Installation guide: Asset tracker | forklift
Skill level: Expert
The installer can identify and connect to common engine and electrical systems on vehicles and assets; such as control modules, sensors, trigger wires, alternators, starters, and solenoids. The installer can use pull-up and pull-down resistors, relays, and diodes.
Time required: 30-90 minutes.
This guide explains how to install an asset tracker on various forklift models. It is a guide for Performance Team.
Always get permission before you drill, and look to make sure you will not damage any adjacent equipment or OSHA required certified ROPS structures. Refer to the ROPS identification help article for more information about identifying ROPS structures.
Depending on where the device is to be mounted, you may use the provided screws or the bolts with lock nuts and washers to mount the device. If using the screws or bolts, pre-drilling the holes may make the task easier. Based on the application, zip ties VHB tape may also be used to mount the device.
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If you are unable to determine what parts makeup the manufacturer defined ROPS structure reasonable efforts should always be made to mount devices in locations where the device can be secured using zip ties and VHB tape.
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Use at least two 1" wide strips of VHB tape placed down the full length of the edges of the asset tracker's longest side.
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In this guide:
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Locate the ignition, battery+ and battery- connections.
The connections are located at a terminal block to the right of the driver's control arm. The position of individual connections on the terminal block may vary.
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Connect the ignition, battery+ and battery- connections to the terminal block using terminal rings.
Do not splice or poke and wrap the connections to the terminal block.
You may need to use a multimeter to confirm connection voltages.
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Locate the deadman input at the contact panel.
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Connect a 36 volt fused relay to the deadman input using a ring terminal. This will change the input polarity from positive to negative as necessary. 4-pin relay option
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Access the motor side of the lift by removing the rear cover and lifting the hatch.
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Locate the battery+ and battery- connections by following the route of the main harness from the battery.
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Connect the battery+ and battery- connections to the points indicated in the image below using a terminal ring.
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Locate the ignition by following the circuit going to the strobe light.
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Connect the ignition to the point indicated in the image below by using a heat shrink butt connector.
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Locate the deadman input at the contact panel.
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Connect a 48 volt fused relay to the deadman input using a ring terminal (see image below). This will change the input polarity from positive to negative as necessary. 4-pin relay option
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Access the motor side of the lift by removing the rear cover and lifting the hatch.
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Locate the battery+ and battery- connections by following the route of the main harness from the battery.
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Connect the battery+ and battery- connections to the points indicated in the image below using a terminal ring.
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Locate the ignition by following the circuit going to the strobe light.
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Connect the ignition to the point indicated in the image below using a heat shrink butt connector.
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Locate the deadman. The deadman is a 12 volt positive trigger on the 10 pin molex connector (see image below).
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Identify the deadman connection wire labeled JR11-5 (see image above).
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Connect the device’s input 1 (blue wire) to the deadman connection wire using a heat shrink butt connector and inline fuse.
It is not necessary to connect a relay to the deadman.
The install type chosen during validation must reflect the deadman’s polarity.
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Locate the ignition, battery+ and battery- connections.
The connections are located to the right of the driver's position at the control board.
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Locate the control board and connect the device as follows (see images below):
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Device battery+ to forklift battery+ (on a 6 pin molex labeled P12, wire 40-1).
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Device battery (-) negative to forklift battery (-) negative on a 6 pin Molex labeled P12, wire 13-1.
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Device ignition to forklift ignition circuit (on a 10 pin molex labeled P6, wire 37-1).
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Locate the deadman. The deadman is on the 30 pin molex connector labeled P7.
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Identify the deadman connection wire on pin14.
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Connect the device’s input 1 (blue wire) to the deadman connection wire by splicing.
This will be a negative trigger.
It is not necessary to connect a relay to the deadman.
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Locate the ignition, battery+ and battery- connections.
These connection points may be located directly in front of the driver's position or to the right of the driver above the contact panel.
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Connect the device using ring terminals or heat shrink butt connectors as follows:
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Device battery+ (red wire) to forklift battery+ (labeled B+)
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Device battery (-) negative (black wire) to forklift battery (-) negative labeled (B-).
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Device ignition (white wire) to forklift ignition
Ignition, battery+ and ground (battery -) will be bundled as spare wires.
There may be multiple of the same wire. Keep joint power, ignition or ground wires together.
Do not split any joint wires. Splitting joint wires may cause issues.
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Locate the deadman input at the contact panel.
