2200srm0143-910110(08-2004)-uk-en

INSTRUMENT PANELINDICATORS AND

SENDERSH14.00-18.00XM-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];

PART NO. 910110 2200 SRM 143

SAFETY PRECAUTIONSMAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctlyfastened, and that the load being lifted is balanced. Make sure the crane, cables, andchains 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 repairon 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 PUTTHE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-nance 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 partsmust meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed beforeusing 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 fuelare flammable. Be sure to follow the necessary safety precautions when handling thesefuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparksaway from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in thismanual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!

Instrument Panel Indicators and Senders Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1Description ......................................................................................................................................................... 2

Steering Column Gauges, Meters, and Indicators....................................................................................... 2LED Display Panel ........................................................................................................................................ 2

Battery Discharge Indicators.................................................................................................................... 2Brush Wear Indicators .............................................................................................................................. 9Motor Temperature Indicators ................................................................................................................. 9

LX Series Display Panel................................................................................................................................ 11Hourmeter Functions................................................................................................................................ 11Battery Indicator Function ....................................................................................................................... 12Status Code Function................................................................................................................................ 13

ZX Series Display Panels .............................................................................................................................. 13Display Panel............................................................................................................................................. 13Basic Display Panels ................................................................................................................................. 13Performance Display ................................................................................................................................. 16Brush Wear Indicators .............................................................................................................................. 19

Adjustments - General....................................................................................................................................... 20Replacement - General Information ................................................................................................................. 20Meter Replacement ............................................................................................................................................ 21Sender Replacement .......................................................................................................................................... 22

Fuel Level Sender.......................................................................................................................................... 22Pressure and Temperature Sender ............................................................................................................... 22

ITW Display Panel Replacement ...................................................................................................................... 23Remove ........................................................................................................................................................... 23

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement .......................................... 24Remove ........................................................................................................................................................... 24Display Panel Assembly, Replace ................................................................................................................. 24Indicator LEDs .............................................................................................................................................. 25Battery Indicators.......................................................................................................................................... 25Digital Display (Performance Display Panel Only) ..................................................................................... 25Status Code or Performance Level Switches and Indicator LEDs (Performance Display PanelOnly) ............................................................................................................................................................... 25Basic Display Panel, Replace Parts.............................................................................................................. 25Performance Display Panel, Replace Parts.................................................................................................. 27

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replacement ................................................ 28Remove and Replace...................................................................................................................................... 28

Specifications...................................................................................................................................................... 28Meter Specifications ...................................................................................................................................... 28Sender Specifications .................................................................................................................................... 29

Troubleshooting.................................................................................................................................................. 29

2004 HYSTER COMPANY i

Table of Contents Instrument Panel Indicators and Senders

TABLE OF CONTENTS (Continued)

This section is for the following models:

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];

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2200 SRM 143 General

GeneralNOTE: Battery indicator meters, used on electric lifttrucks, are described in the SRM section Battery In-dicators 2260 SRM 138.

The gauges and meters provide information to the op-erator on the condition of various systems. Gaugesmay be either direct reading (mechanical) or indi-rect (electrical). Unlike mechanical gauges, electri-cal gauges have electrical meter-movements, lightemitting diode (LED) or digital displays inside thecase. These meters, receive an electrical signal froma sender unit, usually in the engine or transmissioncase. The indicators of electric lift trucks receive anelectrical signal from a sensor (motor temperature)or a control board. This section only describes theelectrical "gauges", meters, senders and instrument

panel displays. "Gauges" will be referred to as me-ters.

The meters and displays are used to provide oper-ator information on the status of many systems in-cluding: (1) engine coolant temperature, (2) engineor transmission oil pressure or temperature, (3) fuellevel, (4) battery current (ammeter), battery voltage(voltmeter), battery or state of charge (battery indi-cators), (5) motor temperature, (6) motor brush wear,(7) traction system status and (8) elapsed time. SeeFigure 1, Figure 2, Figure 4, Figure 5, Figure 6, Fig-ure 7, Figure 9 and Figure 10. However, every truckor piece of equipment is not equipped with each oneof these meters.

1. ENGINE2. TRANSMISSION3. GENERATOR OR AMMETER4. CURRENT5. OIL6. WATER

7. TEMPERATURE8. PRESSURE9. HOURS10. FUEL11. FUEL LEVEL - FULL12. FUEL LEVEL - 1/2

13. FUEL LEVEL - EMPTY14. BATTERY15. BRUSH WEAR TRACTION

MOTOR16. BRUSH WEAR LIFT MOTOR17. MAINTENANCE

Figure 1. International Meter Face Symbols

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Description 2200 SRM 143

DescriptionMany meters have meter-movements that move anindicating needle attached to a shaft (or pin). Theshaft rotates to swing the needle when current flowsthrough the movement. The movement operates onthe same principle (electromagnetic) that rotatesa motor shaft. However, shaft rotation of a meteris limited to much less than even one full revolu-tion. The amount of rotation or deflection of theneedle is directly related to the amount of currentflow through the meter-movement. Meter faces (orscales) are calibrated to indicate a range of valuesthat are converted from a directly proportional cur-rent flow through the sender. See Figure 1 andFigure 2 for some typical examples of meter faceswith various calibrations.

Meters such as ammeters, voltmeters and somehourmeters, are able to convert this proportionalcurrent within the meter case. Many other metersand displays require a separate sender. See Figure 2.Senders convert a specific pressure, temperature orfluid level into a current flow that is directly relatedto a given voltage (electrical system voltage) applied.See Figure 3.

STEERING COLUMN GAUGES, METERS,AND INDICATORS

Some lift trucks use a cluster of gauges, meters, andindicator lights at the base of the steering column.See Figure 4. The left side includes an hourmeterand engine coolant temperature gauge. For dieseland gasoline units, the right side has a fuel levelgauge. Below the fuel level gauge is a four functionindicator that has separate warning indicators forthe alternator, engine and transmission oil pressure,and transmission oil temperature. For LPG units,the fuel gauge is replaced by a bezel with the Hysteremblem. The indicator with the gasoline pump sym-bol will now indicate low LPG tank pressure. How-ever, the optional pressure switch must be installedin the LPG system. The indictor for oil pressure andtemperature (oil clutch units or powershift transmis-sions) are combined in a two-function warning lightin the lower right position.

LED DISPLAY PANEL

Some lift trucks have a Light Emitting Diode (LED)warning display on the instrument panel. SeeFigure 7, Figure 9, and Figure 10. The followingparagraphs describe how the circuit for each func-tion operates and how to check its operation. TheLED warning display must be replaced as a completeunit. The sensors for the LED warning display canbe replaced as separate parts.

Battery Discharge Indicators

NOTE: See the SRM section Battery Indicators2260 SRM 138 for a more complete description of theoperation and the adjustment and repair procedures.

