DIRECT™ V1.10
TROUBLESHOOTING
MAXON # 295211-501
DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL CONTENTS
General Information .............................................................................................................................................................. 2
Direct™ Call Outs ................................................................................................................................................................. 3
Troubleshooting ................................................................................................................................................................... 4
Testing the DC/DC converter .............................................................................................................................................. 11
Troubleshooting Diagram ................................................................................................................................................... 13
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
GENERAL INFORMATION
The Purkeys Direct™ system improves the charging of liftgate batteries by utilizing a DC-DC Converter to boost the voltage
to optimally charge the batteries. The boost in voltage is needed to overcome the voltage drops in the long cables from the
vehicle’s primary electrical system. Also, in cold temperatures batteries require a higher voltage to get fully charged. The
DC-DC Converter in the Direct™ system compensates for temperature as well as for voltage drops and gets the best voltage
to the remotely located liftgate batteries. The result is well charged liftgate batteries that will last longer and that will 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.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
DIRECT™ CALL OUTS
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
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TROUBLESHOOTING
STATIC CONDITION- Not connected to a charging source and not charging. (See figures 1 and 2 below showing the
liftgate battery LED and LED status reference located on the right side of the Direct™ controller.)
Figure 1
Figure 2
LED STATUS
CONDITION
ACTION NEEDED
REFERENCE
Slow Flashing Green
Liftgate batteries in good state
of charge. (More than 12.4
volts)
None
Slow Flashing Orange
Liftgate batteries in low state
of charge. (Voltage between
6.0 and 12.39 volts.)
Charge and test batteries
Rapid Flashing Orange
Blown ground fuse
Repair circuit and replace fuse
Ref # 1
No LED
Open circuit from liftgate
battery positive and Direct™
control unit or disconnected
ground in liftgate battery box
Repair circuit and then reset
circuit breaker or fuse
Ref # 2
See next page for troubleshooting reference 1 and 2.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
REFERENCE # 1- Rapid Flashing Orange LED. Repair circuit and replace ground fuse. (See figure 3 below for ground
fuse location)
Figure 3
Figure 4
REFERENCE # 2- No LED. Open circuit from liftgate battery positive or liftgate battery ground and the Direct™ Control
Unit. Follow the steps below to troubleshoot the No LED Status. (See figure 4)
1. Using a volt meter measure the voltage between the ground from seven way stud and the liftgate battery
positive stud inside the Direct™ Control Unit. (See V1 in figure 4) Should read liftgate battery voltage of
12.4 volts or higher. If you read 12.4 volts or higher and still have no LEDs then please call 800-2191269 for customer service. If zero move to step 2.
2. Measure the voltage between the Liftgate battery positive stud inside the Liftgate battery box and the
ground stud (See V2 in figure 4). If measurement matches battery voltage, the issue is the cable from
one of these studs to the Direct™ Control unit. Repair or replace this cable. If measurement does not
match battery voltage, move to step 3.
3. Measure the voltage between the DC/DC Converter side of the circuit breaker to the negative post on the
Liftgate battery (See V3 in figure 4). If measurement matches battery voltage, the issue is between the
input side of the circuit breaker to the red junction stud. Repair or replace. If measurement does not
match battery voltage, the issue is from the Liftgate battery positive wire through the circuit breaker.
Repair or replace.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
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DUAL/SINGLE POLE STINGER OPERATION AND TROUBLESHOOTING (Must be configured for charging from
Dual/Single pole. If not then refer to Aux operation and troubleshooting) - Plug in the stinger and then start the
tractor. (See figures 5 and 6 below showing the Source LED and LED status reference located on the right side of the Direct™
controller.)
Figure 5
Figure 6
LED STATUS
CONDITION
ACTION NEEDED
REFERENCE
Solid Green
Charging mode on stinger
None
Slow Flashing Orange
Input voltage from the stinger
cord has dropped to less than
11.0 volts
Determine where the problem
exists and repair or replace
defective portion.
Slow Flashing Green
Stinger charging option is in
standby mode.
Start the tractor
Rapid Flashing Orange
Blown fuse on the stinger
circuit
Repair the circuit and then
replace the fuse
Ref # 3
No LED
No voltage from the stinger
cord
Determine where the problem
exists and repair or replace
the circuit
Ref # 4
Ref # 4
See next page for troubleshooting reference 3 and 4.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
REFERENCE # 3- Rapid Flashing Orange LED. Blown Fuse on the Stinger circuit. Repair the circuit and replace the
fuse. (See figure 7 below for Source fuse location)
Figure 7
Figure 8
REFERENCE # 4- Slow Flashing Orange or No LED. Input voltage from the stinger cord has dropped to less than 11.0
volts or there is no voltage from the stinger cord. Follow the steps below to troubleshoot the Slow Flashing Orange LED
or No LED Status. (See figure 8)
4. While the Dual/Single pole stinger cord is plugged in and the tractor running use a volt meter and
measure the voltage between the Dual pole positive stud and the Dual pole negative stud inside the
Direct™ controller. (See V1 in figure 8) Should read more than 11.1 volts. If yes then the Direct™
controller is defective. If no then proceed to step 5.
5. While the Dual/Single pole stinger cord is plugged in and the tractor running use a volt meter and
measure the voltage between the positive and negative poles in the Dual/single pole receptacle. (See V2
in figure 8) Should read 11.3 volts or higher. If yes then repair or replace the wiring between the
Dual/Single pole and the Direct™ controller. If no then the issue is with the tractor or the Dual/Single
pole. Repair or replace.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
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AUX OPERATION AND TROUBLESHOOTING (Must be configured for charging from seven way. If not then refer
the Dual/Single pole Stinger operation and troubleshooting) – Plug in the seven way and start the tractor. (See
figures 9 and 10 below showing the Source LED and LED status reference located on the right side of the Direct™ controller.)
