Maxon TC Kit 6 Owner's manual

Brand: Maxon

Model: TC Kit 6

Type: Owner's manual

Maxon TC Kit 6 is a device that helps to maintain the state of charge of liftgate batteries, even when the liftgate is not in use. It is able to amplify any input voltage to the correct voltage necessary to charge and maintain the liftgate batteries. This allows the batteries to be charged when connected to any tractor with no dual pole connection necessary, as long as the input voltage is between 9 and 14 volts. The Maxon TC Kit 6 also has a shutdown mode that can be enabled when the lock out pin is active. In this mode, the charger output is shutdown and will not charge an external battery.

Owner’sManual

P/N:283040‐500

Trail Charger with Lockout

283040‐01 Version1.0407/05/2011

Owners Manual

Owners

Manual

 Operation

 Installation

 Wiring Diagram

Tro bleshooting

221N.14

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

www.purkeysfleetelectric.com



Tro

bleshooting

 Parts Breakdown

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

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

btt i With t th lt (l ti l ) t h t th h th lift t btt i f

es.

With



enecessaryvo

age

(

pressure

)



opus

curren



roug



e

lift

e

es

or

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tochargeandmaintaintheliftgatebatteries.Thisinputvoltagecanbeobtainedthroughthe7‐

auxiliar



whichnowallowsthelift

atebatteriestobechar

edwhenconnectedtoan

tractorwithnodual

y y p, g g y

poleconnectionnecessary.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

backfeedtothetractor’sbattery

pack.

TheTrailChargerwithLockoutshasashutdownmodeofoperation:

•

Shutdown Mode:

This mode is enabled when the lock out pin is active In this mode the charger output is

•

Shutdown



Mode:



This



mode



enabled



when



the



lock



out



active

.



this



mode



the



charger



output



shutdownandwillnotchargeanexternalbattery.Thismodehasthehighestpriorityandover‐ridesallother

modes. ThisfeatureisusedwhentheTCispoweredoffoftheauxcircuit.Aleadisconnectedtothestoplight

circuittothesixpinconnectoroftheTC

withLO’s.WhenthebrakesareappliedtheTCwithLO’ sturnsoffsothat

thetrailer’sBSsystemgetsfullavailablepower.WhenthebrakesarereleasedtheTCturnsbackon.

221N.14

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

www.purkeysfleetelectric.com

TRAILCHARGERWITHLOCK OUT

VERSION1.04

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.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)

‐ Yellowwire“D”,labeled“IgnitionPin#4”

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

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

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

Bl i “B” lbld“L k t It”

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

OUTPUT GROUND BRAKE LOCKOUT WIRE

‐

uew

re

“B”

,



“L



npu

t”

OUTPUT



GROUND

,

BRAKE



LOCKOUT



WIRE

Step3:Oncethewiresareroutedproperlythe

Trail Charger input and ignition wires can be

Figure2

Trail



Charger



input



and



ignition



wires



can



insertedintotheDeutschconnectorbody.The

input(red)wirewillslideintothe#1position.The

ignition(yellow)wirewillslideintothe#4position.

(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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step4: Thepositive(red)outputwirewillslideinto

the#2position.Thenegative(black)outputwire

willslideintothe#3position.

(SeeFigure4)

INSTALLATION



INSTRUCTIONS

Figure4

Step5: Verifyallthewiresareintheircorrect

positionsandlockedinplace.(SeeFigure5)

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

h i h

ema

n

arness.

• Figure5‐2:Red10AWGTrailChargeroutput

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

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

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

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

mainharness.

Figure5

St 6

O bth i itdit th

Insert Flush,locked

ep

nce

w

resare

nser



o

e

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

Figure6)

intoplace

221N.14

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

www.purkeysfleetelectric.com

Page4

Figure6

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step7: 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 7)

INSTALLATION



INSTRUCTIONS

contamination

.

(See



Figure



Step8: Oncethewireisinsertedintothe

connectortheoran

elockcanbeinserted.Make

Figure7

Insert

surethatthelockisproperlyseated.(SeeFigure8)

Seat

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

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

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

Figure8

electricalconnections.(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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step10: 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

INSTALLATION



INSTRUCTIONS

the



tubing



and



into



the



appropriate



socket



the



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

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

seated.(SeeFigure10)

Figure10

Step11: Thelastconnectionscannowbemadeat

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

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

til

(

S Fi

11)

erm

s.

