Professional Documents
Culture Documents
INDICATORS AND
SENDERS
H14.00-18.00XM-12 (H360-450H, EC5-6) [A214];
S6.00-7.00XL (S135-155XL, S155XLS) [B024, C024];
E3.50-5.50XL (E70-120XL) [C098];
S3.50-5.50XL (S70-120XL) [D004];
H13.00-16.00XL (H300-360, H330-360XL-EC) [D019];
H36.00-H48.00E (H800-1050E) [D117];
H8.00-12.00XL (H165-280XL) [E007];
H20.00-H32.00F (H440-700F, FS) [E008];
H6.00-7.00XL (H135-155XL) [F006, G006];
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
Keep the unit clean and the working area clean and orderly.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
Be sure to follow the WARNING and CAUTION notes in the instructions.
Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Table of Contents
TABLE OF CONTENTS
General ...............................................................................................................................................................
Description .........................................................................................................................................................
Steering Column Gauges, Meters, and Indicators.......................................................................................
LED Display Panel ........................................................................................................................................
Battery Discharge Indicators....................................................................................................................
Brush Wear Indicators ..............................................................................................................................
Motor Temperature Indicators .................................................................................................................
LX Series Display Panel................................................................................................................................
Hourmeter Functions ................................................................................................................................
Battery Indicator Function .......................................................................................................................
Status Code Function................................................................................................................................
ZX Series Display Panels ..............................................................................................................................
Display Panel.............................................................................................................................................
Basic Display Panels .................................................................................................................................
Performance Display .................................................................................................................................
Brush Wear Indicators ..............................................................................................................................
Adjustments - General.......................................................................................................................................
Replacement - General Information .................................................................................................................
Meter Replacement ............................................................................................................................................
Sender Replacement ..........................................................................................................................................
Fuel Level Sender ..........................................................................................................................................
Pressure and Temperature Sender ...............................................................................................................
ITW Display Panel Replacement ......................................................................................................................
Remove ...........................................................................................................................................................
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement ..........................................
Remove ...........................................................................................................................................................
Display Panel Assembly, Replace .................................................................................................................
Indicator LEDs ..............................................................................................................................................
Battery Indicators..........................................................................................................................................
Digital Display (Performance Display Panel Only) .....................................................................................
Status Code or Performance Level Switches and Indicator LEDs (Performance Display Panel
Only) ...............................................................................................................................................................
Basic Display Panel, Replace Parts ..............................................................................................................
Performance Display Panel, Replace Parts..................................................................................................
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replacement ................................................
Remove and Replace......................................................................................................................................
Specifications......................................................................................................................................................
Meter Specifications ......................................................................................................................................
Sender Specifications ....................................................................................................................................
Troubleshooting..................................................................................................................................................
1
2
2
2
2
9
9
11
11
12
13
13
13
13
16
19
20
20
21
22
22
22
23
23
24
24
24
25
25
25
25
25
27
28
28
28
28
29
29
Table of Contents
ii
General
General
NOTE: Battery indicator meters, used on electric lift
trucks, are described in the SRM section Battery Indicators 2260 SRM 138.
The gauges and meters provide information to the operator on the condition of various systems. Gauges
may be either direct reading (mechanical) or indirect (electrical). Unlike mechanical gauges, electrical gauges have electrical meter-movements, light
emitting diode (LED) or digital displays inside the
case. These meters, receive an electrical signal from
a sender unit, usually in the engine or transmission
case. The indicators of electric lift trucks receive an
electrical signal from a sensor (motor temperature)
or a control board. This section only describes the
electrical "gauges", meters, senders and instrument
1.
2.
3.
4.
5.
6.
ENGINE
TRANSMISSION
GENERATOR OR AMMETER
CURRENT
OIL
WATER
7.
8.
9.
10.
11.
12.
