Maxon P7000-K User manual

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 ..............................................................................................................................................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

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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 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
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-way
auxiliary pin, which now allows the liftgate batteries to be charged when connected to any tractor with no dual 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
and will not charge an external battery. This mode has the highest priority and overrides all other modes. This feature
is used when the Trail Charger is powered off of the aux circuit. A lead is connected to the stop light circuit to the six
pin connector of the Trail Charger with Lockouts. When the brakes are applied the Trail Charger with Lockouts turns
off so that the trailer’s ABS system gets full available power. When the brakes are released the Trail Charger turns back
on.
This system provides three ways to power the Trail Charger. Dual pole, single pole or from the aux circuit of the
seven way. Any tractor can provide power the Trail Charger with this system. It automatically selects the correct
source.

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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

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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

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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 Instructions
Done by Trailer Manufacturer or Installer

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Date: 7.5.2012
Version: 1.00
P7000-K Owner’s Manual
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.
Strip ¼” of the insulation off of the blue, orange and white
wires.
Nose Box Installation Instructions
4.
5.
6.

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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.

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Date: 7.5.2012
Version: 1.00
P7000-K Owner’s Manual
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.
Connect the ring terminal on the blue (10) gauge wire to
the aux pin (center)
Connect the ring terminal on the white (10) gauge wire to
the ground pin. (Top)
Nose Box Installation Instructions
11.
12.
10.

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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.

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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.

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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.

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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

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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

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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

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

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Date: 7.5.2012
Version: 1.00
P7000-K Owner’s Manual
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.
16.
17.
18.
Maxon Battery Box Installation Instructions
Done by Installer

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Date: 7.5.2012
Version: 1.00
P7000-K Owner’s Manual
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.
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.
19.
20.
21.
Maxon Battery Box Installation Instructions
Done by Installer

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Date: 7.5.2012
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P7000-K Owner’s Manual
Job complete.
22.
Maxon Battery Box Installation Instructions
Done by Installer
22.

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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
nose box. The diagram
simply indicates
internal composition.

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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. Unplug both the four-pin Deutsch connector and the six-pin connector from the Trail Charger. (See picture #2)
Steps 3 to 12 are with no load (zero current flow)
3. With an ohmmeter or continuity tester, measure from the white ground insulated stud and the liftgate battery
negative stud. (See figure #1 –Ohm #1) It should read zero on ohms and buzz on continuity. If yes, continue
to step 4. If no, check both connections to see if they are tight. If that does not fix the issue, repair or replace
the wire as necessary.
4. With a voltmeter (Do NOT use a test light) measure the voltage from the black insulated stud to the white
insulated stud. (See figure #1 –V1) Should read more than 13.3 volts. If yes, continue to step 5. If no, repair
the circuit from the combo nose box on the front of the trailer to the black and white insulated studs in the
battery box. The yellow LED light illuminated indicates there is power and the fuse is not blown.
5. Measure the voltage from the fourth stud of the five stud strip and to the white insulated ground stud. (See
figure #1 –V2) It should read more than 13.3 volts. If yes, continue to step 6. If no, check the in-line fuse from
the black insulated power stud to the fourth stud of the five stud strip. (See figure #1 –Arrow) If the fuse is
blown make sure the leads are not grounded and then replace the fuse.
6. The green LED lights on the control module should be illuminated. (See figure #1 –Circle) If yes, continue to
step 7. If no, ensure the nut on the third stud of the five stud strip and the white insulated ground studs are
tight. If they are both tight, the control module is defective and needs replaced.
7. Measure the voltage from the second stud (Ignition) on the five-stud strip to the white insulated ground
stud. (See figure #1 –V3) It should read more battery voltage. If yes continue to step #8. If no, ensure the nut
securing the wire on the second stud of the five stud strip is tight. If it is, the issue is the control module and it
needs to be replaced.
8. Measure the voltage from pin #1 on the four-pin connector to the white insulated stud. (See figure #2 –V4) It
should read the same voltage as at the front of the trailer... If yes, continue to step 8. If no, repair or replace
the wire from the black insulated stud to pin #1.
Ω1
V1
Figure #1
V3
V2
Picture #1
Picture #2