Intermec 203-802 Series User manual

Vehicle Power
Install Kit
Installation Instructions

ii Vehicle Power Install Kit Installation Instructions
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.
© 2008-2011 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.

Contents
Vehicle Power Install Kit Installation Instructions iii
Contents
Using the Vehicle Power Install Kit. . . . . . . . . . . . . . . . . . . . . 5
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What You Need To Do . . . . . . . . . . . . . . . . . . . . . 5
Determining Your Vehicle’s Voltage Level. . . . . . . . . . . . . . . 6
Installing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Gray Vehicle Battery Power Cable. . . . 7
Connecting to the Vehicle Battery . . . . . . . . . . . . . . . . 7
Connecting to the Side Battery Terminal . . . . 8
Connecting to the Top Battery Terminal . . . . 9
Connecting to a Two-Battery Vehicle
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fastening the Ground Strap . . . . . . . . . . . . . . . . . . . . 11
Connecting the Dock-to-Fuse Block Cable . . . . . . . 11
Jump-Starting Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 12

iv Vehicle Power Install Kit Installation Instructions

Vehicle Power Install Kit Installation Instructions 5
Using the Vehicle Power Install Kit
The vehicle power install kit (P/N 203-802-xxx) lets you connect
an Intermec computer, printer, and/or other equipment to the
electrical system of your vehicle. After you install this kit, your
vehicle can provide power to operate a vehicle dock, printer, and
all other connected equipment. It will also charge the internal
battery of both the computer or the printer.
This kit contains all of the hardware necessary to connect the
battery cable directly to the vehicle battery. This direct
connection reduces installation problems and allows for
improved vehicle battery filtering.
What You Need
•Common hand tools, such as a wrench
•Wire crimping and stripping tool
•Electric drill and drill bits
•Voltmeter
•Cable clamps or wire-ties
What You Need To Do
1Determine your vehicle’s voltage level.
2Install the power cable.
These instructions describe how to perform each step.
Note: For help installing the vehicle dock with other equipment,
contact your local Intermec representative.

6 Vehicle Power Install Kit Installation Instructions
Determining Your Vehicle’s Voltage Level
Before installing this kit, make sure that your vehicle’s electrical
system is in good working condition for all types of installations.
The charging circuit must work properly and vehicle generated
electrical “noise” must be minimized.
Excess electrical noise can be severe enough to defeat the
electrical filtering that is built into Intermec cables, printers, and
vehicle docks. Defective ignition wiring, damaged insulation, or a
faulty vehicle electrical component can cause electrical noise,
possibly causing unpredictable behavior in printers and docks.
To determine your vehicle’s voltage level
1Measure the vehicle battery voltage with a voltmeter. It
should read approximately 13.0 VDC with the engine OFF.
For 24 V vehicle systems, check each battery individually.
2Start the vehicle engine. Continue monitoring the battery’s
voltage while you run the vehicle’s engine at a fast idle for five
minutes.
The voltage should read below 14.5 VDC. It must not exceed
18.0 V. If the battery voltage exceeds 18.0 VDC, there is a
problem with the vehicle electrical system which must be
diagnosed and repaired before the Intermec equipment will
work properly. Check your engine for a bad voltage regulator
or a poor ground, either of which cause excessive voltage.
Installing the Power Cable
Before installing the power cable, note these installation
guidelines:
•Choose a mounting location for the Intermec equipment and
the cables. Make sure that the mounting location is
convenient for the vehicle operator and that the cables will
reach from the power source to the equipment.
•Use cable clamps or wire-ties to secure cables at least every
46 cm (18 in).
Note: If the vehicle voltage is too high or too low, the Intermec
equipment may not work.

Vehicle Power Install Kit Installation Instructions 7
Installing the Gray Vehicle Battery Power Cable
1Route the gray battery power cable (P/N 236-106-xxx) from
the equipment toward the vehicle battery.
2Cut the gray battery power cable near the battery leaving
enough of the cable to reach the battery terminals.
3Strip the battery power cable jacket 31 to 36 cm (12 to 14 in).
4If necessary, shorten the red wire of the gray battery power
cable.
5Strip 6.4 mm (0.25 in) of insulation from the red wire on the
gray battery power cable.
6Find the fuse link assembly (P/N 236-107-001), and securely
crimp the fuse link splice onto the red wire.
7Strip 6.4 mm (0.25 in) of insulation from the brown wire on
the power cable.
8Crimp the 3/8-inch terminal ring onto this wire.
Connecting to the Vehicle Battery
You can connect to the vehicle battery by connecting to the side
battery terminal, the top battery terminal, or a two-battery
vehicle system. For a two-battery vehicle system, you only
connect to one of the batteries.
Note: Do not secure the gray battery power cable to any
moving parts on the vehicle. Make sure the cable is at least 6
inches from the exhaust system.
Terminal ring
Brown wire
Crimp here
Vehicle
battery
cable
(gray)
Red wire
Fuse link
splice
Fuse link assembly
(P/N 236-107-001)
Verify that the cable to battery connections are correct.
Electrical energy from vehicle batteries can harm equipment
and people.

