NACCO MATERIALS HANDLING GROUP, INC.

Participant’s Guide

Electrical System
Overview
 Electrical System Overview

NACCO MATERIALS HANDLING GROUP, INC.

Participant’s Guide

©NMHG 2009
1400 Sullivan Drive
Greenville, NC 27834-2011
252.931.5100

The purpose of this program is to familiarize Service Technicians with truck

systems and maintenance procedures. This program MUST be used in
conjunction with the truck Service Manual.

Refer to the Service Manual for complete maintenance and safety procedures
prior to performing ANY service or maintenance on these lift trucks.

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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

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.............................................................................................................................................................. 22
Notes .................................................................................................................................................... 23

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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.

Learning Objectives – At the completion of this module you will be able to do

the following:

Identify the function and operation of specific sensors.

Identify symbols and connections used within wiring diagrams and
schematics.

Skills Objectives – At the completion of this module you will be able to do the
following:

Use a schematic or wiring diagrams to answer questions about the

electrical system.
Use the schematic to troubleshoot switches, sensors and circuits of
the electrical system.

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Acronyms Used in This Module

CAN Controller Area Network
CDF Configuration Data File
CPS Connector Plug Socket
CRP Connector Receptacle Pins
DTC Diagnostic Trouble Code
LCD Liquid Crystal Display
NTC Negative Temperature Coefficient
RTST Return to Set Tilt
SAS Steer Axle Sensor
SWS Steer Wheel Sensor
TSP Troubleshooting Procedure
VSM Vehicle System Manager

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Types of Wiring Diagrams

There are many ways to use diagrams to describe the operation of an electrical
unit. The types that are most applicable to the trucks are the block diagram, the
schematic diagram, and the terminal diagram.

The Block Diagram

The diagram is used to show, at a high level, the relationships among
components.

Figure 1 Block diagram

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A system block diagram is a block diagram that shows the electrical relationships
among the components of an entire system.

Figure 1a Block diagram for the Control System

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The Schematic Diagram

A schematic diagram uses graphical symbols to show the electrical connections,
components, and functions of a circuit. A schematic diagram is not accurate in
terms of the physical size, shape, or location of a particular component. The
schematic diagram is particularly useful for providing an overview of system
operations.

Figure 2 Schematic diagram of the traction motor controller

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The Terminal Diagram

Troubleshooting Procedure (TSP) schematics are useful for providing the
relevant connections for an electrical problem as indicated by a Diagnostic
Trouble Code (DTC).

Figure 3 Terminal diagram showing Service Brake Pressure sensor signals

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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.

Figure 4 Hall Effect Sensor illustration for steering wheel position

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.

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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.

Figure 5 Operator Interlock

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.

Figure 5a Seat occupied, Parking Brake Interlock shown

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.

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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

Position Sensors Level Sensors

Seat Occupancy Brake Fluid Level
Accelerator Pedal Position
Steer Wheel Position
Park Brake Position

Optional Sensors
Temperature Sensors Pressure Sensors Impact Sensor
Display Ambient Temperature Hydraulic Filter Impact Monitor
Load Weight

Position Sensors Level Sensor

Steer Axle Position Hydraulic Oil Level
Return To Set Tilt
Battery Gate

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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.

Figure 6 Schematic symbol for a NTC sensor

Traction and Pump Motor Temperature Sensors

The motor temperature sensors send analog output signals to their respective
motor controllers, which forwards these signals to the VSM via CANbus.

Figure 7 Motor temperature sensor

Hydraulic Oil Temperature Sensor

The hydraulic oil temperature is supplied battery negative voltage; as the oil’s
temperature increases the output signal voltage to the VSM decreases.

Figure 8 Hydraulic oil temperature sensor schematic

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Display Ambient Temperature Sensor – Optional

The ambient temperature sensor controls the LCD heater in the freezer display.
The sensor has three wires; only two of the wires are used. Sensor output is
proportional to the ambient temperature. The sensor is supplied 5 volts from the
display and connected to battery negative. The ambient temperature sensor is
only available for trucks equipped with the optional freezer display.

