forklift power supply installation guideepsfiles.intermec.com/eps_files/eps_man/932-011.pdf · •...

Forklift Power Supply

Installation Guide

ii Forklift Power Supply Installation Guide

Intermec Technologies Corporation

Worldwide Headquarters 6001 36th Ave.W. Everett, WA 98203 U.S.A.

www.intermec.com

The information contained herein is provided solely for the purpose of allowing customers to operate and service Intermec-manufactured equipment and is not to be released, reproduced, or used for any other purpose without written permission of Intermec Technologies Corporation.

Information and specifications contained in this document are subject to change without prior notice and do not represent a commitment on the part of Intermec Technologies Corporation.

© 2008-2009 by Intermec Technologies Corporation. All rights reserved.

The word Intermec, the Intermec logo, Norand, ArciTech, Beverage Routebook, CrossBar, dcBrowser, Duratherm, EasyADC, EasyCoder, EasySet, Fingerprint, INCA (under license), i-gistics, Intellitag, Intellitag Gen2, JANUS, LabelShop, MobileLAN, Picolink, Ready-to-Work, RoutePower, Sabre, ScanPlus, ShopScan, Smart Mobile Computing, SmartSystems, TE 2000, Trakker Antares, and Vista Powered are either trademarks or registered trademarks of Intermec Technologies Corporation.

There are U.S. and foreign patents as well as U.S. and foreign patents pending. Wi-Fi is a registered certification mark of the Wi-Fi Alliance.

Document Change Record This page records changes to this document. The document was originally released as Revision 001.

Version Number Date Description of Change

002 6/2009 Updated to include new printer models and output cable number.

001 4/2008 First release of document

Forklift Power Supply Installation Guide iii

iv Forklift Power Supply Installation Guide

Contents

ContentsBefore You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viiiGlobal Services and Support . . . . . . . . . . . . . . . . . . . . viii

Warranty Information . . . . . . . . . . . . . . . . . . . . viiiWeb Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ixTelephone Support . . . . . . . . . . . . . . . . . . . . . . . . ixService Location Support. . . . . . . . . . . . . . . . . . . ix

Who Should Read This Manual . . . . . . . . . . . . . . . . . . .x

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Understanding the DC Power Supply Kit . . . . . . . . . . . . . . . 2

Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Power Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 3Understanding Power Supply LEDs . . . . . . . . . . . . . . 3Using the Input Power Cable . . . . . . . . . . . . . . . . . . . . . 4Using the Inline Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Using the Output Power Cable . . . . . . . . . . . . . . . . . . . 6

Contents of the Forklift Power Supply Kit . . . . . . . . . . . . . . 6

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Installing the Forklift Power Supply . . . . . . 9

Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . 10Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . 10Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Preparing the Power Input Cable . . . . . . . . . . . . . . . . . . . . . 11

Mounting the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 11Direct Versus Isolation Mounting on the

Lift Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Creating a Custom Electrical Isolation Mount . . . . 13Using a Standard Power Supply Mount . . . . . . . . . . 14

Forklift Power Supply Installation Guide v

Contents

Installing the Input Power Cable. . . . . . . . . . . . . . . . . . . . . . 14

Connecting the Power Cable to the Forklift . . . . . . . . . . . . 15

Terminating the Input Cable . . . . . . . . . . . . . . . . . . . . . . . . . 16Cutting and Stripping the Input Power Cable . . . . 16Attaching Heat Shrink Tubing . . . . . . . . . . . . . . . . . . 17Preparing the Cable Ends . . . . . . . . . . . . . . . . . . . . . . . 18

Connecting to the Forklift Battery . . . . . . . . . . . . . . . . . . . . 19Connecting to Side-Mount Battery Terminals . . . . 19Connecting to Top-Mount Battery Terminals . . . . 20Securing the Battery Cable . . . . . . . . . . . . . . . . . . . . . . 21Connecting the Output Power Cable . . . . . . . . . . . . 21Sample Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Identifying and Correcting Problems. . . . . . . . . . . . . . . . . . 26Inspecting the Hardware. . . . . . . . . . . . . . . . . . . . . . . . 26Checking the Electrical Measurements . . . . . . . . . . . 26

Measuring the Voltage . . . . . . . . . . . . . . . . . . . . 26Performing Continuity Testing . . . . . . . . . . . . 26

Substituting Components . . . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

vi Forklift Power Supply Installation Guide

Contents

Forklift Power Supply Installation Guide vii

Before You Begin

Before You BeginThis section provides you with safety information, technical support information, and sources for additional product information.

Safety InformationYour safety is extremely important. Read and follow all warnings and cautions in this document before handling and operating Intermec equipment. You can be seriously injured, and equipment and data can be damaged if you do not follow the safety warnings and cautions.

