Intermec CK61 User manual

Vehicle Dock Kit
Installation
Instructions

ii Vehicle Dock 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 Technolgies 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.
© 2003-2007 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.

Vehicle Dock Kit Installation Instructions iii
Document Change Record
This page records changes to this document. This document was
originally released as Revision A.
Revision
Letter Date Description of Change
C 03/2007 Added pin-out information for the 3-pin
notched DC power connector. Rewrote
instructions to address multiple mobile
computers.

iv Vehicle Dock Kit Installation Instructions

Vehicle Dock Kit Installation Instructions v
Contents
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Vehicle Electrical Considerations. . . . . . . . . . . . . . . . . . . . . .7
Installing the Vehicle Battery Power Cable . . . . . . . . . . . . . .8
Connecting to the Side Battery Terminal . . . . . . . . . . . . . . .9
Connecting to the Top Battery Terminal. . . . . . . . . . . . . . .10
Fastening the Ground Strap . . . . . . . . . . . . . . . . . . . . . . . .11
Verifying the Dock Power Cable Polarity. . . . . . . . . . . . . . .12
Performing the Final Connections. . . . . . . . . . . . . . . . . . . .12
Installing an Optional Printer . . . . . . . . . . . . . . . . . . . . . . .13
Installing the Vehicle Dock and Printer. . . . . . . . . . . . . . . .14
Installing the Vehicle Dock With Other Equipment . . . . . .14
Jump-Starting Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . .15

vi Vehicle Dock Kit Installation Instructions

Vehicle Dock Kit Installation Instructions 7
Installation Guidelines
These instructions detail tasks for various installation options.
Your tasks include:
• Route and install the gray battery power cable to the vehicle
battery terminals
• Install an in-line fuse holder
• Install the mounting hardware and vehicle dock
• Connect the black dock power cable to the vehicle dock and
the battery power cable. Depending on your installation, this
may simply involve connecting the keyed connector, or it may
involve cutting the connector off and wiring directly to the
fuse block.
Installation Tools Required
• Wire crimping and stripping tool
• An electric drill, #26 drill bit
• Common hand tools set of standard wrenches, flat blade
screwdriver, Phillips screwdriver, wire cutter, utility knife, and
small punch.
Vehicle Electrical Considerations
Your vehicle’s electrical system must be in good working
condition.
Power Cables for Vehicle Battery Kit P/N 203-344-001
Description Part Number
Dock power cable (black) 236-105-001
Battery cable (gray) 236-106-005
Power Cables for Vehicle Battery Kit P/N 203-344-002
Description Part Number
Dock power cable (black) 206-875-009
Battery cable (gray) 226-325-002

8 Vehicle Dock Kit Installation Instructions
Installing the Vehicle Battery Power Cable
Use cable clamps or wire-ties at least every 46 cm (18 in) when
installing cables on a vehicle. This eliminates loose or sagging
cables, guards against breakage and ensures that they do not pose
a hazard to the vehicle operator or to other workers.
These instructions detail how to route the cable, install the
in-line fuse, and make the battery connection onto a side
terminal post or top terminal post type battery.
Decide the mounting location for the vehicle dock and the
cables. When you are certain your arrangement works and that
cables will reach from the batteries to the power converter to the
dock, proceed with these steps.
To install the gray vehicle battery power cable
1Route the gray battery power cable (P/N 236-106-00X) from
the vehicle dock toward the vehicle battery area.
2Cut the gray battery power cable near the battery allowing
enough length to reach the battery terminals.
3Strip the battery power cable jacket back 31-36 cm (12-14
in).
4Shorten the red wire of the gray battery power cable if desired.
5Strip 6.4 mm (0.25 in) of insulation from the red wire of the
gray battery power cable.
6Locate the fuse link assembly (P/N 236-107-001).
7Securely crimp the fuse link splice onto the red wire.
8Strip approximately 6.4 mm (0.25 in) of insulation from the
brown wire on the power cable.
9Crimp the 3/8" terminal ring onto this wire.
Note: Completely install the vehicle battery (gray)
cable that connects to the vehicle battery before
connecting the vehicle dock power (black) cable.

Vehicle Dock Kit Installation Instructions 9
Connecting to the Side Battery Terminal
1Remove both battery terminal side post bolts from the vehicle
battery.
2Screw a 3/8" nut as far as it will go onto a 3/8" x1 1/2" post
furnished in kit.
3Slip a 3/8" washer onto the battery terminal post.
4Slide the positive (red wire) fuse link terminal ring from the
battery cable onto the positive (+) battery terminal post.
5Slip a second 3/8" washer onto the battery terminal post.
6Slide the vehicle positive battery cable onto the battery
terminal post.
7Thread the post assembly (Steps 2-6) into the positive battery
terminal. Tighten the battery terminal post securely.
8Tighten the nut installed in Step 2 to secure washers and
cables firmly in place.
It is very important to make sure that you make the
correct cable to battery connections, because
electrical energy from vehicle batteries can harm
equipment and people.
Fuse link assembly
Crimp here
Brown wire
Vehicle battery
Red wire Fuse link
Terminal rings
(gray) cable
(P/N 236-107-001)
splice

