Maxon P7000-K Owner's Manual

Text of Maxon P7000-K User Guide:

• Maxon P7000-K, 13 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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 strip and mark the connector. 4. 7. 8. 9. Maxon Battery Box Installation Instructions Done by Installer

• Maxon P7000-K, 10 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual Route the jacketed conductor toward the back of the trailer via the center channel. Secure with wire ties as you go. 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. When you reach the liftgate battery box, you are done with the routing and ready to start the battery box installation. 18 16. Nose Box Installation Instructions 17.

• Maxon P7000-K, 11 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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). Maxon Battery Box Installation Instructions Done by Installer 2. 1. 3.

• Maxon P7000-K, 9 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. 13. Nose Box Installation Instructions 14. 15.

• Maxon P7000-K, 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. 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. If yes, continue to step 8. If no, the wire from the relay coil to th

• Maxon P7000-K, 2 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. Without the necessary voltage (electrical pressure) to push current through the liftgate batteries for recharging, no recharging can occur. To charge a group 31 flooded cell battery

• Maxon P7000-K, 14 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. Add heat shrink to the area where you cut the jacket off and apply heat. 8. 11. 12. 12. 10. Maxon Battery Box Installation Instructions Done by Installer

• 4 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. Job completed. 5. 6. 4. 7. Maxon Plant Installation Instructions Installed at Plant

• Maxon P7000-K, 7 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. Place the supplied #10 eyelet on the white wire, crimp and solder. Nose Box Installation Instructions 7. 8. 9.

• Maxon P7000-K, 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. The terminals are as follows: Conn - Pin Name Notes: J1-1 Vin Provides the input voltage to the converter. J1-2 Vout Output to the battery to be charged. Keep wiring as short as possible. J1-3

• Maxon P7000-K, 15 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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 heat shrink on the white wire. Crimp the 3/8 ring terminals on the white and black wires. Then crimp the #10 ring terminal on the yellow and orange wires. 14. 13. 15. Maxon Battery Box Installation Instructions Done by Installer

• Maxon P7000-K, 31 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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 16. Parts List

• 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: RATE TIMING Slow 1 second on, 1 second o

• Maxon P7000-K, 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. 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. Testing the brake lock out 1. Plug the six-pin con

• Maxon P7000-K, 19 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. LED’s are located on the outside of the nos

• Maxon P7000-K, 5 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. Secure the short white (10) gauge cable that is in the convoluted tubing to the trailer for a redundant ground. Open the seven way nose box so that you can access the terminals where the wires for the trailer are connected. 1. 2. 3. Nose Box Installation Ins

• Maxon P7000-K, 30 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual PURKEY# FH00018 MAXON# 906879-01 FUSE CUBE NUT PURKEY# FH00014 MAXON# 906878-01 SINGLE FUSE CUBE BRACKET PURKEY# FH00016 MAXON# 906648-01 RED CAP FOR SINGLE FUSE CUBE PURKEYS# TM00020 MAXON# 906881-02 BLACK 3/8 JUNCTION STUD PURKEYS# TM00037 MAXON# 906881-03 WHITE 3/8 JUNCTION STUD PURKEYS# TB-5 MAXON# 906640-01 5 POST TERMINAL STRIP Parts List

• Maxon P7000-K, 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. 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. If yes, continue to step 18. If no, repair or replace the black wire between the black insulated s

• Maxon P7000-K, 12 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. Connect the white (10) gauge cable from the black installed stud to the battery ground post on the right side. 4. 5. 6. Maxon Battery Box Installation Instructions Done by Installer

• 3 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual 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. (View from inside the battery box) 2. 3. 1. Maxon Plant Installation Instructions Installed at Plant

• Maxon P7000-K, 29 Date: 7.5.2012 Version: 1.00 P7000-K Owner’s Manual PURKEY# 11020CLO MAXON# 906849-01 20 AMP DC/DC CONVERTER PURKEY# H-00078 MAXON# 906678-01 T/C 4 PIN DEUTSCH HARNESS PURKEY# H-00079 MAXON# 906679-01 BRAKE HARNESS PURKEY# H-00080 MAXON# 906680-01 2 AMP FUSE HOLDER ASSEMBLY PURKEY# H-00072 MAXON# 906673-01 10GA WHITE GROUND WIRE PURKEY# F00037 MAXON# 906880-01 30 AMP FUSE CUBE Parts List

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