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Summary of Contents for Purkeys DIRECT-03
- Page 1 DIRECT™-03 INSTALLATION GUIDE INST033 Doc 2.02...
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Page 3: Table Of Contents
CONTENTS General Information ................2 Direct-03 Diagram ................3 Mounting the Direct Controller ............4 Aux Harness Installation ..............5 7-Way Nosebox Tips ..............7 Main Harness Installation ...............8 Part List ..................12 Limited Commercial Warranty Policy ..........16 P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net... -
Page 4: General Information
GENERAL INFORMATION The Purkeys Direct™ system improves the charging of liftgate batteries by utilizing a DC/DC Converter to boost the voltage for optimal charging. The boost in voltage overcomes the normal voltage drop caused by the extended distance between the liftgate batteries and the vehicle charging system. -
Page 5: Direct-03 Diagram
DIRECT-03 INSTALLATION GUIDE DIRECT-03 DIAGRAM P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net... -
Page 6: Mounting The Direct Controller
MOUNTING THE DIRECT CONTROLLER Step 1: Mount the Direct Controller at the front of the trailer via the mounting holes on the mounting plate. Direct Controller Mounting Complete. -
Page 7: Aux Harness Installation
¼ inch heat shrink over the blue wire. Slide the supplied black ¼ inch heat shrink over the white wire. Step 4: Crimp the supplied 10-gauge #10 eyelets onto both the blue and white wires. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net... - Page 8 Step 5: Solder the crimped connection, then position the heat shrink over the crimps and apply heat to the 2 terminals. Note: Place the cable clamps along the 7-way aux harness every 6 inches to ensure proper support for the cable. Avoid sharp edges and possible chaffing points.
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Page 9: 7-Way Nosebox Tips
• Ensure the 7-way or stinger cord has a tight fit and has good electrical contact at the tractor and trailer receptacles. Figure 1: 7-Way Nosebox SERVICE TIP - Purkeys offers the Liftgate Double Check tool, which can simplify the diagnosis of liftgate charging system problems caused by excessive voltage drop. For more information on the tool, please call 1-800-219-1269 or visit our website at www.purkeys.net. -
Page 10: Main Harness Installation
MAIN HARNESS INSTALLATION Step 1: Route the Direct jacketed 4-conductor main harness for the DC/DC converter behind the front plate, then behind the header plate through the air/electrical tube to the center channel. Step 2: Route the Direct jacketed 4-conductor main harness in the center channel toward the back of the trailer. - Page 11 4-conductor main harness out of the box (making it easier to work on), and cut off the excess at the mark. Step 6: Cut about 8 inches off the jacketed portion of the 4 wires. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
- Page 12 Step 7: Apply the supplied ¾ inch black heat shrink where the jacket was stripped off. Step 8: Strip 3/8 inch of insulation off all 4 wires. Step 9: Slide the supplied red ¼ inch heat shrink over the orange, yellow, and black wires.
- Page 13 4 terminals. Step 12: Re-route the jacketed 4-conductor main harness back into the battery box (see diagram on page 3 for stud location). • Connect the 8-gauge black wire to the red positive input stud. • Connect the 8-gauge white wire to the black ground stud. • Connect the 14-gauge orange wire to the liftgate (+) stud. • Connect the 16-gauge yellow wire to the ignition stud. Main Harness Installation Complete. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
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Page 14: Part List
PART LIST PART# MOD00077 DIRECT CONTROLLER REPLACEMENT PART# H-00286 50 FT MAIN HARNESS PART# H-00315 70 FT MAIN HARNESS PART# H-00314 25 FT MAIN HARNESS PART# H-00288 7-WAY AUX HARNESS... - Page 15 DIRECT-03 INSTALLATION GUIDE PART# BK-1049 (Revision B) TERMINAL BAG KIT PART# BK-1054 (Revision B) HARDWARE BAG KIT PART# DIRECT-03 DIRECT WITH 7-WAY CONNECTION P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
- Page 16 PART# F00062 30 AMP MIDI FUSE PART# INST033 DIRECT-03 INSTALLATION GUIDE PART# INST030 DIRECT DIAGNOSTIC GUIDE...
- Page 17 DIRECT-03 INSTALLATION GUIDE NOTES P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
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Page 18: 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 19 DIRECT-03 INSTALLATION GUIDE P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
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