INSTRUMENT PANEL

INDICATORS AND
SENDERS
H16.00-18.00XM/XMS-12
(H400-450HD/HDS) [A236];
H16.00-22.00XM-12EC
(H400-500HD/HDS-EC) [B214]

PART NO. 1638482 2200 SRM 1278

 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 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 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!
Instrument Panel Indicators and Senders Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
Instrument Panel Meters, Indicators, and LCD Display ............................................................................ 1
Connector ....................................................................................................................................................... 7
Seat Switch Logic .......................................................................................................................................... 8
Central Warning Light Output ..................................................................................................................... 8
Buzzer Output ............................................................................................................................................... 8
Instrument Panel ............................................................................................................................................... 9
Remove ........................................................................................................................................................... 10
Sender Replacement .......................................................................................................................................... 11
Fuel Level Sender .......................................................................................................................................... 11
Pressure Sender............................................................................................................................................. 11
Brake Pressure Sender.................................................................................................................................. 12
Low Coolant Sender....................................................................................................................................... 12
Vacuum Switch .............................................................................................................................................. 12
Specifications...................................................................................................................................................... 13
Troubleshooting.................................................................................................................................................. 14

This section is for the following models:

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];

H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214]

2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1278
General
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 diodes
(LEDs), or digital displays inside the case. These me-
ters receive an electrical signal from a sender unit,
usually in the engine or transmission case. This
Description
GENERAL
Many meters have meter movements that move an
indicating needle attached to a shaft (or pin). The
shaft rotates to swing the needle. Shaft rotation of a
meter is limited to less than one full revolution. Me-
ter faces are calibrated to indicate a range of values.
For examples of meter faces and indicators, see Fig-
ure 1.
Many meters and displays require a separate sender.
Figure 1. Instrument Panel and Indicators
Description
section only describes electrical meters, senders, and
instrument panel displays.
Meters and displays are used to provide operator in-
formation on the status of many systems, including
engine oil pressure, fuel level, system voltage, engine
coolant temperature, transmission oil temperature,
and hour or fault code display. See General.
INSTRUMENT PANEL METERS,
INDICATORS, AND LCD DISPLAY
WARNING
If any of the instruments do not operate as de-
scribed in the following tables, DO NOT oper-
ate lift truck until problem is corrected.
See Figure 1 and Table 1.
1
Description 2200 SRM 1278

Table 1. Instrument Panel and Indicators

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
1 Cummins Orange maintenance light is ON when maintenance is
Maintenance Warning required. A fault code may be shown on the error LCD
Light (Liquid Crystal Display) display. The central warning
lights will be ON.

2 Coolant Level If the engine coolant is low, the red light will come ON.
Warning Light The buzzer will sound. The central warning lights will
be ON.

CAUTION
Do not continue to operate the lift truck when the
red light is ON, or lift truck damage may occur.
3 Engine Oil Level Red engine oil level warning light comes ON and buzzer
Warning Light sounds when the engine oil level is low. The central
(Optional) warning lights will be ON.

CAUTION
Do not continue to operate the lift truck when the
red light is ON. Immediately shut down the engine
or lift truck damage may occur.
4 Engine Air Filter Orange engine air filter warning light is ON when the air
Warning Light filter is dirty or has an obstruction. If the light is ON,
clean or replace the filter element. The central warning
lights will be ON.

5 Fuel Filter/Water Orange light comes ON when the water level in the water
Separator Warning separator is high. Drain the water. A fault code may be
Light (Diesel Engine shown on the fault indicator. The central warning lights
Only) will be ON.

6 Seat Belt Warning Orange light is ON for 10 seconds after the key is placed
Light in the ON position.

WARNING
Before driving the lift truck, always fasten your
safety belt, or personal injury may occur.
7 Auto Lubrication Orange light comes ON when the grease level in the
Warning Light grease container is low. The central warning lights will be
(Optional) ON. If the lights are ON, refill with appropriate lubricant.

2
2200 SRM 1278 Description

Table 1. Instrument Panel and Indicators (Continued)

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
8 Hydraulic Oil Level Red light comes ON when the hydraulic oil level in the
Warning Light hydraulic tank is low. The buzzer sounds. The central
(Optional) warning lights will be ON.