(

ee

gure

11)

Step12: Thered10AWGTrailChargeroutput

positivewirelabeled“liftgatepositive”cannowbe

Figure11

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

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

TheblackTrailChargeroutputgroundwireshould

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

batteryasshown.(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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step13: OncetheTrailChargerismountedthe

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

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

wheel

lateandthenthrou

htheelectrical

airline

INSTALLATION



INSTRUCTIONS

Figure13

p g /

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

(SeeFigure13)

Step14: Routethemainharnessoutthefrontof

thetrailer.Makesurethecableisprotectedfrom

chaffing.(SeeFigure14)

Figure14

Step15: Nowroutethethreewires(red10AWG,

black10AWGandblue16AWG)intothe7way

nosebox.Coverwithconduitandsecurewitha

wiretie.(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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step16: Routetheblack10AWGwiretotheground

screwinthe7waybox.Cuttolengthandslideapiece

oftheblackheatshrinkoverthewire.Nowcrim

and

INSTALLATION



INSTRUCTIONS

soldera#10eyeletonthewireandapplyheattothe

heatshrink.Onceproperlyterminatedremovethenut

andaddthiswiretothegroundstud.(SeeFigure16)

NOTE:Itisstronglysug gestthatthesewiresbelabeled

duetothecolordifferencefromthestandard.

Figure16

Step17: Nowthered10AWGwirecanbecuttolength

andconnectedusingthefuseholderwiththeorange

ld(30 f

)

Slid i f h d h hi k

s

(30

amp

use

)

.

Slid

eap

eceo

t

ere



eats



overthewireandcrimpandsolderthetwowires

togetherandcoverwiththeheatshrink,thenapply

heat.OnceconnectedremovethenutfortheAUX/ ABS

studandaddthiswire,thenretightenthenuttospec.

(SeeFigure17)

Step18: Cuttheblue16AWGwireandconnecttothe

blackfuseholderwithblackleads(2ampfuse).Slidea

Figure17

NOTE: Westronglysuggestthatthesewiresbelabeled

duetothecolordifferencefromthestandard.

pieceofredheatshrinkoverthebluewire,crimpand

solderthetwowirestogether,coverwiththeheat

shrinkandapplyheat.Onceconnectedremovethenut

forthebrake/stopstudandaddthiswire,retightento

spec.(SeeFigure18)

NOTE: We strongly suggest that these wires be labeled

221N.14

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

www.purkeysfleetelectric.com

Figure18

NOTE:



strongly



suggest



that



these



wires



labeled



duetothecolordifferencefromthestandard.

Page8

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

INSTALLATION INSTRUCTIONS

Step19: Thefrontofthetrailerisnowfinished.

Reinstallthe7waynoseboxcover,coverany

exposedwireswithconduitandsecurewithwire

ties.(SeeFigure19)

INSTALLATION



INSTRUCTIONS

Figure19

Step20: Installationisnowcomplete,connectatractor

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

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

greenLEDlightshouldbeilluminated.Measurethe

liftgate battery voltage should be near 14 0 volts

Step

21:

Now the metal cover can be installed to

liftgate



battery



voltage

,

should



near



volts

.

Checkthebrakelockoutfunctionbyverifyingthatthe

greenLEDontheTrailChargerflashesslowlywhenthe

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

LEDshouldgobacktosolid.

Step



21:

Now



the



metal



cover



can



installed



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

installation.(SeeFigure20)