Figure 9 Optional display ambient temperature sensor

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.

Figure 10 Traction motor speed sensor, pump sensor similar

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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.

Service Brake Pressure Sensor

The service brake pressure fastens to the master cylinder. As pressure on the
pedal increases the output voltage from the sensor increases.

Figure 11 Service brake pressure schematic symbol, connections, performance

The sensor helps determine Power Assisted Braking. A non-adjustable pressure

threshold value is set by the factory. When braking pressure exceeds the
threshold value the VSM sends a signal to the traction motor controller to
decelerate the traction motor. Motor deceleration is proportional to braking
pressure. Power Assisted Braking is designed to reduce brake wear by 50%.

Hydraulic Pressure Sensor

For trucks with the optional CDF enabled Load Weight feature a lift pressure
sensor is required. As lift pressure increases the signal voltage from the sensor
increases. The output voltage is calculated by the VSM which sends a signal to
the display for the load weight to be displayed only when the mast is not in use.

Figure 12 Hydraulic lift pressure schematic symbol, connections, performance

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Hydraulic Filter Pressure Switch – Optional

The hydraulic filter pressure switch is a normally open switch. The VSM supplies
12 volts to the switch. When the filter pressure reaches the non-adjustable pre-
set pressure threshold the switch closes sending a signal to the VSM. The VSM
sends a signal for the display to display an icon that the filter is restricted. The
hydraulic filter pressure option is a CDF enabled option.

Figure 13 Hydraulic filter pressure switch schematic symbol, connections, performance

Position Sensors
Hall Effect position sensors provide position information for components that
have angular, linear, or rotational motion.

Park Brake and Return To Set Tilt Position (RTST) Sensors

The park brake position sensor and RTST sensor are identical in operation. The
sensors operate on 5 volts supplied by the VSM. The park brake sensor sends
an output signal to the VSM. When the park brake is applied the output signal is
interpreted by the VSM to mean that the park brake is applied. The VSM signals
the Display to display the park brake icon.

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.

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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

Accelerator Pedal Position Sensor

An analog rotary accelerator pedal position sensor is standard for all trucks
regardless of accelerator pedal configuration. The sensor has dual outputs,
channel A and channel B. Channel A is the primary channel; output voltage for
channel A is 1.0 – 4.5 volts. Output voltage for channel B is .5 – 2.25 volts.
During normal operation output voltage for channel B is always one half of
channel A. Output voltage increases as the pedal is depressed.

Figure 16 Accelerator pedal position schematic symbol, connections

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Steer Wheel Position Sensor

Steering wheel rotation is monitored by the steering wheel position sensor
(SWS). When the steering wheel is rotated an analog signal is sent to the VSM
which sends a signal to the hydraulic motor controller that flow for steering is
required. The sensor is supplied 5 volts from the VSM.

Figure 17 Steering wheel position sensor (SWS) schematic symbol, connections

Steer Axle Position Sensor – Optional

The steer axle position sensor (SAS) is capable of reading absolute angle
position of the steer tires. The sensor is required for trucks with optional
synchronous steering. The sensor operates on 5 volts supplied by the VSM.

Figure 18 Steer axle position sensor (SAS) schematic symbol, connections

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Battery Gate Switch – Optional

If the truck is configured for horizontal battery removal a battery gate switch is
required. The switch is a normally open switch. If the battery gate is not installed
the VSM will disable truck operation. The VSM will send a signal to the Display
for the battery gate switch icon to be displayed.

Figure 19 Battery gate switch, schematic symbol, connections

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.

Figure 20 Brake fluid level switch, schematic symbol, and connections

Hydraulic Oil Level Sensor - Optional

An optional ultrasonic level sensor is fastened to the top of the hydraulic tank.
The sensor has three wires. An output signal of .5V indicates low fluid. The
sensor’s range and output signals are shown below:

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

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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.

Figure 20a Hydraulic level sensor schematic symbol, connections

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.

Figure 21 Impact monitor connections

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Sequence of Operation – Schematics

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Notes
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