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Participant’s Guide
Electrical System
Overview
Electrical System Overview
Participant’s Guide
©NMHG 2009
1400 Sullivan Drive
Greenville, NC 27834-2011
252.931.5100
Refer to the Service Manual for complete maintenance and safety procedures
prior to performing ANY service or maintenance on these lift trucks.
Table of Contents
Introduction .......................................................................................................................................... 5
Acronyms Used in This Module ........................................................................................................ 6
Types of Wiring Diagrams .................................................................................................................. 7
The Block Diagram ......................................................................................................................... 7
The Schematic Diagram ................................................................................................................. 9
The Terminal Diagram ................................................................................................................. 10
Sensors ................................................................................................................................................. 11
Standard Sensors............................................................................................................................ 13
Optional Sensors ........................................................................................................................... 13
Temperature Sensors ......................................................................................................................... 14
Traction and Pump Motor Temperature Sensors ................................................................ 14
Hydraulic Oil Temperature Sensor......................................................................................... 14
Display Ambient Temperature Sensor – Optional .............................................................. 15
Speed Sensors ..................................................................................................................................... 15
Pressure Sensors ................................................................................................................................. 16
Service Brake Pressure Sensor ................................................................................................ 16
Hydraulic Pressure Sensor ....................................................................................................... 16
Hydraulic Filter Pressure Switch – Optional ........................................................................ 17
Position Sensors ................................................................................................................................. 17
Park Brake and Return To Set Tilt Position (RTST) Sensors ............................................ 17
Seat Sensor ................................................................................................................................. 18
Accelerator Pedal Position Sensor .......................................................................................... 18
Steer Wheel Position Sensor.................................................................................................... 19
Steer Axle Position Sensor – Optional .................................................................................. 19
Battery Gate Switch – Optional .............................................................................................. 20
Level Sensors ...................................................................................................................................... 20
Brake Fluid Level ...................................................................................................................... 20
Hydraulic Oil Level Sensor - Optional .................................................................................. 20
Impact Sensor ..................................................................................................................................... 21
Impact Monitor – Optional ..................................................................................................... 21
Sequence of Operation – Schematics.............................................................................................. 22
.............................................................................................................................................................. 22
Notes .................................................................................................................................................... 23
Introduction
Module Summary – This module covers the function and operation of truck
sensors and Hall Effect sensors, and the interpretation of electrical schematic
diagrams to troubleshoot electrical problems.
Skills Objectives – At the completion of this module you will be able to do the
following:
A system block diagram is a block diagram that shows the electrical relationships
among the components of an entire system.
Sensors
Hall Effect sensors are used for the majority of sensors on these trucks. Hall
Effect sensors vary output voltage based on changes in a magnetic field. Moving
the sensor closer or further away from its target varies the output signal voltage.
The software in the VSM interprets the output signal to operate the truck safely
and efficiently.
The Hall Effect sensors have three wires; power supply, battery negative, and
output signal. The voltage output wire for these sensors goes to the VSM. The
sensors operate on 5 volts supplied by the VSM.
If the power, ground, or signal wire is open, the sensor can't operate. A short to
ground (STG) on either the power wire or the signal wire also eliminates the
sensor signal. If the output signal falls below .5 volts a failure condition or
warning will be given to the operator. If the output signal exceeds 4.5 volts a
failure condition or warning will also be given to the operator.
Let’s look at the Seat Occupancy sensor (Figures 5 and 5a)—when the operator
sits on the truck seat, it brings the magnet in the sensor closer to the Hall Effect
junction. The Hall Effect junction responds to the presence of a magnetic field by
sending a signal to a transistor in the sensor which generates an output signal to
the VSM. The computer in the VSM then knows to turn off the interlock for seat
occupancy.
With the truck on and the operator seat unoccupied, the sensor provides a
specific voltage output based on the magnetic field strength. The voltage output
tells the VSM that the seat is unoccupied. The VSM then activates the interlock,
preventing further truck operation, and the seat unoccupied icon appears on the
display.
With the truck on and the operator seat occupied, the sensor senses a magnetic
field. A signal is sent to the VSM, releasing the operator interlock.
When the Hall Effect junction senses a magnetic field, the sensor creates a
voltage output to the VSM, which interprets the signal as “Hall Effect sensor is
ON.” The VSM knows to react to this message in certain ways, depending on the
sensor and the appropriate values for the function the sensor is reading.
Hall Effect Sensors and switches are used on the truck in the following
applications.
Standard Sensors
Temperature Sensors Speed Sensors Pressure Sensors
Traction Temperature Traction Speed Service Brake
Pump Temperature Pump Speed
Hydraulic Oil Temperature
Optional Sensors
Temperature Sensors Pressure Sensors Impact Sensor
Display Ambient Temperature Hydraulic Filter Impact Monitor
Load Weight
Temperature Sensors
All the temperature sensors are NTC (Negative Temperature Coefficient) variable
resistance sensors. They have a 2-pin sealed connector. As the temperature
increases the resistance of the sensors will decrease.
Speed Sensors
Rotational speed sensors provide RPM readings of components that have a
variable speed rotation. The traction and pump motors are equipped with a dual
channel Hall Effect speed sensor and phonic wheel. The sensors can be
serviced without disassembling the motors. The sensors send analog signals to
their respective motor controllers which forwards the signal to the VSM via
CANbus.
Pressure Sensors
The service brake pressure and hydraulic pressure sensors are solid-state strain
gauge type measurement devices; as the sensor is subjected to pressure the
resistance value of the sensor changes. Each sensor has a 3-pin sealed
connector. They operate on 5 volts supplied by the VSM. These sensors send
an analog signal directly to the VSM.
Position Sensors
Hall Effect position sensors provide position information for components that
have angular, linear, or rotational motion.
Figure 14 Park brake, RTST position sensors schematic symbol, connections, performance
The RTST sensor is optional, and must be enabled in the CDF. The sensor will
stop mast tilt at specific customer set points. The length of the attached wire
harnesses are the only physical differences in the park brake and RTST sensors.
Seat Sensor
The seat sensor has four wires. When the sensor detects at least 50 pounds in
the sensor boundary area, it sends an analog signal to the VSM. The VSM
interprets the signal to mean that the seat is occupied.
Figure 15 Seat sensor, schematic symbol, connections, sensor location and boundary
Level Sensors
Brake Fluid Level
The brake fluid level switch is located inside the brake fluid reservoir. The switch
is a normally open switch. If the fluid level becomes low the switch closes
sending a signal to the VSM. The VSM sends a signal to the Display for the low
brake fluid icon to be displayed.
Sensor Range
Fluid Level Distance From Sensor Output Signal Voltage
13.75 inches .5V Low fluid condition
2.00 inches 4.5V Full fluid condition
The low hydraulic fluid level icon will appear only on the operator screen after the
key is turned on and prior to traction, steering or hydraulic functions. If a low fluid
condition exist activating traction, steering, or hydraulic functions will cause the
icon to disappear. The icon will not appear again until the key is cycled.
Steering and hydraulic functions will not cause the low fluid icon to appear on the
display.
Impact Sensor
Impact Monitor – Optional
The impact monitor is a CAN device that is able to detect soft and hard impacts.
A soft impact requires a long duration impact force; however, the force is not very
strong. A hard impact requires a short duration impact force, but the force is very
strong.
The impact settings are adjustable. When an impact occurs the monitor records
the event and the type of impact. Depending on impact settings the VSM can
shut the truck down.
Notes
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