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9

Figure20

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

WIRING DIAGRAM

LOCKOUTJ2‐2

IGNITIONJ1‐4

INPUTJ1‐1

OUTPUTJ1‐2

WIRING



DIAGRAM

GROUNDJ1‐3

123

654

7‐WA Y

221N.14

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

www.purkeysfleetelectric.com

Page10

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

WIRING DIAGRAM LEGEND

Components

1. 7‐WayConnector

2. 7‐WayAuxPin

3. 30AmpFuse

‐

Way Brake Circuit

WIRING



DIAGRAM



LEGEND

‐

Way



Brake



Circuit

5. 5AmpFuse

6. 7‐WayGroundCircuit

7. Liftgate BatteryPositive

8. Liftgate BatteryNegative

9. TrailCharger

J1‐1Inputfrom7‐wayauxpin

J1‐2Outputtoliftgate batterypositive

J1‐3Groundtoliftgate batterynegative

J1‐4Ignitionsplicedfrominputwirefrom7‐wayauxpin

J2‐1Notusedinthisapplication

J2‐2Brakecircuitsensefrom7‐waybrakecircuit

J2‐3Notusedinthisapplication

J2‐4Notusedinthisapplication

5 Nt d i thi li ti

‐



use



n

thi

sapp

J2‐6Notusedinthisapplication

10. 30AmpFuse

Connection 1

Connection 2

Color

Connection



Connection



Color

A. 7‐WayAuxPin TrailChargerInputJ1‐1Red

B. 7‐WayBrakeCircuit TrailChargerLockoutJ2‐2Blue

C. 7‐WayGround Liftgate BatteryNegative Black

D. InputWire(Splice) TrailChargerIgnition Yellow

221N.14

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

www.purkeysfleetelectric.com

E. TrailChargerOutput Liftgate BatteryPositive Red

F. TrailChargerGround Liftgate BatteryNegative Black

Page11

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

TROUBLESHOOTING GUIDE

Before beginning the troubleshooting procedures, the liftgate batteries need to be 12.4 volts or

higher and test good.

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

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

RatedCCA __________ ______________________________

TROUBLESHOOTING



GUIDE

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

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

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

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

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

LEDindications:

TheSTATUSLEDwillindicateseveraldifferentconditionsoftheTrailChargerwithLockouts.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 Fault:n/a

InputCommandShutdown:n/a InputCommandReduce:n/a

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

InputCommandShutdown:n/a InputCommandReduce:n/a

LED,Green,mediumblink SHUTDOWNmode(Pg.14) Fault:None

InputCommandShutdown:ON InputCommandReduce:n/a

LED,Green,slowblink Reducepowermode,charging(Pg.14) Fault:None

Input Command Shutdown: OFF

Input Command Reduce: ON

Input



Command



Shutdown:



OFF

Input



Command



Reduce:



LED,Green,solid ChargingorCharged(WorkingProperly) Fault:None

InputCommandShutdown:OFF InputCommandReduce:OFF

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

A. Inputover‐voltagelimit.(T/Sprocedurepg.13)

B. Inputunder‐voltagelimit.(T/Sprocedurepg.13)

(/ )

221N.14

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

www.purkeysfleetelectric.com

Page12

C. Outputover‐voltagelimit.

(

Sprocedurepg.13

)

D. Outputover‐currentlimit/OutputFET’soverthermallimits.(T/Sprocedurepg.14)

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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

TROUBLESHOOTING GUIDE

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

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

2. WiththeTrailChargeroperating,testthevoltageattheTCpin#1andTCpin#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:__________.

Test the voltage at the aux pin of the 7

way nose box at the front of the trailer Note the voltage

TROUBLESHOOTING



GUIDE

Test



the



voltage



the



aux

.



the



‐

way



nose



box



the



front



the



trailer

.

Note



the



voltage



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

4. 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.

5. Ifhigherthanallowed,repairthewiringfromthenoseboxtotheTrailCharger.

Note: Thetrailerwiringcouldbefindandtheproblemisinthepowersource(tractorand7‐waycord)

whichshouldalsobetestedperTMC’sRP‐137.

B.CheckingforINPUTovervoltagecondition–HighRateBlinkingRedLED

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

2. 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.

C.CheckingforOUTPUTovervoltagecondition–HighRateBlinkingRedLED

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

2. WiththeTrailChargeroperating,testthevoltageattheTCpin#1andTCpin#3.Alsorecordthe

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

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

3. 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13

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.Defectiveorseverelydischargedbatteriescanimpactthetestresults.

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

TROUBLESHOOTING GUIDE

Temperature Compensation

17.5

TROUBLESHOOTING



GUIDE

15.5

16.5

ltage (Vdc)

13 5

14.5

Output V

D Ch ki f t diti d/ FET th th l li it

Hi h Rt Bli ki RdLED

-40 -20 0 20 40 60 80 100

Temperature (Deg. C)

.

ng

orovercurren

con

diti

onan

or

FET

over

e

erma



s

–



e

Bli

ng



LED

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

2. WiththeTrailChargeroperating,placeacliponammeteraroundthewirefromTCpin#2tothe

liftgatebatterypositive.Measureandrecordtheamps.Amps:__________

1. Theampsshouldnotexceed23amps.

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

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

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

221N.14

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

www.purkeysfleetelectric.com

Page14

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

TROUBLESHOOTING GUIDE

Checkingtheshutdownmode–MediumRateBlinkingGreenLED

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

2. WiththeTrailChargeroperating,unplugthesixpinconnectorfromtheTrailCharger.ThegreenLED

shouldstopblinking.

