Purkeys DIRECT-04 User manual

DIRECT™-04
INSTALLATION GUIDE
INST041 Doc 2.01

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CONTENTS
General Information........................................................................2
Direct-04 Diagram for Straight Truck.............................................3
Mounting the Direct Controller ......................................................4
Straight Truck Input Harness Installation ......................................5
Main Harness Installation...............................................................7
Part List.........................................................................................11
Limited Commercial Warranty Policy ..........................................16

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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. Also, in cold
temperatures batteries require increased charging voltages to
maintain a high state of charge. The DC/DC Converter in the
Direct system compensates for temperature as well as for voltage
drop and provides the best voltage to the remotely located liftgate
batteries. The result is well-charged liftgate batteries that will last
longer and have ample power for liftgate operation.
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” the liftgate battery charge time to
take full advantage of the available power, without compromising
the source batteries’ ability to crank the engine. Simply put,
the Direct system provides opportunity charging for the liftgate
batteries that is essential in low mileage, high frequency liftgate
operation applications. The LED indicators clearly show the
status of the source as well as the status of the liftgate batteries.
A quick glance at the Direct Controller assures the driver that
the liftgate batteries are ready to go, or alerts the driver that the
batteries need maintenance.
GENERAL INFORMATION

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DIRECT-04 INSTALLATION GUIDE
DIRECT-04 DIAGRAM FOR STRAIGHT TRUCK

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Note: If the L-bracket is not
used, mount the Direct
Controller at the front of the
trailer via the mounting holes
on the mounting plate.
Direct Controller Mounting Complete.
MOUNTING THE DIRECT CONTROLLER
Step 1: Mount the Direct
Controller at the front of the
trailer via the mounting holes
on the L-bracket.

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DIRECT-04 INSTALLATION GUIDE
STRAIGHT TRUCK
INPUT HARNESS INSTALLATION
Step 1: Route the jacketed
2-conductor input harness
toward the vehicle battery
box.
Step 2: Once you are near
the vehicle battery box,
begin routing the jacketed
2-conductor input harness
into the battery box through a
dome nut or rubber grommet.
Step 3: Position the jacketed
2-conductor input harness
so that it will reach the
positive and negative battery
studs. Mark the jacketed
2-conductor main harness so
it can be taken back out of
the battery box to be trimmed
and the inline fuse assembly
and 3/8” eyelet can be added.
Note: Place the cable clamps along the input harness every 6
inches to ensure proper support for the cable. Avoid sharp edges
and possible chaffing points.
Note: Ensure that the jacketed 2-conductor main harness enters
the vehicle battery box through a dome nut or rubber grommet
to prevent chaffing the harness, which could result in possible
electrical short in the system.

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Step 4: Cut about 6 inches off
the jacketed portion of the
white and blue wires. Apply
the supplied ¾ inch black
heat shrink where the jacket
was stripped off.
Step 5: Slide the supplied red
¼ inch heat shrink over the
blue wire. Slide the supplied
black ¼ inch heat shrink over
the white wire. Crimp a 3/8
ring terminal onto the white
wire and the fuse assembly
onto the blue wire. Position
the heat shrink over the
crimps and apply heat.
Step 6: Connect the fused, blue
wire to the battery positive
post and the white wire to the
battery negative post. Tighten
connections.
Note: It may be necessary to re-route the jacketed 2-conductor
back into the battery box before making any terminations to the
wires to prevent the cable from not fitting through the dome nut or
rubber grommet.
Straight Truck Input Harness Installation Complete.

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DIRECT-04 INSTALLATION GUIDE
Step 1: Route the Direct
jacketed 4-conductor DC/DC
converter main harness down
the front of the straight truck
box and back to the liftgate
battery box.
Step 2: Once you are near the
liftgate battery box, begin
routing the Direct jacketed
4-conductor main harness
into the liftgate battery box
through a dome nut or rubber
grommet.
MAIN HARNESS INSTALLATION
Note: Place the cable clamps along the 4-conductor jacketed main
harness every 6 inches to ensure proper support for the cable.
Avoid sharp edges and possible chaffing points.
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 possible
electrical short in the system.
Step 3: 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.

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Note: If your battery box includes a slide-out tray, include enough
slack to allow the tray to fully extend without tugging the wire
connections.
Step 4: Pull the jacketed
4-conductor main harness out
of the box (making it easier
to work on), and cut off the
excess at the mark.
Step 5: Cut about 8 inches off
the jacketed portion of the 4
wires.
Step 6: Apply the supplied ¾
inch black heat shrink where
the jacket was stripped off.
Step 7: Strip 3/8 inch of
insulation off all 4 wires.