10 Vehicle Dock Kit Installation Instructions
Repeat Steps 2 through 8 for the negative (brown) wire from the
battery cable, hooking up the negative cables to the negative (-)
battery terminal.
Connecting to the Top Battery Terminal
1Remove the battery clamp posts from the vehicle battery
terminals.
2Replace the battery clamp posts removed in Step 1 with 5/16"
x1-1/2" posts and nut furnished in the installation kit.
Tighten nut securely.
3Slip a 3/8" 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.
5Slip a second 3/8" washer onto the battery clamp bolt.
6Thread a second 3/8" nut onto the battery clamp bolt.
7Tighten the nut.
Because electrical energy from vehicle batteries can
harm equipment and people, it is very important to
make sure that you make the correct cable to
battery connections.
Battery
Positive battery post
Positive battery cable
Fuse link
Brown wire (negative)
Power cable
Red wire (positive)
Batttery terminal
post (positive)
Nut
Washers

Vehicle Dock Kit Installation Instructions 11
Repeat Steps 3 through 6 for the negative (brown) wire from the
battery cable, connecting the wire to the negative (-) battery
terminal.
Fastening the Ground Strap
The white connector on the battery power cable has a braided
green wire grounding strap that you must fasten to the vehicle’s
sheet metal to ensure proper cable shielding.
To fasten this 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. Make sure the
hole 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” screw and flat washer to secure the green
grounding strap.
Washers
Nut (2)
Positive battery terminal
Battery
Positive battery cable
5/16" x 1-1/2" post
Fuse link
Brown wire (negative)
Gray power cable
Red wire (positive)

12 Vehicle Dock Kit Installation Instructions
Verifying the Dock Power Cable Polarity
Below are the pin descriptions for the notched DC power
connector on the dock power cable. Use a volt meter to verify
whether +12 volts is on pin 2 before you make the final cable
connection.
Vehicle Dock Power Cable 3-Pin Male Power Connector
Performing the Final Connections
1Connect the keyed rectangular connector end of the dock
power cable P/N 236-105-001 to the previously installed gray
battery cable.
2Attach the circular notched DC power connector of the dock
power cable to the installed vehicle dock.
Use this illustration to verify that you have
installed your vehicle dock power cables correctly.
Pin 3, ground
Pin 1, chassis ground (optional)
Pin 2, 12 volts

Vehicle Dock Kit Installation Instructions 13
Installing an Optional Printer
If you are adding a printer to your system, you need the power
cables to connect the printer and vehicle dock to the vehicle
battery. You must place a separate order for a remote terminal
cable:
• DB 9-pin to DB 25-pin cable (P/N 226-084-002)
This cable allows you to locate the printer and the vehicle dock
up to 1.83 m (6 ft) apart.
Note: See your Intermec representative for
information about docks that support other mobile
computers not mentioned on this page, such as the
CK61 or CN2.
COM A 9-pin male
serial port connector
Notched DC power
COM B 9-pin male
serial port connector
700 Color Vehicle Dock
connector
USB/serial adapter
CN3 Vehicle Dock
Mounting kit
attachment plate
connector
Audio out jack
Vehicle power
cable connector

14 Vehicle Dock Kit Installation Instructions
For installation in a system that includes a printer refer the
following wiring diagram.
Installing the Vehicle Dock and Printer
1Install a printer-specific “Y” power cable to supply power to
both the vehicle dock and to the printer.
2Connect one end of this cable to the printer and the other end
to the vehicle dock.
3Connect the keyed rectangular connector on the printer-
specific gray battery cable to the “Y” power cable.
You must also connect the printer-specific data cable between the
vehicle dock and the printer. This cable allows the mobile
computer to communicate with the printer. Plug the appropriate
end of this cable into the vehicle dock and the other end into the
printer.
Installing the Vehicle Dock With Other
Equipment
Have your installation team do your installation. They are
experienced with a wide variety of installations. For example, you
could be installing the vehicle dock with an additional in cab
radio or satellite tracking device. You would need to modify the
black dock cable to connect into a vehicle fuse block that the
installation team would install.
Cables for Vehicle Dock, Printer, and Vehicle Battery
Description Part Number Quantity
“Y” power cable 226-325-101 1
Battery cable (gray) 236-106-005 1
Battery
-+
Vehicle dock
Printer
“Y” power cable
Remote data cable
Battery cable

Vehicle Dock Kit Installation Instructions 15
To modify the black dock cable to connect into a vehicle fuse block
• Switch to using the fuse block cable P/N 226-109-003, or
Cut off the white connector from the end of the dock power
cable and wire it directly to the fuse block.
Jump-Starting Your Vehicle
Always disconnect the power cables from the dock and printer
before attempting to jump-start your vehicle.
Note the difference in polarity between these two
cables.
Wiring for Fuse Block Cable and Dock Power Cable
Cable White Wire Black Wire
Dock power (black) P/N 236-105-001 Negative Positive
Fuse block (gray) P/N 226-109-003 Positive Negative
Failure to follow these instructions may result in
damage to your mobile computer equipment.

Worldwide Headquarters
6001 36th Avenue West
Everett, Washington 98203
U.S.A.
tel [phone]
fax [phone]
www.intermec.com
Vehicle Dock Kit Installation Instructions
*962-000-021C*
P/N 962-000-021C