wire



(1)tolengthtobeabletoconnecttothefuse

assembly(E).Striptheendofthebluewire(1) 

approximately¼”.Slideapieceoftheredheat

shrinkoverthewire.Insertthestrippedwireinto

thebuttconnectorofthefuseassembly(E),crimp

andsolder.

Placeheatshrinkoverconnectionand

221N.14

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

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Page10

applyheat.(SeeFigure24)

Figure24

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step25: Connecttheorangefuseassembly((F)FH‐

3IN1‐3)fromthebagkittothe 7‐waybrakepin(C).

Tightenproperly..(SeeFigure25)

Figure25

Step26:.Routetheorangewireofthefuseassembly

(F)fromthe7‐wa ynoseboxtothe3in1nosebox.

Cuttheorangewireofthefuseassemblytolengthto

beabletoconnecttotheoran

ewire(3)ofthemain

harness.Striptheendofbothoftheorangewires

approximately¼”.Slideapieceoftheredheatshrink

overthewire.Insertthestrippedwiresintothebutt

connectorfromthebagkit,crimpandsolder.Place

heatshrinkoverconnectionandapplyheat.(See

Figure26)

Figure26

Step27: Mountthe3in1noseboxtothefrontofthe

trailerusingthescrewsfromthehardwarekit.(See

Figure27)

221N.14

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

www.purkeysfleetelectric.com

Page11

Figure27

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Step28:.Connectthewhitechassisgroundwire(11)

toagoodchassisgroundonthefrontofthetrailer.

(SeeFigure28)

Figure28

Step29:Thesystemisnowreadytotest.Checkthe

auxpinpoweredoperationbyconnectingatractorto

thetrailerviathe7‐wayreceptacle,turnthekeyonand

check operation of Trail Charger. (No single or dual

check



operation



Trail



Charger.



(No



single



dual



poleshouldbeconnected.)TheTrailCharger’sgreen

LEDlightshouldbeilluminated(SeeFigure29).

Measuretheliftgatebatteryvoltage,shouldbe near

14.0volts.TheredandgreenLEDlight(SeeFigure30)

shouldbeilluminatedonthemodule.Checkthebrake

lockoutfunctionbyverifyingthatthegreenLEDonthe

Trail Charger flashes slo l hen the brakes are

Step32: Checkthesingle/dualpolepoweredoperation

by connecting a tractor via a single or dual pole stinger

Trail



Charger



flashes



slo

yw

hen



the



brakes



are



applied.Whenthebrakesarereleased,theLEDshould

gobacktosolid.

Figure29



connecting



tractor



via



single



dual



pole



stinger



cord.TheTrailCharger’sgreenLEDlight(SeeFigure30)

shouldbeilluminated.ThegreenLEDlight(SeeFigure

32)shouldbeilluminatedonthemodule.

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

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

221N.14

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

www.purkeysfleetelectric.com

Page12

Figure30

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

INSTALLATION INSTRUCTIONS

INSTALLATION



INSTRUCTIONS

Figure32

Step33: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

rovided

)

toattachthecovertothebatter

box.

(p ) y

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

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

installation.(SeeFigure31)

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

thewatertorundownaw ayfromtheTrailCharger.

ure31

221N.14

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

www.purkeysfleetelectric.com

Page13

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

WIRING DIAGRAM

WIRING



DIAGRAM

MODULE

OCKOUTY‐2

INPUTX1

IGNITIONX4

GROUNDX3

OUTPUTX2

Yell

Pur

85 86

87A

10 9 8 7 6

5 4 3 2 1

MODULE PIN #

’

ite

7‐WA Y

MODULE



llow

GREEN

LED

YELLOW

LED

221N.14

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

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Page14

510

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

WIRING DIAGRAM LEGEND

Components:

A. 7‐WayReceptacle

B. AuxPinof7‐Way

C. BrakeCircuitPinof7‐Way

D. GroundPinof7‐Way

WIRING



DIAGRAM



LEGEND

Components(Cont.):