9 Hydraulic Oil Filter
Restriction Warning
Light (Optional)
CAUTION
Do not continue to operate the lift truck when the
red light is ON, or lift truck damage may occur.
This hydraulic oil filter restriction light will come ON
when the hydraulic oil filter restriction is high. The filter
needs cleaning or replaced. The central warning lights
will be ON.

NOTE: The central warning lights will stay ON until

power reset.
10 Wet Brake System Red warning light comes ON when the brake cooling oil
High Temperature temperature is high. The buzzer sounds. The central
Warning Light warning lights will be ON.

CAUTION
Do not continue to operate the lift truck when the
red light is ON, or lift truck damage may occur.
11 Brake System Low Red warning light comes ON when the brake pressure is
Pressure Warning low. The buzzer will sound. The central warning lights
Light will be ON.

WARNING
Do not continue to operate the lift truck when the
red light is ON. Immediately shut down the engine
or personal injury may occur.
12 Parking Brake Red warning light is ON when the parking brake is
Warning Light applied.

3
Description 2200 SRM 1278

Table 1. Instrument Panel and Indicators (Continued)

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
13 Start Aid/Diagnostic This warning light is ON for 15 seconds after the key is
Warning Light turned to the ON position when the engine temperature
is below 3 C (27 F). It indicates that the cold start aid
has been activated. After 15 seconds the light will go
OFF to indicate that the engine can be started.
If this warning light is ON when the engine is running, or
has been shutdown, an electrical fault has been detected.
This warning light FLASHES when the coolant
temperature is over 110 C (230 F), or the intake air
temperature is over 76 C (169 F). Engine performance
may decrease.
14 Engine Stop Warning If the red engine stop warning light comes ON, there is a
Light critical fault condition. The fault code will be displayed
on the error LCD display. The buzzer will also sound.
The central warning lights will be ON. The engine may
shut down. Immediately shut down the engine.

NOTE: Engine shutdown can be reset. Turn the key switch

to OFF and then to ON, and restart the engine. If the fault
is still present, the engine will only run for a limited time.
15 Transmission Fault Red light comes ON when a transmission fault occurs.
Warning Light The fault code will be displayed on the error LCD display.
The transmission may shift to NEUTRAL and/or engine
performance may decrease. The buzzer may sound. The
central warning lights will be ON.

16 RSP/Transmission Red light will FLASH ON if there is a redundant

Pressure Feedback shutdown path (RSP) error. The fault code will be
Warning Light displayed on the error LCD display. The transmission
may shift to NEUTRAL. The buzzer will sound. The
central warning lights will come ON. Shutdown mode
remains selected until the controller is switched OFF.
17 Engine Oil Pressure When the engine is running, the gauge indicates normal
Gauge engine oil pressure, and the needle is approximately in
the middle. When the engine oil pressure is near the
critical value, the gauge symbol will FLASH red. When
the engine oil pressure is critical the red engine stop
light will come ON. The buzzer will sound. The central
warning lights will be ON. Engine performance may
decrease or the engine may shut down. Immediately
shut down the engine.

NOTE: Engine shutdown can be reset. Turn the key switch

to OFF and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a
limited time.

4
2200 SRM 1278 Description

Table 1. Instrument Panel and Indicators (Continued)

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
18 Fuel Level Gauge When the fuel level is 10% or less of the tank capacity,
the gauge symbol will FLASH red. The central warning
lights will come ON.

19 Voltmeter Gauge The voltmeter indicates the system voltage. When the
ignition is ON and the engine is not running, the gauge
symbol will be red. When the engine is running and the
system voltage is below 22.5 VDC, the gauge symbol will
FLASH red. The central warning lights will come ON.

20 Transmission Oil Gauge indicates the transmission oil temperature.

Temperature Gauge During normal operation, the needle will be in the
green zone. If the temperature is high or one of the
temperature sensors is out of range, shorted to ground or
not connected, the gauge symbol will FLASH red. There
will be a fault code on the error LCD display. The buzzer
may sound. The central warning lights will be ON. The
transmission may shift to NEUTRAL and/or engine
performance may decrease.