TEMPERATURE
PRESSURE
HOURS
FUEL
FUEL LEVEL - FULL
FUEL LEVEL - 1/2
Description
Description
Many meters have meter-movements that move an
indicating needle attached to a shaft (or pin). The
shaft rotates to swing the needle when current flows
through the movement. The movement operates on
the same principle (electromagnetic) that rotates
a motor shaft. However, shaft rotation of a meter
is limited to much less than even one full revolution. The amount of rotation or deflection of the
needle is directly related to the amount of current
flow through the meter-movement. Meter faces (or
scales) are calibrated to indicate a range of values
that are converted from a directly proportional current flow through the sender. See Figure 1 and
Figure 2 for some typical examples of meter faces
with various calibrations.
Meters such as ammeters, voltmeters and some
hourmeters, are able to convert this proportional
current within the meter case. Many other meters
and displays require a separate sender. See Figure 2.
Senders convert a specific pressure, temperature or
fluid level into a current flow that is directly related
to a given voltage (electrical system voltage) applied.
See Figure 3.
Description
Description
NOTE: METER FACE NUMBERS, INCREMENTS, AND COLORED BANDS CAN BE DIFFERENT THAN SHOWN.
1. HOURMETER (ENGINE POWERED OR
ELECTRIC LIFT TRUCKS)
2. AMMETER
3. COLORED BANDS
4. VOLTMETER
5. ENGINE COOLANT TEMPERATURE
6.
7.
8.
9.
10.
Description
Figure 4. Typical Meters on Steering Column Assembly for Lift Trucks With Engines
Description
A.
B.
C.
D.
1.
2.
3.
4.
HOURMETER
ENGINE COOLANT TEMPERATURE GAUGE
4-PIN CONNECTOR
FUEL LEVEL GAUGE
5. INDICATOR LIGHTS
6. 8-PIN CONNECTOR
7. COVER WITH LOGO
Description
Figure 5. Steering Column Meters for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)
Description
1. INSTRUMENT CLUSTER
2. HOURMETER
3. ENGINE COOLANT TEMPERATURE GAUGE
1.
2.
3.
4.
5.
6.
7.
8.
ALTERNATOR INDICATOR
ENGINE OIL PRESSURE
FUEL LEVEL
HOUR METER
Figure 6. Meter Face Symbols for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)
Description
WARNING
A. TO DISPLAY PANEL
1.
2.
3.
4.
5.
6.
7.
8.
13.
71.
72.
74.
75.
76.
77.
78.
79.
Description
2. JUMPER
3. BATTERY
10
Description
Legend for Figure 9
1. DISPLAY UNIT
2. FOUR DIGIT DISPLAY
3. FUNCTION INDICATOR, STATUS CODE (GREEN
LED)
4. FUNCTION INDICATOR, BATTERY (GREEN LED)
5. FUNCTION INDICATOR, HOURMETER (GREEN
LED)
6. MOUNT FOR DISPLAY UNIT
7. INSTRUMENT PANEL
WARNING
Lift truck movement can cause an injury or
damage. Raise the drive wheels from the floor
to prevent lift truck movement. Use the correct procedure in the Operating Manual or the
section Periodic Maintenance of the Service
Manual to raise the drive wheels.
The operation of the motor temperature indicators
can be checked during periodic maintenance. The
battery must be removed from the lift truck for access
to the motors. See Figure 8.
Use a jumper cable so that the battery can be connected and still have motor access. Disconnect the
sensor wires from the outside of the motor case.
Touch the ends of the sensor wires together. The
LED indicator will illuminate if the circuit is operating correctly. The thermal switch can be replaced
if it has a malfunction. However, the motor must be
disassembled to replace the thermal switch.
The early unit has a four digit display and three LED
function indicators. The indicators show which function value is displayed by the digits. Not all functions are available on all lift truck models. Following is a list of the functions: Battery Indicator, Status Codes, Traction Hourmeter and Pump Hourmeter. Later units have the same digital display and
the same function indicators with the additional motor brush wear indicator and temperature alarm indicator LEDs.