T. FuseCube,30Amp

U. LiftgateBatteryPositive

V. LiftgateBatteryNegative

W. JunctionStud,Insulated,Red

il Ch ii h Ci

E. Fuse,

Amp

F. Fuse,2Amp

G. ComboNoseBox(SingleandDualPole)

H. Relay,30Amp

J. Fuse,2Amp

K. Fuse,30Amp

L. DualPoleRece

taclePositive

X. Tra



argerFourPos

onDeutsc



onnect

1. Input

2. Output

3. Ground

4. Ignition

Y. TrailChargerSixPositionDeutschConnection

1. Notusedinthisa

lication

M. DualPoleReceptacleNegative

N. SinglePoleReceptaclePositive

P. SinglePoleReceptacleCaseGround

Q. FrameGround,FrontofTrailer

R. Module,3in1Version2

S. Fuse,2Amp

2. LockoutPin

3. Notusedinthisapplication

4. Notusedinthisapplication

5. Notusedinthisapplication

6. Notusedinthisapplication

Z. GreenLEDAssembly

Yellow LED Assembly

Wire# ConnectFrom: ConnectTo: Color:

1. 7‐WayAuxPin(B) Relay87Terminal(H‐87) Blue

2. 7‐WayGroundPin(D) DualPoleNegative(M) White

3. 7‐Wa

BrakePin

(

)

TrailChar

erLockout

(

Y‐2

)

Oran

Yellow



LED



Assembly

y ()

g (

)

4. Relay87Terminal(H‐87) Relay85Terminal(H‐85) Blue

5. Relay30Terminal(H‐30) DualPoleNegative(M) Black

6. Relay86Terminal(H‐86) Module(R‐3) Yellow

7. DualPolePositive(L) JunctionStud(W) Black

8. DualPoleNegative(M) LiftgateBatteryNegative(V) White

9. DualPoleNegative(M) SinglePoleCaseGround(P) White

Dual Pole Positive (L)

Single Pole Positive (N)

Black

Dual



Pole



Positive



(L)

Single



Pole



Positive



(N)

Black

11. SinglePoleCaseGround(P) FrameGroundFrontofTrailer(Q) White

12. Module(R‐5) LiftgateBatteryPositive(U) Red

13. Module(R‐1) LiftgateBatteryNegative(V) White

14. SpliceFromWire6 Module(R‐10) Yellow

15. Module(R‐2) JunctionStud(W) Purple

16. Module(R‐4) TrailChargerIgnition(X‐4) Blue

221N.14

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www.purkeysfleetelectric.com

Page15

17. JunctionStud(W) TrailChargerInput(X‐1) Black

18. TrailChargerGround(X‐3) LiftgateBatteryNegative(V) White

19. TrailChargerOutput(X‐2) LiftgateBatteryPositive(U) Red

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

Testingthecombinationnosebox(single/dualpole)portionofthe3in1system.

1. Pluginasingleordualpolestingercordfromthetractororabatterywithabatterychargerconnectedtoit.If

utilizingasinglepolecord,thetractormustbecoupledwiththe

trailertoprovideagroundsource.Ensurethe

systembeingusedhastheabilitytoprovideupto25ampsat14.0volts.(Donotplugthe7‐waycordinatthis

time.)TheyellowLEDlightshouldilluminate.Ifyes,thesingleordualpolehaspowerandisfunctioning

l k f

proper

y,s

iptostep2.I

no,continuetostep1‐A.

A. Unplugthestingercordandcheckthevoltageattheplug.Ifvoltageisthesameasthesourcevoltage

continuetostep1‐B.Ifno,repairorreplacestingercordandstartoveratstep1.

B. Withthestingercordpluggedin,checkthebacksideofthesingleordualpolereceptacle(whicheveris

beingutilized)andseeifthevoltageisthesameasthesourcevoltage.Continuewiththefollowingusing

thesectionthatpertainswiththeconnectionbeingusedforthetroubleshooting.

DualPole

a) Ifyes,continuetostep1‐C.Ifno,replacethedualpolereceptacleandstartoveratstep1.

SinglePole

a) Ifyes,continuetothenextstep.Ifno,replacethesinglepolereceptacleandstartoveratstep1.

b) Checkthevoltageonthebacksideofthedualpolereceptacleandseeifthevoltageisthesame

asthesourcevoltage.Ifyes,continuetostep1‐C.Ifno,continuetothenextstep.

Check wire #10 between the single pole positive and the dual pole positive for damage or a loose

Check



wire



#10



between



the



single



pole



positive



and



the



dual



pole



positive



for



damage



loose



connection.Alsocheckthe#9wirefordamageoralooseconnection.Repairorreplaceas

necessary.Startoveratstep1.

