NACCO MATERIALS HANDLING GROUP, INC.

Electrical
 Electrical

NACCO MATERIALS HANDLING GROUP, INC.

©NMHG 2014
1400 Sullivan Drive
Greenville, NC 27834-2011
252.931.5100
Rev 2

This document does not replace the Service Manual for this product. Refer to
the Service Manual for complete maintenance and safety procedures prior to
performing ANY service or maintenance on these lift trucks.

NMHG Technical Training

 Electrical

Table of Contents
Introduction ........................................................................................................... 1
Learning Objectives........................................................................................... 1
Upon completion of this module, you will be able to: ......................................... 1
Skill Objectives .................................................................................................. 1
Upon completion of this module, you will be able to: ......................................... 1
Battery Voltage ..................................................................................................... 2
Integrated Fuse Board (IFB) ................................................................................. 2
E-Stop ................................................................................................................... 2
Controller Area Network (CAN) ............................................................................. 3
CAN Devices ........................................................................................................ 3
Display .................................................................................................................. 4
Controllers ............................................................................................................ 4
Traction Controller ............................................................................................. 5
Hydraulic Controller ........................................................................................... 5
Steering Controller ............................................................................................ 6
Steered Caster .................................................................................................. 6
Auxiliary Pump and Motor ..................................................................................... 6
Side Stance – Forward Stance Handle ................................................................. 7
Aft Handle ......................................................................................................... 7
CAN I/O ................................................................................................................ 7
Remote CAN Module ............................................................................................ 8
Option Module....................................................................................................... 8
Electrical Schematics ............................................................................................ 8
Sequence of Operation ......................................................................................... 8
Battery Connected............................................................................................. 8
Integrated Fuse Board ....................................................................................... 8
Ignition Circuit.................................................................................................... 9
IFB Outputs ....................................................................................................... 9
Battery Voltage .............................................................................................. 9
24 Volt Circuits............................................................................................... 9
12 Volt Circuits............................................................................................... 9
5 Volt Circuits................................................................................................. 9
Logic Test .......................................................................................................... 9
Line Contactor ................................................................................................. 10
Operator Presence .......................................................................................... 10
Brake Switch ................................................................................................... 10
Travel Request ................................................................................................ 10
Brake Released ............................................................................................... 10
Hydraulic Request ........................................................................................... 11
Steering Request............................................................................................. 11
Module Summary ................................................................................................ 13
Learning Objectives......................................................................................... 13
Skill Objectives ................................................................................................ 13

NMHG Technical Training i

 Electrical

NMHG Technical Training ii

 Electrical

Introduction
This module covers the function and operation of the Electrical System used on
Narrow Aisle Trucks equipped with Hyster i3 Technology™ or Yale iSi
Technology™.

Learning Objectives
Upon completion of this module, you will be able to:

 Describe the function and operation of electrical system components.

 Identify the location of the components used and their relationship to other
components in the system.

 Understand the sequence of electrical flow in the system.

Skill Objectives
Upon completion of this module, you will be able to:

 Locate components of the electrical system.

 Perform voltage readings to identify faults pertaining to the electrical

system.

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Battery Voltage
Trucks are available in either 24 or 36 volt configurations. The small chassis
truck, known as the Retail Reach, can be ordered as
either 24 or 36 volts. The large chassis truck, known
as the Americas Reach, can only be ordered in the 36
volt configuration. The 24 volt configuration uses a
SB350 red connector. The 36 volt configuration uses
a SB350 grey connector. Battery voltage is supplied
to the Integrated Fuse Board and the Remote
Frequency terminal connection board whenever the 24V SB350 36V SB350
battery is plugged in.