This section explains how to identify and understand warnings, cautions, and notes that are in this document.

Global Services and SupportWarranty InformationTo understand the warranty for your Intermec product, visit the Intermec web site at www.intermec.com and click Support > Returns and Repairs > Warranty.

A warning alerts you of an operating procedure, practice, condition, or statement that must be strictly observed to avoid death or serious injury to the persons working on the equipment.

A caution alerts you to an operating procedure, practice, condition, or statement that must be strictly observed to prevent equipment damage or destruction, or corruption or loss of data.

Note: Notes either provide extra information about a topic or contain special instructions for handling a particular condition or set of circumstances.

viii Forklift Power Supply Installation Guide

http://www.intermec.com


Before You Begin

Disclaimer of warranties: The sample code included in this document is presented for reference only. The code does not necessarily represent complete, tested programs. The code is provided “as is with all faults.” All warranties are expressly disclaimed, including the implied warranties of merchantability and fitness for a particular purpose.

Web SupportVisit the Intermec web site at www.intermec.com to download our current manuals (in PDF). To order printed versions of the Intermec manuals, contact your local Intermec representative or distributor.

Visit the Intermec technical knowledge base (Knowledge Central) at www.intermec.com and click Support > Knowledge Central to review technical information or to request technical support for your Intermec product.

Telephone SupportIn the U.S.A. and Canada, call 1-800-755-5505.

Outside the U.S.A. and Canada, contact your local Intermec representative. To search for your local representative, from the Intermec web site, click About Us > Contact Us.

Service Location SupportFor the most current listing of service locations, go to www.intermec.com and click Support > Returns and Repairs > Repair Locations.

For technical support in South Korea, use the after service locations listed below:

AWOO Systems 102-1304 SK Ventium 522 Dangjung-dong Gunpo-si, Gyeonggi-do Korea, South 435-776 Contact: Mr. Sinbum Kang Telephone: +82-31-436-1191 E-mail: [email protected]

Forklift Power Supply Installation Guide ix




Before You Begin

IN Information System PTD LTD 6th Floor Daegu Venture Center Bldg 95 Shinchun 3 Dong Donggu, Daegu City, Korea E-mail: [email protected] or [email protected]

Who Should Read This ManualThis document is for the person who is responsible for installing, configuring, and maintaining the Forklift Power Supply. The Forklift Power Supply Installation Kit can be used with the PB21, PB22, PB31, PB32, PB50, PB51, and PW50 mobile printers.

This document provides you with information about the features of the forklift power supply, and how to install, configure, operate, maintain, and troubleshoot it.

Before you work with the forklift power supply , you should be familiar with your network and general networking terms, such as IP address.

x Forklift Power Supply Installation Guide

1
Introduction
This chapter introduces the forklift power supply that is used for your mobile printer. This chapter contains these topics:

• Understanding the DC Power Supply Kit

• Installation Guidelines

• Power Supply Considerations

• Contents of the Forklift Power Supply Kit

• Wiring Diagram

1

Chapter 1 — Introduction

Understanding the DC Power Supply KitUse the DC power to help supply power to your mobile printer when it is on a forklift. The DC power supply kits include these items:

• Power supply

• Power supply input cable, 2.44 m (8 feet)

• Fused power cable, 46 cm (18 inch)

• #10 terminal ring

• 3AB, 20A/250 Vx fuse for 12 V installations

• Insulated quick-connect tabs (2)

The power supply provides 12 Vx output that is filtered and regulated. It also provides over-current, over-voltage, over temperature, and shorted-output protection.

Installation GuidelinesYou should be familiar with the brands and models of equipment where this kit is installed. You should also be trained and experienced in forklift electrical systems.

Follow these guidelines and the installation procedures as well as those of the lift manufacturer to ensure a safe and reliable installation:

• Make sure the power supply is securely mounted.

• Make sure the mounting surface is sturdy.

• Make sure the mounting surface provides power supply heat sink.

• Make sure the fuse is close to vehicle power source and is in line with Intermec equipment only.

• Keep cables as short as possible, and secure them at least every 46 cm (18 inch).

Before installing the power supply, familiarize yourself with the forklift manufacturer’s requirements and make sure you have the proper qualifications to perform the installation. For procedures on how to properly mount the forklift power supply, see “Mounting the Power Supply” on page 11.

2 Forklift Power Supply Installation Guide


Order the Smart UPS kit (P/N 203-788-xxx) for a universal power supply (UPS) that provides backup power during battery change out.

Power Supply ConsiderationsFollow these guidelines when installing the power supply:

• The power supply (P/N 851-070-003) accepts input voltage ranging from 6 to 60 Vx for use with forklifts using electrical systems running 12 to 60 Vx. It provides 12 Vx output which is filtered and regulated. It also provides short-circuit, over-voltage, and over-temperature protection.

