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Maxon P7000-K Owner's Manual

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Owners Manual INST007
Maxon Part # 906681-01
P7000-K MAXON #286121-01
P7000-K MAXON PART #286121-01 KIT
General Information ............................................................................................................................................................. 2
Plant Installation Instructions .............................................................................................................................................. 3
Nose Box Installation Instructions........................................................................................................................................ 6
Battery Box Installation Instructions .................................................................................................................................. 11
Wiring Diagram .................................................................................................................................................................. 19
Trouble Shooting ................................................................................................................................................................ 20
Trail Charger with Lockouts Theory of Operation .............................................................................................................. 26
Parts List ............................................................................................................................................................................. 29
OWNERS MANUAL
Date: 7.5.2012
Version: 1.0

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Summary of Contents for Maxon P7000-K

  • Page 1: Table Of Contents

    Version: 1.0 Owners Manual INST007 Maxon Part # 906681-01 P7000-K MAXON #286121-01 OWNERS MANUAL P7000-K MAXON PART #286121-01 KIT General Information ................................2 Plant Installation Instructions .............................. 3 Nose Box Installation Instructions............................6 Battery Box Installation Instructions ..........................11 Wiring Diagram .................................. 19 Trouble Shooting ................................

  • Page 2: General Information

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual GENERAL INFORMATION 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.

  • Page 3: Plant Installation Instructions

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Plant Installation Instructions Installed at Plant Remove the plate assembly from the box. Place flat washers on each of the six long bolts. Mount plate to the back-side of plastic battery box.
  • Page 4 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Plant Installation Instructions Installed at Plant Push the bolts through the pre-drilled hole in the box. (View from outside back of battery box) Add flat washers, lock washers and nuts to bolts and tighten.

  • Page 5: Nose Box Installation Instructions

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Done by Trailer Manufacturer or Installer Mount the combo nose box to the front of the trailer. Mount it close enough so the short conductor can easily reach the seven way nose box. Place the supplied 2ft piece of convoluted tubing over the blue, orange and white wires.
  • Page 6 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Route the blue, orange and white wires that are in the convoluted tubing into the seven way nose box. Cut the blue, orange and white wires to the desired length to eliminate excess wire in the seven way nose box.
  • Page 7 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Place the orange stripped wire into the butt-connector of the orange fuse holder, crimp and solder. Place the blue stripped wire into the butt-connector of the blue fuse holder, crimp and solder.
  • Page 8 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Slide the red heat shrink over the butt-connector on the blue wire to cover the connection. Slide the red heat shrink over the butt-connector on the orange wire to cover the connection.
  • Page 9 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Connect the ring terminal on the orange (16) gauge wire to the stop pin. (bottom) Mount the seven-way nose box back on the trailer. Secure the three wires in convoluted tubing with wire ties.
  • Page 10 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Route the jacketed conductor toward the back of the trailer via the center channel. Secure with wire ties as you When you are near the liftgate battery box, route the jacketed conductor out of the center channel and toward the liftgate battery box.

  • Page 11: Battery Box Installation Instructions

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Install the batteries. Positive posts should be toward the door of the battery box. . Install and then tighten the three nuts on the hold downs.
  • Page 12 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Connect the fuse cube bracket to the positive battery post on the left side. Install nut and tighten. Connect the 16 gauge black wire marked liftgate battery positive) to the right positive battery post.
  • Page 13 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Install the nuts on the rest of the battery posts and tighten. Route the jacketed wire into the rear opening of the battery box. Position the conductor so that it can reach the five stud...
  • Page 14 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Pull the conductor out of the box (easier to work on) and cut of the excess at your mark. Cut the jacketed portion off of the conductor at approximately 8 inches.
  • Page 15 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Strip back the insulation of each of the four (4) wires 3/8 of an inch. Add red ¼ heat shrink on the black and orange and yellow wires and black ¼...
  • Page 16 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Position the heat shrink on each crimp and apply heat. Connect the 3/8 ring terminal of the (10) gauge black wire to the black insulated stud marked positive and install and tighten the nut.
  • Page 17 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Connect the #10 ring terminal of the (16) gauge orange wire to the top stud of the five connector strip marked brake. Install nut and tighten.
  • Page 18 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer Job complete.
  • Page 19 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual LED’s are located on the outside of the nose box. The diagram simply indicates internal composition. Note: The first step to troubleshooting the Trail Charger system should be to ensure the liftgate batteries are in a good state of charge (at least 12.3 volts).
  • Page 20 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Troubleshooting the input (dual or single pole) portion of the charging system (No load) 1. Plug the dual or single pole stinger cord into the combo nose box on the front of the trailer. (See picture #1) The tractor must be running or you can use a combination of a battery and a battery charger.