Earlier units without the LX control card have abattery discharge indicator that is a scale with aseries of 10 LEDs of different colors. See (1, 2, and3 of Figure 7. The LEDs illuminate in a sequence(green, yellow, red) to indicate the discharge of thebattery as the battery voltage decreases during op-eration. No more than two LEDs are illuminated atone time. When the battery is fully charged, the twogreen LEDs at the end of the scale are illuminated.When the battery discharges during operation, theillumination sequence moves to the left. The colorchanges from green to yellow to red. When the bat-tery is discharged to the red section of the batterydischarge indicator, the last two red LEDs begin toflash just before the "lift interrupt" is enabled. Whenthe last two red LEDs are illuminated continuously,the controller for the battery discharge indicatorstops the power to the hydraulic pump. This actionprevents the lift truck from lifting. Enough batterypower is normally available to move the lift truckto a battery charger or to a place where a chargedbattery can be installed.

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2200 SRM 143 Description

Figure 2. Typical Meter Faces for Lift Trucks With Engines

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Legend for Figure 2

NOTE: METER FACE NUMBERS, INCREMENTS, AND COLORED BANDS CAN BE DIFFERENT THAN SHOWN.

1. HOURMETER (ENGINE POWERED ORELECTRIC LIFT TRUCKS)

2. AMMETER3. COLORED BANDS4. VOLTMETER5. ENGINE COOLANT TEMPERATURE

6. TRANSMISSION OIL TEMPERATURE7. HYDRAULIC OIL TEMPERATURE8. ENGINE OIL PRESSURE9. TRANSMISSION OIL PRESSURE10. FUEL LEVEL

1. FLUID TEMPERATURE SENDERS2. FLUID PRESSURE SENDER

3. FUEL LEVEL SENDER

Figure 3. Typical Senders for Lift Trucks With Engines

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Figure 4. Typical Meters on Steering Column Assembly for Lift Trucks With Engines

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Legend for Figure 4

A. LEFT HAND - ALL UNITSB. WIRING DIAGRAMC. GAUGES ON STEERING COLUMND. WIRING DIAGRAM

E. RIGHT HAND - LPG POWERED UNITSF. RIGHT HAND - DIESEL AND GASOLINE

POWERED UNITSG. WIRING DIAGRAM

1. HOURMETER2. ENGINE COOLANT TEMPERATURE GAUGE3. 4-PIN CONNECTOR4. FUEL LEVEL GAUGE

5. INDICATOR LIGHTS6. 8-PIN CONNECTOR7. COVER WITH LOGO

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Figure 5. Steering Column Meters for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)

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Legend for Figure 5

A. LEFT HAND - ALL UNITSB. RIGHT HAND - DIESEL POWERED UNITS

C. RIGHT HAND GASOLINE POWERED UNITSD. RIGHT HAND - LPG POWERED UNITS

1. INSTRUMENT CLUSTER2. HOURMETER3. ENGINE COOLANT TEMPERATURE GAUGE

4. FUEL LEVEL GAUGE5. INDICATOR LIGHTS

1. ALTERNATOR INDICATOR2. ENGINE OIL PRESSURE3. FUEL LEVEL4. HOUR METER

5. TRANSMISSION OIL PRESSURE6. TRANSMISSION OIL TEMPERATURE7. COOLANT TEMPERATURE8. CHECK ENGINE INDICATOR

Figure 6. Meter Face Symbols for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)

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A. TO DISPLAY PANEL

1. BATTERY INDICATOR LED, GREEN (3)2. BATTERY INDICATOR LED, YELLOW (4)3. BATTERY INDICATOR LED, RED (3)4. TEMPERATURE ALARM, TRACTION MOTOR5. TEMPERATURE ALARM, (ILLUMINATES WITH

4 OR 6)6. TEMPERATURE ALARM, HYDRAULIC MOTOR7. BRUSH WEAR INDICATORS, TRACTION

MOTOR8. BRUSH WEAR INDICATORS, HYDRAULIC

MOTOR13. B - BATTERY POSITIVE71. BATTERY NEGATIVE72. BATTERY INDICATOR74. TRACTION MOTOR TEMP.75. TRACTION BRUSH WEAR76. TRACTION BRUSH WEAR77. PUMP MOTOR TEMP.78. PUMP BRUSH WEAR79. PUMP BRUSH WEAR

Figure 7. LED Display Panel (Some EarlierElectric Lift Trucks)

Brush Wear Indicators

The brush wear indicators illuminate when the mo-tor brushes must be replaced. The earlier units havetwo indicators for the traction motor and two for thepump motor. See Figure 7. The later display unithas one indicator for each motor. See Figure 9 andFigure 10. The sensor wires for the brush wear indi-cators are an insert in the brush material when thebrush is made. The sensor wires are insulated fromthe brush material. When the brush wears withinapproximately 0.060 inch of the brush lead, the insu-lation between the sensor wire and the brush mate-rial is destroyed. The connection between the brushand the sensor wire causes the indicator to illumi-nate.

The operation of the brush wear indicators can bechecked during periodic maintenance. The batterymust be removed from the lift truck for access to themotors. See Figure 8.

WARNINGLift truck movement can cause an injury ordamage. Raise the drive wheels from the floorto prevent lift truck movement. Use the cor-rect procedure in the Operating Manual or thesection Periodic Maintenance of the ServiceManual to raise the drive wheels.

Use a jumper cable so that the battery can be con-nected and still have motor access. Disconnect thesensor wires, one at a time, from the outside of themotor case. Touch the end of the sensor wire to bat-tery negative. The LED indicator will illuminate ifthe circuit is operating correctly. The motor brushesmust be replaced when they are worn. If equippedwith brush wear indicators, the condition of the com-mutator and the motor brushes must still be checkedduring periodic maintenance.

Motor Temperature Indicators

The traction motor and the hydraulic pump motorhave thermal switches inside the motors. See Fig-ure 7 and Figure 9. When the temperature increasesto 300 F for Prestolite motors or 338 F for GE motors,the thermal switch closes and the LED (ZX or earlierunits) on the instrument panel display illuminates.This temperature is set by the manufacturer of themotor and is below the temperature where the insu-lation in the motor will have reduced life.

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Figure 8. Connect Battery So Motor Can beOperated

Legend for Figure 8

Connect the battery so that the motor can beoperated. The battery must be removed for access tothe motor. Use a jumper cable to connect the batteryto the lift truck. Raise the drive wheels. See "Howto Raise Drive Wheels" in the section PeriodicMaintenance for your lift truck or the OperatingManual for your lift truck.

1. RAISE DRIVEWHEELS

2. JUMPER3. BATTERY

Figure 9. GE Instrument Panel Display and Plug Connector E40-60XL

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Legend for Figure 9

1. DISPLAY UNIT2. FOUR DIGIT DISPLAY3. FUNCTION INDICATOR, STATUS CODE (GREEN

LED)4. FUNCTION INDICATOR, BATTERY (GREEN LED)5. FUNCTION INDICATOR, HOURMETER (GREEN

LED)6. MOUNT FOR DISPLAY UNIT7. INSTRUMENT PANEL

8. CONNECTOR FOR MOTOR CONTROLLER,TRACTION

9. CONNECTOR FOR MOTOR CONTROLLER,LIFT PUMP

10. TO CONTROL CARD PLUG Y11. RED*12. WHITE13. GREEN14. BARE15. GREEN

*TRACTION CARD PLUG ONLY

WARNINGLift truck movement can cause an injury ordamage. Raise the drive wheels from the floorto prevent lift truck movement. Use the cor-rect procedure in the Operating Manual or thesection Periodic Maintenance of the ServiceManual to raise the drive wheels.