Note:Ifthesinglepoleisbeingutilized,thereshouldbevoltage(sameassourcevoltage)at

boththesinglepolepositiveandthedualpolepositive.Wire#9and#10isusedto

connectthesetwoinparallel.

C. Checkthe30ampfuse(K)foragoodconnectionorblownfuse.Ifblowndeterminetheproblemand

repairthenreplaceandstartoveratstep1.Ifnoproblemfound,continuetothenextstep.

D. Unplugthepackard connectorinthepositivewireoftheyellowLEDthatconnectstothedualpole

positive.Checkthevoltageofthepackard connectorthatisstillconnectedtothedualpolepositive.

Thisshouldbethesameassourcevoltage.Ifyes,andthegroundwireoftheyellowLEDappearstobe

connectedcorrectlywithnodamage,continuetothenextstep.Ifno,thereisaproblembetweenthe

packard connectorandthedualpolepositiveorthegroundwireoftheyellowLED.Repairorreplace

wiring as needed.

wiring



needed.



E. DisconnecttheyellowLEDfromtheconnectionsinthenosebox.Connecta12voltpowersourcetothe

lightandcheckoperation.Iftheyellowlightdoesnotcomeon,replacetheyellowLED.Ifthelightdoes

comeone,retraceboththepositiveandnegativewiringfromthelightbacktothepowersourceto

determinetheproblem.

2. Withpowerstillatthesingleordualpolecombinationbox,checkthevoltagebetweenthejunctionstud(W)and

theliftgatebatterynegative(V),shouldbeclosetothesourcevoltage.Ifyes,skiptothe7‐wayauxpin

portion

f th 3 i 1 t t 3 If hki #7 f bk d bt th jti td(W) d th

221N.14

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

www.purkeysfleetelectric.com



e



n

sys

em,s

ep

.

no,c

w

re



or

rea

sor

amage

ween

e

unc

ons



(W)

an



e

dualpolepositive(L).Repairorreplaceasneeded.(The30ampfuse(K)shouldhavebeencheckedina

previousstep.Ifneeded,doublecheckthatthefuse(K)isnotblown.)Checkthegroundwire#8forbreaksor

damageaswell.Repairorreplaceasneededandrepeatthisstep.

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

Testingthe7‐way(auxpin)portionofthe3in1system.

3. Makesurethesingleordualpolestingercordisdisconnectedfromthecombinationnosebox.Pluginthe7‐way

cablefromthetractorreceptacletothetrailerreceptaclemakesurethatthetractorisrunning.Thegreenand

theyellowLEDshouldilluminate,showingthatthecombinationnoseboxhaspowerfromthe7‐wa yauxpin.If

yes,continuetostep4.Ifgreenilluminatesandtheyellowdoesnot,skiptostep3‐J.Ifneithergreenoryellow

illuminate,continuetostep1‐A.

A. Unplugthe7‐waycablefromthetrailer.Checkthevoltagebetweentheauxpinandthegroundpin,this

shouldbethesameasthetractorbatteryvoltage.Ifyes,plugthe7‐waycablebackintothe trailerand

continuetothenextstep.Ifno,checkthetruck’s7‐waycircuitandensurethatthecircuitmeetsthe

O.E.M.’sspecifications,thenstartatstep3again.

B. Plugthe7‐waycablebackintothetrailer.Checkthevoltagebetweentheauxpin(B)andthegroundpin

(D)onthebackofthe7‐wayreceptacle,shouldbeclosetotractorvoltage.Ifyes,continuetothenext

step. If no, the 7

‐

way receptacle appears to be bad. Follow the 7

‐

way receptacle manufacturer

’

step.





no,



the



way



receptacle



appears



bad.





the



way



receptacle



manufacturer s



proceduresforfurthertestingandreplacementinstructions.Startwithstep3again.

C. Checkthe30ampfuse(E)foragoodconnectionorblownfuse.Ifblowndeterminetheproblemand

repairthenreplaceandstartoveratstep3.Ifnoproblemfound,continuetothenextstep.

