Vulcan-Hart POWER PAL V-16 User manual

POWER PAL™
WIRED/WIRELESS REMOTE
ELECTRIC/HYDRAULIC CONTROLLER
MODEL: V-16
POWER UP PRODUCTS
76 Hardy Drive
Sparks, NV 89431
[phone]
READ ME FIRST OR
VOID YOUR WARRANTY!
COPYRIGHT 01 January 2004

BEFORE YOU START:
READ THE ENTIRE MANUAL
YOUR POWEL PAL KIT INCLUDES THE FOLLOWING:
• WIRED 15 FUNCTION REMOTE KEYPAD WITH 25ft. HEAVY
DUTY COILED CORD
• HARNESS,V-16-PP-05 (2 pcs)
• POWER DISTRIBUTION CENTER
• ENGINE KILL RELAY
• MOUNTING FEET AND SCREWS
• WARRANTY CARD (BACK OF MANUAL)
MODEL # V-16
REVISION 1 January 2004
2

STARTING YOUR INSTALLATION
Installation time: Approximately 60 minutes
Mount the Power Distribution Center (PDC)
Choose a suitable location to mount the PDC. The ideal location is in the
rear of the truck inside the toolbox. The four mounting feet can be mounted to
the sides or the top and bottom of the PDC enclosure. It is best to mount the
PDC with the strain reliefs and wired/wireless button facing down. Remove the
cover from the PDC.
Typical mounting location of Power Pal™
NOTE: Leave enough clearance to route all of your input and
output wires to the PDC enclosure.
Install the Output Harness w/Power Wires
Connect the output harness to the 16 pin Amp connector. The color code
chart on page 5 describes the color codes and functions of the output harness.
The power wires are also included in the harness, the #10 AWG BLACK wire is
for ground (-GND), the #10Awg RED is for power (+12V).
Take caution when connecting the power wires and the output wires. Incorrect
connections may cause harm to the unit.
Connect the ground wire
Connect the #10 AWG black ground wire from the harness to the ground
terminal inside the PDC. Attach the opposite end of the black ground wire to the
J-Box ground connection or a clean metal to metal chassis ground, tighten
securely.
IMPORTANT- (Do not connect to the sub frame, but to the truck’s chassis)
Protect the chassis ground connection with a light coating of grease to prevent
corrosion.
3

Install the Power Wire
Connect the #10 AWG RED wire from the harness to the terminal marked
BATT inside the PDC enclosure. Attach the opposite end to the J-Box connection
which is powered from the switch on your switch panel or appropriate switched
12-Volt power source (this must be fused or have circuit breaker protection with a
minimum of a 10 amp draw).
Install the Wired Remote Keypad
Feed the end of the coiled cord through a strain-relief of the PDC. Insert
the connector into the telephone cord receptacle on the PDC circuit board.
Test the Power Pal™
Turn on the ‘control’ switch providing power to the Power Pal™. A green
indicator LED on the PDC circuit board will light. If the green LED on the circuit
board does not come on, consult the troubleshooting section and correct the
problem before proceeding.
Make sure that the ‘wired/wireless’ switch is in the ‘wired’ position. A
green indicator light on the top right corner of the wired remote keypad will light.
If it does not, consult the troubleshooting section on page 8.
Check the operation of the wired remote keypad. Press each position on
the keypad and check that each position operates the associated output on the
PDC.
NOTE: On the 15 function Power Pals™, the 16th output will activate when each
position is pressed. This 16th position is the auto-throttle function.
The number printed on the PDC circuit board can locate each output. There are
two indicator LEDs located near each output. The GREEN LED will light if the
output is functioning correctly. The RED LED will light to indicate a circuit
problem.
4

OUTPUT HARNESS WIRING SCHEME FOR POWER PAL MODEL # V-16
WIRE COLOR OUTPUT FUNCTION
BLUE WITH BLACK STRIPE STINGER IN
BLACK WITH WHITE STRIPE STINGER OUT
RED WITH BLACK STRIPE LEFT WINCH IN
YELLOW WITH BLACK STRIPE BOOM UP
GREEN WITH BLACK STRIPE BOOM DOWN
WHITE WITH BLACK STRIPE LEFT WINCH OUT
PINK WITH BLACK STRIPE TILT UP
ORANGE WITH BLACK STRIPE TILT DOWN
RED RIGHT WINCH IN
BLACK BOOM IN
BLUE BOOM OUT
YELLOW RIGHT WINCH OUT
GREEN AUX 1
WHITE ENGINE KILL
ORANGE AUX 2
PINK AUTOTHROTTLE
NOTES OF CONCERN:
1. The maximum amperage on any output must be no more than 5 amps.
The electric over hydraulic solenoids does not require more than 5
amps to operate.
2. Overdriving an output will cause the output to temporarily cease
function (RED LED should be on). Correct the problem and test for
proper function.
3. Overload conditions must be fixed as soon as possible.
4. Continuous overloading of an output may cause damage to the circuit
board and will void your warranty.
5. Overload conditions must be fixed as soon as possible.
5

