Maxon TC Kit 6 Owner's manual

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

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