• You should mount the power supply to the forklift chassis or connect it (electrically) through external wire to the forklift chassis. Chassis ground to the printer or other equipment is then established through the power supply output cable.

• Since the power supply produces heat, Intermec advises that you mount it on a metallic surface that is a minimum of 838 to 1032 square cm (130 to 160 square inches which is approximately one square foot or more) to disperse heat. This location should not be in the vicinity of sources of forklift generated heat.

Understanding Power Supply LEDsA single or a pair of green light-emitting diodes (LEDs), located near the output connectors on the power supply (P/N 851-070-003), light up whenever you apply voltage to the output power cable. Mount the power supply in a location that allows easy visibility to LEDs for troubleshooting.

Note: This document assumes that you have already installed the vehicle mount printer on your forklift and that you have the correct power supply and power supply input cable for your forklift before you proceed with the installation.

Note: Use the hardware supplied in the kit, or equivalent, to mount the power supply. Do not use sheet metal screws or other less permanent or rugged mounting solutions.

Forklift Power Supply Installation Guide 3


The main output LED indicate that the main power is functioning (3-pin connector). The secondary power LED indicates the heater power (2-pin connector) is functioning.

Power Supply LED

Using the Input Power Cable

The input cable from the power supply is approximately 2.74 m (9.0 feet) long. One end has a 4-pin connector, the other has a 2-pin connector. By cutting off the unneeded connector, a single cable can meet either 4 or 4.5 A current requirements. The cut end is then terminated for connection to the forklift power source. For instructions on attaching the power cable, see “Mounting the Power Supply” on page 11.

Note: If the secondary LED is not lit, the input power to the DC-DC converter is less than 9 to 10 Vx. It will continue to provide 12 V output power to the main power connector.

Output connector (secondary power)

Green LEDs (power output indicators)

Output connector (main power)

Input connector

Note: Keep the cable as short as possible. Extra cable picks up noise, adds power loss, and can snag on equipment.

The input power cable may be shortened as needed. It should not be extended on 12 V or lower systems. On higher voltage systems, extensions should be kept to a minimum and should be of equivalent or lower gauge (larger diameter) wire. Keep the cable as short as possible. Extra cable picks up noise, adds power loss, and can snag on equipment.



Using the Inline FuseA snap-twist inline fuse holder is furnished as part of this kit. It must be connected as close as possible (electrically and physically) to the forklift power source. It provides catastrophic failure, short-circuit protection for the entire input power cable and the power supply input. The fuse holder contains a 3AB, 20 A/250 Vx (.25 inch x 1.25 inch) fast-blow fuse recommended for installations with 12 V automotive batteries. For other vehicle battery voltages, please refer to the table below. These alternate fuses are not provided with the kit and must be obtained separately. In general, smaller fuse ratings offer faster acting protection.

Note: If your fuse fails, diagnose the problem and then correct it before replacing the fuse with the exact same size and type you are replacing.

Recommended Fuse Values

Lift Voltage Fuse Ratings Description

12V 20A Fast-blow (ships with power supply)

24V 10A Slow-blow, maximum fuse value



Do not replace the fuse with larger fuse values than recommended. Use of a larger fuse may result in damage to equipment.



Using the Output Power Cable

Output power cables (P/N 236-193-001) are approximately 2.2 m (7.2 feet) long and have a durable 2-pin connector to mate with the power supply. The connector on the far end of the cable is specific to the vehicle cradle for the printer. These rugged connectors have heavy-duty metal housings and enhanced strain relief to provide added reliability in the mobile environment. For a diagram of the output cable, see the next section.

Contents of the Forklift Power Supply Kit

Installing the Printer With the Forklift Power Supply Kit

Note: Ensure that you have the correct output power cables for the mobile printer you are installing.

Contents of Forklift Power Kit (P/N 203-880-002)

Description Part Number Quantity

Installation kit, vehicle power supply

203-804-002 1

DC/DC converter 6-60 Vin/12 Vout (power supply)

851-070-003 1

Vehicle dock (AV8) forklift cable (output cable)

236-193-003 1

Forklift Power SupplyInstallation Guide

932-011-xxx 1

6-60 V

Fuse

Printer and vehicle cradle Cable input

DC/DC power supply(“converter”)