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Connect a 36 volt fused relay to the deadman input using a ring terminal. This will change the input polarity from positive to negative as necessary. 4-pin relay option
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Access the motor side of the lift by removing the rear cover and lifting the hatch.
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Locate the battery+ and battery- connections by following the main harness coming from the battery.
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Connect the battery+ and battery- connections to the points indicated in the image below using a terminal ring.
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Locate the ignition by following the circuit going to the strobe light.
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Connect the ignition to the point indicated in the image below using a heat shrink butt connector.
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Locate the deadman input at the contact panel.
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Connect a 36 volt fused relay to the deadman input using a ring terminal. This will change the input polarity from positive to negative as necessary.
Note
These models are 24 volt electric pallet jacks.
They do not require a DC to DC step down converter for device installation.
They do not require a deadman input connection for device installation.
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Locate the battery+ and battery connections; they are spare wires to the left of the driver’s position.
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Connect the device to these wires using heat shrink butt connectors.
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Locate the ignition at the key cylinder.
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Connect the device to the ignition using a heat shrink butt connector.
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Locate the ignition, battery+ and battery- connections under the step plate at the fuse panel .
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Connect the device (see image below) using ring terminals or heat shrink butt connectors as follows:
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Device battery+ to forklift battery+ (blue/yellow wire)
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Device battery (-) negative to forklift chassis ground
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Device ignition to forklift ignition (blue wire)
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Mount the device to the right of the fuse panel under the plastic cover, taking care to avoid the metal enclosure at the fuse panel location.
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Identify the deadman connection wire on the pressure sensor under the seat.
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Connect the device’s input 1 (blue wire) to the deadman connection wire by splicing.
This will be a negative trigger.
It is not necessary to connect a relay to the deadman.
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Locate the ignition, battery+ and battery- connections.
The connections are located under the seat at the battery location.
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Connect the device as follows:
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Device battery+ directly to the forklift battery+ terminal.
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Device battery (-) negative directly to the forklift battery (-) negative terminal.
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Device ignition to the blue wire at the fuse panel.
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Mount the device under the plastic dashboard.
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Identify the deadman connection wire on the pressure sensor under the seat.
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Connect the device’s input 1 (blue wire) to the deadman connection wire by splicing.
This will be a negative trigger.
It is not necessary to connect a relay to the deadman.
The battery and ignition circuits may require a DC to DC step down converter. Installations that are 36 volts or higher require 2 step down converters, and a fuse on both the input and output.
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Locate the ignition, battery+ and battery- connections (see images below).
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Battery+ and ignition are located under the key cylinder.
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Battery- is located to the right of the driver’s position on the main grounding bus.
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Connect the device to the forklift using ring terminals:
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Connect the device battery+ to the forklift battery+
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Connect device battery (-) negative directly to the forklift battery (-) negative terminal.
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Connect the device ignition to the forklift ignition
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Two step down converters are required.
A deadman input connection is not required for this forklift model.
The use of a DC to DC step down converter may be necessary for the battery and ignition circuits. Two converters will be used for each installation of 36v or higher. The use of a fuse is required on the input and output of these circuits.
1. Remove left side access panel, floor panel, right kick panel, and lift battery cover (seat)
2. Locate the battery +/- and ignition. Use ring terminals for all 3 connection points. Step down converters are required.
3. Identify deadman wire located under the driver's seat.
1. Deadman will be a negative trigger from 5v+, a 3 amp inline fuse is required.
2. No relay will be required.
4. Mount device underneath plastic dash.
5. Route wires to connection points via manufacturer pass-through holes.
Verizon Connect shall have no liability whatsoever for any damages that arise from, or are connected with, your use of our services, including the GPS tracking hardware and dash cams, in a manner contrary to the(se) instructions or in violation of law and/or our agreement. Tracking hardware connected to the diagnostic port in any vehicle that has third-party devices also connected to the diagnostic port can cause interference or loss of functionality of the third-party device. These third-party devices include, but are not limited to, wheelchair lifts, lifesaving equipment, emergency lighting, and radar guns. If such a conflict exists, contact Verizon Connect support to have the tracking hardware configured to support the third-party device. Failure to do so relieves Verizon Connect of all liability for damages that arise from or are connected with your use of the devices. Installed devices may only be removed and transferred to another vehicle if the second vehicle has been tested for compatibility, as per the(se) instructions. Transfers between vehicles which do not follow the(se) instructions will void any and all warranties from Verizon Connect, and relieve Verizon Connect of all liability for damages that arise from or are connected with your use of the devices.