Intermec PB50 Bedienungsanleitung

PB50 and PW50

Forklift Power

Supply

Installation Guide

ii PB50 and PW50 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 noticed and do not represent a commitment on the part of

Intermec Technologies Corporation.

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.

Contents

PB50 and PW50 Forklift Power Supply Installation Guide iii

Contents

Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . v

Global Services and Support. . . . . . . . . . . . . . . . . . v

Who Should Read This Manual . . . . . . . . . . . . . .vii

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

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

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

Power Supply Considerations . . . . . . . . . . . . . . . . . . . . . . . .3

Understanding the LEDs . . . . . . . . . . . . . . . . . . . .3

Using the Input Power Cable . . . . . . . . . . . . . . . . .4

Using the Inline Fuse . . . . . . . . . . . . . . . . . . . . . . .5

Using the Output Power Cable. . . . . . . . . . . . . . . .5

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

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

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

Installation Recommendations . . . . . . . . . . . . . . . . . . . . . .10

Installation Summary . . . . . . . . . . . . . . . . . . . . . .10

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . .11

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

Mounting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . .12

Direct Versus Isolation Mounting on the Lift

Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Creating a Custom Electrical Isolation Mount . . .13

Using a Standard Power Supply Mount . . . . . . . .14

Installing the Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . .15

Connecting the Power Cable to the Forklift . . . . . . . . . . . .16

Contents

iv PB50 and PW50 Forklift Power Supply Installation Guide

Terminating the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cutting and Stripping the Power Cable . . . . . . . . 17

Attaching Heat Shrink Tubing . . . . . . . . . . . . . . . 18

Preparing the Cable Ends . . . . . . . . . . . . . . . . . . . 19

Connecting to the Forklift Battery . . . . . . . . . . . . . . . . . . . 19

Connecting to Side-Mount Battery Terminals . . . 20

Connecting to Top-Mount Battery Terminals . . . 21

Securing the Battery Cable . . . . . . . . . . . . . . . . . . 22

Connecting the Output Power Cable . . . . . . . . . . 23

Sample Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Identifying and Correcting Problems . . . . . . . . . . . . . . . . . 28

Troubleshooting the Power Supply . . . . . . . . . . . . 28

Inspecting the Hardware . . . . . . . . . . . . . . . . . . . 28

Checking the Electrical Measurements . . . . . . . . . 29

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Before You Begin

PB50 and PW50 Forklift Power Supply Installation Guide v

Before You Begin

This section provides you with safety information, technical

support information, and sources for additional product

information.

Safety Information

Your 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 Support

Warranty Information

To understand the warranty for your Intermec product, visit the

Intermec web site at www.intermec.com and click Support >

Returns and Repairs > Warranty.

Web Support

Visit 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.

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.

Before You Begin

vi PB50 and PW50 Forklift Power Supply Installation Guide

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 Support

These services are available from Intermec.

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.

Services Description

In the USA and

Canada call 1-800-

755-5505 and

choose this option

Order Intermec

products

• Place an order.

• Ask about an existing

order.

1 and then choose 2

Order Intermec

media

Order printer labels and

ribbons.

1 and then choose 1

Order spare

parts

Order spare parts 1 or 2 and then

choose 4

Te c h n i ca l

Support

Talk to technical support

about your Intermec product.

2 and then choose 2.

Service • Get a return authorization

number for authorized

service center repair.

• Request an on-site repair

technician.

2 and then choose 1

Service

contracts

• Ask about an existing

contract.

• Renew a contract.

• Inquire about repair billing

or other service invoicing

questions.

Before You Begin

PB50 and PW50 Forklift Power Supply Installation Guide vii

Service Location Support

For the most current listing of service locations, 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]

IN Information System PTD LTD

6th Floor

Daegu Venture Center Bldg 95

Shinchun 3 Dong

Donggu, Daegu City, Korea

E-mail: jmy[email protected] or korlim@gw.idif.co.kr

Who Should Read This Manual

This guide is written for trained Intermec service personnel

familiar with forklift service and maintenance. You should be

familiar with forklift service and maintenance.

Before You Begin

viii PB50 and PW50 Forklift Power Supply Installation Guide

PB50 and PW50 Forklift Power Supply Installation Guide 1

1Introduction

This chapter describes installation practices and unique

components of the forklift power supply kit.

Chapter 1 — Introduction

2 PB50 and PW50 Forklift Power Supply Installation Guide

Understanding the DC Power Supply Kit

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 Vxfuse for 12 V installations

• Insulated quick-connect tabs (2)

The power supply provides 12 Vxoutput that is filtered and

regulated. It also provides over-current, over-voltage, over-

temperature, and shorted-output protection.

Installation Guidelines

The installer should be familiar with the brands and models of

equipment where this kit is installed. They should also be trained

and experienced in forklift electrical systems.

The installer must follow these guidelines and the installation

procedures as well as those of the lift manufacturer to ensure a

safe and reliable installation.

• Power supply must be securely mounted.

• Mounting surface must be sturdy.

• Mounting surface must provide power supply heat sink.

• Fuse must be close to vehicle power source and be in line with

Intermec equipment only.

• Keep cables as short as possible, and secure them at least every

46 cm (18 inch).

Installation must not violate the forklift manufacturer’s

requirements and should be done by trained professionals.

Chapter 2 details the step-by-step procedure that you will follow

to properly mount the forklift power supply.

Order the Smart UPS kit (P/N 203-788-xxx) for a universal

power supply (UPS) that provides backup power during battery

change out.

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