Cable output

--

+



Cable assembly (input cable) 226-340-004 1

Fuse holder assembly 315-075-003 1

Fuse, 20 A ceramic FB 315-074-003 1

Bolt, 3/8-16 x 1-1/2-inch 800-099-001 2

Washer, 3/8-inch 803-099-001 4

Nut, 3/8-16 802-099-001 4

Adjustable wire clamps 808-011-001 8

Self-tap screw #6 x 5/8-inch 800-008-003 8

3/8-inch terminal ring 809-165-001 2

#10 terminal ring 809-083-009 3

Self-tapping screw, 800-012-000 1

#8 flat washer 803-084-000 1

Snap-in bushing 807-065-003 1

Screw, 1/4-20 x 1-1/4 inch 801-194-002 2

Flat washer 803-100-001 2

Locking nut 802-117-000 2

Washer, split-lock 803-042-001 2

Cable tie, locking 808-002-000 6

H-S tubing, black, 1/8-inch diameter

321-650-003 30.5 cm

H-S tubing, black, 3/8-inch diameter

321-650-006 15.2 cm

Bead, split w/sleeve 309-065-006 1

Plug, 2-socket circular 311-638-00 1

Plug, 4-socket circular 311-638-006 1

311-638-006 1

Cable, 4 cond 18 AWG, foil-shielded

321-295-005 274.3 cm

Shield bead, .590/.275/1.10L, 300HM 309-091-008 2

309-091-008 2

Contents of Forklift Power Kit (P/N 203-880-002) (continued)

Description Part Number Quantity



Wiring DiagramThis wiring diagram outlines several possible connections to the power source in a forklift. Use this illustration as a reference during the planning phase of your power supply installation.

Power Source Connection Possibilities

Distribution panels work better than direct connect to motors

Power-Acceptable

Negative - WorstRegenerative Braking System, verylarge voltage spikes

Negative - MarginalLarge output spikespossible on motors

Negative-Marginal

Connector to battery - Best + To DC/DC converter

Power-Acceptable


2
Installing the Forklift Power Supply
This chapter describes how to install the forklift power supply. This chapter contains these topics:

• Installation Recommendations

• Preparing the Power Input Cable

• Mounting the Power Supply

• Installing the Input Power Cable

• Connecting the Power Cable to the Forklift

• Terminating the Input Cable

• Connecting to the Forklift Battery

9

Chapter 2 — Installing the Forklift Power Supply

Installation RecommendationsReview the forklifts you want to use before you start. Plan the installation by following these safety and utility recommendations:

• Install the power cable at the forklift power source if possible or at the point where the connection is first made to the lift.

• Keep the power cable length as short as possible.

• Connect the negative lead to a point on the lift that other electronic systems use.

• Read the label on the power supply and verify that the input voltage rating is correct for the forklift in which you will be installing the printer.

• Remember that the supply with the lower input voltage rating (6-60 Vx) has a 4-pin input connector. Design a bracket that would be common to multiple lifts with pre-attached devices to simplify the device installation and service. Designing a common bracket would reduce your installation time because the mounting bracket would be more straightforward and consistent. It would also simplify service because you can take the entire bracket down and replace it with another bracket while troubleshooting the system away from the lift.

Installation OverviewCarry out the primary installation steps in the order outlined below. The sections that follow include detailed steps for each segment of the vehicle power supply installation process.

To install the vehicle power supply1 Connect the input cable to the power supply.

2 Mechanically install and secure the power supply.

3 Route and secure the power cable.

Equipment failure or damage will result if the vehicle power source voltage does not fall within the power supply input voltage rating.



4 Shorten cable as appropriate, then crimp the fuse holder to the joined red and black wires (positive). Crimp a terminal ring to the joined white and green wires (negative). Insulate as instructed.

5 Make final connections to the forklift power source.

Tools ListYou will need the following tools to properly install the forklift power supply:

• Common hand tools (screwdriver, pliers, and so on)

• Heat gun for heat shrink tubing

• Wire crimping and stripping tool

• Electric drill, drill bits

• DC Ohmmeter

Preparing the Power Input CableUse these directions to attach the input cable connector to the power supply.

To connect the power input cable1 Attach the input cable connector (P/N 226-340-004) to the

power supply (P/N 851-070-003).

2 Slide the connector in as far as possible.

3 Turn the cable connector collar clockwise to secure it.

4 Cut the cable at the unused connector end.

5 Discard the unused connector.

6 Remove the cable connector from the power supply with a counterclockwise turn of the cable connector collar. Additional details for installation are covered later in the section, “Terminating the Input Cable” on page 16.

Mounting the Power SupplyThe input power cable is approximately 2.74 m (9.0 feet) long and may be shortened if necessary. The output power cable is approximately 2.2 m (7.2 feet) long and should not be lengthened.



You should take these lengths and the intended location of your electronic equipment into consideration when choosing a mounting location for the power supply.

The mounting surface location must provide 838 to 1032 square cm (130 to 160 square inches) of metallic surface to sink heat generated by the power supply. This metallic mounting surface may be connected to, or actually part of, the forklift chassis as long as the chassis is not electrically connected to the battery negative or positive.