Integrated Fuse Board (IFB)

Main battery power is supplied to the Integrated Fuse Board (IFB) whenever the
battery is connected. One function of the IFB is to pre-charge the capacitors in
the controllers. The IFB also provides power to
the logic circuits when the ignition switch is
moved to the energized position. Once the logic
circuit is satisfied, the IFB supplies output
voltages of battery, 24 and 12 volts, dependent
on truck configuration. There are three possible
IFB’s, a 36 volt IFB with 12 and 24 volt regulators, a 24 volt IFB with a 12 volt
regulator and a 24 volt IFB with no regulators. The IFB is not repairable. The
only replaceable items on the IFB are fuses. The IFB supplies power to the
ignition switch through the E-stop located in the operator’s compartment. All
trucks are configured with an E-Stop. The E-stop interrupts power to the ignition
circuit when activated.

E-Stop
The E-stop on this series does not directly remove electrical power from the main
contactor or controllers. The E-stop receives power from the IFB
and supplies power to the key switch. When the E-stop is
pressed, the input from the key switch circuit to the IFB is
interrupted. This, in turn, interrupts the 36, 24 and 12 volt IFB
outputs to the logic and control circuits of the truck.

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Controller Area Network (CAN)

The truck utilizes CAN Open protocol technology to communicate across its own
network. Devices on the truck communicate integrally using a twisted pair of
wires. Digital signals are sent over the bus. As the digital signal is sent,
information in the data bit identifies which node needs to respond to the
transmission. If there is no acknowledgement of the transmission being
received, the system will generate an error and communicate the error to the
dash display. There are two 120 ohm resistors in the CANbus circuit to reduce
open circuit signal reflection noise. All trucks will have one termination resistor
located inside the dash display. The second termination resistor location will be
dependent on the truck model. The Americas reach termination resistor is
located in the Remote CAN Module located on the front end equipment (reach
mechanism) of the truck. Since the Retail reach does not use a remote CAN
module, it will be configured with an external termination resistor connected to
the truck’s main wiring harness in connector CRP25 on a truck configured with a
side stance handle, or CRP25A on a truck with the Fore/Aft handle.

CAN Devices
There are a number of CAN devices or nodes on the truck based on how the
truck is equipped from the factory. Each CAN node will have a number that
identifies the node. These numbers will be consistent across Class II and III
products that use the Common Control System (CCS) architecture.

All Class II Narrow Aisle Reach trucks will have the following CAN nodes as
standard equipment:

Node ID Component
10 Dash Display
30 Traction Controller
40 Steering Controller
50 Hydraulic Controller
51 Auxiliary Motor
60 Forward Stance / Side Stance Handle
90 CAN I/O
91 Remote CAN Module (Americas Reach)

Optional CAN devices include:

41 Steered Caster Controller
80 Impact Sensor

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Display
All trucks will use a common display. The face of the display will change as
shown in the images. The display will
function similar to
the current display
used on the 3-wheel
stand and OS/OP
products. There are
no longer standard
and premium display offerings on this truck
series. There will still be a freezer or non-freezer display
used, dependent upon truck construction. All displays on the reach trucks will be
24V specific and receive their supply voltage from the IFB. There are two
different display configurations based on the truck. The Fore/Aft stance truck
display is similar to the display currently used on the 3-wheel stand and OS/OP
series. The side stance display has a unique shape, but the functionality and
internal parts are the same. The display receives battery voltage from fuse 12 of
the IFB when the key is turned to the ON position.

Controllers Traction Motor Controller Hydraulic Motor Controller

The traction, hydraulic and

Heat Sink
steering controllers convert
DC power to three-phase
AC power at the frequencies and
currents necessary to drive
their respective motors.
The controllers receive a
pre-charge voltage from the
IFB to charge the
capacitors prior to the
main contactor tips closing. The AC induction motors provide feedback to the
appropriate controller indicating speed, direction of rotation and temperature.
The controllers have the ability to communicate problems through the CAN to the
dash display. The traction and hydraulic controllers mount to a finned heat sink
in the upper compartment. If the temperature of the controller reaches 40°C
(104°F), both fans will energize. The drive compartment also incorporates a
thermal management system that energizes both cooling fans when the
temperature of the traction motor reaches 90°C (194°F). Once the temperature
lowers by 5°, the fans will de-energize.