8 Vehicle Power Install Kit Installation Instructions
Connecting to the Side Battery Terminal
1Remove both battery terminal side post bolts from the
vehicle battery.
2Fasten a 3/8-inch nut to one of the 3/8-inch x 1-1/2-inch
posts (provided).
3Place a 3/8-inch washer on the battery terminal post.
4Slide the positive (red wire) fuse link terminal ring from the
battery cable onto the positive (+) battery terminal post.
5Place another 3/8-inch washer on the battery terminal post.
6Slide the vehicle positive battery cable onto the battery
terminal post.
7Thread the post assembly (Steps 2 through 6) into the
positive battery terminal. Tighten the battery terminal post
securely.
Note: When you remove the battery terminal side post bolts
from the vehicle battery, the vehicle’s computer and radio will
return to default settings.
+
Nut
Red wire (positive)
Washers
Vehicle
battery
Positive
battery
cable
Fuse link
Brown wire (negative)
Positive
battery
post
Power cable
Battery
terminal
post (positive)

Vehicle Power Install Kit Installation Instructions 9
8Tighten the nut installed in Step 2 to secure the washers and
cables firmly in place.
9Repeat Steps 2 through 8 for the negative (brown) wire from
the battery cable, connecting the negative cables to the
negative (-) battery terminal.
Connecting to the Top Battery Terminal
1Remove the battery clamp posts from the vehicle battery
terminals.
2Install a 5/16-inch x 1-1/2-inch post and nut (provided) on
each of the battery terminals, and tighten the nut securely.
3Place a 3/8-inch washer onto the extended end of each
battery clamp bolt.
4Slide the positive (red wire) fuse link terminal ring from the
battery cable onto the positive (+) battery clamp bolt.
5Place another 3/8-inch washer onto the battery clamp bolt.
6Thread another 3/8-inch nut onto the battery clamp bolt,
and tighten the nut.
7Repeat Steps 2 through 6 for the negative (brown) wire from
the battery cable, connecting the wire to the negative (-)
battery terminal.
Gray power cable
Washers
Fuse link
5/16" x 1-1/2" post
-
-
+
Positive
battery cable
Vehicle battery
Positive battery
terminal
Brown wire (negative)
Red wire
(positive)
Nut

10 Vehicle Power Install Kit Installation Instructions
Connecting to a Two-Battery Vehicle System
The next illustration shows the correct way to connect to a 24 V
two-battery system by wiring the printer to one of the batteries.
Connecting to a Two-Battery Vehicle System
Incorrect Connection for a Two-Battery Vehicle System
-
+
-
-
+
12 V 12 V
To printer 12 V
Positive
terminal
Negative
terminal
Negative
terminal
To equipment ground
Chassis ground
Vehicle 24 V
Positive
terminal
Do NOT connect to batteries as shown in the next
illustration. This connection will damage the printer.
-
+
-
-
+
12 V 12 V
Positive
terminal Negative
terminal
Negative
terminal
Chassis ground
To printer 12 V
To equipment ground
Positive
terminal

Vehicle Power Install Kit Installation Instructions 11
Fastening the Ground Strap
The braided green wire grounding strap is connected to the white
connector on the battery power cable. To ensure proper cable
shielding, you need to fasten the grounding strap to the vehicle’s
sheet metal.
To fasten the ground strap
1Drill a small hole into the metal where you intend to fasten
the ground strap.
2Use a punch to dimple and enlarge the hole until it is the
same size as the screw.
3Scrape a small circle of paint from around the hole. Make
sure to expose bare metal to make a good electrical
connection.
4Use a #8 x 5/8-inch screw and flat washer to secure the green
grounding strap.
5Install your equipment. For more information, see your
equipment’s installation instructions.
Connecting the Dock-to-Fuse Block Cable
1Locate your vehicle fuse block.
2In the fuse block, locate the spade lug contacts that attach
directly to the battery.
3In the dock-to-fuse block cable (P/N 226-109-103), locate the
white quick connect contact wire.
4Attach the wire to the fuse block’s spade lug with 12 V
positive polarity.
5In the dock-to-fuse block cable, locate the black quick
connect contact wire.
6Attach the wire to the fuse block’s spade lug with negative
polarity (chassis or ground).
Note: When the vehicle ignition is off, these contacts are still
powered.

12 Vehicle Power Install Kit Installation Instructions
Jump-Starting Your Vehicle
Always disconnect the power cables from the Intermec
equipment before attempting to jump-start your vehicle.
Failure to do so may result in damage to your mobile
computer equipment.

Vehicle Power Install Kit Installation Instructions 13

Worldwide Headquarters
6001 36th Avenue West
Everett, Washington 98203
U.S.A.
tel [phone]
fax [phone]
www.intermec.com
© 2011 Intermec Technologies
Corporation. All rights reserved.
Vehicle Power Install Kit Installation Instructions
*931-053-004*
P/N 931-053-004