Side-Mount Battery With View of Negative (-) and Positive (+)

Direct Versus Isolation Mounting on the Lift Chassis

Previously, the power supply was placed directly on the lift chassis. Direct mounting provides both an adequate heat sink and prevents static charge buildup between the metal of the power supply, the printer, and the lift chassis.

Directly mounting the power supply is the most straightforward installation method. This installation is also preferred when there is little risk for other forklift accessory devices making electrical contact with the forklift chassis.

Note: Although you can shorten the input power cable if necessary, you should not extend the cable on 12V or lower systems. On higher voltage systems, keep extensions to a minimum and use a wire of equivalent or lower gauge (larger diameter). Keep the cable as short as possible.



A fault condition, like a wire shorting to the forklift chassis, may present a power path that could negatively impact the power supply, the printer, and any device connected to the shorted wire. Although this is an uncommon secondary failure mode, you can avoid this situation by creating an electrical isolation mount.

Creating a Custom Electrical Isolation MountThere is no kit for isolated mounting solutions since they are unique to each forklift installation. Your custom solution should consist of:

• a metal plate 840 to 1030 square centimeters (130 to 160 square inches) minimum to provide the heat sink for the DC/DC supply.

• a way to mechanically attach the metal plate to the chassis of the vehicle while preventing direct metal-to-metal contact with insulating hardware.

• insulating hardware (plastic shoulder washers or rubber isolators) or an insulating surface (plastic, wood, or rubber) between the power supply and lift chassis.

Mounting the power supply on a metal plate also requires a small resistor (~100 ohms/1 watt minimum) to be electrically connected between the plate and the chassis of the vehicle to prevent static charge buildup. The isolation hardware and resistor are also not included in the installation kit.

Smaller metallic surfaces may be adequate when good air flow is available or if the portable printer is going to be used in a refrigerated area. Mountings exposed to direct sunlight may require more heat sink area.

Note: Lift vehicles in countries requiring CE Mark certification and that have a connection between the battery negative and the forklift chassis require additional installation steps. To confirm this requirement, consult the respective lift manufacturer Electrically isolating the power supply from the chassis maintains conformance to CE requirements. Isolating the power supply from the vehicle chassis may provide additional protection from other risks encountered on forklifts.



Using a Standard Power Supply MountThe installation kit includes the standard hardware for mounting the power supply. Use mounting Method A when you can easily access the back side of the mounting location to install a lock nut and washer. Use mounting Method B where the back side of the mounting location is inaccessible. Note that this method requires that the mounting plate be thick enough to accept and retain sufficient thread to provide a secure and reliable mechanical installation.

To use mounting Method A1 Mark and center punch the two mounting holes on the

mounting surface.

2 Use a 1/4-inch drill bit to make the two mounting holes.

3 Use 1/4-inch hex bolts with flat washers and locking nuts to install the power supply.

To use mounting Method B1 Mark and center punch the two mounting hole locations on

the mounting surface.

2 Use a #7 drill bit (equal to a hole diameter of 5.1 cm) to make the mounting holes.

3 Use a 1/4-20 tap to thread the mounting holes.

4 Place a lockwasher on each bolt.

5 Insert the bolt/lockwasher assemblies through the power supply holes and into the threaded mounting holes.

Installing the Input Power CableFollow these guidelines and other instructions closely when installing power cables:.

Never work on a powered system.



• Completely install power cables before making connections to equipment.

• Route the power cables from the general area where the power supply will be mounted.

• If the power cable passes through a firewall or other sheet metal, use a snap-in bushing (P/N 807-065-003) threaded through a 1.43 cm or 9/16-inch hole.

• Make sure that cable routing does not interfere with other equipment or forklift controls.

• Ensure that cable routing does not invite damage to the cable.

• Secure the cables at least every 46 cm (18 inch) throughout the cable run. Use adjustable clamps or wire-tie to existing forklift cable runs.

Connecting the Power Cable to the ForkliftThe fuse holder from the input power cable must be connected as close (physically and electrically) as possible to the positive side of the forklift power source. The remaining colored wires must be connected to the negative side of the forklift power source.

If this installation will be on a gas-powered forklift, you must install either an On/Off switch (minimum 15A dc rating such as ITW P/N 163-900-034) or an automatic shut-off device in series with the in-line fuse holder.

These devices prevent discharge of the forklift battery while the lift is off the holder. Charge Guard, Inc. 400 Highland Avenue, Altoona, PA 16602 (814.941.4100) manufactures a CHARGE GUARD™ device for this purpose.

Note: In this installation, the shield wire must be connected to the metal surface on which the power supply is mounted. Prior to connecting power, recheck to make sure the fuse is connected to the positive connection on the DC/DC input, and that the negative lead connects to the return to the battery at a location not shared with motors, flyback diodes, or other sources of electrical noise.