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Traction Controller
The traction controller used on this model is a ZAPI ACE2 voltage invertor rated
at 400 amps for the 24 volt controller and 350 amps for the 36 volt controller on
the Retail reach. On the Americas reach, there is a 350
amp 36 volt controller or a 400 amp high-performance or
EE rated controller. The controller consists of the
electronic components that make up the circuits, and a
solid heat sink mounting plate. The controller converts
DC battery voltage to AC voltage for the traction motor.
There is a feedback circuit from the motor indicating
motor speed and direction as well as motor temperature.
The controller is thermally protected. If the controller
temperature exceeds 75°C (167°F), the maximum current
of the controller is reduced in proportion to the thermal
increase. When the temperature reaches 100°C (212°F)
the controller shuts down. The controller prevents the main contactor from
closing if the power or logic circuits are not functioning properly, if the accelerator
circuit is out of range or if any of the designated inputs do not occur in the right
sequence. The controller is connected to the main truck wire harness via
CPS11, a 23 pin Ampseal connector and has a sealing rating of Ingress
Protection rating of 65 (IP65).

Hydraulic Controller
The standard hydraulic controller used on this model is a ZAPI ACE2 voltage
invertor. There is also a high performance
hydraulic controller available for the Americas large
chassis truck that uses a ZAPI ACE3 voltage
invertor. The amperage rating is dependent on the
truck configuration. The 36 volt standard, high-
performance and EE controller on the small chassis
Americas reach is rated at 400 amps, while the 24
volt Retail reach controller is rated at 450 amps.
The controllers on the 36 volt Americas large
chassis truck are rated at 550 amps for the
standard controller, 675 amps for the high-
performance controller and 400 amps for EE
controller.
The controller converts DC battery voltage to AC voltage to run the hydraulic
pump motor. There is a feedback circuit from the hydraulic motor indicating
motor speed as well as motor temperature. The controller is thermally protected.
If the controller temperature exceeds 75°C (167°F) the maximum current of the
controller is reduced in proportion to the thermal increase. When the
temperature reaches 100°C (212°F) the controller shuts down. The controller
communicates via the CAN. The controller is connected to the main wire
harness via CPS12, a 23 pin Ampseal connector and has a sealing rating of
IP65.

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Steering Controller
The steering controller used on this model is a ZAPI EPS AC-0
Steer Motor voltage invertor rated at 70 amps. The controller consists of the
Controller
electronic components that make up the circuits, and a solid heat
sink mounting plate. The controller converts DC battery voltage to
AC voltage for the steering motor. There is a feedback circuit from
the steering motor indicating motor speed and direction as well as
motor temperature. The maximum current limit for the steering
controller is 40 amps.

The controller is thermally protected. The controller will operate

properly in ambient temperatures from -30°C (-22°F) to 40°C
(104°F). If the internal controller temperature exceeds 75°C (167°F)
the controller shuts down. The controller communicates via the
CAN. The controller is connected to the truck via one 23 pin
Ampseal connector, CPS59 and has a sealing rating of IP54.

Steered Caster

Steer Caster Motor Controller

The steered caster controller is also a ZAPI EPS AC-0 voltage invertor
rated at 70 amps. The controller is identical to the steering controller.
There is a negative input to pin A11 to identify the controller as the
steered caster controller. The controller communicates via the CAN.
The controller is connected to the truck via one 23 pin Ampseal
connector, CPS82 and has a sealing rating of IP54.

Auxiliary Pump and Motor

The auxiliary pump and motor is only on the Americas
reach. It is supplied battery volts once the main
contactor tips close. The motor is used to supply
hydraulic oil to the auxiliary functions. When an
auxiliary function is requested, a CAN signal is sent to
the motor to activate it.

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Side Stance – Forward Stance Handle

The main operator control interface is either a Side
Stance or Forward Stance
multifunction control handle. Both
handles are CAN devices, supplied
24 volts from the IFB. The side
stance handle also incorporates an
optional heater. When the operator
selects a function, the handle sends a digital signal to the
appropriate device to run the function being requested.