D. Withthe30ampfuse(E)removedfromtheholder,checkthevoltagebetweentheinput sideofthefuse

holderandthe7‐wa ygroundpin(D),shouldbeclosetotractorvoltage.Ifyes,reinstallfuseand

continuetonextstep.Ifno,repairorreplacewirebetweenthefuse(E)andthe7‐wayauxpin(B).Start

ith t 3 i

ith

s

ep

aga

E. Inthecombinationnosebox,checkthevoltagebetweentherelay87terminal(H‐87)andthedualpole

receptacleground(M),shouldbeclosetotractorvoltage.Ifyes,continuetothenextstep.Ifno,repair

orreplacethe#1wire,thenstartatstep3again.

F. Checkthevoltagebetweentherelay85terminal(H‐85)andthedualpolereceptacleground(M),should

beclosetotractorvoltage.Ifyes,continuetothenextstep.Ifno,repairorreplacethe#4wire,then

startatstep3again.

G. Unplugthepackard connectorinthepositivewireofthegreenLEDthatconnectstotherelay(H)85

terminal.Checkthevoltageofthepackard connectorthatisstillconnectedtotherelay(H)85terminal.

Thisshouldbeclosetotractorvoltage.Ifyes,andthegroundwireofthegreenLEDappearstobe

connectedcorrectlywithnodamage,continuetothenextstep.Ifno,thereisaproblembetweenthe

packard connectorandthe7‐wa yauxpin(B)orthegroundwireoftheyellowLED.Repairorreplace

wiringasneeded.

Disconnect the green LED from the connections in the nose box Connect a 12 volt power source to the

Disconnect



the



green



LED



from



the



connections



the



nose



box

.

Connect



volt



power



source



the



lightandcheckoperation.Ifthegreenlightdoesnotcomeon,replacethegreenLED.Ifthelightdoes

comeone,retraceboththepositiveandnegativewiringfromthelightbacktothe7‐wayauxpin(B)and

groundpin(D)todeterminetheproblem.

J. Inthecombinationnosebox,checkthevoltagebetweentherelay(H)86terminalandthedualpole

receptacleground(M),shouldbezero.Ifyes,continuetothenextstep.Ifno,checkthe2ampfuse(J)

foragoodconnectionorblownfuse.Ifblown,determinetheproblemandrepairthen

replaceandstart

221N.14

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

www.purkeysfleetelectric.com

overatstep4.

K. Inthecombinationnosebox,checkthevoltagebetweentherelay(H)30terminalandthedualpole

receptacleground(M),thisshouldbeclosetobatteryvoltage.Ifyes,continuetothenextstep.Ifno,

replacetherelay(H).

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

4. Checkthevoltagebetweenthejunctionstud(W)andtheliftgatebatterynegative(V),shouldbeclosetotractor

batteryvoltage.Ifyes,skiptothemoduleportionofthe3in1system,step5.Ifno,checkwires#1,#5,and#7

forbreaksordamagebetweenthejunction

stud(W)andthe7‐wa yauxpin(B).Repairorreplaceasneeded.

(The30ampfuses(B)and(K)shouldhavebeencheckedinapreviousstep.Ifneeded,doublecheckthatthe 

fuses(E)and(K)arenotblown.)Checkthegroundwires#2and#8forbreaksordamageaswell.Repairor

l dd d h

rep

aceasnee

an

repeatt

isstep.

Testingthemoduleportionofthe3in1system.

5. ModuleLEDLights:

• RedandgreenLEDlightsturnonforonesecondandthenoffwheneverthemoduleispowered.

• RedandGreenLEDli

htonindicatesthatthemoduleisturnin

ontherela

andthe7‐wa

aux

inis

g g y

y p

poweringtheTrailChargerandtheTrailChargerignitionispowere d.

• GreenLEDlightonindicatesthatthemoduleisturningontheTrailCharger.

• RedandgreenLEDlightsalternateonandoffrapidly,themoduleisdetectinglowvoltagefromthenosebox.

TheTrailChargerwillbeturnedoffuntilthemodulesees13.2voltsorgreaterfromthenosebox.

Troubleshooting

“

no LED lights illuminate on the module

”

Troubleshooting



LED



lights



illuminate



the



module

6. Ensuretheliftgatebatteriesareatleast12.3voltsorhigher.

7. Unplugthe10pinconnectorinthemoduleharnessandthenreconnect.BoththeredandgreenLEDlights

shouldilluminateforonesecondandthenturnoff.Ifyes,themoduleisgettingpowerfromtheliftgatebatteries

andisturnedon,skiptostep11.Ifno,continuetothenextstep.