The following paragraphs describe how the circuit for
each function operates. The display panel must be
replaced as a complete unit. The sensors for brush
wear and motor temperature can be replaced as separate parts.
The digits show the operating hours when the
hourmeter function indicator is ON. When the battery indicator is ON, the digits show the charge
condition of the battery. See Figure 9 and Figure 10.
The status code indicator is ON when the digits show
the status code number. The brush wear or temperature alarm indicators of the later units will be ON if
the traction or pump motor brushes are too worn or
the motor is too hot. Refer to the descriptions Brush
Wear Indicators and Motor Temperature Indicators
for a complete description of the operation of these
indicators.
Hourmeter Functions
The hourmeter function on the instrument panel
display is controlled by the EV-100/200 "LX" series
control card. There can be a display for the operating time of the traction circuit. On some units,
there can also be a display for the operating time
of the pump circuit. Only those units that have the
EV-100LXP pump control card can have the optional
pump hourmeter function.
11
Description
Wire No.
1
2
3
4
5
6
7
8
9
95
96
93
94
98
99
13
10
Connection/Function
Traction Motor Temperature
Pump Motor Temperature
Traction Motor Brush (A) Wear
Traction Motor Brush (B) Wear
Pump Motor Brush (A) Wear
Pump Motor Brush (B) Wear
Not Used
Battery Negative
Battery Positive from Key Switch
1. DISPLAY UNIT
2. BRUSH WEAR INDICATOR, HYDRAULIC
MOTOR (YELLOW LED)
3. TEMPERATURE ALARM, HYDRAULIC MOTOR
(RED LED)
4. TEMPERATURE ALARM (RED LED)
(ILLUMINATES WITH 3 OR 5)
5. TEMPERATURE ALARM, TRACTION MOTOR
(RED LED)
6. BRUSH WEAR INDICATOR, TRACTION MOTOR
(YELLOW LED)
12
Description
on the display. Every third display will show the
battery charge instead of the status code.
NOTE: See the section EV-100/200 LX Series Diagnostic Motor Controller and Handset 2200 SRM
460 for a description of the different status code displays.
13
Description
Function
No Connection
Battery Negative ( )
Parking Brake Switch
Brake Fluid Switch
Hyd. Contactor Coil
Seat Switch
Key Switch (IGN)
Battery Positive (+) (from Fuse 6)
HOURMETER
BATTERY METER
PARKING BRAKE INDICATOR
BRAKE FLUID TOO LOW INDICATOR
SEAT BELT INDICATOR
6.
7.
8.
9.
Figure 11. Basic (Early) Display Panel for EV-100/200ZX Motor Controllers
Figure 12. Basic (Later) Display Panel for EV-100/200ZX Motor Controllers
14
Description
Legend for Figure 12
(1) Battery Charge Indicator With Lift Interrupt. Later Basic display panels have a battery
indicator that is a scale with a series of 5 round
LEDs in three colors (green, orange, red). See Figure 12. There are two green LEDs and bars at the
top, two orange LEDs and bars in the center and
a red LED and bar at the bottom. As the battery
voltage decreases during operation, different LEDs
illuminate to indicate a discharged battery. No more
than two LEDs are illuminated at one time. When
the battery is fully charged, the two green LEDs
of the scale are illuminated. When the battery discharges during operation, the LEDs illuminate from
top to bottom (green to red). The red LED indicates
that the battery is discharged. The battery must
be charged or a charged battery must be installed
before lift truck operation can continue.
15
Description
(3) Warning light, fasten seat belt. The red light
is ON for eight to ten seconds after the key is turned
to the ON position.
(4) Digital Display. This indicator is blank when
the lift truck is operating correctly. The status codes
and the hourmeter values are shown on this fourdigit LCD display. When a fault occurs, the status
code will be shown with a dash ( ) in the left digit
position. The warning light, Service Interval (11) will
also be illuminated when a fault occurs.