The operation of the motor temperature indicatorscan be checked during periodic maintenance. Thebattery must be removed from the lift truck for accessto the motors. See Figure 8.

Use a jumper cable so that the battery can be con-nected and still have motor access. Disconnect thesensor wires from the outside of the motor case.Touch the ends of the sensor wires together. TheLED indicator will illuminate if the circuit is oper-ating correctly. The thermal switch can be replacedif it has a malfunction. However, the motor must bedisassembled to replace the thermal switch.

LX SERIES DISPLAY PANEL

WARNINGSome adjustments can cause the lift truck tooperate differently than normal. This differentoperation of the truck can result in personalinjury or damage. Do NOT try to make adjust-ments for the instrument panel display with-out using the procedures in the section EV-100/200 LX Series Diagnostic Motor Controller andHandset 2200 SRM 460.

There are two instrument panel displays used onsome electric lift trucks that have the EV-100/200"LX" series control cards. Both instrument paneldisplays are shown in Figure 9 and Figure 10. Theseinstrument panel displays are optional on someelectric lift trucks with the EV-100 or EV-200 LXseries motor controller.

The early unit has a four digit display and three LEDfunction indicators. The indicators show which func-tion value is displayed by the digits. Not all func-tions are available on all lift truck models. Follow-ing is a list of the functions: Battery Indicator, Sta-tus Codes, Traction Hourmeter and Pump Hourme-ter. Later units have the same digital display andthe same function indicators with the additional mo-tor brush wear indicator and temperature alarm in-dicator LEDs.

The following paragraphs describe how the circuit foreach function operates. The display panel must bereplaced as a complete unit. The sensors for brushwear and motor temperature can be replaced as sep-arate parts.

The digits show the operating hours when thehourmeter function indicator is ON. When the bat-tery indicator is ON, the digits show the chargecondition of the battery. See Figure 9 and Figure 10.The status code indicator is ON when the digits showthe status code number. The brush wear or tempera-ture alarm indicators of the later units will be ON ifthe traction or pump motor brushes are too worn orthe motor is too hot. Refer to the descriptions BrushWear Indicators and Motor Temperature Indicatorsfor a complete description of the operation of theseindicators.

Hourmeter Functions

The hourmeter function on the instrument paneldisplay is controlled by the EV-100/200 "LX" seriescontrol card. There can be a display for the oper-ating time of the traction circuit. On some units,there can also be a display for the operating timeof the pump circuit. Only those units that have theEV-100LXP pump control card can have the optionalpump hourmeter function.

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The instrument panel display shows the operatingtime of 0000 to 9999 hours. The traction time is dis-played for four seconds after the lift truck has beenoperating and the key is turned to the OFF position.If there is a pump hourmeter, the pump time will nowbe displayed for another four seconds.

Battery Indicator Function

NOTE: See the SRM section Battery Indicators2260 SRM 138 for a more complete description of theoperation and the adjustment and repair procedures.

The battery indicator reading is displayed on the fourdigit display when the green function indicator abovethe battery symbol is ON. See Figure 9 and Figure 10.

9-Pin Connector Wiring

Pin No. Wire No. Connection/Function

123456789

959693949899-

1310

Traction Motor TemperaturePump Motor TemperatureTraction Motor Brush (A) WearTraction Motor Brush (B) WearPump Motor Brush (A) WearPump Motor Brush (B) WearNot UsedBattery NegativeBattery Positive from Key Switch

1. DISPLAY UNIT2. 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)

7. STATUS CODE FUNCTION INDICATOR (GREENLED)

8. HOURMETER FUNCTION INDICATOR (GREENLED)

9. FOUR DIGIT DISPLAY10. BATTERY FUNCTION INDICATOR (GREEN LED)11. CONNECTOR, HYDRAULIC PUMP CARD12. CONNECTOR, TRACTION CARD13. 9-PIN MOTOR CONNECTOR

Figure 10. ITW Instrument Panel Display E40-60XL

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This battery indicator uses the traction control shuntto measure the current during operation. This cur-rent and battery voltage are checked at the sametime for an accurate reading of battery voltage witha load (during use). This method of checking voltageand current is much more accurate than other meth-ods used by battery indicators on earlier lift trucks.This method allows more usage of the battery. Lifttruck operation can be different than with other bat-tery indicators when a battery is low or a differentbattery is connected.

The battery indicator function shows the batterycharge by the numbers between 0 and 100. Thedigital display will flash when the display reads 19.At a display of 9 (80% discharged), the control willdisable the lift pump circuit. After the circuit hasdisabled the lift pump, charge or change the battery.

The control also checks the battery voltage each timea battery is connected. The traction control will pre-vent lift truck operation if the battery voltage is notcorrect as set by the traction function of the controlcard. A status code of -16 (voltage too high) or -15(voltage too low) will show on the instrument paneldisplay. The battery can have a voltage that is toohigh or too low. A battery with the correct voltage canalso be over discharged from use or other reasons andhave a voltage that is less than the minimum voltagerange.

Status Code Function

The status codes are code numbers for differentsymptoms that the control card can sense. The con-trol card will show this code number on the digitaldisplay. The control card will flash the status code

on the display. Every third display will show thebattery charge instead of the status code.

NOTE: See the section EV-100/200 LX Series Diag-nostic Motor Controller and Handset 2200 SRM460 for a description of the different status code dis-plays.

ZX SERIES DISPLAY PANELS

Display Panel

WARNINGSome adjustments can cause the lift truck tooperate differently than normal. This differentoperation of the truck can result in personalinjury or damage. Do NOT try to make adjust-ments for the instrument panel display with-out using the procedures in the section EV-100/200ZX Motor Controller Parameter Tables 2200SRM 595.

There are two display panels available on lift truckswith the EV-100ZX SCR motor controller. The lifttrucks can only have one of the two display panels: a basic display that gives the operator basic infor-

mation about the operation of the lift truck a performance display that includes diagnostic ca-

pabilities similar to the Handset.

Basic Display Panels

The EV-100 "ZX" Series motor controller can havetwo Basic display panels that include one of two typesof Battery Indicators. See Figure 11 and Figure 12.

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Standard Display 18-Pin Connector

Pin Function

1-1112131415161718

No ConnectionBattery Negative ( )Parking Brake SwitchBrake Fluid SwitchHyd. Contactor CoilSeat SwitchKey Switch (IGN)Battery Positive (+) (from Fuse 6)

1. HOURMETER2. BATTERY METER3. PARKING BRAKE INDICATOR4. BRAKE FLUID TOO LOW INDICATOR5. SEAT BELT INDICATOR

6. KEY SWITCH LEADS7. RED/BRN IGN TERMINAL8. BRN BAT TERMINAL9. 18-PIN CONNECTOR

Figure 11. Basic (Early) Display Panel for EV-100/200ZX Motor Controllers

Figure 12. Basic (Later) Display Panel for EV-100/200ZX Motor Controllers

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Legend for Figure 12

1. BATTERY DISCHARGE INDICATOR2. PARKING BRAKE SYMBOL AND LED

3. FASTEN SEAT BELT SYMBOL AND LED4. DIGITAL DISPLAY

EARLY DISPLAY PANEL

When the key is turned to the ON position, a startprogram will cause each warning light to illuminateto show that the function is operating. This laterdisplay panel has the following functions:

(1) Hourmeter. The hourmeter display shows theoperating time of 0000 to 9999 hours. The time forthe traction circuit is shown for four seconds after thelift truck has been operating and the key is turned tothe OFF position.