Installation of the Engine Kill Circuit
An engine kill relay is included in the V-16 Power Pal™ kit. Refer to figure
1 for identification of the relay terminals. Use an insulated female ¼” push-on for
connecting the wires to the relay terminals.
Cut the fuel shut-off switch wire in the engine compartment and connect one
side of the wire to terminal 30, and the other side of the wire to terminal 87a of
the relay.
Connect the engine kill wire from the output harness (white wire) to terminal 85
of the relay.
Run a ground wire from a chassis ground to terminal 86 of the relay. Mount the
relay in the engine compartment.
30
87a
87
85
86
Figure 1
Test the System
Apply power to the Power Pal™ and test the functionality of the system.
Make sure that each button on the keypad turns on the correct output.
If the function does not come on, check the indicator LED at the output on the
PDC circuit board. If the red LED comes on when you press a button, there is an
overload or short circuit in the wiring for that output. Locate and correct the
problem as necessary.
If all outputs function correctly, turn off power to the Power Pal™ and
replace the cover. Tighten the strain reliefs. The Power Pal™ handheld remote
comes with a protective pouch and an adhesive Velcro™ strip, which can be
used for mounting.
Installation of the Power Pal™ PDC is complete.
Install the Batteries into the Transmitter
Remove the wireless keypad from its pouch and place it face down on a
table or bench. Remove the two screws on the battery cover. Install the ‘AA’
alkaline batteries into the battery holder and replace the battery cover.
6

Install the Antenna
Install the antenna using the provided 90oantenna-mounting bracket. The
antenna is designed to fit this bracket and it should be used for optimum range.
An ideal location for mounting the antenna is by the rear deck of the rear toolbox
which contains the Hydraulic Controller. Mount the bracket to a flat bare metal
surface that is well grounded.
Route the coax antenna cable from the mounting bracket to the Power
Pal™ PDC. Insert the cable through the mounting bracket and attach the
antenna mount to the bracket. Attach and tighten the antenna to the threaded
cable mount on the bracket. A loose antenna may cause intermittent operation
and limit the distance of operation.
Route the other end of the antenna cable through the black strain relief on
the Power Pal™ enclosure. Attach the cable connector to the antenna connector
on the receiver board. Be careful not to over tighten the cable.
Program the Receiver Board
Apply power to the Power Pal™ PDC. Be sure the ‘wired/wireless’ button
is in the ‘wireless’ mode.
In the wireless mode, the green indicator light in the top right of the wired keypad
will be off and the wired remote will not function.
The transmitter keypad will not display a green power light like the wired keypad.
The wireless keypad will display a RED flashing light when the positions are
activated on the keypad.
Located on the receiver board is the programming button. Press the
programming button and hold down. The RED LED indicator on the receiver
board will turn on solid. While holding the button, press the top left-most position
on the wireless transmitter keypad.
When the programming is accepted, the indicator light will begin to flash.
Release the receiver button, and then release the position on the transmitter. If
the red indicator goes out when attempting to program, release both buttons and
repeat the procedure. Be sure the transmitter has a good, visual ‘line of sight’ to
the antenna.
Test the Wireless Keypad
There are over 10 billion transmit codes available, so there will never be
two transmitters that will operate the same truck. Your transmitter code is
unique.
Be sure that the wired/wireless switch is in the ‘wireless’ position.
• Test the operation of all the functions of the wireless keypad.
• Test the operating range of the wireless keypad.
If the wireless keypad does not function properly, consult the wireless
troubleshooting section that came with the wireless kit.
7

NOTE: The wired keypad and the wireless keypad will not operate at the
same time.
This completes the installation of the Power Pal™ Wireless System.
8