3. IfitdoesnotstopblinkingthentheTrailChargerisdefectiveandneedstobereplaced.

If it does stop blinking then pin #2 from the six pin plug on the Trail Charger needs to be checked for

TROUBLESHOOTING



GUIDE



does



stop



blinking



then



from



the



six



plug



the



Trail



Charger



needs



checked



for



voltage.

5. Ifpin#2hasmorethan3.0voltstheTrailChargerwillturnoffandhaveamediumrateblinkinggreen

LED.Normallythebrakecircuitisconnectedtothiscircuit.Whenthebrakesareoff,youshouldsee0.0

voltsshouldbeatpin#2.Whenthebrakesareapplied,youshouldseebatteryvoltage.Repairthe

circuitasneeded.

Checkingthereducedpowermode– SlowRateBlinkingGreenLED

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

2. WiththeTrailChargeroperating,unplugthesixpinconnectorfromtheTrailCharger.ThegreenLED

shouldstopblinking.

3. IfitdoesnotstopblinkingthentheTrailChargerisdefectiveandneedstobereplaced.

If it does stop blinking then pin #1 from the six pin plug on the Trail Charger needs to be checked for



does



stop



blinking



then



from



the



six



plug



the



Trail



Charger



needs



checked



for



voltage.Thisshouldhaveareadingof0.0volts.Ifvoltageispresentthenmakethenecessaryrepairs.

5. IfthegreenLEDdoesstopblinkingthenpin#6shouldbecheckedforvoltage.Anyvoltageunder5.0

voltswillcausethegreenLEDtoblinkslowly.

Note: Thiscircuitisonlyusedwhentheinteriorlightsareconnected.

221N.14

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

www.purkeysfleetelectric.com

Page15

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

PARTS BREAKDOWN

283040‐01 COMPLETEKIT(TC,Harness,BagKit,Cover)

CompleteKitContents: Qty

906849‐01 TRAILCHARGERWITHLOCKOUT 1

283041 53FTMOD3TRAILCHARGERHARNESS 1

267522

TRAIL CHARGER COVER

PARTS



BREAKDOWN

267522

‐

TRAIL



CHARGER



COVER

284570‐01 53FTTRAILCHARGERMOD6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

907104‐01 30AMPFUSEHOLDERASSEMBLY 1

907105‐01 2AMPMINIFUSEHOLDERASSEMBLY 1

906873‐01 SECONDARYLOCK 1

907015‐01 DEUTSCHPLUG 1

907089‐01 6WAYSQUARECONNECTOR 1

907090‐01 6WAYSQUARELOCK 1

906877‐01 1‐1/4"CLEARIDTUBING,0.17ft 2

906878‐01 SINGLEFUSECUBEBRACKET 1

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

906880‐01 FUSECUBE,30AMP 1

*1/4"REDHEATSHRINK,2incheslong 2

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

*12‐10GA#10EYELET 1

*323/32"SMALLZIPTIES 14

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

907102‐01 2AMPATMMINIFUSE 1

221N.14

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

www.purkeysfleetelectric.com

Page16

*Itemsnotavailableseparately,mustorder53ftTrailChargerMod6BagKit(284570‐01).

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

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

267522‐01283041283040‐01

906849

284570

906874

906849

‐

284570

‐

906874

‐

906875‐01 907104‐01(Includes30AmpFuse) 907105‐01

221N.14

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

www.purkeysfleetelectric.com

Page17

906873‐01 907015‐01 907089‐01(WithUnusedHolePlugs)

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

907090‐01 906877‐01 906878‐01

906879

¼” RdHtSh i k

906880

906879

‐

¼”



906880

‐

12‐10Ga.#10Eyelet¼”BlackHeatShrink SmallZip‐Ties

221N.14

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

www.purkeysfleetelectric.com

Page18

¾”BlackHeatShrink 284556‐01 5/8”NylonClamps

TRAILCHARGERWITHLOCK OUT

VERSION1.04

07/05/2011

¼”x20x¾”Bolts¼”FlatWasher¼”x20NylonLockNut

#12 1 ½” H

#12 ¾” H

#10 1” H

#12

x



½”



ex

crews

#12

x

¾”



ex

crews

#10

x

1”



ex

crews

3/8”x16JamNut 907095 907102‐01

221N.14

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

www.purkeysfleetelectric.com

Page19

Maxon TC Kit 6 Owner's manual

Maxon TC Kit 6 Owner's manual

Maxon TC Kit 6 Owner's manual

Related papers

Other documents