(2) Voltmeter. The earlier Basic Display Panel hasa battery indicator without lift interrupt (voltmeter).This meter has a green, yellow and red band on themeter face to indicate the voltage of the battery. Theneedle starts in the green band with a fully chargedbattery and moves to the red band as the batterydischarges. The battery must have a current draw(load) to check the battery charge. Hold the tilt leverin the tilt BACKWARD position or for the N30XMH,hold the rotate lever in the ROTATE position andlook at the indicator. If the needle is in the red band,charge the battery. Operating the lift truck with theneedle in the red band can decrease battery life. Con-tinued operation with a discharged battery can dam-age the battery, motors or the contactors.

(3) Warning light, parking brake indicator. Thered light is ON when the parking brake is appliedand the seat switch is closed, and goes OFF when theparking brake is released.

(4) Warning light, brake fluid reservoir is low(Early Only). The red light is ON for one secondwhen the key is turned to the START position andmust go OFF after one second. If the warning lightis ON during operation, the brake fluid level in thereservoir is too low.

(5) Warning light, fasten seat belt. The red lightis ON for eight to ten seconds after the key is turnedto the ON position.

LATER DISPLAY PANEL

When the key is turned to the ON position, a startprogram will cause each warning light to illuminateto show that the function is operating. This laterdisplay panel has the following functions:

(1) Battery Charge Indicator With Lift Inter-rupt. Later Basic display panels have a batteryindicator that is a scale with a series of 5 roundLEDs in three colors (green, orange, red). See Fig-ure 12. There are two green LEDs and bars at thetop, two orange LEDs and bars in the center anda red LED and bar at the bottom. As the batteryvoltage decreases during operation, different LEDsilluminate to indicate a discharged battery. No morethan two LEDs are illuminated at one time. Whenthe battery is fully charged, the two green LEDsof the scale are illuminated. When the battery dis-charges during operation, the LEDs illuminate fromtop to bottom (green to red). The red LED indicatesthat the battery is discharged. The battery mustbe charged or a charged battery must be installedbefore lift truck operation can continue.

The battery charge indicator uses the traction controlshunt to measure the current during operation. Thiscurrent and battery voltage are checked at the sametime for an accurate reading of battery voltage witha load (during use). This method can make operationof the lift truck different when the battery is low or adifferent battery is connected. This method permitsbetter use of the battery charge.

The controller also checks the battery voltage eachtime a battery is connected. The traction control willprevent lift truck operation if the battery voltage isnot correct as set by traction function 15. A statuscode of -16 (voltage too high) or -15 (voltage too low)will indicate on the display panel. The battery canhave a voltage that is too high or too low. A batterywith the correct voltage can also be deeply dischargedfrom use or other reasons and have a voltage that isless than the minimum of the voltage range.

Batteries that have different ampere hour ratings orare of different ages can sometimes be used in thesame lift truck. It can be necessary to adjust trac-tion Function 14 so that the weakest battery is notdamaged. Follow the procedure for adjusting trac-tion Function 14 in the Checks And Adjustments.

(2) Warning light, parking brake indicator. Thered light is ON when the parking brake is appliedand the seat switch is closed, and goes OFF when theparking brake is released.

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(3) Warning light, fasten seat belt. The red lightis ON for eight to ten seconds after the key is turnedto the ON position.

(4) Digital Display. This indicator is blank whenthe lift truck is operating correctly. The status codesand the hourmeter values are shown on this four-digit LCD display. When a fault occurs, the statuscode will be shown with a dash ( ) in the left digitposition. The warning light, Service Interval (11) willalso be illuminated when a fault occurs.

When it is time for periodic maintenance, the warn-ing light, Service Interval (11) will be illuminatedand a status code -99 will be indicated. The regis-ter in the controller card must be reset by the serviceperson before this warning light will go OFF.

The hourmeter display shows the operating time of0000 to 9999 hours. The time for the traction circuitis shown for four seconds after the lift truck has beenoperating and the key is turned to the OFF position.The indicator lights for the traction motor (8) and forthe hourmeter (12) will also be illuminated duringthis time. If there is an SCR control card for the hy-draulic pump motor, this time will then be shown onthe hourmeter for another four seconds. The indi-cator lights for the hydraulic motor (9) and for thehourmeter (12) will also be illuminated during thistime.

Performance Display

When the key is turned to the ON position, a startprogram will cause each warning and indicator lightto illuminate to show that the function is operating.The functions and operation of the indicators forthese early and later display panels is the same. SeeFigure 13 and Figure 14. These display panels havethe following functions:

(1) Battery Charge Indicator With Lift Inter-rupt. This battery charge indicator shows thebattery charge with an LED bar graph. There arefour green bars, four orange bars, and two red bars.When the battery is discharged during operation, theLED bar that is illuminated decreases sequentiallyfrom the top green bar through the orange bars tothe red bars. When the battery is discharged to thered LED bars, the battery is 73% discharged and thelift interrupt function will not permit operation ofthe hydraulic motor. The battery must be charged

or a charged battery must be installed before lifttruck operation can continue. The top green bar willbe illuminated when the battery is more than 90%charged.

The battery charge indicator uses the traction controlshunt to measure the current during operation. Thiscurrent and battery voltage are checked at the sametime for an accurate reading of battery voltage witha load (during use). This method can make operationof the lift truck different when the battery is low or adifferent battery is connected. This method permitsbetter use of the battery charge.

The controller also checks the battery voltage eachtime a battery is connected. The traction control willprevent lift truck operation if the battery voltage isnot correct as set by traction function 15. A statuscode of -16 (voltage too high) or -15 (voltage too low)will indicate on the display panel. The battery canhave a voltage that is too high or too low. A batterywith the correct voltage can also be deeply dischargedfrom use or other reasons and have a voltage that isless than the minimum of the voltage range.

Batteries that have different ampere hour ratings orare of different ages can sometimes be used in thesame lift truck. It can be necessary to adjust trac-tion Function 14 so that the weakest battery is notdamaged. Follow the procedure for adjusting trac-tion function 14 in the Checks And Adjustments.

(2) Digital Display. This indicator is blank whenthe lift truck is operating correctly. The status codesand the hourmeter values are shown on this four-digit LCD display. When a fault occurs, the statuscode will be shown with a dash ( ) in the left digitposition. The warning light, Service Interval (11) willalso be illuminated when a fault occurs.

The hourmeter display shows the operating time of0000 to 9999 hours. The time for the traction circuitis shown for four seconds after the lift truck has beenoperating and the key is turned to the OFF position.The indicator lights for the traction motor (8) and forthe hourmeter (12) will also be illuminated duringthis time. If there is an SCR control card for the hy-draulic pump motor, this time will then be shown onthe hourmeter for another four seconds. The indi-cator lights for the hydraulic motor (9) and for thehourmeter (12) will also be illuminated during thistime.

