Purkeys DIRECT PLUS Installation Manual
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Purkeys DIRECT PLUS Installation Manual

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A MISSION CRITICAL ELECTRONICS BRAND
PLUS/FLEX/MAX NOSEBOX
INSTALLATION GUIDE
INST165 R7.00

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Summary of Contents for Purkeys DIRECT PLUS

  • Page 1 A MISSION CRITICAL ELECTRONICS BRAND PLUS/FLEX/MAX NOSEBOX INSTALLATION GUIDE INST165 R7.00...

  • Page 3: Table Of Contents

    Installation Connections Inside the Nosebox ........11 Interior Light Installation with Severe Service ..........12 Interior Light Power from the 7-way Auxiliary Circuit ......13 Direct Plus Diagram: 7-way Interior Light Connection ....13 Direct Flex and Max Diagram: 7-way Interior Light Connection..14 Momentary Switch (optional).................15 Severe Service Installation (Max Only) ............16...

  • Page 4: General Information

    GENERAL INFORMATION The Purkeys Direct™ nosebox system combines all the best features of our original liftgate charging systems with a space-saving nosebox that helps standardize the front of the trailer. It also includes an interior light controller (harness sold separately) designed to turn the lights on inside a trailer and automatically shut them off either: •...

  • Page 5: Diagrams

    DIRECT NOSEBOX INSTALLATION GUIDE DIAGRAMS DIRECT PLUS P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 6: Direct Flex

    DIRECT FLEX...

  • Page 7: Direct Max

    DIRECT NOSEBOX INSTALLATION GUIDE DIRECT MAX P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 8: Mounting The Nosebox

    Note: Do not block the LED status decal on the side of the Direct when mounting the nosebox. Note: The Direct Plus nosebox must be mounted with the wires facing down to help prevent water intrusion. Direct Controller Mounting Complete.

  • Page 9: Main Harness Installation

    Note: Ensure that the jacketed 4-conductor main harness enters the liftgate battery box through a dome nut or rubber grommet to prevent chaffing the harness, which could result in a possible electrical short in the system. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 10 Step 4: Position the Direct jacketed 4-conductor main harness so it will reach the 2-stud strip and all the slack has been taken up. Mark the jacketed 4-conductor main harness so it can be taken back out of the battery box to be terminated.
  • Page 11 1/4 inch heat shrink over the white wire. Step 10: Crimp 3/8 ring terminals onto the white and black 8-gauge wires. Crimp #10 ring terminals onto the 14-gauge orange and 16-gauge yellow wires. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 12 Step 11: Position the heat shrink over the crimps and apply heat to the 4 terminals. Step 12: Re-route the jacketed 4-conductor main harness back into the battery box. • Connect the 8-gauge black wire to the red positive input stud. •...

  • Page 13: Interior Light Installation Without Severe Service

    INTERIOR LIGHT INSTALLATION WITHOUT SEVERE SERVICE These interior light instructions apply if you are installing the Purkeys interior light harness (Purkeys Part Number H-00522: 50 ft Interior Light Harness) to power interior lights off of the liftgate or auxiliary battery.

  • Page 14: Interior Light Installation With Severe Service

    INTERIOR LIGHT INSTALLATION WITH SEVERE SERVICE These interior light instructions apply if you are installing the Purkeys severe service kit (Direct Max only). Step 1: Inside the nosebox, connect the severe service positive terminal to the interior light input power terminal (see Figure 2) using a 10 gauge wire.

  • Page 15: Interior Light Power From The 7-Way Auxiliary Circuit

    • Make sure each fastened connection is torqued to at least 48 in-lbs. • It is required that you insulate each terminal crimp. Direct Plus Diagram: 7-way Interior Light Connection DIRECT PLUS 7WAY INT LIGHT SOURCE CONNECTION P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 16: Direct Flex And Max Diagram: 7-Way Interior Light Connection

    Direct Flex and Max Diagram: 7-way Interior Light Connection...

  • Page 17: Momentary Switch (Optional)

    If your trailer is being spec’ d with a momentary switch at the back of the trailer (the momentary switch is not included in the Purkeys kit), wire the circuit as shown below using the supplied pigtail harness shown in the drawing below (Purkeys Part Number 800-196).

  • Page 18: Severe Service Installation (Max Only)

    SEVERE SERVICE INSTALLATION Installing Cables to the Nosebox (Direct Max Only) Step 1: Remove cover on the side of the DIRECT MAX. Step 2: Install 4-gauge cables as shown. Make sure each connection is torqued to 5 ft-lbs. Replace the side cover. Note: The mega fuse used here is a 200 amp fuse.

  • Page 19: Routing The Severe Service Cables

    4-gauge red cable will reach the left (input) side of the 150 amp circuit breaker and the 4-gauge black cable will reach the liftgate battery negative post. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 20 Step 5: Pull the 4-gauge red and black cables back out of the battery box so it is easier to work on them. Cut off the excess. Step 6: Strip 1/2 inch of the insulation off the 4-gauge red and black cables.
  • Page 21 Step 10: Slide the supplied red rubber boot over the 4-gauge red cable and connect this cable to the left side of the 150 amp circuit breaker. Severe Service Installation Complete. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 22: Led Logic

    LED LOGIC Source LED STATUS LOGIC Charging State – DC/DC converter is on and system is charging. Note: For aux source, the turn-on voltage is 13.2 V. For dual pole source, the turn-on voltage is 13.2 V after 5 minutes or 13.8 Solid Green V immediately.
  • Page 23 The Direct will then look for next available source. No Source Static State – No tractor Lift Battery connected to the trailer and the LED Slow liftgate batteries are more than Flashing 12.4 volts. Green P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 24 LED STATUS LOGIC No Source LED Static State – No tractor Lift Battery LED connected to the trailer and Slow Flashing the liftgate batteries are less Orange than 12.4 volts. Off State – Source voltage below 12.8 volts and extend period is over.
  • Page 25 12.2 volts. Off State (Fault) – Board temperature has reached 100C and turned off Solid Orange on All charging from all sources. LEDs Charging will begin again after board temperature is below 65C. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 26: Interior Light Control

    Interior Light Control The interior light timer defaults to 60 minutes. However, it can be changed to 15, 30, 60, or 90 minutes. To change the timer length: • Press the “ON/OFF” button 10 times within 10 seconds • All LEDs will flash white once, then display current timer setting (see table below) •...

  • Page 27: Interior Light Control Timer

    3 minutes to ensure the interior trailer lights are turned off while the vehicle is in motion. If the battery voltage is below 12.2 volts, the timer will automatically set to 3 minutes to preserve the battery. P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...
  • Page 28 NOTES...
  • Page 29 DIRECT NOSEBOX INSTALLATION GUIDE NOTES P: 479.419.4800 | F: 479.419.4801 | www.purkeys.net...

  • Page 31: Limited Commercial Warranty Policy

    Product or failure of a part not manufactured by Purkeys. This warranty shall not apply if any Purkeys product is used for a purpose for which it is not designed or is in any way altered without the specific prior written consent of Purkeys. ANY...

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Direct flexDirect max

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