Aft Handle
The optional aft handle is not a CAN device.
The aft handle is supplied 24 volts from the
IFB when the ignition circuit is energized. The
aft handle incorporates a sensor that senses
the operators hand when facing the aft
position with their left hand on the handle.
The aft handle supplies an analog input to the
traction controller to enable handle function
once the operator has pressed the horn
button on the underside of the handle. The
paddle switch in the handle is used to activate
travel. It supplies a .5 -4.5 volt analog input to
pin A3 of the traction controller. In the neutral
position, pin A3 is supplied 2.5 volts. As the
paddle switch is moved in the fork direction, the voltage increases. As the
paddle switch is moved in the opposite direction, the voltage decreases. The
paddle switch requires periodic calibration.

CAN I/O
The CAN I/O, input/output module, is a micro-
processor driven device that is able to read a
variety of digital and analog inputs and
broadcast them over the CANbus network.
It replaces the former master controller and
acts as the master controller on this series.
The CAN I/O receives battery voltage once the ignition switch is moved to the on
position. The primary function of the CAN I/O is to receive analog and digital
input signals and convert those signals to analog and digital output signals the
truck needs to function. It has the ability to broadcast over the CAN network
reducing the wiring required in the wire harness. The CAN I/O on this truck
series uses one 35 pin Ampseal connector, CPS31 and has a sealing rating of
IP65.

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Remote CAN Module

The Remote CAN module is only found on the Americas
reach. The Remote CAN module is supplied 24 volts from the
IFB when the ignition circuit is energized. It supplies the
negative to the tilt, sideshift, extend/retract and auxiliary coils
located on the pantograph. It also receives input signals from
the reach position sensor and the height proximity switch.
The remote CAN module houses one of the termination
resistors.

Option Module
The option module is not a CAN device. The option module is supplied 24 volts
from the IFB when the ignition circuit is energized. It supplies 24 volts to the
video monitor and 5 volts to the tilt sensor and laser circuits.

Electrical Schematics
The Training Department has created electrical training schematics for this truck
that can be found on MaterialsHandlingCentral.com. The number of the
schematics is STL-1910. The training schematics are designed to be used in
conjunction with the STL-1909 Sequence of Operation flowchart.

Sequence of Operation
The Sequence of Operation flowchart should be used to help understand the flow
of electrical circuits on this truck series. Following the flow will aid in diagnosing
problems with the truck and troubleshooting circuits.

Battery Connected
When the battery is initially connected, the battery positive cable is connected to
one side of the line contactor. The Integrated Fuse Board (IFB) is supplied
battery voltage through wire 1 and the heater relay (if equipped) is supplied
battery voltage through 20 amp fuse 1. Battery negative is supplied to all the
negative circuits connected to the negative battery cable as well as circuits
utilizing wire 13. There is a Positive Temperature Coefficient thermistor (PTC) in
the circuit that pre-charges the capacitors in the controllers once the battery is
connected. If the controllers fail to pre-charge, a fault will occur and the truck will
not operate.

Integrated Fuse Board

Once the IFB board receives battery positive signal, it supplies battery volts to
the E-stop through fuse 10. If the E-stop button is in the run position, battery
positive is supplied to the ignition circuit (Key switch) and the RF Terminal.

NMHG 8
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Ignition Circuit
When the key switch is moved to the run position, battery positive is supplied to
pin 7 of the IFB.

IFB Outputs
At this time the IFB output voltages are sent out. The IFB is capable of sending
out three different voltages depending on the truck configuration.

Battery Voltage
The battery voltage at pin 1 of the IFB supplies battery positive to the traction,
hydraulic and steering controllers. Battery positive is also supplied to the CAN
I/O module, the steering tiller handle, the hydraulic coils on the Retail reach, as
well as to the back-up alarm and strobe light. The traction controller, in turn,
supplies battery voltage to the line contactor coil and the brake coil via pin A17.