When it is time for periodic maintenance, the warning light, Service Interval (11) will be illuminated
and a status code -99 will be indicated. The register in the controller card must be reset by the service
person before this warning light will go OFF.
The hourmeter display shows the operating time of
0000 to 9999 hours. The time for the traction circuit
is shown for four seconds after the lift truck has been
operating and the key is turned to the OFF position.
The indicator lights for the traction motor (8) and for
the hourmeter (12) will also be illuminated during
this time. If there is an SCR control card for the hydraulic pump motor, this time will then be shown on
the hourmeter for another four seconds. The indicator lights for the hydraulic motor (9) and for the
hourmeter (12) will also be illuminated during this
time.
Performance Display
When the key is turned to the ON position, a start
program will cause each warning and indicator light
to illuminate to show that the function is operating.
The functions and operation of the indicators for
these early and later display panels is the same. See
Figure 13 and Figure 14. These display panels have
the following functions:
(1) Battery Charge Indicator With Lift Interrupt. This battery charge indicator shows the
battery charge with an LED bar graph. There are
four green bars, four orange bars, and two red bars.
When the battery is discharged during operation, the
LED bar that is illuminated decreases sequentially
from the top green bar through the orange bars to
the red bars. When the battery is discharged to the
red LED bars, the battery is 73% discharged and the
lift interrupt function will not permit operation of
the hydraulic motor. The battery must be charged
16
Description
Function
Traction Card PY 5
Pump Card PY 5
No Connection
Traction Card PY 14
Traction Card PY 13
Pump Card PY 14
Pump Card PY 13
No Connection
Traction Card PY 4
Pump Card PY 4
Brush Wear Indicator & Temperature Jumper*
*
Parking Brake Switch
Brake Fluid Switch
No Connection
No Connection
Key Switch (IGN)
No Connection
*Pin 11 to 12 Jumper (In Wire Harness). BWI and Temperature LEDs Disabled if Cut.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Figure 13. Early Performance Display Panels for EV-100/200ZX Motor Controllers
17
Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Figure 14. Later Performance Display Panels for EV-100/200ZX Motor Controllers
(3) Warning Light, Fasten Seat Belt. The red light
is ON for eight to ten seconds after the key is turned
to the ON position.
(4) Warning Light, Brake Fluid Reservoir Is
Low (Early Only). The red light is ON for one second when the key is turned to the START position
and must go OFF when the key is in the ON position.
If the warning light is ON when the key is in the ON
position, the brake fluid level in the reservoir is too
low.
(5) Warning Light, Parking Brake Indicator.
The red light is ON when the parking brake is applied and the seat switch is closed, and goes OFF
when the parking brake is released.
18
Description
will not be shown. A Handset or a PC must be used
to show this additional information. A Handset or
a PC must be used to clear the status code from the
register.
If the button is pushed twice and then held down,
the indicator light for the hydraulic pump motor (9)
will illuminate. The status codes in memory for the
detected faults will be displayed, starting with the
most recent fault. If the push button is released, the
display will stop. If the button is pushed twice to
start the sequence again, the display will start from
the beginning. The hourmeter time and the battery
charge at the time of the fault will not be shown. A
Handset or a PC must be used to show this additional
information. A Handset or a PC must be used to clear
the status code from the register.
There can be 16 status codes in the memory for each
system (traction or lift). Push and hold the push button to display all the status codes in the memory for
detected faults of the traction system. The Traction
Motor Indicator will be ON to show that the status
codes are for the traction system. If the push button
is released then pushed and held again, the digital
display will start over showing all the status codes
for the traction system. Push the button twice and
hold the push button to display all the status codes
in the memory for detected faults of the lift system.
The Lift Pump Motor Indicator will be ON to show
that the status codes are for the lift system. If the
push button is released then pushed twice and held
again, the digital display will start over showing all
the status codes for the lift system.