16


Enhanced Display 18-Pin Connector

Pin Function

123456789101112131415161718

Traction Card PY 5Pump Card PY 5No ConnectionTraction Card PY 14Traction Card PY 13Pump Card PY 14Pump Card PY 13No ConnectionTraction Card PY 4Pump Card PY 4Brush Wear Indicator & Temperature Jumper**Parking Brake SwitchBrake Fluid SwitchNo ConnectionNo ConnectionKey Switch (IGN)No Connection

*Pin 11 to 12 Jumper (In Wire Harness). BWI and Temperature LEDs Disabled if Cut.

1. BATTERY DISCHARGE INDICATOR2. DIGITAL DISPLAY3. FASTEN SEAT BELT INDICATOR4. BRAKE FLUID TOO LOW INDICATOR5. PARKING BRAKE INDICATOR6. STEERING PUMP MOTOR INDICATOR7. BRUSH WEAR INDICATOR8. TRACTION MOTOR INDICATOR9. LIFT PUMP MOTOR INDICATOR10. MOTOR TEMPERATURE INDICATOR

11. STATUS CODE/MAINTENANCE INDICATOR12. HOURMETER INDICATOR13. STATUS CODE BUTTON14. PERFORMANCE LEVEL BUTTON15. PERFORMANCE LEVEL LEDS16. KEY SWITCH LEADS17. RED/BRN IGN TERMINAL18. BRN BAT TERMINAL19. 18-PIN CONNECTOR

Figure 13. Early Performance Display Panels for EV-100/200ZX Motor Controllers

17


1. BATTERY DISCHARGE INDICATOR2. DIGITAL DISPLAY3. FASTEN SEAT BELT INDICATOR4. BRAKE FLUID TOO LOW INDICATOR5. PARKING BRAKE INDICATOR6. STEERING PUMP MOTOR INDICATOR7. BRUSH WEAR INDICATOR8. TRACTION MOTOR INDICATOR

9. LIFT PUMP MOTOR INDICATOR10. MOTOR TEMPERATURE INDICATOR11. STATUS CODE/MAINTENANCE INDICATOR12. HOURMETER INDICATOR13. STATUS CODE BUTTON14. PERFORMANCE LEVEL BUTTON15. PERFORMANCE LEVEL LEDS

Figure 14. Later Performance Display Panels for EV-100/200ZX Motor Controllers

(3) Warning Light, Fasten Seat Belt. The red lightis ON for eight to ten seconds after the key is turnedto the ON position.

(4) Warning Light, Brake Fluid Reservoir IsLow (Early Only). The red light is ON for one sec-ond when the key is turned to the START positionand must go OFF when the key is in the ON position.If the warning light is ON when the key is in the ONposition, the brake fluid level in the reservoir is toolow.

(5) Warning Light, Parking Brake Indicator.The red light is ON when the parking brake is ap-plied and the seat switch is closed, and goes OFFwhen the parking brake is released.

A warning buzzer will make a noise if the operatorleaves the seat (key moved to ON position) and theparking brake is not applied.

(6) Indicator Light, Steering Pump Motor. Thislight will illuminate with another warning light if afault occurs in the steering pump motor. If the brushwear sensor is activated in the motor, the warninglight, brush wear (7) will go ON and the indicatorlight for the steering pump motor will show whichmotor has the problem.

(7) Warning Light, Motor Brushes Are Worn.When the sensor for brush wear closes, this warninglight and the indicator light for the motor that hasthe problem will both illuminate.

(8) Indicator Light, Traction Motor. This lightwill illuminate with another warning light if a faultoccurs in the traction motor. Example: If the brushwear sensor is activated in the motor, the warninglight, brush wear (7) will go ON and the indicatorlight for the traction motor will show which motorhas the problem.

(9) Indicator Light, Hydraulic Motor. This lightwill illuminate with another warning light if a faultoccurs in the hydraulic pump motor. Example: If thetemperature over limit switch closes in the motor, thewarning light, motor temperature over limit (10) willgo ON and the indicator light for the hydraulic motorwill show which motor has the problem.

(10) Warning light, Motor Temperature OverLimit. The traction motor and the hydraulic pumpmotor have thermal switches inside the motors.When the temperature increases to the limit set bythe manufacturer of the motor, the thermal switchcloses and the warning light on the display panelilluminates. The indicator light for traction motor

18


(8) or for the hydraulic motor (9) will show whichmotor has the problem.

(14, 15) Set Lift Truck Performance. The lifttruck can be set to four performance levels by theoperator. (If the customer does not want this func-tion available to the operator, a service person canset all four levels to the same setting.) Each time theoperator pushes the button (14), performance levelwill increase by one step. At the maximum (rabbit)level, the performance levels will begin at the lowest(turtle) level again. The four performance levels setby the manufacturer are:1. Low performance for handling fragile loads.2. Medium speed for less consumption of battery

charge during a work shift.3. Higher performance with higher consumption of

battery charge during a work shift.4. Maximum lift truck performance with maximum

consumption of battery charge.

The performance settings can be made with eitherthe PC or the Handset (Functions 11, 12, and 13).

The four performance levels can be set to any level upto the maximum limits. Two or more adjacent per-formance levels can be set to the same limits. Theperformance levels must be set at the same or in as-cending order (from turtle to rabbit). The registerinterlocks will not permit a higher performance levelsetting toward the turtle than the adjacent registerstoward the rabbit.

Fault Code Memory. The control cards for the trac-tion motor controller and hydraulic pump motor eachhave memory registers in which the last 16 statuscodes can be stored. Each status code is stored withthe hourmeter time and the battery charge at thetime of the fault. The status code for the last faultwill be indicated on the Status Code Indicator (2). Ifthe key is turned to OFF, the status code will be re-moved from the four digit display.

The push button (13) will cause the status codes forthe for the faults to be shown on the Status Code Indi-cator (2). When the button is pushed and held down,the indicator light for the traction motor (8) will illu-minate. The status codes in memory for the detectedfaults will be displayed, starting with the most re-cent fault. If the push button is released, the displaywill stop. If the button is pushed again, the displaywill start from the beginning again. The hourmetertime and the battery charge at the time of the fault

will not be shown. A Handset or a PC must be usedto show this additional information. A Handset ora PC must be used to clear the status code from theregister.

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 thedetected faults will be displayed, starting with themost recent fault. If the push button is released, thedisplay will stop. If the button is pushed twice tostart the sequence again, the display will start fromthe beginning. The hourmeter time and the batterycharge at the time of the fault will not be shown. AHandset or a PC must be used to show this additionalinformation. A Handset or a PC must be used to clearthe status code from the register.

There can be 16 status codes in the memory for eachsystem (traction or lift). Push and hold the push but-ton to display all the status codes in the memory fordetected faults of the traction system. The TractionMotor Indicator will be ON to show that the statuscodes are for the traction system. If the push buttonis released then pushed and held again, the digitaldisplay will start over showing all the status codesfor the traction system. Push the button twice andhold the push button to display all the status codesin the memory for detected faults of the lift system.The Lift Pump Motor Indicator will be ON to showthat the status codes are for the lift system. If thepush button is released then pushed twice and heldagain, the digital display will start over showing allthe status codes for the lift system.

