Intermec 851-040-001, Installation Manual

Page 1: ...Vehicle Power Supply Installation Guide...

Page 2: ...Vehicle Power Supply INSTALLATION GUIDE NPN 962 054 004 Revision C October 2002...

Page 3: ...ent We welcome your comments concerning this publication Although every effort has been made to keep it free of errors some may occur When reporting a specific problem please describe it briefly and i...

Page 4: ...on 2 1 Installation Summary 2 1 Tools Required 2 2 Before you Begin 2 3 Power Supplies 2 3 Connect Power Input Cable 2 3 Mount the Power Supply 2 4 Power Cable Installation 2 5 Power Cable Connections...

Page 5: ...stitute 3 3 Trouble Charts 3 3 Power supply reset 3 3 FIGURES Figure 1 1 Power Supplies 1 3 Figure 2 1 Cut and Strip Cable Ends 2 7 Figure 2 2 Heatshrink Locations 2 8 Figure 2 3 Side Mount Battery Te...

Page 6: ...ands and models of equipment where this kit is installed They should be trained and experienced on vehicle electrical systems Installers must follow these guidelines and the Installation Procedures pr...

Page 7: ...r Input Connector Input Voltage 851 040 001 066776 01 4 pin keyed 6 36 V dc 851 041 001 066777 01 2 pin keyed 15 96 V dc The power supply shall be mounted to the vehicle chassis ground or connected el...

Page 8: ...n Vehicle Power Supply Installation Guide 1 3 Figure 1 1 Power Supplies Model 851 040 001 P N 066776 01 6 36 V 10 A Model 851 041 001 P N 066777 01 15 96 V 3 5 A Input Connector Output Connector Green...

Page 9: ...ble electrically and physically to the vehicle power source It provides short cir cuit protection for the entire input power cable and the power supply input The fuse holder contains a 3AB 20 ampere 2...

Page 10: ...be close to vehicle power source Keep cables as short as practical Secure cables at least every 18 inches Installation Summary Installation consists of five 5 primary steps which should be undertaken...

Page 11: ...099 001 2 washer 3 8 803 099 001 4 nut 3 8 16 802 099 001 4 adjustable wire clamps 808 011 001 8 self tap screw 6 X 5 8 800 008 001 8 3 8 terminal ring 809 165 001 2 10 terminal ring 809 083 009 3 se...

Page 12: ...ng information Remember that the supply with the lower input voltage rat ing 6 36 V dc has a 4 pin input connector while the power supply with the higher input voltage rating 15 96 V dc has a 2 pin in...

Page 13: ...you may have to fabricate a flexible wire or braid to bond the mounting surface to vehicle chassis ground Appropriate hardware is furnished in this installation kit for mounting the power supply Use m...

Page 14: ...g requires 9 16 hole if the power cable passes through a firewall or other sheet metal Make sure that cable routing does not interfere with other equipment or vehicle controls Make sure that cable rou...

Page 15: ...smaller terminal rings are provided to accomodate most installation needs This kit contains additional bolts nuts and washers in the event you will connect the input power cable directly to a vehicle...

Page 16: ...sulation 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 the 1 8 heatshrink tubing onto it...

Page 17: ...wire Tubing must be in place before terminating wire ends Crimp terminal rings and fuse holder ends then position all heatshrink tubing in the locations shown Use a heat gun to shrink tubing 1 Green a...

Page 18: ...4 Crimp the fuse holder to the positive wires from the cable 5 Shorten the remaining positive wires pigtail if de sired and position a short length of heatshrink tubing onto this pigtail 6 Crimp this...

Page 19: ...cond 3 8 washer onto the bolt 6 Slide the vehicle positive battery cable onto the bolt 7 Thread the bolt assembly steps 1 6 above into the positive battery terminal Tighten the bolt until it bot toms...

Page 20: ...cle Power Supply Installation Guide 2 11 1 Bolt 2 Nut 3 Vehicle battery 4 Vehicle battery cable 5 Fuse holder 6 Washers 1 Figure 2 3 Side Mount Battery Terminals 2 6 3 4 5 NOTE See Note on page 2 5 wh...

Page 21: ...Slip a 3 8 washer onto the end of each bolt 4 Slide the positive fuse holder red wire terminal ring onto the positive battery bolt 5 Slip a second 3 8 washer onto that bolt 6 Thread a second 3 8 nut...

Page 22: ...Supply Installation Guide 2 13 1 3 8 nut 2 3 8 X 1 1 2 bolt 3 Vehicle battery 4 Vehicle battery cable 5 Fuse holder 6 3 8 washers 1 Figure 2 4 Top Mount Battery Terminals 6 2 3 4 5 NOTE See Note on p...

Page 23: ...n place 6 Sheet metal Screw Goes Here Figure 2 5 Cable Clamp Final Connections Once the computer dock or other device is mechanically installed you can connect the output power cable between the power...

Page 24: ...in general should be followed in the order given The Trouble Charts will instruct you when to use a particular method Basic Diagnostic Procedures 1 Inspection 2 Voltage and Continuity Measurements 3 C...

Page 25: ...o blows the most likely cause s would be a shorted or miswired power in put cable or a faulty or incorrect power supply Electrical Measurements Voltage Connector pin out information is provided to all...

Page 26: ...nt input power cable fuse failures or if the power supply shutdowns without good cause do not hesitate to substitute a known good pow er supply Trouble Charts The following trouble chart assumes that...

Page 27: ...t Meaning Remedy LED Lighted Power Supply is working Test or sub stitute out put power cable LED NOT lighted No output power from supply Reset the power sup ply LED NOT lighted No output from power su...

Page 28: ...ed Observe Result Meaning Test or Remedy LED Voltage Voltage NOT lighted Normal NOT pres ent No output from power supply Power Supply not working No input pow er to the power supply Test for input vol...

Page 29: ...Power Supply Installation Guide Table 3 3 Power Supply Pinouts Connector Negative Positive Case chassis gnd Input Power conn LV Pin 1 Pin 2 Pin 3 Pin 4 NC Input Power conn HV Pin 1 Pin 2 NC Output Po...

Page 30: ...er Supply Installation Guide 3 7 Black Figure 3 1 Input Power Cable 1 2 1 2 3 4 Pin View Pin View 1 2 1 2 DC DC DC DC DC DC 3 4 108 0 3 0 Note During installation you will cut and discard one of these...

Page 31: ...SECTION 3 Troubleshooting Information 3 8 Vehicle Power Supply Installation Guide...

Page 32: ...ate Headquarters 6001 36th Avenue West Everett Washington 98203 tel 425 348 2600 fax 425 355 9551 www intermec com 962054004 Revision C 962054004 Vehicle Power Supply Installation Instructions October...