Date: 7.5.2012 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 ..............................................................................................................................................
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. To charge these liftgate batteries, the correct voltage must be applied to these batteries.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Plant Installation Instructions Installed at Plant 1. 2. 3. 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.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 7. Maxon Plant Installation Instructions Installed at Plant 4. Push the bolts through the pre-drilled hole in the box. (View from outside back of battery box) 5. Add flat washers, lock washers and nuts to bolts and tighten. 6. Job completed.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions Done by Trailer Manufacturer or Installer 1. 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. 2. Secure the short white (10) gauge cable that is in the convoluted tubing to the trailer for a redundant ground. 3.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions 4. 5. 6. 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. Place one piece of the provided red heat shrink over the blue wire and one piece over the orange wire. Place one piece of the provided black heat shrink over the white wire.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions 7. Place the orange stripped wire into the butt-connector of the orange fuse holder, crimp and solder. 8. Place the blue stripped wire into the butt-connector of the blue fuse holder, crimp and solder. 9. Place the supplied #10 eyelet on the white wire, crimp and solder.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions 10. 11. 12. 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. Slide the black heat shrink over the #10 eyelet connection. Apply heat to all three pieces of heat shrink.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions 13. 14. 15. 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. Route the jacketed conductor behind the front cover and then under the head plate through the air/electrical tube to the center channel.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Nose Box Installation Instructions 16. Route the jacketed conductor toward the back of the trailer via the center channel. Secure with wire ties as you go. 17. When you are near the liftgate battery box, route the jacketed conductor out of the center channel and toward the liftgate battery box. Secure with wire ties as you go. 18 When you reach the liftgate battery box, you are done with the routing and ready to start the battery box installation.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 1. 2. 3. 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. Connect inter-cell connectors (positive to positive and negative to negative).
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 4. Connect the fuse cube bracket to the positive battery post on the left side. Install nut and tighten. 5. Connect the 16 gauge black wire marked liftgate battery positive) to the right positive battery post. 6. Connect the white (10) gauge cable from the black installed stud to the battery ground post on the right side.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 7. Install the nuts on the rest of the battery posts and tighten. 8. Route the jacketed wire into the rear opening of the battery box. 9. Position the conductor so that it can reach the five stud strip and mark the connector.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 10. Pull the conductor out of the box (easier to work on) and cut of the excess at your mark. 11. Cut the jacketed portion off of the conductor at approximately 8 inches. 12. Add heat shrink to the area where you cut the jacket off and apply heat. 12.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 13. Strip back the insulation of each of the four (4) wires 3/8 of an inch. 14. Add red ¼ heat shrink on the black and orange and yellow wires and black ¼ heat shrink on the white wire. 15. Crimp the 3/8 ring terminals on the white and black wires. Then crimp the #10 ring terminal on the yellow and orange wires.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 16. 17. 18. 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. Connect the 3/8 ring terminal of the (10) gauge white wire to the white insulated stud and install and tighten the nut.
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. 19. 20. 21. Connect the #10 ring terminal of the (16) gauge yellow wire to the third stud marked relay. Install nut and tighten. Battery box installation completed.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Maxon Battery Box Installation Instructions Done by Installer 22. 22. Job complete.
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). 1. Disconnect batteries 2. Test each battery with an approved battery tester. If good, continue with the troubleshooting guide.
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. Note: if you utilize the latter, it must be able to provide 13.5 to 14.5 volts and up to 25 amps when loaded and still maintain the correct voltage levels. 2.
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. 10. With an ohmmeter or continuity tester, measure from pin #3 to the white insulated stud. (See figure #2 – Ohm #2) It should read zero with the ohmmeter or hear the buzzer with the continuity tester.
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. 7. Measure the voltage between the green LED connector (relay side) and the dual pole receptacle ground. (See figure #3 – V9) It should measure more than 13.3 volts.
Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual V12 V11 Figure #4 V13 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. When it drops to zero volts, the control module should have both LED lights illuminated. If yes, continue to step 14.
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. 17. Measure the voltage between the #1 pin of the four pin Deutsch plug and the white insulated ground stud. (See figure #6 – V17) It should read more than 13.3 volts.
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. Note: If you do not have a clip-on ammeter, use a voltmeter to read voltage when the Trail Charger is operating. You should see considerably higher voltage.
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.
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.
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.
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Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Parts List PURKEY# BK-1008 MAXON# 906656-01 HARDWARE BAG KIT FOR T/C PLATE PURKEYS# MOD00036-K MAXON# 906693-01 6 WIRE MODULE PURKEYS# INST007 MAXON# 906681-01 P7000-K OWNERS MANUAL 31 16.
