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7.4.1 Cable Installation Routing
Power cables, whether used for charging or truck power are connected
to the battery via terminal post (stud) and nut. Some Ready Power
battery models have specific terminal posts for charge and truck
cables. Be sure to follow the directions printed on the battery lid when
connecting cables to these battery terminals. Incorrect connections will
result in a battery unable to charge or power the fork truck.
NOTE:
The terminal post torque specifications in the Deka Ready Power
Service Manual must be observed when installing power cables to the
battery terminals posts. Under-torqued terminal post nuts can cause
cable or battery damage.
Power cables should always be routed away from potential pinch points
and remain in the confines of the lift equipment to prevent snagging on
racking or other warehouse obstacles. Avoid using sharp radius bends
which may cause cable damage and heating. You may use cable ties to
assist in securing the cables' position.
Power cables should be routed to avoid damaging thinner communica-
tion cables that are immediately adjacent. Placing power cables
beneath, not on top of, communication cables and running power
cables away from communication ports, will prevent unnecessary wear
or stress.
For specialized installation, specific to fork lift OEMs or dealers,
contact the local Deka representative or Navitas Product Support for
more in-depth installation manuals customized to specific installation
applications.
7.4.2 CAN Charge Cables
Specific power cables and harness are required to be used to facilitate
CAN charging. There are three possible configurations of cables that
allow for CAN charging. Those configurations are:
1. Dedicated CAN charge cable - The gray connector plugs into the
BMID (black box on battery lid). The black "pass through" connects to
the CAN 1 (Black)port on the battery lid. The user peripheral (UIM, BDI
or Truck CAN Comms) connects to the other side of the pass through.
2. Standard charge cable with CAN adapter harness – The
charge cable has a single gray connector that connects into the CAN
adapter harness. The other gray connector of the CAN adapter har-
ness connects to the BMID if equipped. The black connector of the
CAN harness connects to the CAN 1 (Black) port on the battery lid.
The user peripheral (UIM, BDI or Truck CAN Comms) connects to the
remaining black connector on the CAN harness.
3. CAN charging without use of external BMID – The charge cable
is specifically designed to connect to the CAN 2 (Gray) port on the
battery lid. No other connections are necessary.
7.4.3 Dual Cable Setups
If the battery is set up for dual cable charging, a "Y" harness must be
installed. This harness joins the communication portion of each of the
individual charge cables before being connected to the battery commu-
nication port. If the "Y" harness is damaged, missing or not connected
properly, the battery will not charge.
7.4.4 36v 550ah 18-125-13/15 (original)
Specific Cables
The communication portion of the battery cable connects to the CAN 2
port (gray 12 pin Deutsch connector) on the battery. This is found under
the access lid located at one of the narrow ends of the battery.
Certain installations may require a specific battery cable with a tight
radius lug to allow for better cable routing. Contact the local Deka
service representative for more information
7.4.5 48v 1050ah Specific Cables
Like the 36v 550Ah 18-125-13/15 (original), the communication portion
of the charge cable will connect to the CAN 2 port (gray 12 pin Deutsch
connector) on the battery. Unlike other Ready Power batteries, the
battery terminals cannot be accessed from the outside of the battery.
Instead, the power cables pass through sealed glands on battery and
are connected to the terminal posts internally. This requires specific
cables and trained staff to perform cable replacement. Contact the
local Deka service representative for assistance.
7.4.6 Counterweight Mounted Connectors
Some applications may use connector(s) mounted to the Ready Power
counterweight lid. The mounted connector(s) allow for ease of connect-
ing to the charger. When mounted connector(s) are used, a dedicated
power cable to the truck will also be present.
CAUTION:
It is important that the battery and truck use CAN integration
to prevent the fork truck to move while the battery is connected to the
charger. An alternative is to use a "patch cable" between the battery
and truck. When the battery is charging or connected to the charger, the
truck is disconnected from the battery, preventing movement.
7.5 Charger Installation
All charger installations share common guidelines that help to ensure
long lasting use and easy maintenance; the local Deka representative
can offer insight and/or installation services. Please refer to the charger
manufacturer's installation manual for specific instructions.
7.5.1 Charger Mounting
Chargers should be mounted on stands, pedestals, shelves, or other
accessories designed for the application. The charger mounting lo-
cation should allow for proper ventilation on all sides and access to
internal parts for servicing. Refer to the specific charger's guidelines
for this spacing.
Install bollards or other types of barriers to prevent the forklifts from
contacting and damaging the chargers.
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