WIRED POWER PAL TROUBLESHOOTING SECTION
The power LED on the PDC circuit board does not come on.
• The PDC is not getting power. Be sure that the power and ground
wires are connected properly.
• Using a DC test lamp, check that there is power applied to the BATT
terminal of the PDC.
• Check with a voltage meter the power applied is 12 volts.
• Check for a tight, metal to metal chassis ground.
There is no green light in the upper right hand corner of my wired keypad.
• Make sure the coiled cord is properly inserted into the jack on the PDC
circuit board.
• Check the ‘wired/wireless’ switch; switch to the ‘wired’ position.
Some or no outputs function when I press a button on the remote.
• Check for the green indicator light on the keypad.
• Make sure all output wires are properly connected to their destination.
• Check suspected output wire for a secure connection at the output
stab of the PDC circuit board.
• Short or overload condition. While pressing the position on the
keypad, look at the indicator LED on the PDC board that is associated
with the suspected function. If the RED LED is lit, there is an overload
condition or a short circuit in the output wiring. Correct the condition.
• If only the green LED is lit, there is an open connection somewhere
between the output of the circuit board and the solenoid valve. Check
your wiring.
• If no LED’s light up, contact Power Up Products for further assistance.
I press a button and the wrong function comes on.
• Check that the output wires are connected to the correct output
position.
• Following the wiring scheme on page 5.
If you require further assistance, contact Power Up Products Technical
Assistance. Monday through Friday from 8:00 to 4:00 PST. [phone]
9

WIRELESS POWER PAL TROUBLESHOOTING SECTION
The red light on the receiver card does not come on when the program
button is pressed.
• Check to make sure the receiver card is properly mounted and
seated into the connector on the PDC board, secured with three (3)
screws.
• Make sure that there is power going to the Power Pal box. A green
LED on the PDC board labeled ‘Power’ should be on.
• Check to make sure that your ‘control’ switch is turned on.
• Using a voltmeter, check that there is 12 volts on the 'Batt'. Terminal
and that the PDC has a metal-to-metal chassis ground. Inspect the
connections for loose wires, loose connections, and poor crimps.
The program light stays on solid or goes out when I attempt to program the
receiver card.
• Use the top left position on the transmitter keypad to program. Any
other button does not allow the unit to program.
• Remove the receiver antenna from the connector on the receiver
card. Hold the transmitter close to the receiver card and attempt to
program again. If the program is accepted, THOROUGHLY check
your antenna for loose connections, kinked cable, broken cabling, or
excess cable that is coiled.
• Check the status of your batteries. Replace them with fresh alkaline
‘AA’ batteries.
I programmed the receiver to the transmitter, but the unit still won’t
function.
• Check to make sure the ‘wired / wireless’ switch is in the wireless
position.
• Try moving around the vehicle and operating the transmitter. If the
unit operates intermittently, check your antenna connections
thoroughly.
• Remove the antenna cable from the receiver card. Hold the
transmitter near the receiver card. If the unit operates correctly,
inspect the entire antenna system for poor connections, kinked,
broken, or excess coiled cable.
The transmitter works, but it is intermittent and / or the range is not what it
should be.
• The area of operation may have a high amount of radio frequency
(RF) noise. Try the transmitter in another area and see if the
intermittence stops or changes.
• Check your batteries. Use only alkaline ‘AA’ batteries.
• Make sure that the antenna connections are tight and clean. DO
NOT splice the antenna cable to extend or shorten. Make sure that
the antenna is tight and secure on its base and that the antenna base
is free of oil, dirt, and corrosion inside and out.
10

.
• Check to make sure that the transmitter antenna is tightly screwed
into the transmitter.
• Check the operation of the wired keypad. If it is intermittent, check
the power and ground into the Power Pal.
• If it is always the same function that is intermittent check the output
wire coming from the Power Pal to the distant function.
NOTE: If there is another truck that is operating wireless nearby
the two signals will cancel each other becoming intermittent, or
cease to operate.
If you need further assistance, our technical assistance department can be
reached Monday through Friday, 8:00 a.m. to 4:00 p.m. Pacific Time. 775-336-
2400.
11

WARRANTY REGISTRATION
The Power Pal™ System is guaranteed for one year against defects in material
and workmanship. This registration form must be returned within 30 days of
vehicle purchase to validate the warranty.
Customer information:
Name ___________________________________________________
Address__________________________________________________
City______________________State___________Zip Code_________
Phone____________________ Fax____________________
Power Pal™ Serial Numbers:
PDC serial number ______________________________________
Wired Keypad serial number _______________________________
Wireless Keypad serial number _____________________________
Purchased From:
Name ___________________________________________________
Address__________________________________________________
City ______________________State___________Zip Code ________
Date of Purchase _______________________
Type of Vehicle:
Make ____________________________
Model ___________________________
Year _____________________________
MAIL TO:
Power Up Products
Attention: Warranty Registration
76 Hardy Drive
Sparks, NV 89431
Phone: [phone]
Fax: [phone]
12