Vehicle Power Supply Installation Guide
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... vii Warranty Information vii Web Support viii Telephone Support viii Who Should Read This Guide ix 1 Introduction 1 About the DC Power Supply Kit 2 Installation Guidelines 2 Power Supply Options 3 About the LEDs 4 Input Power Cable 5 Output Power Cable 6 Configuration Chart 6 Installation Diagrams 7 Wiring Diagram 9 2 Installation Process 11 Installation Recommendations 12 Installation Summary 12 Tools Required 13 Preparing...
... vii Warranty Information vii Web Support viii Telephone Support viii Who Should Read This Guide ix 1 Introduction 1 About the DC Power Supply Kit 2 Installation Guidelines 2 Power Supply Options 3 About the LEDs 4 Input Power Cable 5 Output Power Cable 6 Configuration Chart 6 Installation Diagrams 7 Wiring Diagram 9 2 Installation Process 11 Installation Recommendations 12 Installation Summary 12 Tools Required 13 Preparing...
Vehicle Power Supply Installation Guide
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Installing the Power Cables 17 Power Cable Connections 18 Cable Termination - Overview of Process 19 Preparing the Power Cable 19 Heat Shrink Tubing 20 Finishing the Cable Ends 21 Power Source Connections 22 Direct Battery Connections 22 Side-Mount Battery Terminals 22 Top-Mount Terminals 23 Cable Clamps 25 Connecting the Output Power Cable 25 Sample Installations 26 3 Troubleshooting Information 29 Identifying and...
Installing the Power Cables 17 Power Cable Connections 18 Cable Termination - Overview of Process 19 Preparing the Power Cable 19 Heat Shrink Tubing 20 Finishing the Cable Ends 21 Power Source Connections 22 Direct Battery Connections 22 Side-Mount Battery Terminals 22 Top-Mount Terminals 23 Cable Clamps 25 Connecting the Output Power Cable 25 Sample Installations 26 3 Troubleshooting Information 29 Identifying and...
Vehicle Power Supply Installation Guide
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... Mounting surface must be sturdy. • Mounting surface must provide power supply heat sink. • Fuse must not violate fork lift manufacturer's requirements and should be familiar with Intermec equipment only. • Keep cables as short as those of equipment where this kit is installed,... for 12V installations • Insulated quick-connect tabs (2) The power supply provides filtered and regulated 12 VDC output. ...
... Mounting surface must be sturdy. • Mounting surface must provide power supply heat sink. • Fuse must not violate fork lift manufacturer's requirements and should be familiar with Intermec equipment only. • Keep cables as short as those of equipment where this kit is installed,... for 12V installations • Insulated quick-connect tabs (2) The power supply provides filtered and regulated 12 VDC output. ...
Vehicle Power Supply Installation Guide
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... inches (840 to the output power cable. Output connector (secondary power) Green LEDs (power output indicators) Output connector (main power) Power Supply (P/N 851-070-003) 6-60V, 14A Green LED (power output indicator) Output connector Power Supply (P/N 851-041-003) 15-96V, 4.5A 4 Vehicle Power Supply Installation Guide Note: If...metallic surface to mount it is less than 9-10 volts. Introduction Since the power supply will produce heat, it on the power supply, will continue to provide 12V output power to the LEDs for troubleshooting. Note: Use the hardware supplied in a location...
... inches (840 to the output power cable. Output connector (secondary power) Green LEDs (power output indicators) Output connector (main power) Power Supply (P/N 851-070-003) 6-60V, 14A Green LED (power output indicator) Output connector Power Supply (P/N 851-041-003) 15-96V, 4.5A 4 Vehicle Power Supply Installation Guide Note: If...metallic surface to mount it is less than 9-10 volts. Introduction Since the power supply will produce heat, it on the power supply, will continue to provide 12V output power to the LEDs for troubleshooting. Note: Use the hardware supplied in a location...
Vehicle Power Supply Installation Guide
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...fast-blow. It must be connected as close as possible. By cutting off the unneeded connector, a single cable can snag on page 14 for detailed instructions for attaching the power cable. The fuse holder contains a 3AB, 20-ampere/250 VDC (1/4x1-1/ 4 inch) fast-blow fuse, ... 10A Slow blow 36V 6A Slow blow (maximum fuse value) 48V 5A Slow blow (maximum fuse value Vehicle Power Supply Installation Guide 5 Introduction Input Power Cable Note: Keep the cable as short as possible (electrically and physically) to a minimum and use only equivalent or lower gauge (larger diameter...