24 Volt Circuits
The IFB supplies the 24 volt circuits via pins 4, 5 and 9. Pin 4 supplies 24 volts
to the dash display, aft handle, impact monitor, mast sensor, steer centering
proximity sensor(s), strobe light relay, CAN I/O module, horn, fans, height
encoder, height proximity switch, hydraulic coils, remote CAN module, options
module, and heater thermostat. Pin 5 supplies 24 volts to the side stance or
fore/aft handle. Pin 9 supplies the optional side stance handle heater with 24
volts.

12 Volt Circuits
The IFB supplies the 12 volt circuits via pin 3. Twelve volts is supplied to the 12
volt accessory plug and optional monitor. The 12 volt circuit is also used as the
supply voltage for the lighting package. Once the traction and hydraulic
controllers receive their supply input from the IFB, the traction and hydraulic
controllers also supply 12 volts to their respective encoder bearing via pin A8.

5 Volt Circuits
There are 5 volt circuits supplied by the steering controllers and the option
module. The steering controller supplies 5 volts to the steering tiller handle and
the motor encoder bearing through pin A2. The steered caster controller
supplies 5 volts to the caster motor encoder bearing through pin A2. The option
module has two 5 volt outputs, one on pin B1 for the laser option and one on pin
C1 for the tilt sensor.

Logic Test
Once the IFB supplies the controllers, they perform a logic test to ensure all
controllers are functioning properly. If the logic test is passed, the traction
controller will supply a pulse width modulated negative on pin A16 of the traction
controller to the main contactor coil to close the main contact tips.

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Line Contactor
Once the line contactor tips close, the power circuits of the traction, hydraulic and
steering controllers are supplied battery voltage. Additionally, the auxiliary motor
power circuit is energized.

Operator Presence
When the operator presence switch is depressed, battery negative is supplied to
the traction controller on pin A6. At this time, the dash display should indicate
the truck is ready to operate.

Brake Switch
When the operator depresses the brake switch, battery positive is supplied to the
traction controller on pin A10. The brake coil does not release at this time but
waits for a traction request.

Travel Request
When the operator requests a function, a digital signal is sent through the CAN to
the appropriate controller(s). If the operator has requested a traction function,
the brake is released and the traction motor is pulsed via the controller.

Brake Released
The traction controller sends a pulse width modulated negative to the brake coil
to release the brake. Once the brake is released, the voltage to hold the brake in
the released position is reduced. The brake remains released as long as a
traction function is activated. When a function is no longer requested, the
traction controller will remove the negative to the brake coil once the traction
motor speed has been reduced to the appropriate RPM. At this time, the brake
will reapply and hold the truck in the stopped position until another traction
request is received.

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Hydraulic Request
When the operator requests a hydraulic function, a digital signal is sent through
the CAN to the appropriate device including the CAN I/O. Depending on the
function selected, either the hydraulic controller for lift/ lower or the auxiliary
pump motor is energized. Additionally, if an attachment function is selected, the
CAN I/O sends the appropriate output signal to energize the selected coil on the
Retail reach, or the CAN I/O sends a digital signal to the Remote CAN Module on
the Americas reach to energize the appropriate negative signal to the selected
attachment function.

Steering Request
When the operator requests steering, an analog signal is sent from the Steer unit
to the main steering controller in the form of a sine wave. The main steer
controller pulses the main steer motor. If the truck is equipped with a steered
caster, a digital signal is sent from the main steering controller to the steered
caster controller requesting caster movement. The encoder bearing on both the
steer motor and steered caster report wheel position to their respective
controllers.

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 Electrical

NMHG 12
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Module Summary
This module covered the function and operation of the Electrical System used on
Narrow Aisle Trucks equipped with Hyster i3 Technology™ or Yale iSi
Technology™.

Learning Objectives
You should now be able to:

 Describe the function and operation of electrical system components.

 Identify the location of the components used and their relationship to other
components in the system.

 Understand the sequence of electrical flow in the system.

Skill Objectives
You should now be able to:

 Locate components of the electrical system.

 Perform voltage readings to identify faults pertaining to the electrical

system.

13 Technical Training
NMHG • 1400 Sullivan Drive • Greenville, NC • 27834 (12/14)