8. Withthe10pinconnectorunplugged,checkthevoltagebetweenpin#1andpin#5ofthe10pinconnector

fromtheharness.Shouldreadthesameasliftgatebatteryvoltage.Ifyes,replacethemoduleandstartagainat

step6.Ifno,continuetothenextstep.

9. Withthe10pinconnectorunplugged,checkthevoltagebetweentheliftgatebatterypositive(U)andpin#5of

the10pinconnectoroftheharness.Shouldreadzero.Ifyes,continuetothenextstep.Ifno,thereisa

problem

withthe#12wire.Checkthefuse(S)foragoodconnectionorablownfuse.Ifblown,determinethe 

problemandrepairthenreplacefuse.Inspectthe#12wirefordamage.Repairorreplaceasnecessary.And

startagainatstep6.

10.

With the connector unplugged, check the voltage between the liftgate battery negative (V) and pin #1 of the 10

10.

With



the



connector



unplugged,



check



the



voltage



between



the



liftgate



battery



negative



(V)



and



the



pinconnectoroftheharness.Shouldreadzero.Ifyes,moduleisgettingpowerandneedstobereplaced.Ifno,

thereisaproblemwiththe#13wire,inspectfordamageandrepairorreplaceasnecessary.Startagainatstep

Troubleshootingtheoutputofthemodule(ignitioncontroller)

11. UnplugthefourpinandsixpinDeutschconnectorsfromtheTrailCharger.

Ul th 10 i t i th dl h Ch k th lt bt th iltdjti td(W)

221N.14

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

www.purkeysfleetelectric.com

ug

e

p

nconnec

or

n

emo

e

arness.



evo

age

ween

e

nsu



unc

ons



(W)



andthe#2pinofthe10pinconnectoroftheharness.Shouldreadzero.Ifyes,continuetothenextstep.Ifno,

thereisaproblemwiththe#15wire,inspectfordamageandrepairorreplaceasnecessary.

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

TROUBLESHOOTING GUIDE

TROUBLESHOOTING



GUIDE

13. Withthe10pinconnectorpluggedin,ensurethatthemodule’sgreenLEDlightisilluminatedandthencheckthe

voltagebetweenthe#4pinofthefourpinDeutschConnector(X‐4)andtheliftgatebatterynegative(V).Should

bethesameasthevoltagereadingbetweentheinsulatedjunctionstud(W)andtheliftgatebatterynegative(V).

Ifyes,moduleisworkingandisturningontheTrailCharger.Ifno,continuetothenextstep.

14. Unplugthe10pinconnector.Checkthevoltagebetweenthe#4pinofthe10pinconnectorofthemoduleand

theliftgatebatterynegative(V).Shouldbethesameasliftgatebatteryvoltage.Ifyes,moduleisworkingandis

turningontheTrailCharger.Ifno,themoduleneedstobereplaced.

TroubleshootingtheTrailCharger

Note: ThisportionoftestingshouldbeconductedwithNO singleordualpolepowersourceconnected.

15. Disconnectandtesttheliftgatebatteriesindividually.Alloftheliftgatebatteriesmustpassaloadtestorbe

replacedbeforeproceeding.

16. TheSTATUSLEDlightoftheTrailChargerwillindicateseveraldifferentconditions.Thisisaccomplishedbythe

useofaBi‐ColorLEDthatwillindicatewitheitherasolidcolororablinkingcoloratthreedifferentblinkrates.

(Seetablebelow):

RATE

TIMING

RATE

TIMING

Slow 1secondon,1secondoff

Medium ½secondon,½secondoff

High ¼on,¼off

Definitionofindicationsarefoundbelow:

LEDof

Moduleoff,ignitionorinputvoltagenotpresent

LED,Red,highblink FAULT,anyonthefaultlistbelow

LED,Green,mediumblink SHUTDOWNmode(Pg.20) InputCommandShutdown:ON

LED,Green,slowblink Reducepowermode,charging(Pg.20) InputCommandShutdown:OFF

LED,Green,solid ChargingorCharged(WorkingProperly) InputCommandShutdown:OFF

AREDLEDblinkingatahighrate indicatesoneofthefollowingfaultconditionsexist:

• Inputunder‐voltagelimit.(T/Sprocedurestep17onpg.20)

• Inputover‐voltagelimit.(T/Sprocedurestep18onpg.20)

221N.14

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www.purkeysfleetelectric.com

• Outputover‐voltagelimit.(T

Sprocedure step19onpg.20)

• Outputover‐currentlimit/OutputFET’soverthermallimits.(T/Sprocedurestep20onpg.21)

AfastblinkingREDfromanyfaultindicationhasahigherpriority thanallotherindicationsiftheignitionison.