...fast-blow. It must be connected as close as possible. By cutting off the unneeded connector, a single cable can snag on page 14 for detailed instructions for attaching the power cable. The fuse holder contains a 3AB, 20-ampere/250 VDC (1/4x1-1/ 4 inch) fast-blow fuse, ... 10A Slow blow 36V 6A Slow blow (maximum fuse value) 48V 5A Slow blow (maximum fuse value Vehicle Power Supply Installation Guide 5 Introduction Input Power Cable Note: Keep the cable as short as possible (electrically and physically) to a minimum and use only equivalent or lower gauge (larger diameter...
Vehicle Power Supply Installation Guide
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...No No Yes Order the Smart UPS kit (P/N 203-788-xxx) for the universal power supply (UPS) that you have the correct output power cables for your particular installation. Use of the cable is specific to the vehicle mount computer or docking device in your location. These .... Introduction Should the fuse fail, diagnose and correct the underlying problem, and then replace with larger than recommended fuse values. Chapter 1 - Output power cables are approximately 6.0 feet (1.83 m) to 7.0 feet (2.13 m) long and have heavy-duty metal housings and enhanced strain relief to provide added...
...No No Yes Order the Smart UPS kit (P/N 203-788-xxx) for the universal power supply (UPS) that you have the correct output power cables for your particular installation. Use of the cable is specific to the vehicle mount computer or docking device in your location. These .... Introduction Should the fuse fail, diagnose and correct the underlying problem, and then replace with larger than recommended fuse values. Chapter 1 - Output power cables are approximately 6.0 feet (1.83 m) to 7.0 feet (2.13 m) long and have heavy-duty metal housings and enhanced strain relief to provide added...
Vehicle Power Supply Installation Guide
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... Installation Recommendations Review the lift vehicles to simplify the device installation and service. Plan the installation following these safety and utility recommendations. • Install the power cable at the vehicle power source if possible or at the point where the connection is first made to the lift. • Keep the...
... Installation Recommendations Review the lift vehicles to simplify the device installation and service. Plan the installation following these safety and utility recommendations. • Install the power cable at the vehicle power source if possible or at the point where the connection is first made to the lift. • Keep the...
Vehicle Power Supply Installation Guide
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... • Heat gun for heat shrink tubing • Wire crimping and stripping tool • Electric drill, drill bits • DC Ohmmeter Parts List Description Power cable Fuse holder assembly Fuse, 20 A ceramic FB Bolt, 3/8-16 x 1-1/2" Washer, 3/8" Nut, 3/8-16 Adjustable wire clamps Self-tap screw #6 x 5/8" 3/8"... #10 terminal ring Self-tab screw #8 x 5/8" #8 flat washer Snap-in bushing Screw, m/s 1/4-20 x 1-1/4" Flat washer, 1/4" Locking nut, 1/4-20 Lockwasher, 1/4" Cable tie, locking Intermec Part Number 226-340-004 315-075-003 315-074-003 800-099-001 803-099-001 802-099-001 808-011-001 800...
... • Heat gun for heat shrink tubing • Wire crimping and stripping tool • Electric drill, drill bits • DC Ohmmeter Parts List Description Power cable Fuse holder assembly Fuse, 20 A ceramic FB Bolt, 3/8-16 x 1-1/2" Washer, 3/8" Nut, 3/8-16 Adjustable wire clamps Self-tap screw #6 x 5/8" 3/8"... #10 terminal ring Self-tab screw #8 x 5/8" #8 flat washer Snap-in bushing Screw, m/s 1/4-20 x 1-1/4" Flat washer, 1/4" Locking nut, 1/4-20 Lockwasher, 1/4" Cable tie, locking Intermec Part Number 226-340-004 315-075-003 315-074-003 800-099-001 803-099-001 802-099-001 808-011-001 800...
Vehicle Power Supply Installation Guide
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... the unused connector end. 5 Discard the unused connector. 6 Remove the cable connector from the power supply with a counterclockwise turn of the input connectors will go. 3 Turn the cable connector collar clockwise to a minimum and should be lengthened. Installation Process Parts List Description Intermec Part Number h/s tubing, black, 1/8" diameter 321-650-003 h/s tubing, black, 3/8" diameter...
... the unused connector end. 5 Discard the unused connector. 6 Remove the cable connector from the power supply with a counterclockwise turn of the input connectors will go. 3 Turn the cable connector collar clockwise to a minimum and should be lengthened. Installation Process Parts List Description Intermec Part Number h/s tubing, black, 1/8" diameter 321-650-003 h/s tubing, black, 3/8" diameter...