5
Description 2200 SRM 1278

Table 1. Instrument Panel and Indicators (Continued)

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
21 Coolant Temperature Gauge indicates the coolant temperature. When the
Gauge temperature is near the critical value, the gauge symbol
will FLASH red and the engine warning lights will
come ON. When the engine temperature is critical, the
engine stop light will come ON. The central warning light
will come ON. The buzzer will sound. There will be a
fault code displayed on the error LCD display. Engine
performance may decrease or the engine may shut down.
Immediately shut down the engine.

NOTE: Engine shutdown can be reset. Turn the key switch

to OFF and then to ON position, and restart the engine.
If the fault is still present, the engine will only run for a
limited time.
22 Hourmeter/Error LCD The hourmeter operates while the engine is running.
Display Periodic maintenance recommendations are based on
these hours. It also displays engine and transmission
faults. Additional information is indicated when faults
occur. If more than one fault is present, the faults will
scroll. For access and explanation of fault codes that start
with an E, see the section Cummins Diesel Engine
Fault Code Guide 600 SRM 1269. For fault codes that
start with a t or tE, see the section Transmission,
(TE13 and TE17) 1300 SRM 1271.

6
2200 SRM 1278 Description

CONNECTOR
Instrument panel is connected to the system by
means of one connector. Connector is located at rear
of instrument panel. SeeFigure 2 and Table 2.

Figure 2. Connector

Table 2. Pin Description

Pin Description Pin Description

1 Battery positive input 13 Brake system pressure input
2 Seat switch input 14 Can - H
3 Not used 15 Can - L
4 Ground 16 Not used
5 Engine coolant level input 17 Buzzer output
6 Brake system temperature input 18 Hydraulic oil level input
7 Park brake input 19 Central light output
8 Engine oil level input 20 Hydraulic filter input
9 Engine combustion air filter input 21 Not used
10 Fuel filter input 22 Not used
11 Neutral gear input 23 Engine oil pressure gauge input
12 Lubrication system input 24 Fuel level gauge input

7
Description 2200 SRM 1278

SEAT SWITCH LOGIC BUZZER OUTPUT

This function warns the operator when leaving the
seat without applying park brake. Two seconds after
having detected this condition, buzzer is activated
and stays ON for 10 seconds.
The seat switch is connected to pin number 2. When
seat is occupied, pin number 2 is connected to ground.
When seat is not occupied, input to pin number 2 is
open.
CENTRAL WARNING LIGHT OUTPUT
This output is at pin 19 and switches to ground at
all fault codes or warning lights, except for seat
belt warning light and parking brake warning light,
including the flashing gauge symbols. The central
warning light will be ON.
This output is at pin number 17 and switches to
ground when any of the following conditions occur:
Engine errors activating the buzzer
High brake system temperature
Low system voltage
Low brake system pressure
Low hydraulic oil level
Low engine oil level
Low engine coolant level
Low engine oil pressure
High engine coolant temperature
Pressure feedback sensor failure and/or RSP con-
nect error
Transmission oil temperature is above 120 C
(248 F) or out of range
Transmission errors activating the buzzer
When the operator is not present and park brake is
not applied, the buzzer will sound for 10 seconds.

Table 3. Sender Description

Item Function
Engine Oil Pressure The engine oil pressure sender is assembled in the engine.
Sender

Low Coolant Sender The low coolant sender is mounted in the coolant system
radiator near the top of the tank. It senses the fluid level and,
when low, sends a signal to the control panel and lights the
coolant system fluid low warning indicator.

CAUTION
Do not continue to operate the lift truck if the red light
is ON during operation.
Fuel Level Sender The fuel level sender is installed in the fuel tank and indicates
(Diesel Engine Only) when the fuel is low. An internal float sends a signal to the
control panel and lights the fuel level low warning indicator.
A signal is also sent to the fuel level gauge to indicate the
amount of fuel remaining in the tank.

CAUTION
Do not continue to operate the lift truck if the red light
is ON during operation.

8
2200 SRM 1278 Instrument Panel

Table 3. Sender Description (Continued)

Item Function
Vacuum Switch The vacuum switch is mounted on the air filter housing (left
side of the truck). It senses the air intake pressure and sends
a signal to the instrument panel. It switches warning light 4
ON when the air intake pressure drops below 6.4 kPa (0.9 psi).