Brush Wear Indicators

The brush wear indicators illuminate when the mo-tor brushes must be replaced. The sensor wires forthe brush wear indicators are an insert in the brushmaterial when it is made. The sensor wires are in-sulated from the brush material. When the brushwears within approximately 0.060 inch of the brushlead, the insulation between the sensor wire and thebrush material is destroyed. The connection betweenthe brush and the sensor wire causes the indicator toilluminate.

The operation of the brush wear indicators can bechecked during periodic maintenance. The batterymust be removed from the lift truck for access to themotors.

19

Replacement - General Information 2200 SRM 143

Adjustments - GeneralThere are no adjustments to perform except for somebattery indicators. Refer to Battery Indicators2260 SRM 138 to adjust the battery indicators. Re-fer to EV-100/200 LX Series Diagnostic Motor

Controller and Handset 2200 SRM 460 to adjustthe I.T.W. display panel.

Replacement - General Information

WARNINGBefore replacing any components, fully lowerall parts of the mast and tilt it forward until thetips of the forks touch the ground. This actionwill prevent the mast from lowering suddenlyif the control lever is accidently moved.

ALWAYS disconnect the battery and removethe key before replacing components.

Never have any metal on your fingers, arms orneck. These metal items can accidentally makean electrical connection and cause an injury.

NOTE: None of the electrical components of this sec-tion can be repaired. All bad components must bereplaced.

Meters, display panels, most indicators and sendersare not repairable items. The most accurate and usu-ally easiest checks for proper operation of individual

meters, indicators or senders is direct replacement.The most common cause of failure is poor connec-tions, or damaged or improper wiring and not the me-ter indicator or sender. This section only has the re-placement procedures. Before a meter, display panel,indicator or sender is replaced, make the followingchecks:

1. Check that other meters and electrical circuitsoperate correctly.

2. Check that the battery is fully charged, hasa good ground (diesel, gasoline and LPG unitsonly) and the cable terminals are clean and tight.

3. Check that the wiring and connections to the me-ter, indicator or sender are tight and in good con-dition.

20

2200 SRM 143 Meter Replacement

Meter ReplacementMeters are usually mounted to an instrument panel.See Figure 15. Access to the back of the panel ormounting surface is required for meter replacement.Replace a meter as follows:

1. Make sure the key is in the OFF position.

WARNINGMeters normally have voltage at the terminals.A short circuit of this voltage can result inmeter damage or personal injury. To preventa short circuit during meter replacement,disconnect the battery negative cable at thebattery negative terminal. Install a lock or tagon the connector to prevent connection.

2. Put tags on the meter wires for correct identifica-tion during installation. Remove the wires fromthe meter terminals.

NOTE: If the meter is illuminated, remove bulbsocket and bulb from the meter.

3. Remove the nuts and washers that fasten themounting bracket to the meter housing.

4. Remove the meter and install the replacementmeter in the panel. Make sure the meter is inthe correct position for reading by the operator.

5. Install the mounting bracket, washers and nuts.Tighten the nuts.

CAUTIONA short circuit and damage can occur if wiresare not installed correctly. Make sure wireconnectors do not touch the other meter termi-nals or wire connectors, metal brackets, or thebracket mounting nuts. Make sure the wiresare not pulled tight and are not touching otherparts to damage the insulation.

6. Connect the wires to the meter electrical termi-nals. Tighten the nuts if the nuts are requiredfor correct connection.

NOTE: If the meter is illuminated, install the socketwith the bulb into the meter housing.

1. HOURMETER2. AMMETER (FARIA)3. OIL TEMPERATURE (DATCON)4. (A.C.) METERS

5. AMMETER6. VOLTMETER7. TEMPERATURE8. OIL PRESSURE AND FUEL LEVEL

Figure 15. Meters and Mount Brackets

21

Sender Replacement 2200 SRM 143

Sender ReplacementFUEL LEVEL SENDER

WARNINGAll fuel vapors are extremely explosive. Do notallow sparks or flames around vehicles or fuelstorage and service areas. Make sure there isno source of open flame or sparks in the vicin-ity. Use caution to prevent sparks from tools.

The fuel level sending unit is mounted to the fueltank surface (usually top surface) with screwsthrough the sender plate and gasket. See Figure 16.Correct sender operation and screw hole alignmentcan only be obtained with the plate mounted in oneposition. Replace the sender as follows:

A. FULL POSITION B. EMPTY POSITION

1. ELECTRICALTERMINAL

2. PLATE

3. SENDER UNIT4. FLOAT ARM5. FLOAT

Figure 16. Fuel Level Sender

1. Turn key switch to OFF position and disconnectnegative battery cable at battery. Install lock ortag on connector to prevent connection.

2. Disconnect sender wire at sender.

WARNINGElectrical shock from voltage can cause per-sonal injury. Put electrical tape on the wireconnector to electrically insulate the connec-tor if the wire is accidentally energized.

CAUTIONFuel level senders are not accurate if the armis bent during removal and installation. Theremust also be clearance for operation. Do notbend the float arm.

3. Remove screws that fasten sender plate to fueltank. Remove sender.

4. Carefully install new sender with new gasket.

5. Make sure screw holes are aligned and installscrews. Tighten screws enough to partially com-press gasket to prevent leaks.

6. Remove tape from wire connector. Install connec-tor on sender terminal.

PRESSURE AND TEMPERATURE SENDER

Pressure senders have a hollow threaded fitting fas-tened to the base. See Figure 17 and Figure 18. Thismakes it possible for the sender to sense the pressureand also to fasten the sender to the equipment. Thesender can be tightened or loosened using a wrenchon the flats of the hex shape of the fitting. The body ofthe temperature sender has threads to fit a threadedhole in the equipment. Replace either sender as fol-lows:

NOTE: Make sure the system fluid is drained to alevel below the sender to prevent leakage when thesender is removed.

1. Turn key switch to OFF position.

2. Disconnect sender wire.

3. Turn sender counterclockwise with a wrench un-til free. Remove and discard old sender.

4. Install new sender and tighten with a wrench.

5. Connect sender wire.

22

2200 SRM 143 ITW Display Panel Replacement

1. ELECTRICAL TERMINAL2. HEX3. THREADED BODY4. SENSOR ELEMENT5. CASE OF ENGINE OR TRANSMISSION

Figure 17. Typical Pressure and TemperatureSender

1. ELECTRICAL TERMINAL2. SENDER3. HEX4. THREADED FITTING5. HOLE-TO-SENSOR ELEMENT6. CASE OF ENGINE OR TRANSMISSION

Figure 18. Fluid Pressure Sender

ITW Display Panel ReplacementREMOVE

The display panel is in the instrument panel. Thedisplay panel cannot be repaired and must be re-placed if it has a malfunction. See Figure 10.

1. Move the lift truck to a safe, level area. Turnthe key to the OFF position and remove the key.Put a DO NOT OPERATE tag on the steeringwheel. Put blocks under the drive wheels to keepthe lift truck from moving. See the section Peri-odic Maintenance or the Operating Manualfor your lift truck to place the blocks.