19
Adjustments - General
There are no adjustments to perform except for some
battery indicators. Refer to Battery Indicators
2260 SRM 138 to adjust the battery indicators. Refer to EV-100/200 LX Series Diagnostic Motor
NOTE: None of the electrical components of this section can be repaired. All bad components must be
replaced.
3. Check that the wiring and connections to the meter, indicator or sender are tight and in good condition.
WARNING
20
Meter Replacement
Meter Replacement
Meters are usually mounted to an instrument panel.
See Figure 15. Access to the back of the panel or
mounting surface is required for meter replacement.
Replace a meter as follows:
1. Make sure the key is in the OFF position.
WARNING
CAUTION
2. Put tags on the meter wires for correct identification during installation. Remove the wires from
the meter terminals.
6. Connect the wires to the meter electrical terminals. Tighten the nuts if the nuts are required
for correct connection.
1.
2.
3.
4.
HOURMETER
AMMETER (FARIA)
OIL TEMPERATURE (DATCON)
(A.C.) METERS
5.
6.
7.
8.
AMMETER
VOLTMETER
TEMPERATURE
OIL PRESSURE AND FUEL LEVEL
21
Sender Replacement
Sender Replacement
FUEL LEVEL SENDER
WARNING
WARNING
All fuel vapors are extremely explosive. Do not
allow sparks or flames around vehicles or fuel
storage and service areas. Make sure there is
no source of open flame or sparks in the vicinity. Use caution to prevent sparks from tools.
The fuel level sending unit is mounted to the fuel
tank surface (usually top surface) with screws
through the sender plate and gasket. See Figure 16.
Correct sender operation and screw hole alignment
can only be obtained with the plate mounted in one
position. Replace the sender as follows:
Electrical shock from voltage can cause personal injury. Put electrical tape on the wire
connector to electrically insulate the connector if the wire is accidentally energized.
CAUTION
Fuel level senders are not accurate if the arm
is bent during removal and installation. There
must also be clearance for operation. Do not
bend the float arm.
3. Remove screws that fasten sender plate to fuel
tank. Remove sender.
4. Carefully install new sender with new gasket.
5. Make sure screw holes are aligned and install
screws. Tighten screws enough to partially compress gasket to prevent leaks.
6. Remove tape from wire connector. Install connector on sender terminal.
B. EMPTY POSITION
1. ELECTRICAL
TERMINAL
2. PLATE
3. SENDER UNIT
4. FLOAT ARM
5. FLOAT
22
1.
2.
3.
4.
5.
ELECTRICAL TERMINAL
HEX
THREADED BODY
SENSOR ELEMENT
CASE OF ENGINE OR TRANSMISSION
1.
2.
3.
4.
5.
6.
ELECTRICAL TERMINAL
SENDER
HEX
THREADED FITTING
HOLE-TO-SENSOR ELEMENT
CASE OF ENGINE OR TRANSMISSION
Figure 18. Fluid Pressure Sender
WARNING
Disconnect the battery and separate the connector before opening the compartment cover
or inspecting or repairing the electrical system. If a tool causes a short circuit, the high
current flow from the battery can cause an
injury or parts damage.
23
DIP switch for the correct voltage to the up position and all others to the down position. Install
the column cover on the steering column.
24
NOTE: ON = UP AS SHOWN.
36V SW#1 ON, OTHERS OFF.
48V SW#2 ON, OTHERS OFF.
NOTE: SET DIP SWITCHES TO TRUCK VOLTAGE. IF
TRUCK VOLTAGE IS NOT KNOWN, SET 36/48V (U.S.)
TRUCKS TO 48V.
1. DISPLAY PANEL
2. STEERING
COLUMN
3. ELECTRICAL
CONNECTOR
4. DIP SWITCHES
5. BROWN
6. RED/BROWN
INDICATOR LEDS
NOTE: The parts of the Basic Display Panel can be replaced with the display panel on the steering column.