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DIRECT-04 INSTALLATION GUIDE
Step 8: Slide the supplied red
¼ inch heat shrink over the
orange, yellow, and black
wires. Slide the supplied black
¼ inch heat shrink over the
white wire.
Step 9: 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.
Step 10: Position the heat
shrink over the crimps and
apply heat to the 4 terminals.
Step 11: 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.

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Main Harness Installation Complete.

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DIRECT-04 INSTALLATION GUIDE
PART LIST
PART# MOD00077
DIRECT CONTROLLER
REPLACEMENT
PART# H-00286
50 FT MAIN HARNESS
PART# H-00345
20 FT SELECT/DIRECT INPUT
HARNESS

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PART# BK-1049 (Revision B)
TERMINAL BAG KIT
PART# BK-1054 (Revision B)
HARDWARE BAG KIT
PART# DIRECT-04
DIRECT STRAIGHT TRUCK

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DIRECT-04 INSTALLATION GUIDE
PART# FH00043
MIDI FUSE HOLDER
PART# F00062
30 AMP MIDI FUSE
PART# PL00079
DIRECT MOUNTING PLATE

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PART# INST041
DIRECT-04 INSTALLATION
GUIDE
PART# INST030
DIRECT DIAGNOSTIC GUIDE

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DIRECT-04 INSTALLATION GUIDE
NOTES

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LIMITED COMMERCIAL WARRANTY POLICY
Purkeys Fleet Electric, Inc. (hereafter “Purkeys”), warrants each product to be free of
defects in material or workmanship under normal use and service. This warranty is for
the benefit of Original Equipment Manufacturers, Dealers, Warehouse Distributors,
Fleets, or other End Users (hereafter “Customers”) and covers products manufactured
by Purkeys and sold new to Customers either directly by Purkeys or by its authorized
dealers, distributors, or agents. The length of the Warranty Period is 24 months.
The warranty period commences on the in-service or install date and is not
transferable. Failure to provide the in-service or install date on the warranty claim form
will cause the warranty period to begin on the date the part was manufactured or date
of sale recorded on the original sales invoice, whichever is earlier.
A completed warranty claim form should accompany all parts submitted to Purkeys
for consideration for repair or replacement under warranty. The submitted claim form
should contain all of the information required. Lack of a properly or fully completed
claim form will result in delay or denial of warranty claim. Claims must be submitted no
later than 30 days after part is removed.
This warranty does not apply if, in sole judgement of Purkeys, the product has been
damaged or subjected to accident, faulty repair, improper adjustment, improper
installation or wiring, neglect, misuse, or alteration or if the product failure is caused
by defects in peripheral vehicle components or components attached to the 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 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.
Transportation for products and parts submitted to Purkeys for warranty consideration
must be prepaid by Customer. Repaired or replaced products and or components
will be returned to Customer pre-paid by Customer or “freight collect” to the address
provided by Customer in the warranty claim form. No charge will be made for labor or
material in effecting such repairs.
The Warranty provided by Purkeys hereunder is specifically limited to repair or
replacement of the Product as Purkeys deems most appropriate in its sole discretion.
Purkeys neither assumes nor authorizes any other person to assume on its behalf any
other warranty or liabilities in connection with Purkeys products. The Warranty does
not apply to fuses or other “consumable” or maintenance items which are or may be a
part of any Purkeys product.
THIS WARRANTY DOES NOT APPLY TO LOSS OF VEHICLE OR EQUIPMENT,
LOSS OF TIME, INCONVENIENCE, OR OTHER INCIDENTAL OR
CONSEQUENTIAL DAMAGES. PURKEYS SPECIFICALLY DISCLAIMS AND SHALL
NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES arising out of
or from the use of Purkeys products by the Customer.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, INCLUDING
COMMON LAW WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE,
MERCHANTABILITY, AND ANY OTHER EXPRESS OR IMPLIED WARRANTIES.
ALL OTHER SUCH WARRANTIES ARE SPECIFICALLY DISCLAIMED.
This Limited Commercial Warranty supersedes all previous Warranty Policies issued
by Purkeys and any of its suppliers.

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DIRECT-04 INSTALLATION GUIDE