CAUTION
Lift truck performance will be limited when the orange
light is ON.
Air Brakes Low The low pressure sender is mounted in the manifold on the
Pressure Sender cab tilt frame and senses the brake system pressure. When
pressure drops below specified value, the sender sends a signal
to the instrument panel and lights the low pressure warning
light 11.

WARNING
Never operate a truck with a brake malfunction.
Wet Brakes Low The low pressure sender is mounted in the combination
Pressure Sender valve and senses the brake system pressure. When pressure
drops below specified value, the sender sends a signal to the
instrument panel and lights the low pressure warning light 11.

WARNING
Never operate a truck with a brake malfunction.
Brake Temperature The brake temperature senders are mounted in the wheel hubs
Sender (Wet Brakes (one on the left-side hub and one on the right-side hub) and
Only) sense the brake fluid temperature. If the fluid temperature
exceeds high temperature specifications, the senders send a
signal to the instrument panel and lights warning light 10.

WARNING
Never operate a truck with a brake malfunction.

Instrument Panel
ALWAYS disconnect the battery and remove op-
WARNING erator key before replacing components.
Before replacing any components, fully lower
all parts of the mast and tilt it forward until the Never have any metal on your fingers, arms, or
tips of the forks touch the ground. This action neck. These metal items can accidentally make
will prevent the mast from lowering suddenly an electrical connection and may cause an in-
if the control lever is accidently moved. jury.

9
Instrument Panel 2200 SRM 1278

Meters, display panels, most indicators, and senders panel in place. Left side first, then right side.
are not repairable items. The most accurate and usu- See Figure 5.
ally easiest check for proper operation of individual
meters, indicators, or senders is direct replacement. 5. Pull instrument panel away from the console.
The most common causes of failure are poor connec- See Figure 6.
tions or damaged or improper wiring, and not the me-
6. Disconnect plug from socket.
ter indicator or sender. This section only has the re-
placement procedures. Before a meter, display panel,
indicator, or sender is replaced, make the following
checks.

1. Check that other meters and electrical circuits

operate correctly.

2. Check that the battery is fully charged and has a

good ground, and cable terminals are clean and
tight.

3. Check that the wiring and connections to meter,

indicator, or sender are tight and in good condi- 1. RETAINING SCREWS
tion. 2. FUSE PANEL COVER

REMOVE Figure 4. Fuse Panel Screws

NOTE: There are no serviceable parts of the instru-

ment panel. If one of the components fail, the instru-
ment panel must be replaced.

1. Locate the fuse panel. See Figure 3.

1. PANEL CLIPS

Figure 5. Fuse Panel Clips

1. FUSE PANEL

Figure 3. Fuse Panel Location

2. Disconnect ground lead of battery.

3. Loosen four retaining screws and remove the fuse

panel cover. See Figure 4.
Figure 6. Instrument Panel Removal
4. From the fuse panel side, using a flat blade
screwdriver, depress clips holding instrument

10
2200 SRM 1278 Sender Replacement

Sender Replacement
FUEL LEVEL SENDER 6. Verify screw holes are aligned and install screws.
Tighten screws enough to partially compress gas-
WARNING ket to prevent leaks.
Before replacing any components, fully lower 7. Remove tape from wire connector and install con-
all parts of the mast and tilt it forward until the nector on sender terminal.
tips of the forks touch the ground. This action
will prevent the mast from lowering suddenly
if the control lever is accidently moved.

ALWAYS disconnect the battery and remove op-

erator key before replacing components.

Never have any metal on your fingers, arms, or

neck. These metal items can accidentally make
an electrical connection and may cause an in-
jury.

