02 ELECTRIC SYSTEM

IN-DEALER TRAINING J2.2-3.5XN

HYSTER, and FORTENS are registered trademarks in the European Union and certain other jurisdictions. MONOTROL is a registered
trademark, and DURAMATCH and are trademarks in the United States and in certain other jurisdictions. Copyright © 2013 Hyster Europe. All rights reserved.
INTRODUCTION

2
CONTROLLERS

Vehicle System Manager (VSM) is the heart of the truck

All the settings are in the VSM which controls and monitors all the safety features
Communication between controllers by CANbus (protocol CANOpen).
Termination resistors located inside left traction controller and pump controller
Diagnostic plug on the steering column

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CONTROLLERS

VSM

Two different VSM versions

Manual hydraulics or e-hydraulics
E-hydraulics can be used for both
Two 35 pin connectors, CPS1 and CPS2

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CONTROLLERS

VSM

Located underneath the floor plate

VSM software's can be updated with PC Service Tool.
Two different files can be uploaded to the VSM
Application file = basic software for VSM operation
Configuration Data File (CDF) = truck serial number specific software
Once a CDF file with a specific S/N is uploaded into a VSM, it can never be erased

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CONTROLLERS

VSM Pin out

Please refer to your binder for the VSM pin

out schematic

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CONTROLLERS

D
isplay

Two different Displays available

Standard with an “S” label
‘Freezer’ option with “F” label
14 buttons and one key switch
Displays Icons
8 pins AMP seal connector
12 Volt supply from the VSM
Analog outputs:
Key switch signal
Optional buzzer
Standard Cooler/Freezer
Optional temperature sensor (freezer)
Application Application
All other outputs  CANbus system

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CONTROLLERS

Traction controllers (Left + Right)

One controller per traction motor

Manufacturer is Danaher
23 pin AMP seal connector for inputs and
outputs to the controller
Traction controllers are operated by the VSM
Jumpers for controller identification (left or
right)
Other jumper wire installed for termination
resistor connection
One controller activates cooling fans
One activates park brake release system

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CONTROLLERS

Traction controllers (Left + Right)

High currents = High temperatures

Controller is fitted on a ribbed cooling plate (heat sink)
Air is forced besides the heat sink by electric fans
To prevent components damages, the VSM monitors the temperature and give a warning or
cut off some function when the temperature rises too much

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CONTROLLERS

Pump controller

Manufacturer is Danaher
Controls the AC pump motor
located in the rear of the truck
High power connections
One control connector
All communications to the VSM, via
CANbus
Mounted on a heat sink
Two electric driven cooling fans
Important is to keep the cooling ribs
clean

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CONTROLLERS

Mini Lever Module (MLM)

Optional E-hydraulic feature

Premium VSM required
Located on the armrest
Converts movement in a rotation motion for Hall-Effect sensors
Converts horn button input in a CANbus signal to the VSM
Fwd/Rev switch on the armrest is also connected to the MLM
MLM is not serviceable

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FUSES AND RELAYS

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FUSES AND RELAYS

Line contactor

Located in the counterweight

Controlled by the key switch relay
Provides voltage to all major components
Line contactor open = No voltage on traction and pump controllers
A PTC across contactor poles tips provides a small current only to energize controllers logics

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FUSES AND RELAYS

Fuse box

Located in the counterweight

Protected by a plastic cover

Relays

Not all relays are interchangeable

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SENSORS AND SWITCHES

Many different sensors and switches for a

high level of controllability

Majority are Hall-Effect sensors

Hall-Effect sensors output voltage changes

with magnetic field

Magnetic field changes with sensor target

position

Three wires
Power supply (5V)
Battery negative
Output signal

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SENSORS AND SWITCHES

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SENSORS AND SWITCHES

Seat Occupancy sensor

If operator gets seated:

Magnet in the sensor goes closer to the Hall-Effect junction
This causes the Hall Effect junction to send a signal to a transistor in the sensor
This generates an output signal to the VSM
The computer in the VSM then knows to turn off the interlock for seat occupancy