Vehicle Power Supply Installation Guide
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...mounting hole locations. 2 Use a #7 drill bit to make the two mounting holes. 3 Use 1/4" hex bolts with other instructions closely when installing power cables. To use mounting method A 1 Mark and center punch the two mounting hole locations. 2 Use a 1/4" drill bit to make the mounting holes... installation. Installation Process Use Method B where the back side of the mounting location is inaccessible. Vehicle Power Supply Installation Guide 17 Installing the Power Cables Follow these guidelines and other equipment or vehicle controls. • Ensure that the mounting plate be thick...
...mounting hole locations. 2 Use a #7 drill bit to make the two mounting holes. 3 Use 1/4" hex bolts with other instructions closely when installing power cables. To use mounting method A 1 Mark and center punch the two mounting hole locations. 2 Use a 1/4" drill bit to make the mounting holes... installation. Installation Process Use Method B where the back side of the mounting location is inaccessible. Vehicle Power Supply Installation Guide 17 Installing the Power Cables Follow these guidelines and other equipment or vehicle controls. • Ensure that the mounting plate be thick...
Vehicle Power Supply Installation Guide
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... the metal surface on which the power supply is assumed that the negative lead connects to the return to accommodate most installation needs. 18 Vehicle Power Supply Installation Guide Power Cable Connections The fuse holder from the input power cable must install either an On/Off ...switch (minimum 15A DC rating such as possible, both physically and electrically, to various possible vehicle power sources. Charge Guard, Inc...
... the metal surface on which the power supply is assumed that the negative lead connects to the return to accommodate most installation needs. 18 Vehicle Power Supply Installation Guide Power Cable Connections The fuse holder from the input power cable must install either an On/Off ...switch (minimum 15A DC rating such as possible, both physically and electrically, to various possible vehicle power sources. Charge Guard, Inc...
Vehicle Power Supply Installation Guide
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.... 6 Twist the red and black (positive) wires together. 7 Twist the shield wire and slide on page 18 if you need to connect the input power cable directly to work with an ohmmeter. Finally, you must be the same as instructed. Then, you must cut the... the 1/8-inch heat shrink tubing. Chapter 2 - Installation Process This kit contains additional bolts, nuts, and washers should you are approximate lengths. To prepare the power cable 1 Cut the power cable near the power source or battery. 2 Strip the cable jacket back 12-14 inches (30-36 cm). 3 Slide heat shrink tubing over...
.... 6 Twist the red and black (positive) wires together. 7 Twist the shield wire and slide on page 18 if you need to connect the input power cable directly to work with an ohmmeter. Finally, you must be the same as instructed. Then, you must cut the... the 1/8-inch heat shrink tubing. Chapter 2 - Installation Process This kit contains additional bolts, nuts, and washers should you are approximate lengths. To prepare the power cable 1 Cut the power cable near the power source or battery. 2 Strip the cable jacket back 12-14 inches (30-36 cm). 3 Slide heat shrink tubing over...
Vehicle Power Supply Installation Guide
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Note: Tubing must be in the illustration that the negative input connector wires connect to prevent contact with heat shrink applied Strip the cable jacket 12-14 inches (30-36 cm) Note: Make sure that follows. 2 Use a heat gun to shrink tubing. 3 Use the 1/8-inch shrink sleeve... and a 12 inch (30 cm) length of the input connector. Installation Process Heat shrink tubing Green and white wires (negative) see note below Input power cable Red and black wires (positive) see note below Shield wire with other two wires connect to separate and pull out the shield wire. Chapter 2 - ...
Note: Tubing must be in the illustration that the negative input connector wires connect to prevent contact with heat shrink applied Strip the cable jacket 12-14 inches (30-36 cm) Note: Make sure that follows. 2 Use a heat gun to shrink tubing. 3 Use the 1/8-inch shrink sleeve... and a 12 inch (30 cm) length of the input connector. Installation Process Heat shrink tubing Green and white wires (negative) see note below Input power cable Red and black wires (positive) see note below Shield wire with other two wires connect to separate and pull out the shield wire. Chapter 2 - ...
Vehicle Power Supply Installation Guide
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...second 3/8-inch washer onto that bolt. 5 Slide the vehicle positive battery cable onto the bolt. 6 Thread the bolt assembly (steps 2-5, above) into the positive (+) battery terminal. Note: No additional hardware is provided for connecting the power cable to the metal surface on the top. Securely tighten but do not ... Connections The next few pages show you the hardware (nuts, bolts, and washers) included in this kit if you are connecting the power cable directly to a side-mount battery terminal as it will go onto a 3/8 x 1-1/2inch bolt furnished in the kit, then slip a 3/8-inch washer...
...second 3/8-inch washer onto that bolt. 5 Slide the vehicle positive battery cable onto the bolt. 6 Thread the bolt assembly (steps 2-5, above) into the positive (+) battery terminal. Note: No additional hardware is provided for connecting the power cable to the metal surface on the top. Securely tighten but do not ... Connections The next few pages show you the hardware (nuts, bolts, and washers) included in this kit if you are connecting the power cable directly to a side-mount battery terminal as it will go onto a 3/8 x 1-1/2inch bolt furnished in the kit, then slip a 3/8-inch washer...