The fuel level sending unit is mounted to fuel tank

surface (usually top surface) with screws through
the sender plate and gasket. See Figure 7. Correct
sender operation and screw hole alignment can only
be obtained with plate mounted in one position.
Replace sender as follows:

WARNING
All fuel vapors are extremely explosive. Do not
have sparks or flames around vehicles or fuel
storage and service areas. Make sure there is 1. ELECTRICAL 3. SENDER UNIT
no source of open flame or sparks in the vicin- TERMINAL 4. FLOAT ARM
ity. Use caution to prevent sparks from tools. 2. PLATE 5. FLOAT

1. Turn key switch to OFF position. Disconnect
battery positive cable at battery. Install a lock
or tag on connector to prevent connection.
2. Disconnect sender wire at sender.
3. Remove screws that fasten sender plate to tank.
4. Remove sender.
5. Carefully install new sender. Use a new gasket.
Figure 7. Fuel Level Sender
PRESSURE SENDER
NOTE: If applicable, replace O-ring when replacing
sender.
1. Turn key switch to OFF position.
2. Disconnect electrical connector.
3. Remove pressure sender. See Figure 8.

11
Sender Replacement 2200 SRM 1278

NOTE: Verify system fluid is drained so the level is

below sender to prevent leakage when sender is re-
moved.

1. Turn key switch to OFF position.

2. Disconnect sender wire. See Figure 10.

Figure 10. Low Coolant Sender

Figure 8. Pressure Sender
3. Remove sender.
4. Install new pressure sender.
4. Install a new sender.
BRAKE PRESSURE SENDER 5. Connect sender wire.
NOTE: If applicable, replace O-ring when replacing
sender.
VACUUM SWITCH
1. Turn key switch to OFF position.
1. Turn key switch to OFF position.
2. Disconnect amp connector. See Figure 11.
2. Disconnect electrical connector.
3. Remove vacuum switch.
3. Remove pressure sender. See Figure 9.
4. Install a new vacuum switch.
4. Install new pressure sender.

1. AMP CONNECTOR

Figure 9. Brake Temperature Sender Figure 11. Vacuum Switch

LOW COOLANT SENDER

WARNING
High temperature risk. Radiator temperature
may be high and radiator may be pressurized.

12
2200 SRM 1278 Specifications

Specifications
Item Design Data
Instrument Panel
Supply voltage 22-32 VDC
Nominal and test voltage 26 VDC
Working temperature 25 C ( 13 F) to +65 C (149 F)
Storage temperature 40 C ( 40 F) to +80 C (176 F)
Transparent surface Glass
Gauges
Instrument panel gauges Actuator: PWM coil type
Needle stroke: 90 degrees
Reading tolerances: 4 degrees
Hourmeter/Error LCD Display
View angle 12 oclock
Polarized Transflective. Positive
Drive method 1/2 Duty
Driving voltage 5.0 VDC
Indication Engine running hours
Maximum 99,999 hours
Error codes indication
Senders
Operating voltage 24 VDC
Engine oil pressure sender
Body threads 1/8-27 NPTF Dryseal
Low coolant sender
Body threads 1/4-18 PTF - SAE Short
Hex (across flats) 25.4 mm (1.0 in.)
Sender terminal threads Mates with Packard Electric Division 15300027
Series 280 "METRI - PACK Connector Assembly
Fuel sender plate
Number of holes 6
Hole size 5.5 mm (0.22 in.)
Air brakes low pressure sender
Body threads 1/8-27 NPT
Hex (across flats) 11 mm (0.43 in.)

13
Troubleshooting 2200 SRM 1278

Item Design Data

Wet brakes low pressure sender
Body threads 1/4" NPT
Hex (across flats) 27 mm (1.063 in.)
Wet brakes temperature sender
Body threads 3/8" NPTF
Vacuum switch
Body threads 1/8-27 NPT

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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- Fasten the connector or connectors.

tors not connected.

No Indication - Only One Meter wires damaged or not con- Replace display connectors. Install
Meter nected. connectors on proper meter termi-
nals.

Separate sender wire damaged or Replace broken wire or connector. In-

not connected. stall connector on sender terminal.

Meter malfunction. Voltage is at ter- Replace fault display.

minal.

Sender malfunction. No voltage is at Replace sender.

terminal.

Incorrect Indication Battery is discharged. Charge battery.

Meter movement or needle is dam- Replace fault display.

aged or has a malfunction.

Separate sender malfunction. Replace sender.

Sender will not sense because sys- Clean and flush system. Check for
tem has corrosion. bent or cracked sensor tubing.

14
 TECHNICAL PUBLICATIONS

2200 SRM 1278 1/07 (5/06) Printed in United Kingdom