Instructions are not included for connecting to various possible forklift power sources. A trained professional installer, knowledgeable on the brands and models of forklifts should perform this installation. Both large and smaller terminal rings are included to accommodate most installation needs.

This kit contains additional bolts, nuts, and washers for connecting the input power cable directly to a forklift battery. These parts are described in more detail in the procedures below.

Terminating the Input CableFollow this procedure to terminate the input power cable (P/N 226-330-004).

To terminate the power cable1 Cut the cable to length, cut off a portion of the outer cable

jacket, and strip the individual wire ends of the cable as instructed.

2 Slip heat shrink tubing (furnished in this kit) onto the cable or wires before terminating them.

3 Prepare the cable ends by installing the fuse holder in series with the positive wires and install a terminal ring on the negative wires.

4 Mechanically complete the connections to the forklift power source or battery and electrically connect the shield wire to the forklift chassis ground using a self-tapping screw and flat washer.

Cutting and Stripping the Input Power CableFollow this procedure to cut and strip the input power cable (P/N 226-330-004) for termination.

To cut and strip the power cable1 Cut the power cable near the power source or battery.

2 Strip the cable jacket back 30 to 36 cm (12 to 14 inch).

3 Slide heat shrink tubing over cable jacket.

4 Strip 0.6 cm (0.25 inch) of insulation from individual wires.

5 Twist the white and green (negative) wires together.

6 Twist the red and black (positive) wires together.



7 Twist the shield wire and slide on the 1/8-inch heat shrink tubing (P/N 321-650-006).

Sliding the Heat Shrink Tubing Onto Twisted Wires

Attaching Heat Shrink TubingThis kit contains a 15 cm (6 inch) length of 0.95 cm (3/8-inch) diameter heat shrink tubing (P/N 321-650-006) which you will cut into three pieces, and a 30 cm (12 inch) length of 0.32 cm (1/8-inch) diameter heat shrink tubing (P/N 321-050-003) for the shield wire.

To install heat shrink tubing1 Crimp terminal rings and fuse holder ends, then position all

heat shrink tubing in the locations shown.

Red and black wires (positive)

Shield wire with heat shrink applied

Strip the cable jacket 30-36 cm (12-14”)

Input power cable

Heat shrink tubing

Green and white wires (negative)

Note: Make sure to verify the wire connections with an ohmmeter.

Note: Make sure that the wires that are to connect the negative input connect to pins 1 and 2 of the input connector. Then check that the other two wires connect to pins 3 and 4 of the input connector.

Note: You must attach the heat shrink tubing before terminating the wire ends.



2 Use the heat gun to shrink tubing.

3 Wrap the 1/8-inch shrink sleeve tubing (P/N 321-650-003) over shield wire.

Preparing the Cable EndsUse these instructions to prepare the cable ends.

To prepare the cable ends1 Strip 0.6 cm (.25 inch) of insulation from individual wires.

2 Crimp a terminal ring (P/N 809-083-009) onto the white-green twisted pair (negative) of wires.

3 Crimp one end of the fuse holder assembly (P/N 315-075-0013) on the red-black twisted pair (positive).

4 Position short lengths of heat shrink tubing as shown in Step 2. Crimp the other end of the fuse holder assembly to the twisted pair of wires and then attach then a terminal ring (P/N 809-083-009) on to it.

Note: Be sure to shield wire to the metal surface on which the power supply is mounted.

Note: All crimps should be checked to ensure the wire is completely captured in the terminal ring or fuse holder. Loose connections will fail.

1/8”

3/8” 3/8” 3/8”

Shield wire

Green and white twisted pair

Red and black twisted pair

Fuse holder assembly



5 Crimp the small terminal ring (P/N 809-083-009) on the shield wire.

Connecting to the Forklift BatteryThe next few pages show you the intended purpose of nuts, bolts, and washers that are included in this kit if you will be connecting the power cable directly to a forklift battery.

Additional hardware is not provided in this kit for connecting the power cable to other forklift power sources. See the manufacturer’s technical manual for the forklift if necessary.

Your forklift has either a side-mount battery with the terminals on the side; or a top-mount battery with the terminals on the top. Determine which battery is in your forklift and proceed with the applicable instructions.

Connecting to Side-Mount Battery TerminalsPerform the following procedure to attach the forklift battery cable to a side-mount battery terminal.

To connect the forklift battery cable to a side-mount battery terminal

1 Disconnect the negative battery cable, then disconnect the positive battery cable, and remove the bolts from each cable.

2 Screw a 3/8-inch nut (P/N 802-099-001) as far as it will go onto a 3/8-inch x 1-1/2 inch bolt (P/N 800-099-001) furnished in the kit, and then slip a 3/8-inch washer (P/N 803-099-001) onto the bolt.