WARNINGDisconnect the battery and separate the con-nector before opening the compartment coveror inspecting or repairing the electrical sys-tem. If a tool causes a short circuit, the highcurrent flow from the battery can cause aninjury or parts damage.

2. Disconnect and separate the battery connector.

3. If installed, remove the cowl cover under the in-strument panel.

4. Install labels for correct connection during in-stallation and disconnect all electrical plugs andwires from the back of the display panel.

5. Remove the screws or nuts that fasten the dis-play panel assembly to the instrument panel.Lift the display panel up out of the instrumentpanel.

6. Install the replacement display panel and installthe screws or nuts. Make sure the panel can beread by the operator.

7. Correctly connect all electrical plugs or wires ac-cording to the labels made during removal.

8. Remove the blocks from under the drive wheels,remove the DO NOT OPERATE tag, connect thebattery, and install the key.

23

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement 2200 SRM 143

Column Mount Display Panel (EV-100/200ZX MotorControllers) Replacement

REMOVE

The display panel is in the instrument panel. Thedisplay panel cannot be repaired and must be re-placed if it has a malfunction. The display panelsmust be replaced as a unit.

NOTE: Most parts of the column mounted displaypanel can be replaced. However, the LED indicatorscannot be replaced separately. The LEDs are partof the circuit board assembly. The major replace-able parts of this display panel are: 1) key switch;2) housing, top cover, and O-ring seal; 3) housingand light filter for LED warning lights; 4) hourme-ter and gasket; 5) battery indicator; 6) buzzer andcircuit board; and 7) jumper harness and the wiresto the key switch.

NOTE: The only replaceable parts of the Perfor-mance display panel are the O-ring seal, key switch,wires to the key switch, and the housing that fastensto the steering column. All other parts of the panelmust be replaced as a single unit. See Display PanelAssembly, Replace of this section.

DISPLAY PANEL ASSEMBLY, REPLACE

Follow this procedure to replace the Basic or Perfor-mance display panel as an assembly:

1. Disconnect the battery and remove the key.

2. Remove the front steering column cover withthe display panel assembly attached. Carefullydisconnect the 18-pin connector, the key switchwires and, on the Basic panel, the two-pin con-nector from inside the column cover.

3. Remove the four screws that fasten the displaypanel to the column cover.

4. Install the replacement display panel assemblyto the cover of the steering column and tightenthe screws. Install the connectors and the keyswitch wires. On the Basic panel, set the DIPswitches near the connector for the panel to thevoltage of the lift truck. See Figure 19. Move the

DIP switch for the correct voltage to the up posi-tion and all others to the down position. Installthe column cover on the steering column.

NOTE: ON = UP AS SHOWN.

36V SW#1 ON, OTHERS OFF.48V SW#2 ON, OTHERS OFF.

NOTE: SET DIP SWITCHES TO TRUCK VOLTAGE. IFTRUCK VOLTAGE IS NOT KNOWN, SET 36/48V (U.S.)TRUCKS TO 48V.

1. DISPLAY PANEL2. STEERING

COLUMN3. ELECTRICAL

CONNECTOR

4. DIP SWITCHES5. BROWN6. RED/BROWN

Figure 19. Dip Switches

24

2200 SRM 143 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement

INDICATOR LEDS

NOTE: The indicator LEDs of the Basic displaypanel are part of the circuit board and must bereplaced as an assembly. See Basic Display Panel,Replace Parts of this section. The LED indicators ofthe Performance display panel cannot be replaced.If these LED indicators are bad, replace the displaypanel. See Display Panel Assembly, Replace of thissection.

BATTERY INDICATORS

There are two types of battery indicators for thesetrucks. One type is a meter movement with coloredbands showing the battery charge (Basic displaypanel). The other type is a Light Emitting Diode(LED) display with LEDs of different colors showingbattery charge (Performance display panel).

NOTE: The battery indicator is replaced as one of thecomponents of the display panel. See procedure un-der Basic Display Panel, Replace Parts of this sec-tion. The battery indicator of the Performance dis-play panel cannot be replaced as a separate compo-nent. The indicator must be replaced as part of thePerformance display panel. See Display Panel As-sembly, Replace of this section.

See the section Battery Indicators 2260 SRM 138to adjust these battery indicators.

DIGITAL DISPLAY (PERFORMANCEDISPLAY PANEL ONLY)

NOTE: The digital display of the Performance dis-play panel cannot be replaced as a separate compo-nent. The display must be replaced as part of thePerformance display panel. See Display Panel As-sembly, Replace of this section.

STATUS CODE OR PERFORMANCELEVEL SWITCHES AND INDICATOR LEDS(PERFORMANCE DISPLAY PANEL ONLY)

NOTE: These switches of the Performance displaypanel cannot be replaced as separate components.The switches must be replaced as part of the Perfor-mance display panel. See Display Panel Assembly,Replace of this section.

BASIC DISPLAY PANEL, REPLACE PARTS

NOTE: The parts of the Basic Display Panel can be re-placed with the display panel on the steering column.If the assembly housing will be replaced, remove thecomplete assembly from the steering column as de-scribed in Display Panel Assembly, Replace.

NOTE: The following is a complete disassembly pro-cedure. Do ONLY those steps necessary to replacethe part you want replaced.

Remove and replace the components of the Basic dis-play panel as follows:

1. Disconnect the battery and remove the key.

2. Remove the eight screws that fasten the top coverto the panel housing. The screws are at the bot-tom of the housing. See Figure 20. The hourme-ter is fastened to the top cover with the electricalconnector on the circuit board inside the housing.Carefully lift the top cover up off the housing andthe indicator LEDs without damaging the O-ringgasket. The gasket for the LED indicators canstick to the LED housing as the top cover is re-moved. Do not lose or damage the gasket. Dis-connect the three wire connector for the hourme-ter.

3. If the housing or filter for the indicators will bereplaced, remove the screws that fasten the LEDhousing to the cover. If the hourmeter or hourme-ter gasket will be replaced, remove the screwsthat fasten it to the top cover. Install the replace-ment parts to the top cover. Make sure that thehourmeter is installed so that it can be read afterthe cover is installed.

4. Remove the nut that fastens the key switch. Re-move the key switch from the housing. Make anote of which wires are on which terminals anddisconnect the wires. Install the wires on thesame terminals of the replacement switch.

5. Align the notch in the shaft housing of the keyswitch with the tab in the housing of the displaypanel. Install the replacement switch. Tightenthe nut and connect the wires.

25

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement 2200 SRM 143

Figure 20. Standard Display Panel

26

2200 SRM 143 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement

Legend for Figure 20

1. TOP COVER2. FILTER FOR LED INDICATORS3. HOUSING FOR LED INDICATORS4. KEY SWITCH5. ASSEMBLY HOUSING6. O-RING GASKET7. BUZZER8. FIBER INSULATING WASHERS

9. CIRCUIT BOARD (LH) FOR BATTERYINDICATOR

10. BATTERY INDICATOR11. JUMPER HARNESS12. HOURMETER13. GASKET FOR HOURMETER14. CIRCUIT BOARD FOR LED INDICATORS15. GASKET FOR LED INDICATORS

NOTE: It is not necessary to do Step 6 if only themeter movement of the battery indicator will be re-placed on the existing circuit board. Carefully lift themeter movement up off the pins of the circuit boardwithout bending the pins. See Figure 20. Carefullyinstall the replacement meter movement on the pins.Make sure the pins are correctly aligned on the backof the meter before pushing the meter on the pins.