Figure 9
Figure 10
LED STATUS
CONDITION
ACTION NEEDED
REFERENCE
Solid Green
Charging mode on AUX
None
Slow Flashing Orange
Input voltage from the AUX of
the seven way has dropped to
less than 11.0 volts
Determine where the problem
exist and repair or replace
defective portion.
Ref # 6
Slow Flashing Green
AUX of seven way charging
option is in standby mode.
Start the tractor
Could be due to voltage drop
caused by load on AUX
(i.e. interior lights)
Rapid Flashing Orange
Blown Fuse on the AUX circuit
Repair the circuit and then
replace the fuse
Ref # 5
No LED
No voltage from the AUX of
the seven way connection
Determine where the problem
exists and repair or replace
the circuit
Ref # 6
See next page for troubleshooting reference 5 and 6.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
REFERENCE # 5- Rapid Flashing Orange LED. Blown Fuse on the AUX of seven way circuit. Repair the circuit and
replace the fuse. (See figure 11 below
for Source fuse location)
Figure 11
Figure 12
REFERENCE # 6- Slow Flashing Orange or No LED. Input voltage from the AUX of the seven way has dropped to less
than 11.0 volts or there is no voltage from the AUX of the seven way connection. Follow the steps below to troubleshoot
the Slow Flashing Orange or No LED Status. (See figure 16)
6. Plug in the seven way cord. Start the tractor and let the engine run. Use a volt meter and measure the
voltage between the AUX ground stud and the AUX positive stud inside the Direct™ controller. (See V1
in figure 12) Should read more than 11.1 volts. If yes then the Direct™ controller is defective. If no then
proceed to step 7.
7. Plug in the seven way cord. Start the tractor and let the engine run. Use a volt meter and measure the
voltage between the AUX center pin and the top ground pin on the seven way receptacle on the trailer.
(See V2 in figure 12) Should read more than 11.3 volts. If yes then repair or replace the wiring between
the seven way receptacle on the trailer and the Direct™ controller. If no then the issue is in the seven
way nose box or the tractor.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
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LIFT BATTERY LED OPERATION AND TROUBLESHOOTING (Source LED must be solid green. If not, see
Dual/Single pole stinger operation and troubleshooting or aux operation and troubleshooting) - (See figures 13 and
14 below showing the source LED at charging voltage and LED status reference located on the right side of the Direct™ controller.)
Figure 13
Figure 14
LED STATUS
CONDITION
ACTION NEEDED
REFERENCE
Solid Green
Charging
None
Slow Flashing Green
Not Charging
Check the DC/DC converter and
circuit protection
Page 11
Slow Flashing Orange
Not Charging
Check the DC/DC converter and
circuit protection
Page 11
No LED
Not Charging
Check the DC/DC converter and
circuit protection
Page 11
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
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TESTING THE DC/DC CONVERTER (See figure 15 below showing the LEDs on the DC/DC converter.)
Figure 15
LED STATUS
CONDITION
ACTION NEEDED
REFERENCE
Solid Green
DC/DC converter is on
Ensure circuit protection on
output side is in working order
Ref # 7 Step 5
Amber Light
DC/DC converter is off
Input voltage is too low
Ref # 8
Rapid Flashing Red
DC/DC converter has a fault
Determine the fault
Ref # 7 and 8
No Light
No voltage
Determine the fault
Ref # 7 and 8
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
Reference #7: Steps to testing the DC/DC converter
1. With the DC/DC converter off measure the voltage at the liftgate batteries. (See V1 on diagram page 13)
Should be over 12.4 volts.
2. Start the tractor so that the DC/DC converter turns on. Green LED on the Direct™ Controller illuminates.
3. Measure the voltage at the liftgate batteries. (See V1 on diagram page 13) Should be higher than the
12.4 volts. If yes then continue to step 4. If no then skip to step 5.
4. With a clip on ammeter measure the current flow. (See clip-on ammeter on diagram on page 13) If there
is current flow and voltage rises then the system is operating correctly.
5. Check out the circuit protection. (It will be a circuit breaker or a fuse cube) Reset the circuit breaker or
replace the fuse cube if blown. Once complete go back through and repeat steps 3 and 4.
Reference #8: Steps to testing the power to the DC/DC converter
1. With a voltmeter measure the input voltage. (See V2 on diagram on page 13) Should be 9.0 volts or
higher. If yes, continue to step 3. If no, continue to step 2.
2. With a voltmeter measure the output voltage. (See V3 on diagram on page 13) Should be 11.0 volts or
higher. If yes, repair the wiring between the Direct™ controller and the plate system in the liftgate battery
box. If no, then follow Direct™ Controller Troubleshooting.
3. With a voltmeter measure the voltage at the ignition input. (See V4 on diagram on page 13) Should read
battery voltage. If yes then the system is functioning correctly. If no, proceed to step 4.
4. With a voltmeter measure the output voltage. (See V3 on diagram on page 13) Should see battery
voltage. If yes, repair or replace the wire from the Direct™ controller to the ignition stud on the plate
assembly inside the liftgate battery box. If no then follow Direct™ Controller Troubleshooting.
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DIRECT™ TROUBLESHOOTING V1.10
OWNERS MANUAL
TROUBLESHOOTING DIAGRAM
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