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SENSORS AND SWITCHES

Seat Occupancy sensor

Key ON and seat unoccupied:

The sensor provides a specific voltage output based on the new magnetic field strength
The voltage output tells the VSM that the seat is unoccupied
The VSM then activates the interlock, preventing further truck operation
The VSM activates the seat unoccupied icon on the display

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SENSORS AND SWITCHES

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SENSORS AND SWITCHES

Brake pressure sensor

Provides actual brake pressure information to

the VSM
Pressure comes from the outlet line of the
master brake cylinder
3 wires sensor:
Power supply
Signal ground
Signal voltage back (from 0.5 to 4.5 Volts)
Foot brake pressure is used for brake lights if
installed
Foot brake pressure operates the E-boost
function (braking with traction motor)

A. Signal Batt (-)

B. B – 5V Supply
C. Output

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SENSORS AND SWITCHES

Park brake position sensor

VSM controls the park brake

A sensor tells the VSM what is the current
park brake position
If the VSM applies the park brake and if the
position sensor do not indicates a
movement, then the VSM triggers a fault
message

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SENSORS AND SWITCHES

Park brake system pressure switch

Warns the operator when there is not

enough oil pressure to release the park
brake
Pressure switch is located on the park
brake block manifold

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SENSORS AND SWITCHES

Brake fluid level switch

A digital switch senses the level of the fluid

in the reservoir
The switch is wired directly to the VSM
Low brake fluid levels cause an indication
on the display
There is no control interlock related to this
input

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SENSORS AND SWITCHES

Traction motor temperature sensors

Inside each traction motor housing

2-wire sensor
Provides temperature information to the
traction controller
If the temperature rises above a set value,
the software reacts by reducing the
performance

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SENSORS AND SWITCHES

Traction motor speed sensors

Located on the transmission

Provides a signal to the controller on the
current motor speed
Used to control the motor and the vehicle
speed
Measures speed and rotation direction
4-wire sensor
Very good access to the sensors

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SENSORS AND SWITCHES

Hydraulic motor temperature + speed

Pump motor also has a speed and a temperature

sensor installed
Same function as the traction motors speed and
temperature sensors
Speed sensor measures both speed and
direction
Although the direction is measured, there is no
software in place to react on it (not necessary)

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SENSORS AND SWITCHES

Accelerator pedal sensor

Standard or Monotrol is fitted with an analog rotary

sensor
Dual outputs:
Channel A (1.0 to 4.5 V)
Channel B (0.5 to 2.25 V)
Channel A  primary signal
Channel B  ½ of channel A (normal operation)
Used for diagnostics during operation
Output voltages increases when pedal is pressed
Automatic calibration for 0 to 100% accurate movement
stroke
Traction motor target speed, acceleration, and
deceleration are transmitted via CAN to the traction
controllers

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SENSORS AND SWITCHES

Fwd/Rev Sensor

Two options available:

A direction pedal
A direction switch
Both Monotrol pedal and manual lift lever F/R switch are
equipped with Hall-effect sensors
These sensors provide a signal between 0.5–4.5 Volts to
indicate the selected direction
The direction switch on the armrest with e-hydraulics provides
an input to the MLM module which sends the signal to the
VSM through CANbus

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SENSORS AND SWITCHES

Seat sensor

Located under the seat

Wired directly to the VSM
Detect the absence or presence of an
operator
Used for interlock control of the traction and
hydraulics

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SENSORS AND SWITCHES

Spool position sensors (Manual hydraulic valve)

Hydraulic motor is always proportionally controlled

Speed depends on the position of the hydraulic levers
With e-hydraulics, the signal comes from MLM module
With manual hydraulic valve signal comes from the spool
positions sensors
One Hall Effect position sensor per spool provides an input to
the VSM
The spool position sensors need to be calibrated

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SENSORS AND SWITCHES

Mini levers

These mini levers are different than the previous model or the 1-8 ton series model
The lever itself is a mechanical device
The levers can be serviced separately
A mechanism transfers the movement of the lever into a rotation motion
The sensors themselves are sealed on the MLM module
This helps prevent dirt & dust contamination