  • Page 21: Troubleshooting

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 9. Measure the voltage from pin #4 to the white insulated stud. (See figure #2 – V5) Should read battery voltage. If yes, continue to step 9. If no, replace or repair the wire from the second stud on the five wire strip to the #4 pin.
  • Page 22 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 6. Measure the voltage between the relay coil (by back probing) and the dual pole receptacle ground. (See figure #3 – V8) It should measure the same as tractor battery voltage. If yes, continue to step 7. If no, replace or repair the wire from the aux pin to the relay.
  • Page 23 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Figure #4 13. Measure the voltage between the relay junction stud (the third stud from the top on the five stud junction strip) and the white insulated ground stud. (See figure #5 – V14) It should measure battery voltage, then drop to zero volts.
  • Page 24 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 16. Measure the resistance between the white insulated ground stud and the liftgate battery ground. (See figure #6 – Ohm 3) It should read zero. If yes, continue to step 17. If no, repair or replace the white wire between the white insulated ground stud and the liftgate battery ground.
  • Page 25 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 3. Place a clip on ammeter around the red lead between pin #2 of the four pin Deutsch plug and the fuse cube connected to the liftgate battery positive. (See picture #9) Should read current. If yes, the Trail Charger is operating. If zero the Trail Charger is defective and needs to be replaced.

  • Page 26: Trail Charger With Lockouts Theory Of Operation

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual TRAIL CHARGER WITH LOCKOUTS THEORY OF OPERATION The 11020CL0 is a specially designed DC/DC converter that is used to charge a battery from a 12V source. An example is a battery that is mounted on the trailer of a vehicle. The distance between the alternator of the vehicle and the trailer-mounted battery makes it difficult to get adequate charging voltage to the battery.
  • Page 27 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual FUNCTIONAL DESCRIPTION STB: Switch to battery. An STB input gets connected to a positive voltage source to activate its function. STG: Switch To Ground. An STG input gets connected to ground in order to activate its function. Connections to the unit are made via a 4-pin Deutsch connector and a 6 pin Deutsch connector.
  • Page 28 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual LED indications: The STATUS LED will indicate several different conditions of the Trail Charger. 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:...

  • Page 29: Parts List

    Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Parts List PURKEY# 11020CLO PURKEY# H-00078 MAXON# 906849-01 MAXON# 906678-01 20 AMP DC/DC CONVERTER T/C 4 PIN DEUTSCH HARNESS PURKEY# H-00079 PURKEY# H-00080 MAXON# 906679-01 MAXON# 906680-01 BRAKE HARNESS 2 AMP FUSE HOLDER ASSEMBLY...
  • Page 30 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Parts List PURKEY# FH00018 PURKEY# FH00014 MAXON# 906879-01 MAXON# 906878-01 FUSE CUBE NUT SINGLE FUSE CUBE BRACKET PURKEY# FH00016 PURKEYS# TM00020 MAXON# 906648-01 MAXON# 906881-02 RED CAP FOR SINGLE FUSE CUBE BLACK 3/8 JUNCTION STUD...
  • Page 31 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Parts List PURKEY# BK-1008 PURKEYS# MOD00036-K MAXON# 906656-01 MAXON# 906693-01 HARDWARE BAG KIT FOR T/C PLATE 6 WIRE MODULE PURKEYS# INST007 MAXON# 906681-01 P7000-K OWNERS MANUAL...