Purkeys DIRECT Diagnostics Manual
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Purkeys DIRECT Diagnostics Manual

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DIRECT™
DIAGNOSTIC GUIDE
INST030 Doc 3.02

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Summary of Contents for Purkeys DIRECT

  • Page 1 DIRECT™ DIAGNOSTIC GUIDE INST030 Doc 3.02...

  • Page 3: Table Of Contents

    Wire Diagram and Legend .............4 Diagnostics ..................6 Excessive Voltage Drop Diagnostics ........6 Static Diagnostics ...............7 Stinger/Aux Diagnostics .............9 Charging Diagnostics ............14 Testing the DC/DC Converter ............16 Diagnostic Diagram ..............19 Summary ..................20 Limited Commercial Warranty Policy ..........24 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 4: General Information

    The Direct system is automatic and has easy to interpret LED indicators to assure drivers and technicians of proper system function. The Direct Controller increases the time that the DC/ DC Converter can charge the liftgate batteries by monitoring the source power and “extending”...

  • Page 5: Direct Controller Call-Outs

    DIRECT DIAGNOSTIC GUIDE DIRECT CONTROLLER CALL-OUTS P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 6: Wire Diagram And Legend

    30 Amp Circuit Breaker DC/DC Converter DC/DC Converter Output Stud DC/DC Converter Input Stud (+) DC/DC Converter Input Stud (-) 2 Amp Inline Fuse from Liftgate Batteries Direct Controller Input Source (Dual/Single Pole, 7-Way, Straight Truck Battery Pack, or Reefer Unit)
  • Page 7 Input Stud (-) DC/DC Converter DC/DC Converter Yellow Ignition Ignition Stud Direct Controller DC/DC Converter Black Power Out to DC/DC Input (+) converter Trailer Battery Sense Postive Liftgate Orange (Controller Power) Battery (+) P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 8: Diagnostics

    If there is excessive voltage drop between the source battery and the Direct Controller, both Source and Lift Battery LEDs will briefly turn green, indicating that the Direct is trying to charge the batteries. Then both LEDs will toggle orange for a few seconds.

  • Page 9: Static Diagnostics

    STATIC DIAGNOSTICS Not connected to a charging source or not charging (at rest) (see Figure 2 for location of Liftgate Battery LED; see Figure 3 for LED status reference, located on right side of Direct Controller). Figure 2 Figure 3...
  • Page 10 REFERENCE #1 Rapid Flashing Orange LED: Repair ground circuit and/or replace ground fuse (see Figure 4 for ground fuse location). Figure 4 Figure 5...

  • Page 11: Stinger/Aux Diagnostics

    2-amp fuse and replace if necessary. If there is still no voltage reading, repair or replace the wires between the battery box and the Direct Contoller. Once these steps are completed, if there are still no LEDs, call customer service, as the Direct Controller may not be functioning properly. STINGER/AUX DIAGNOSTICS Plug in the stinger and start the tractor (see Figure 6 for location of Source LED;...
  • Page 12 Figure 6 Figure 7 LED STATUS CONDITION ACTION NEEDED REFERENCE Charging mode Solid Green from stinger or None. aux. Determine where Slow Input voltage from the problem exists Flashing the source is less and repair or Ref #4 Orange than 12.4 volts. replace defective portion.
  • Page 13 If this is occurring, replace the fuse or circuit breaker with a new unit and test the system. REFERENCE #3 Rapid Flashing Orange LED: Blown fuse on the stinger circuit. Replace the fuse (see Figure 8 for source fuse location). Figure 8 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 14 Figure 9 Figure 10...
  • Page 15 1. With the stinger cord still plugged in, and the tractor running, use a voltmeter to measure the voltage between the dual pole positive stud and the dual pole negative stud inside the Direct Controller (see V1 in Figure 9 or 10). It should read 13.8 volts or greater.
  • Page 16 (see Figure 11), as the problem may be a failing circuit breaker. Either replace circuit breaker with a new part or connect the blue wire from the Direct Controller to the unprotected side of the circuit breaker. Circuit protection is provided by the 30 amp fuse inside the Direct Controller.

  • Page 17: Charging Diagnostics

    Charging from the source (the source LED is Solid Green). The Lift Battery LED status is as listed in table below (see Figure 12 for location of Liftgate Battery LED; see Figure 13 for LED status reference located, on right side of Direct Controller.) Figure 12 Figure 13...

  • Page 18: Testing The Dc/Dc Converter

    TESTING THE DC/DC CONVERTER See Figure 14 to see the LED on the DC/DC converter. A rapid flashing red LED on the converter is normal if the trailer is disconnected from a running truck. It will continue to flash for a short period of time.
  • Page 19 REFERENCE #9 Steps to test power to the DC/DC Converter: 1. Look at the Source LED on the Direct Controller and ensure that it is Solid Green. If no, refer to the Stinger or Aux Diagnostics sections. If yes, measure the voltage at the DC/ DC Converter Input (+) stud and Ground (-) Liftgate Battery (Fused) stud (see V1 on Figure 15).
  • Page 20 b. If the voltage at the liftgate batteries is below 14.0 volts, use a voltmeter to monitor the voltage at the liftgate batteries for 2–5 minutes (see V5 on Figure 15). If the voltage rises, the DC/DC converter is functioning properly; allow time for the batteries to charge. c. Using a clip-on ammeter, measure current flow (see clip-on ammeter on Figure 15).

  • Page 21: Diagnostic Diagram

    DIRECT DIAGNOSTIC GUIDE DIAGNOSTIC DIAGRAM Figure 15 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 22: Summary

    SUMMARY LED Status Logic Charging State – Source voltage was greater than 13.8 volts. DC/ DC converter is on. Tractor must be running and alternator good to achieve 13.8 volts. A batteries surface charge cannot reach this value. Solid Green Note: The turn on voltage is 13.2 on Lift Battery volts after 5 mins or 13.8 volts and Source...
  • Page 23 If voltage at on Lift Battery dual pole does not drop below 12.6 and Source volts, then the Direct will extend until 60 minutes has expired. No Source Static State - No tractor connected Lift Battery...
  • Page 24 LED Status Logic Off State (Fault) – Open circuit in lift battery or source circuit. No LED This could also be caused by the liftgate battery voltage being below 6 volts. Excessive Voltage Drop – Tractor is running and the voltage is above 13.8 volts. The controller turns on the DC/DC converter and current starts to flow.
  • Page 25 DIRECT DIAGNOSTIC GUIDE P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 26: Limited Commercial Warranty Policy

    Purkeys. ANY Product alleged by a Customer to be defective must be inspected by Purkeys as a part of the warranty claims process in order to confirm that the part has failed as a result of a defect in material or workmanship.
  • Page 27 DIRECT DIAGNOSTIC GUIDE P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

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