CV41 Vehicle Mounting Kit Reference Guide
CV41 Vehicle Mounting Kit Reference Guide........... 3 Secure the Smart Dock to a Vehicle.................... 3 Supply Power to the Smart Dock...................... 7 Connect a 10-60 VDC Power Connection......... 7 Connect a 72-96 VDC Power Connection........ 11 Mount the Power Supply.................. 11 Install the Output Cable.................. 12 Install the Input Cable.................... 12 Connect to the Vehicle Battery............. 13 Fasten the Ground Strap.................. 16 Connect an External Power Supply.............. 16 Attach the CV41 to the Smart Dock................... 17 ii CV41 Mounting Kit And Power Supply Instructions
CV41 Vehicle Mounting Kit Reference Guide To use the CV41 Vehicle Mount Computer, you must mount the smart dock to a vehicle and supply power to it. Use these instructions to learn how to: Secure the Smart Dock to a Vehicle Supply Power to the Smart Dock Attach the CV41 to the Smart Dock Mounting and connecting power to the CV41 should be performed by trained service personnel only. When you mount the CV41, make sure that it: does not obstruct the driver s vision or safe operation if it is mounted on a vehicle. can easily be accessed by the driver while they are seated if it is mounted on a vehicle. is protected from rain or inclement weather. is protected from high concentrations of dust or debris. Secure the Smart Dock to a Vehicle Use the RAM Mounting Kit to secure the smart dock to a flat surface or to a beam on a vehicle. The kit was designed to restrain and isolate the CV41 from shocks and vibrations that can potentially damage it. Note: Using hardware that is not approved by Intermec may void the warranty of the CV41. CV41 Vehicle Mounting Kit Reference Guide 3
RAM Mounting Kit Parts Number Description 1 Mounting balls 2 Pivot arm 3 Clamp mount with hardware 4 Mounting plate Screws and lock washers for smart dock (not shown) Note: If you are mounting the CV41 to a flat surface, you need to use your own hardware to secure the RAM ball to the surface of your choice. 4 CV41 Vehicle Mounting Kit Reference Guide
You need the following tools to install the RAM mounting kit: Phillips screwdriver Small wrench To install the RAM Mounting Kit 1 Determine whether you are attaching the CV41 to a flat surface or to a beam. 2 If you attaching the CV41 to a flat surface: a Place a mounting ball against the surface to serve as a template and mark the hole locations. b Drill and tap holes on the surface that you have marked. c Using your own hardware, secure the mounting ball to the surface. CV41 Vehicle Mounting Kit Reference Guide 5
If you are attaching the CV41 to a beam: a Attach the upper and lower clamp mount to a beam. b Secure the the clamp mounts using the screws and nuts provided to a torque value of 17-20 in/lb (0.95-1.10 N/m). Note: The clamp mount can only attach to beams that are up to 2.5 in (63.5 mm) wide and 2 in (50.8 mm) thick. Use longer screws (not included) to attach the clamp mount to a thicker beam. 3 Attach a mounting base to the smart dock using the four screws and lock washers provided. 6 CV41 Vehicle Mounting Kit Reference Guide
4 Attach the smart dock by placing the pivot arm over the two mounting bases and tightening the knob on the pivot arm. 5 Continue to the next section to learn how to supply power to the smart dock. Supply Power to the Smart Dock You use the smart dock to power and charge the CV41. Before you can attach the CV41 to the smart dock, you need to supply power to it. You can do this by: a 10-60 VDC power connection a 72-96 VDC power connection an external power connection Connect a 10-60 VDC Power Connection Use this section to learn how to connect the smart dock to a 10-60 VDC power connection. You can wire the 10-60 VDC power connection as an: ignition controlled connection. With this type of connection, the CV41 turns on when the vehicle is turned on, and goes into suspend mode when the vehicle is turned off. CV41 Vehicle Mounting Kit Reference Guide 7
Auto-On controlled connection. With this type of connection, the CV41 turns on when the vehicle is turned on, or when the power switch on the back of the smart dock is placed in the on position. manually controlled connection. With this type of connection, you must manually turn the CV41 on and off. When connecting to this type of connection, make sure that the input power cable is connected to a fused circuit on the vehicle. The circuit requires a 10 Amp maximum time delay (slow blow) high interrupting rated fuse. If the supply connection is made directly to the battery, the fuse should be installed in the positive lead within five inches of the battery positive (+) terminal. For North America, you need to use a UL listed fuse. You must connect the 10-60 VDC power connection to the correct electrical polarity. See the following illustration and table for more information. Cable for 10-60 VDC Power Connection Cable Color Coding Wire Color Connection Type Green Ground Black DC - Blue Ignition input Red DC + (10-60 VDC nominal) 8 CV41 Vehicle Mounting Kit Reference Guide