3 Slide the positive (red wire with fuse link) terminal ring from the input power cable onto the bolt.

4 Slip a second 3/8-inch washer (P/N 803-099-001) onto that bolt.

5 Slide the forklift positive battery cable onto the bolt.

6 Thread the bolt assembly (steps 2 through 5, above) into the positive (+) battery terminal. Securely tighten the bolt until it bottoms out, but do not overtighten the bolt.

7 Tighten the nut securely against the washers and cables.

8 Use a self-tapping screw (P/N 800-008-003) and flat washer (P/N 803-084-000) to connect shield wire to the metal surface on which the power supply is mounted.



9 Repeat steps 2 through 8 for the negative wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal.

Connecting to Top-Mount Battery TerminalsPerform the following procedure to attach the forklift battery cable to a top-mount battery terminal.

To connect the forklift battery cable to a top-mount battery terminal

1 Disconnect the negative battery cable, and then disconnect the positive battery cable.

2 Remove the bolts from the forklift battery terminals.

3 Replace those bolts with 3/8-inch x 1-1/2-inch bolts (P/N 800-099-001)and nuts (P/N 802-099-001) from the installation kit. Tighten the nuts.

4 Reinstall the positive battery cable, and then tighten the nut securely.

5 Slip a 3/8-inch washer (P/N 803-099-001) onto the extended end of each bolt.

6 Slide the positive (fuse link with red wire) terminal ring from the input power cable onto the positive (+) battery bolt.

7 Slip a second 3/8-inch washer (P/N 803-099-001) onto the bolt.

8 Thread and tighten a second 3/8-inch nut (P/N 802-099-001) onto the bolt.

Forklift battery cable

Fuse holder

3/8” washer

3/8 x 1-1/2” bolt

3/8” nut

Forklift battery



9 Use a self-tapping screw (P/N 800-008-003) and a flat washer (P/N 803-084-000) to connect the shield wire to the metal surface on which the power supply is mounted.

10 Repeat steps 6 through 8 for the negative battery cable wire (white-green pair) from the input power cable, connecting the wire to the negative (-) battery terminal.

Securing the Battery CableSecure the cables every 46 cm (18 inch) using locking wire ties or adjustable cable clamps.

To install cable clamps1 Remove the paper backing from the clamp

(P/N 808-011-001) and stick the clamp in place.

2 Drill a pilot hole with a #26 drill bit (equal to a hole diameter of 3.73 mm) and use #6 sheet metal screws to permanently hold clamps in place.

Connecting the Output Power CableOnce the printer, vehicle cradle, or other device is mechanically installed, you can connect the output power cable to the power supply output and the mobile computer. Connectors are keyed and operate the same as the input power connectors.

Forklift battery

Forklift battery cableFuse holder

Washers

Bolt

Nut

#6 sheet metal screw goes here



To finish the connection1 Connect the output cable (P/N 236-193-003) to the mobile

printer.

2 Connect the other end of the output cable to the main output of the DC/DC power supply (P/N 851-070-003).

3 Slide the output cable as far as it will go into the power supply.

4 Turn the output cable connector collar clockwise to secure it.

5 After all connections are secure, connect power to the system.

Sample InstallationsIn this installation example, the power supply is securely attached with good air flow, easy access, and neatly tied-off cabling.

Note: See “Troubleshooting Charts” on page 27 for power fault diagnostic information.



Additionally, this installation allows:

• easy access to power supply components, LED visibility is good.

• power cables are out of the way and tied off, there is adequate heat sink, and there is good access for cooling.

• good access for component service.

• full access to the UPS battery.

Here is another example of an effective installation:

In this example, the benefits include:

• UPS is accessible without disconnecting it from the lift



• Battery swap is accommodated without removing the UPS entirely

• Metal area contact is reduced, but ventilation is good, reducing the need for additional heat sink

• No direct sunlight in this environment helps maintain lower operating temperature

A poorly planned installation presents several challenges,

including:

• Difficult access to power supply components, LED visibility in operation is impossible

• Damage could occur to lift or power supply components if something fails

• UPS battery removal is difficult due to location

• The installation is tedious, time-consuming, and difficult to work on

• Troubleshooting problems will be as difficult

• Enclosed environment will significantly reduce the air flow, raising the temperature of all the components


3
Troubleshooting
This chapter contains information for troubleshooting the forklift power supply. This chapter contains these topics:

• Identifying and Correcting Problems

• Troubleshooting Charts

25

Chapter 3 — Troubleshooting

Identifying and Correcting ProblemsThe following is an overview for troubleshooting the forklift power supply installation:

1 Inspect the hardware.

2 Check the electrical measurements.

3 Substitute components.

Use the procedures within this chapter to identify and the power supply problems you may encounter during installation. Connector pin-out information is also furnished for your convenience.