6. If the battery indicator, circuit board for thehourmeter or the buzzer will be replaced, re-move the screws that fasten the circuit boardto the housing. Disconnect the connector fromthe circuit board. Remove the buzzer from thebottom of the circuit board. Make sure to installthe fiber washer when installing the replace-ment buzzer on the replacement circuit board. Ifnecessary, carefully lift the meter movement upoff the pins of the circuit board without bendingthe pins. See Figure 20. Carefully install thereplacement meter movement on the pins of thereplacement circuit board. Make sure the pinsare correctly aligned on the back of the meterbefore pushing the meter on the pins. Connectthe electrical connector to the circuit board andinstall the circuit board assembly in the housing.

7. If the LED indicator assembly will be replaced,first remove the 18-pin connector. It is neces-sary to remove the front steering column coverwith the display panel assembly attached for ac-cess to the connector. After removing the screws

that fasten the front cover, carefully disconnectthe connector. It can be necessary to disconnectthe key switch wires (Step 4) and the two wireconnector for enough clearance to disconnect the18-pin connector. Remove the two screws thatfasten the LED assembly to the housing. Installthe replacement LED assembly, carefully con-nect all connectors and wires. Install the frontsteering column cover with the display panel as-sembly attached. Install the LED gasket over theLED indicators.

8. If necessary, install a new O-ring gasket. Care-fully install the O-ring gasket in the groove ofthe top cover. Carefully install the top cover as-sembly over the LED indicators and assemblyhousing without damaging either the LED gas-ket or O-ring gasket. Make sure the O-ring gas-ket is still correctly aligned with the cover andhousing before installing the screws. Install theeight screws that fasten the top cover to the panelhousing and tighten them in a cross pattern.

PERFORMANCE DISPLAY PANEL,REPLACE PARTS

NOTE: The only replaceable parts of the Perfor-mance display panel are the O-ring seal, key switch,wires to the key switch and the housing that fastensto the steering column. All other parts of the panelmust be replaced as a single unit. See Display PanelAssembly, Replace of this section.

27

Specifications 2200 SRM 143

Dash Mount Display Panel (EV100/200ZX MotorControllers) Replacement

REMOVE AND REPLACE

The display panel is in the dash. See Figure 21. Thedisplay panel cannot be repaired and must be re-placed if it has a malfunction. These display panelsmust be replaced as a unit.

1. Disconnect the battery.

2. Disconnect the plug connector on the back of thedisplay panel. Access is under the dash.

3. Remove the four nuts that fasten the displaypanel and lift it up out of the dash.

4. Install the replacement display panel in thedash.

5. Install and tighten the nuts that fasten the dis-play panel in the dash and install the plug con-nector.

1. DASH PANEL2. DISPLAY PANEL3. MOUNT NUTS

4. PLUGCONNECTOR

Figure 21. Dash Mount Display Panels

SpecificationsMETER SPECIFICATIONS

Item Design Data

Operating Voltage

Hourmeter

Engine-Powered Equipment 12V, 24V

Electric Motor-Powered Equipment 12V, 24V, 36V, 48V, 72V, 80V or multiple 30 to 130V

All Other Meters 12V, 24V

Terminal Threads #10-32 UNF or #6-32 UNC

Range of Meter

Hourmeter 0.0 to 9.999.9 Hours

Ammeter 0 to 60 Amps

Voltmeter 10 to 16 Volts

Temperature Gauge (Range Based on Require-ments)

38 to 104 C (100 to 220 F)38 to 121 C (100 to 250 F)38 to 182 C (100 to 360 F)

28

2200 SRM 143 Troubleshooting

Item Design Data

Pressure Gauge (Range Based on Requirements) 0 to 552 kPa (0 to 80 psi)0 to 1380 kPa (0 to 200 psi)0 to 2068 kPa (0 to 300 psi)

Method of Mounting To Panel with Bracket

SENDER SPECIFICATIONS

Item Design Data

Operating Voltage

All Senders 12-Volt System

Terminal Threads (Electrical)

All Senders #10-32 UNF-2A

Fastener Data (To Fit in a Threaded Hole)

Temperature Sender

Body Threads 1/2-14 Dryseal

Hex (Across Flats) 23.4 mm (0.92 in.) for a 15/16 in. Wrench

Pressure Sender

Fitting Threads 1/8-27 Dryseal NPTF

Hex (Across Flats) 22.4 mm (0.88 in.) for a 7/8 in. Wrench

Fuel Sender Plate

Number of Holes 5 (Not Equally Spaced)

Hole Size 5 - 5.1 mm (0.196 - 0.200 in.)

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

METER

No Indication - All Meters Battery disconnected. Clean the battery terminals and bat-tery cable connectors. Install connec-tors.

Battery malfunction or discharged. Charge or replace battery.

Wiring group connector or connec-tors not connected.

Fasten the connector or connectors.

29

Troubleshooting 2200 SRM 143

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No Indication - Only OneMeter

Meter wires damaged or not con-nected.

Replace the broken wires or connec-tors. Install connectors on proper me-ter terminals.

Separate sender wire damaged ornot connected.

Replace broken wire or connector. In-stall connector on sender terminal.

Meter malfunction. Voltage is at ter-minal.

Replace meter.

Sender malfunction. Voltage is atterminal.

Replace sender.

Incorrect Indication Battery is discharged. Charge battery.

Meter movement or needle is dam-aged or has a malfunction.

Replace meter.

Separate sender malfunction. Replace sender.

Sender will not sense because sys-tem has corrosion.

Clean and flush system.

30

TECHNICAL PUBLICATIONS

2200 SRM 143 8/04 (12/03)(11/99)(3/99)(6/98)(9/96)(2/95)(5/91)(4/89)(1/79) Printed in United Kingdom

tocInstrument Panel Indicators and SendersSafety Precautions Maintenance and RepairGeneralDescriptionSteering Column Gauges, Meters, and IndicatorsLED Display PanelBattery Discharge IndicatorsBrush Wear IndicatorsMotor Temperature Indicators

LX Series Display PanelHourmeter FunctionsBattery Indicator FunctionStatus Code Function

ZX Series Display PanelsDisplay PanelBasic Display PanelsPerformance DisplayBrush Wear Indicators

Adjustments - GeneralReplacement - General InformationMeter ReplacementSender ReplacementFuel Level SenderPressure and Temperature Sender

ITW Display Panel ReplacementRemove

Column Mount Display Panel (EV-100/200ZX Motor Controllers) ReplRemoveDisplay Panel Assembly, ReplaceIndicator LEDsBattery IndicatorsDigital Display (Performance Display Panel Only)Status Code or Performance Level Switches and Indicator LEDs (PeBasic Display Panel, Replace PartsPerformance Display Panel, Replace Parts

Dash Mount Display Panel (EV100/200ZX Motor Controllers) ReplaceRemove and Replace

SpecificationsMeter SpecificationsSender Specifications

TroubleshootingMeter

2200srm0143-910110(08-2004)-uk-en

Documents

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