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SENSORS AND SWITCHES

Steering wheel position sensor

3-wire Hall-Effect sensor located on the

steering column
Tells the current position of the steering
wheel to the VSM
Used for synchronized steering

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SENSORS AND SWITCHES

Steering axle position sensors

Determine the current position of the steering axle

3-wire Hall-Effect sensor
Signal used to control the right and left traction
motors
During very sharp corner traction motors rotate in
the opposite directions
This is why the position of the steer axle is
important
This sensor needs to be calibrated

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SENSORS AND SWITCHES

Hydraulic filter restriction switch

CDF enabled option

N.O. switch
Gets 12 V from the VSM
If filter pressure reaches a non-adjustable pre-
set pressure threshold, switch closes and
sends a signal to the VSM
If filter is restricted icon is displayed

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SENSORS AND SWITCHES

Hydraulic Oil Level Sensor

Optional 3-wire ultrasonic level sensor

If fluid Level Distance from Sensor = 35 cm
(low)
Output Signal Voltage = 0.5V
If fluid Level Distance from Sensor = 5 cm
(high)
Output Signal Voltage =4.5V

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SENSORS AND SWITCHES

Hydraulic Oil Temperature Sensor

Battery negative voltage

If temperature increases then output signal
voltage decreases

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SENSORS AND SWITCHES

Display Ambient Temperature Sensor

Not directly connected to VSM

Activates a heater inside the display

Required for the optional freezer display

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SENSORS AND SWITCHES

Tilt angle sensor

Mounted on the mast

Senses the position of the mast as a reference
to the frame
Allows easier control to get the mast in a
straight vertical position
While tilting, mast will stop for a moment and
will then continue its movement
This stop indicates the set position
The set position can be calibrated
Optional feature useful in many applications

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SENSORS AND SWITCHES

Impact Sensor

Located on the right hand side of the truck near the

drive tire
It is a CAN device reporting impact events to the VSM
Impacts data are stored in the VSM
Impact Log can be displayed
Data includes
Traction hour meter reading
Date
Type of impact
Password if option is enabled
2 types of impacts (Soft and Hard)
Interpretation of the impacts is adjustable
Impact events can disable the traction (setting)

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SENSORS AND SWITCHES

Load Weight Sensor

Optional feature
Determines the load by sensing the lift
pressure
The sensor provides an input to the VSM
Weight is shown on the display
This sensor needs to be calibrated
Load weight is displayed only when the
mast is not in operation

1. Load weight sensor

2. Tee fitting sensor
3. Mast hose

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SENSORS AND SWITCHES

Key switch

Incorporated in the Display

It is a reed type switch that is activated with
a small permanent magnet
This prevents dirt and dust contamination
This signal is hard wired to the key switch
relay (so not communicated to the VSM by
CANbus

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SENSORS AND SWITCHES

Main disconnect switch

Located on the arm rest

Disconnects the power supply between
battery and
Line contactor coil
Key switch relay
VSM

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SENSORS AND SWITCHES

Horn switches

3 different horn switches locations:

On the steering wheel
On the armrest
On the rear support bracket
The horn switches are one of the few
mechanical switches left on this product

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SENSORS AND SWITCHES

Battery gate magnet switch (side removal)

A switch is indicates if the gate is open or closed

Used as an input for the VSM
The truck cannot be operated gate open
In this case an interlock message is shown

Light switches

Optional feature
The main lights (work lights) are controlled via the
dashboard
Later on it can be done through a separated lights
module connected to the CANbus

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OUTPUTS AND ACTUATORS

Horn

Activated at battery voltage

Button is hard wired to the horn
Horn is not controlled by the VSM
Located underneath the floor plate
3 wires:
Power supply
Ground
Signal wire

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OUTPUTS AND ACTUATORS

Interlock coils on manual valve

For safety regulations, hydraulic system

should not be able to be operated when
seat is unoccupied
Therefore interlock solenoids are installed
on the manual hydraulic valve
These are On/Off valves
They are controlled by the VSM