To connect 10-60 VDC power 1 Make sure that the CV41 is not attached to the smart dock, and that the power switch on the dock is in the off position. 2 Connect the power cable supplied with the dock as close as possible to the battery terminals of the vehicle. 3 Wire the connection. For an ignition controlled connection, the ignition wire must be connected, and the Auto-On feature needs to be disabled. Use the following illustration to help you. EXISTING CIRCUITRY ON VEHICLE FORKLIFT BATTERY MAIN SWITCH CV41 VEHICLE MOUNTED COMPUTER in Quick Mount Smart Dock 10A slow fuse Close to power source +Vo IGNITION -Vo 8 7 COM1 or COM2 Connector on Dock RED BLACK GREEN BLUE 1 2 3 4 5 6 Circular Power Connector on Dock For an Auto-On controlled connection, use the following illustration to help you. CV41 Vehicle Mounting Kit Reference Guide 9
EXISTING CIRCUITRY ON VEHICLE FORKLIFT BATTERY MAIN SWITCH CV41 VEHICLE MOUNTED COMPUTER in Quick Mount Smart Dock 10A slow fuse Close to power source +Vo IGNITION -Vo 8 7 COM1 or COM2 Connector on Dock RED BLACK GREEN BLUE (not connected) 1 2 3 4 5 6 Circular Power Connector on Dock For a manually controlled connection, the ignition wire must be left disconnected, and the Auto-On feature must be disabled. Use the following illustration to help you. EXISTING CIRCUITRY ON VEHICLE FORKLIFT BATTERY MAIN SWITCH CV41 VEHICLE MOUNTED COMPUTER in Quick Mount Smart Dock 10A slow fuse Close to power source +Vo IGNITION -Vo 8 7 COM1 or COM2 Connector on Dock RED BLACK GREEN BLUE (not connected) 1 2 3 4 5 6 Circular Power Connector on Dock 4 Route the power cable. When routing the cable make sure that you: route the cable the shortest way possible, while removing any cable that is left over. protect the cable from surfaces that may exceed the maximum temperature rating of the cable, which is 221 ºF (105 ºC). 10 CV41 Vehicle Mounting Kit Reference Guide
protect the cable from any physical damage. do not expose the cable to chemicals or oil that may cause the wiring insulation to deteriorate. route the cable so that it does not interfere with the safe operation and maintenance of the vehicle. 5 Secure the power cable to the vehicle structure at approximately one foot intervals. Be sure not to overtighten and pinch the conductors, or penetrate the outer cable jacket. 6 Connect the DC power cable to the input connector on the back of the smart dock. 7 Attach the CV41 to the smart dock. For more information, see Attach the CV41 to the Smart Dock on page 17. 8 Turn on the smart dock by flipping the power switch on. 9 Configure the Auto-On behavior for your type of connection. For more information, see the CV41 Vehicle Mount Computer User Guide. Connect a 72-96 VDC Power Connection This section explains how to prepare and install the power supply for 72-96 VDC connections. To install the power supply, you need to: Mount the Power Supply Install the Output Cable Install the Input Cable Connect to the Vehicle Battery Fasten the Ground Strap Mount the Power Supply When you mount the power supply, you must provide 840 to 1030 sq cm (130 to 160 sq in) of metallic surface to disperse the heat that is generated by the power supply. After you have found a suitable location, use the hardware that is supplied to mount the power supply to the vehicle. CV41 Vehicle Mounting Kit Reference Guide 11
To mount the power supply using hex bolts and locking nuts Note: Use this procedure if you can access the bottom of the power supply mounting location. 1 Mark and center punch the mounting hole locations. 2 Use a 1/4 drill bit to create the mounting holes. 3 Install the power supply using the 1/4 hex bolts, flat washers, and locking nuts. To mount the power supply using hex bolts Note: Use this procedure if you cannot access the bottom of the power supply mounting location. In order to mount the power supply correctly, the mounting location must be thick enough to accept and retain the power supply. 1 Mark and center punch the mounting hole locations. 2 Use a #7 drill bit to create the mounting holes. 3 Use a 1/4-20 tap to thread the mounting holes. 4 Install the power supply using the 1/4 hex bolts and lock washers. Install the Output Cable 1 Route the output cable from the computer to the power supply. 2 Connect one end of the output cable to the power CV41. 3 Connect the other end of the output cable to the CV41, and turn the connector collar clockwise to secure the cable. 4 Install the input cable. For help, see the next section. Install the Input Cable Note: The wire colors listed in this manual may not be the same as those on the actual wires. Verify all wire connections with a multimeter. 1 Route the power cable from the CV41 to the vehicle battery. 12 CV41 Vehicle Mounting Kit Reference Guide