Inspecting the HardwareAlways check the hardware first. You should check the power supply, the cables and connections, and the fuse.

• If the LED is lit, and you suspect a power failure, check the output cable and its connections.

• If the LED is not lit, the power supply is not producing 12 Vx output power. In this case, a fault can exist anywhere in the system. Use the tables starting on page 30 to isolate, identify, and correct the fault.

• If the LED is flickering, the power supply has detected a fault condition related to temperature, voltage, or current. The LED will flicker until the problem is resolved. In some cases, you may have to remove power to reset the power supply.

Checking the Electrical MeasurementsYou can measure the voltage or test for continuity to troubleshoot the battery cable.

Measuring the VoltageConnector pinout information is provided to allow you to measure voltage at the input power cable connector and at either end of the power output cable.

Performing Continuity TestingThorough continuity testing takes longer than either substitution or taking voltage measurements. An ohmmeter is sufficient to diagnose simple opens or shorts.



If fuses blow sporadically, or power supply shut down occurs randomly, you may want to use a megohmmeter to check cables for high-resistance shorts between wires or between a wire and the cable shield. For more information, see “Troubleshooting Charts” on page 27.

Substituting ComponentsComponent substitution is the most expedient and certain troubleshooting technique. It is especially valuable when trying to resolve intermittent problems.

The disadvantage of substituting components is that you:

• must either have spare parts (power supply and both cables in this instance).

• be prepared to “borrow” components from another working installation.

Follow the guidelines in the following troubleshooting charts, substituting only when directed to do so.

If an installation suffers intermittent input power fuse failures, or if the power supply shuts down without good cause, do not hesitate to substitute a known good power supply.

Troubleshooting ChartsThe following troubleshooting chart assumes that your portable printer or other equipment does not work and that the problem is caused by the power supply or its associated cables. Follow the procedures in the tables in the order they are shown for maximum efficiency.

Some of the troubleshooting remedies tell you to reset the power supply. Use this procedure to reset the power supply.

To reset the power supply• Disconnect the input power cable for 10 seconds and then

reconnect it.

The power supply has automatic over-voltage, over-current, over temperature, and short-circuit protection. If the problem persists, the LEDs will continue to flicker. Disable input power when these faults activate that protection.



Troubleshooting Power Failure With the Main Output LED

LED Meaning Possible Solution

Lit The power supply is working.

Test or substitute output power cable.

Not lit No output from the power supply.

Try the possible solutions in this order: 1 Disconnect the power output

cable.2 Reset the power supply.3 Check the fuse.

Flickers There is an intermittent main power connection.

Check connection to the main power source.

Flickers The power supply detected an over-voltage condition.

The forklift noise spikes are exceeding voltage rating for the power supply. Work with yourforklift manufacturer to look for alternate power connection locations. Check to see whether they have any recommended inline filters or suppressors.

Flickers The power supply detected an over-current condition.

Disconnect the output cable. If the flickering stops, check the cables and add downstream elements.

Flickers The power supply detected an over temperature condition.

Try the possible solutions in this order: 1 Check the case temperature of

the power supply. If too hot to touch, provide better heatsink and more air flow.

2 Replace damaged cables. 3 Protect from direct sunlight

and mount in the shade.

LED not lit No output from the power supply.

Test for input voltage.

No output voltage, input normal

Power supply not working.

Replace power supply.



Voltage not present

No input power to the power supply.

Try the possible solutions in this order:

1 Replace inline fuse if voltage is not present at connector.

2 Replace input power cable if input voltage is still not present at connector.

The fuse is blowing, but no LED is lit

Power system is drawing too much current.

Have the forklift vendor recommended an inline filter and alternate connection point. Check cables for nicks, shorts, and so on.

Troubleshooting Power Failure With the Main Output LED (continued)

LED Meaning Possible Solution

Power Supply Pinouts

Connector Negative Positive Case

Input power connector

Pin 1Pin2

Pin3Pin4

NC



Power Cable Assembly for P/N 226-340-004

Secondary output power connector heater

Pin1 Pin2

Main output power connector

Pin 3 Pin 2 Pin 1

Power Supply Pinouts (continued)

Connector Negative Positive Case

108.0 +/- 3.0”

2 1

Pin view Pin view

4

3

2

1

Note: During installation, you will cut and discard one of these cable connectors.



Note: The cables in the installation kit may contain alternate wire colors. Refer to the following chart for the wire color equivalent.

Cable Wire Cable Equivalents

Wire Color Alternate Color

Green Blue

White Gray

Red Brown

Red Brown

Black Red


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Forklift Power Supply Installation Guide

*932-011-002*P/N 932-011-002

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