3IN1TRAILCHARGERWITHLOCKOUT

VERSION2.04

07/05/2011

TROUBLESHOOTING GUIDE

17. A.CheckingforINPUTundervoltagecondition–HighRateBlinkingRedLED

A. Pluginaknowgoodpowersourceintothetrailer(7‐wa y),thiscanbeatractororportablebattery

source.

B. WiththeTrailChargeroperating,testthevoltageattheinputpin(X‐1)andthegroundpin(X‐3).

Thevoltagemustbeover9.0volts.Ifyes,proceedtostepB.Ifno,recordthereadingandmoveto

the next step Voltage reading:

TROUBLESHOOTING



GUIDE

the



step

.

Voltage



reading:

__________.

C. Testthevoltageattheaux.pin(B)ofthe7‐waynoseboxatthefrontofthetrailer.Notethevoltage

andamountofcurrentflowingandrecord.Voltage:__________Amps:__________

D. Subtractthevoltagereadinginstep2fromthereadinginstep3andcomparetothechart

referencingtheampreadinginstep3.

1) At20ampstheallowablevoltagedropis3.0volts.

2) At15ampstheallowablevoltagedropis2.25volts.

3) At10ampstheallowablevoltagedropis1.5volts.

4) At5ampstheallowablevoltagedropis.75volts.

E. Ifhigherthanallowed,repairthewiringfromthenoseboxtotheTrailCharger(wire#7forpositive

andwire#8fornegative).

18.

Checking for INPUT over voltage condition

–

High Rate Blinking Red LED

18.

Checking



for



INPUT



over



voltage



condition



High



Rate



Blinking



Red



LED

A. Pluginaknowgoodpowersourceintothetrailer,thiscanbeatractororportablebatterysource.

B. WiththeTrailChargeroperating,testthevoltageattheTCpin#1andTCpin#3.Ifthevoltageis

over16.7volts,yourvoltagesourceisdefective(overcharging)andneedstobeeitherrepairedor

replaced.

Ch ki f OUTPUT lt diti

Hi h Rt Bli ki RdLED

ng

or

OUTPUT

overvo

agecon

diti

on

–



e

Bli

ng



LED

A. Pluginaknowgoodpowersourceintothetrailer(7‐wa y),thiscanbeatractororportablebattery

source.

B. WiththeTrailChargeroperating,testthevoltageattheinputpin(X‐1)andthegroundpin(X‐3).

Alsorecordtheambienttemperaturethebatteryboxhasbeensubjectedtointhelast24hours.

Voltagereading:__________ AmbientTemperature:__________

C. Comparethevoltageandambienttemperaturerecordedinstep2tothechartbelow.Thevoltage

andtemperaturefromstep2should benearthecurveonthechart.Note:Ifatrailerismovedthat

hassatoutsideforadaythathasbeensubjectedto0degreesFtemperatureintotheshopitcould

takethebatteriesmorethan24hourstowarmuptotheshoptemperature.Whenmakingthe

comparison,baseitonthetemperaturethetrailerhasbeensubjectedtobeforemovingthetrailer

intotheshop.

Note:

Before replacing the Trail Charger it is suggested that each of the liftgate batteries be tested

221N.14

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

www.purkeysfleetelectric.com

Page20

Note:

Before



replacing



the



Trail



Charger



suggested



that



each



the



liftgate



batteries



tested



individuallyorthatthe systembetestedwithknowngoodbatteriesthathavebeenchargedand

tested.Defe ctiveorseverelydischargedbatteriescanimpactthetestresults.

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Maxon TC Kit 8 Owner's manual

Brand: Maxon

Model: TC Kit 8

Category: Motorcycle Accessories

Type: Owner's manual

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Maxon TC Kit 8 Owner's manual

Maxon TC Kit 8 Owner's manual

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