2 Cut the power cable near the battery leaving enough of the cable to reach the battery terminals. 3 Strip the power cable jacket back 31 to 36 cm (12 to 14 in). Power cable Green and white wire Crimp here Terminal ring (3 places) Red and black wire Fuse link splice Fuse link assembly 4 Slide the heat shrink tubing over the cable jacket. 5 Strip.60 cm (0.25 in) of insulation from the individual wires. 6 Twist the green and white wires (negative) together. 7 Twist the red and black wires (positive) together. 8 Crimp a 3/8 terminal ring onto the green and white wires (negative). 9 On the red and black wires (positive), crimp a 3/8 terminal ring onto one end of the fuse block and another 3/8 terminal ring onto the other end. 10 Crimp the #10 terminal ring onto the ground strap. 11 Connect the input cable to the battery. For help, see the next section. Connect to the Vehicle Battery Verify that the cable to battery connections are correct. Electrical energy from vehicle batteries can harm equipment and people. You can connect to the vehicle battery by connecting to the side battery terminal or the top battery terminal. 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. CV41 Vehicle Mounting Kit Reference Guide 13
+ Connect to the Side Battery Terminal 1 Remove both battery terminal side post bolts from the vehicle battery. Vehicle battery Positive battery post Washers Battery Nut terminal post (positive) Positive battery cable Positive wire Fuse link Power cable Negative wire 2 Fasten a 3/8" nut to one of the 3/8 x 1-1/2 posts (provided). 3 Place a 3/8" washer on the battery terminal post. 4 Slide the positive wire fuse link terminal ring from the power input cable onto the the positive battery post. 5 Place another 3/8" washer on the battery terminal post. 6 Slide the vehicle positive battery cable onto the battery terminal post. 7 Thread the post assembly (Steps 2 through 6) into the positive battery terminal. 8 Tighten the battery terminal post securely. 9 Tigthen the nut installed in Step 2 to secure the washers and cables firmly in place. 10 Repeat Steps 2 through 8 for the negative wire from the power cable, connecting the negative cables to the negative battery terminal. 14 CV41 Vehicle Mounting Kit Reference Guide
11 Connect the ground strap. For help, see Fasten the Ground Strap on page 16. Connect to the Top Battery Terminal 1 Remove the battery clamp posts from the vehicle battery terminals. Positive battery terminal - - Vehicle battery Washers Nut + Positive battery cable Positive wire Gray power cable 5/16" x 1-1/2" post Fuse link Negative wire 2 Remove the nuts and bolts from the vehicle battery terminal, and replace them with the 3/8 x 1-1/2 in nuts and bolts (provided). 3 Reinstall the positive battery clamp post, and tighten the nut securely. 4 Place a 3/8 washer onto each end of the battery clamp bolt. 5 Slide the positive fuse link terminal ring from the input power cable onto positive battery clamp bolt. 6 Place another 3/8 washer onto the battery clamp. 7 Thread another 3/8 nut onto the battery clamp bolt, and tighten the nut securely. 8 Repeat Steps 2 through 7 for the negative battery cable wire from the power cable, connecting the wire to the negative battery terminal. 9 Connect the ground strap. For help, see the next section. CV41 Vehicle Mounting Kit Reference Guide 15
Fasten the Ground Strap The braided black wire is the vehicle grounding strap. To ensure proper cable shielding, you need to fasten the ground strap to the vehicle s sheet metal. To fasten the ground strap 1 Drill a small hole into the metal where you intend to fasten the ground strap. 2 Use a punch to dimple and enlarge the hole until it is the same size as the screw. 3 Scrape a small circle of paint from around the hole. Make sure to expose bare metal to make a good electrical connection. 4 Attach the CV41 to the smart dock. For more information, see Attach the CV41 to the Smart Dock on page 17. 5 Turn on the smart dock by flipping the power switch on. Connect an External Power Supply You can connect the smart dock to an external power supply to power the CV41. The external power supply contains these parts: 16 CV41 Vehicle Mounting Kit Reference Guide
External Power Supply Parts Number Description 1 AC input cable (U.S.A only) 2 DC output cable 3 Connects to DC output cable 4 Connects to CV41 Note: The external power supply is intended for use in a maximum ambient temperature of 77 ºF (25 ºC) maximum. To connect the CV41 to an external power supply 1 Connect the AC input cable to the external power supply. If you are outside of the U.S.A, you need to buy an appropriate power cord for your country. 2 Plug in the external power supply to an electrical outlet. 3 Connect the DC output cable to the external power supply. 4 Connect and secure the watertight connector end of the adapter cable to the smart dock. 5 Attach the CV41 to the smart dock. For more information, see Attach the CV41 to the Smart Dock on page 17. 6 Turn on the smart dock. Attach the CV41 to the Smart Dock After you have installed the RAM Mounting Kit and supplied power to the smart dock, attach the CV41 to the dock. To attach the CV41 to the smart dock 1 Make sure that the CV41 is turned off. 2 Locate the portruding lip on the rear of the CV41. 3 Place the lip of the CV41 over the top of the dock. CV41 Vehicle Mounting Kit Reference Guide 17
4 Slide the CV41 from side-to-side until the CV41 is seated into the smart dock. 5 Push the CV41 down onto the smart dock until you hear a click. 6 If necessary, adjust the viewing angle by adjusting the pivot arm. 18 CV41 Vehicle Mounting Kit Reference Guide
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