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OUTPUTS AND ACTUATORS

Traction motors

2 traction motors installed

Refer to chapter “Traction, transmission and
brakes for more details

Pump motor

Pump motor is an AC electric motor

Manufactured by Sauer Danfoss
It is located in the rear of the truck

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OUTPUTS AND ACTUATORS

Cooling Fans

Total 4 cooling fans on the truck

2 are used to cool the traction controllers
2 are used to cool the hydraulic controller

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OUTPUTS AND ACTUATORS

Lights

Optional features
They are hard wired switches and relays
In the future, VSM will control them via an add-on CAN I/O module

Front and Rear Lights (future configuration)

They will be enabled from the Display with supervisor password

They can be configured (via display) to be controlled:
By pressing a display input
By a motion activated
By a speed activated
By a key switch activated
As well as any SPED listed items

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OUTPUTS AND ACTUATORS

Strobe Light

Hard wired into the truck electrical system

Not controlled by the VSM

Brake lights

Controlled by the VSM and the brake

pressure input

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OUTPUTS AND ACTUATORS

Park brake release solenoid

Park brake is automatically released by an

hydraulic actuator controlled by a solenoid

This solenoid is controlled by RHS traction

controller

Without electric power available, the brakes can

be released with a cable

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OUTPUTS AND ACTUATORS

Synchronized steering coil

Optional feature
Means the steering wheel always return in the same position when driving straight
This is controlled by the VSM
Requires the steering wheel position sensor and the steer axle position sensors inputs
Via a solenoid valve the VSM allows
a certain amount of oil to bypass
the orbitrol so the steering wheel
will get back to a certain position

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OUTPUTS AND ACTUATORS

Coils on E-hydraulic valve

E-hydraulic control valve spools are operated with a pilot pressure system
Means that the spool is pushed up or down by hydraulic pressure
The regulation of the pilot pressure, is done by proportional vales
The VSM controls these valves by a PWM signal (pulse width modulation)
For an accurate control these solenoids need to be calibrated

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OUTPUTS AND ACTUATORS

DC/DC converter

In the counterweight compartment

Converts the battery voltage into 12 Volt

output for:
Lights
Backup alarm
Proportional solenoids valves with
E-hydraulics option

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TYPES OF DIAGRAMS

Different diagrams for different purposes:

Block diagram
Schematic diagram
Terminal diagram

The Block Diagrams

Show, at a high level, the relationships

among components of an entire system

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TYPES OF DIAGRAMS

The Schematic Diagram

Used to show the electrical connections,

components, and functions of a circuit

Not accurate in terms of the physical size,

shape, or location of a particular
component

Provides an good overview of system

operations

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TYPES OF DIAGRAMS

The Terminal Diagram

Used for troubleshooting procedure (TSP)

Provides the relevant connections for an electrical problem as indicated by a Diagnostic
Trouble Code (DTC)

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INTERLOCKS

Standard interlock icons

A. Operator out of seat

B. Release accelerator pedal
C. Release hydraulic levers A B C
D. Impact detected
E. Motor temperature over shut down temp.
F. Direction switch applied
G. Key not in Off position
H. Park brake applied
I. Battery not secured D E F

G H I

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INTERLOCKS

Sped Interlocks

3 SPED interlock icons if certain truck

conditions exist or not met
J K L
J. Lift limit Exceeded
K. E-Hydraulic shutdown switch engaged
L. Traction start Disable or Traction Shutdown
switch Engaged

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PERFORMANCE MODES

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PERFORMANCE MODES

Top Speed Limit

Mode Acceleration 1 and 2 Settings
Setting

Mode 4 Adjustable in “Control Settings” Adjustable in “Control Settings”

Mode 3 Same as Mode 4 80% of Mode 4

Mode 2 80% of Mode 4 70% of Mode 4

Mode 1 60% of Mode 4 60% of Mode 4

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02 ELECTRIC SYSTEM
END