Vehicle Power Supply Installation Guide
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... the positive (fuse link with red wire) terminal ring from the power input cable, connecting the wire to the metal surface on which the power supply is mounted. Repeat steps 6 through 8 for the negative battery cable wire (white-green pair) from the input power cable onto the positive (+) battery bolt. 7 Slip a second 3/8-inch washer onto that...
... the positive (fuse link with red wire) terminal ring from the power input cable, connecting the wire to the metal surface on which the power supply is mounted. Repeat steps 6 through 8 for the negative battery cable wire (white-green pair) from the input power cable onto the positive (+) battery bolt. 7 Slip a second 3/8-inch washer onto that...
Vehicle Power Supply Installation Guide
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... a clamp and adhere the clamp in place. #6 sheet metal screw goes here Recommended Grounding and Power Source Connections Connecting the Output Power Cable Once the computer, dock, or other device is mechanically installed, you can connect the output power cable between the power supply output and the device. Note: See "Troubleshooting Charts" on page 32 for...
... a clamp and adhere the clamp in place. #6 sheet metal screw goes here Recommended Grounding and Power Source Connections Connecting the Output Power Cable Once the computer, dock, or other device is mechanically installed, you can connect the output power cable between the power supply output and the device. Note: See "Troubleshooting Charts" on page 32 for...
Vehicle Power Supply Installation Guide
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Chapter 2 - Installation Process Sample Installations In this installation allows: • Easy access to power supply components, LED visibility is securely attached with adequate heat sink, and good air access for cooling. • Good access for component service. • Full access to the UPS battery. 26 Vehicle Power Supply Installation Guide Additionally, this installation example, the power supply is good. • Power cables are out of the way and tied off, with good air flow, easy access, and neatly tied-off cabling.
Chapter 2 - Installation Process Sample Installations In this installation allows: • Easy access to power supply components, LED visibility is securely attached with adequate heat sink, and good air access for cooling. • Good access for component service. • Full access to the UPS battery. 26 Vehicle Power Supply Installation Guide Additionally, this installation example, the power supply is good. • Power cables are out of the way and tied off, with good air flow, easy access, and neatly tied-off cabling.
Vehicle Power Supply Installation Guide
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... takes longer than either end of the power cable adds protection from accidental nicks and cuts. See the "Troubleshooting Charts" on page 32 for a continuity test. Troubleshooting Information • Make sure cables are adequately dressed (protected) to check cables for the most likely causes: •...around the lift. • The sheath of the power output cable. Inspecting the Fuse Open the twist-lock fuse holder and remove the fuse for more information. Chapter 3 - Failure to aid measuring voltage at the input power cable connector and at random, you substitute a new ...
... takes longer than either end of the power cable adds protection from accidental nicks and cuts. See the "Troubleshooting Charts" on page 32 for a continuity test. Troubleshooting Information • Make sure cables are adequately dressed (protected) to check cables for the most likely causes: •...around the lift. • The sheath of the power output cable. Inspecting the Fuse Open the twist-lock fuse holder and remove the fuse for more information. Chapter 3 - Failure to aid measuring voltage at the input power cable connector and at random, you substitute a new ...
Vehicle Power Supply Installation Guide
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... the tables in this instance) or be prepared to take components from another working Test for proper vehicle supply voltage at source No output from power Disconnect input power cable supply to flicker. Troubleshooting Charts The following troubleshooting charts, substituting only when directed to do so. • If an installation suffers intermittent input...
... the tables in this instance) or be prepared to take components from another working Test for proper vehicle supply voltage at source No output from power Disconnect input power cable supply to flicker. Troubleshooting Charts The following troubleshooting charts, substituting only when directed to do so. • If an installation suffers intermittent input...
Vehicle Power Supply Installation Guide
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... fuse if voltage is not present at connector Replace input power cable if input voltage is still not present at connector Have the forklift vendor recommend in-line filter, alternate connection point, and check cables for nicks, and shorts. Power Supply Pinouts Connector Input Power Connector Negative Positive Case Pin 1 Pin 2 Pin 3 Pin 4 Shield Secondary...
... fuse if voltage is not present at connector Replace input power cable if input voltage is still not present at connector Have the forklift vendor recommend in-line filter, alternate connection point, and check cables for nicks, and shorts. Power Supply Pinouts Connector Input Power Connector Negative Positive Case Pin 1 Pin 2 Pin 3 Pin 4 Shield Secondary...