If the assembly housing will be replaced, remove the
complete assembly from the steering column as described in Display Panel Assembly, Replace.
BATTERY INDICATORS
There are two types of battery indicators for these
trucks. One type is a meter movement with colored
bands showing the battery charge (Basic display
panel). The other type is a Light Emitting Diode
(LED) display with LEDs of different colors showing
battery charge (Performance display panel).
NOTE: The battery indicator is replaced as one of the
components of the display panel. See procedure under Basic Display Panel, Replace Parts of this section. The battery indicator of the Performance display panel cannot be replaced as a separate component. The indicator must be replaced as part of the
Performance display panel. See Display Panel Assembly, Replace of this section.
See the section Battery Indicators 2260 SRM 138
to adjust these battery indicators.
NOTE: The following is a complete disassembly procedure. Do ONLY those steps necessary to replace
the part you want replaced.
Remove and replace the components of the Basic display panel as follows:
1. Disconnect the battery and remove the key.
2. Remove the eight screws that fasten the top cover
to the panel housing. The screws are at the bottom of the housing. See Figure 20. The hourmeter is fastened to the top cover with the electrical
connector on the circuit board inside the housing.
Carefully lift the top cover up off the housing and
the indicator LEDs without damaging the O-ring
gasket. The gasket for the LED indicators can
stick to the LED housing as the top cover is removed. Do not lose or damage the gasket. Disconnect the three wire connector for the hourmeter.
3. If the housing or filter for the indicators will be
replaced, remove the screws that fasten the LED
housing to the cover. If the hourmeter or hourmeter gasket will be replaced, remove the screws
that fasten it to the top cover. Install the replacement parts to the top cover. Make sure that the
hourmeter is installed so that it can be read after
the cover is installed.
4. Remove the nut that fastens the key switch. Remove the key switch from the housing. Make a
note of which wires are on which terminals and
disconnect the wires. Install the wires on the
same terminals of the replacement switch.
5. Align the notch in the shaft housing of the key
switch with the tab in the housing of the display
panel. Install the replacement switch. Tighten
the nut and connect the wires.
25
26
1.
2.
3.
4.
5.
6.
7.
8.
TOP COVER
FILTER FOR LED INDICATORS
HOUSING FOR LED INDICATORS
KEY SWITCH
ASSEMBLY HOUSING
O-RING GASKET
BUZZER
FIBER INSULATING WASHERS
27
Specifications
1. DASH PANEL
2. DISPLAY PANEL
3. MOUNT NUTS
4. PLUG
CONNECTOR
Specifications
METER SPECIFICATIONS
Item
Design Data
Operating Voltage
Hourmeter
Engine-Powered Equipment
12V, 24V
12V, 24V
#10-32 UNF or #6-32 UNC
Range of Meter
28
Hourmeter
Ammeter
0 to 60 Amps
Voltmeter
10 to 16 Volts
Troubleshooting
Item
Design Data
Method of Mounting
SENDER SPECIFICATIONS
Item
Design Data
Operating Voltage
All Senders
12-Volt System
#10-32 UNF-2A
1/2-14 Dryseal
Pressure Sender
Fitting Threads
Hole Size
Troubleshooting
PROBLEM
POSSIBLE CAUSE
PROCEDURE OR ACTION
METER
No Indication - All Meters
Battery disconnected.
Clean the battery terminals and battery cable connectors. Install connectors.
29
Troubleshooting
PROBLEM
No Indication - Only One
Meter
POSSIBLE CAUSE
Meter wires damaged or not connected.
Replace the broken wires or connectors. Install connectors on proper meter terminals.
Replace meter.
Sender malfunction.
terminal.
Incorrect Indication
30
PROCEDURE OR ACTION
Voltage is at
Replace sender.
Battery is discharged.
Charge battery.
Replace meter.
Replace sender.
TECHNICAL PUBLICATIONS
2200 SRM 143