INSTRUMENT PANEL

INDICATORS AND
SENDERS
H40.00-48.00XM-12
(H800-1050HD/HDS) [A917];
RS45-27CH, RS45-31CH, RS46-36CH,
RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH,
RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS
IH (HR45-27, HR45-31, HR45-36, HR45-40,
HR45-41S, HR45-41L, HR45-41LS) [B222];
H40.00-52.00XM-16CH
(H1050HD-CH, 1150HD-CH) [F117]

PART NO. 1616439 2200 SRM 1234

 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 ....................................................................................................................................................... 6
Seat Switch Logic ...................................................................................................................................... 7
Central Warning Light Output................................................................................................................. 7
Buzzer Output ........................................................................................................................................... 7
Instrument Panel Component Replacement .................................................................................................... 9
Instrument Panel........................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Light ............................................................................................................................................................... 10
Replace ....................................................................................................................................................... 10
Sender Replacement .......................................................................................................................................... 10
Fuel Level Sender .......................................................................................................................................... 10
Pressure Sender............................................................................................................................................. 11
Temperature Sender ...................................................................................................................................... 11
Low Coolant Sender....................................................................................................................................... 12
Vacuum Switch .............................................................................................................................................. 12
Crankshaft Position Sensor .......................................................................................................................... 12

This section is for the following models:

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];

RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

©2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1234 Description

General
Meters provide information to the operator on the Meters and displays are used to provide operator in-
condition of various systems. Gauges may be either formation on the status of many systems including
direct reading (mechanical) or indirect (electrical). engine oil pressure, fuel level, transmission oil pres-
Unlike mechanical gauges, electrical gauges have sure, engine coolant temperature, transmission oil
electrical meter movements, light emitting diodes temperature, hour display, and transmission fault
(LEDs), or digital displays inside the case. These me- codes. See Figure 1 and Table 1.
ters receive an electrical signal from a sender unit,
usually in the engine or transmission case. This
section only describes electrical meters, senders, and
instrument panel displays.

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.
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.

Many meters and displays require a separate sender.

Figure 1. Instrument Panel and Indicators

1
Description 2200 SRM 1234

Table 1. Instrument Panel and Indicators

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
1 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 light will come
ON. When the engine temperature is critical, the engine
stop light will come ON. The central warning lights
will come ON. The buzzer will sound. There will be
a fault code displayed on the fault indicator. Engine
performance may decrease or the engine may shut down.
Immediately shut down the engine.

NOTE: Engine shut down can be reset. Turn the key switch
to OFF, and then the ON position, and restart the engine.
If the fault is still present, the engine will only run for a
limited time.
2 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 "E", see the section Cummins Diesel Engine
Fault Code Guide 600 SRM 1232 (F117 and A917)
or Cummins Diesel Engine Fault Code Guide
600 SRM 1172 (B222). For access and explanation
of fault codes that start with a "T" or "TE", see the
sectionTransmission, (TE27 and TE32) 1300 SRM
1220.
3 Start Aid/Diagnostic If this warning light is ON when the engine is running, or
Warning Light 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.
4 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 sound. The
central warning lights will be ON. 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.

2
2200 SRM 1234 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.
5 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.

6 RSP/Transmission Red light will FLASH if there is a redundant shutdown

Pressure Feedback path (RSP) error. The fault code will be displayed on
Warning Light 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.
7 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.
8 Optional Auto Orange light comes ON when the grease level in the
Lubrication Warning grease container is low. The central warning lights will be
Light ON. If the lights are ON, refill with appropriate lubricant.

9 Hydraulic Oil Filter This orange hydraulic oil filter restriction light will come
Restriction Warning ON when the hydraulic oil filter or brake filter restriction
Light (Optional) is high. The filter needs cleaning or replaced. The central
warning lights will be ON.

NOTE: The central warning lights 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.

3
Description 2200 SRM 1234

Table 1. Instrument Panel and Indicators (Continued)

Item
Item Function
No.
NOTE: For all warning lights, there is a light check after power-up.
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.
After starting the engine, wait until the light is OFF
before releasing the park brake or operating the lift truck.

WARNING
Do not 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.

13 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 24 VDC, the gauge symbol will
FLASH red. The central warning lights will come ON.

14 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 be ON.

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

4
2200 SRM 1234 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.
16 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.
17 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.

18 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.
19 Cummins Orange maintenance light is ON when maintenance
Maintenance Warning is required. A fault code may be shown on error LCD
Light display. The central warning lights will be ON.

5
Description 2200 SRM 1234

CONNECTOR
The instrument panel is connected to the system by
means of one connector. The connector is located at
rear of instrument panel. See Figure 2 and Table 2.

Figure 2. Connector

Table 2. Pin Description

Pin Description Pin Description

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

6
2200 SRM 1234 Description

Seat Switch Logic • Brake system pressure warning light is ON

This function warns the operator when leaving the
seat without applying park brake. Two seconds af-
ter having detected this condition, the buzzer is acti-
vated and stays ON for 10 seconds.
The seat switch is connected to pin number 2. When
the seat is occupied, pin number 2 is connected to
ground. When the seat is not occupied, input to pin
number 2 is open.
Central Warning Light Output
This output is at pin number 19 and switches to
ground when any of the following conditions occur:
• Engine oil pressure is low
• Engine coolant temperature is high
• Transmission oil pressure is below 999 kPa
(145 psi)
• Transmission oil temperature is above 132 C
(270 F)
• Fuel level is below 10% of the capacity
• Brake system temperature warning light is ON
• Engine coolant level warning light is ON
• Intake manifold air temperature is high
• Engine stop light is ON
Buzzer Output
This output is at pin number 17 and switches to
ground when any of the following conditions occur:
• Engine oil pressure is low
• Engine coolant temperature is high
• Transmission oil pressure is below 999 kPa
(145 psi)
• Transmission oil temperature is above 132 C
(270 F)
• When the operator is not present and park brake is
not applied. The buzzer will be ON for 10 seconds.
• Intake manifold air temperature is high
Table 3 below describes the senders which send elec-
tronic signals to the display panel.

Table 3. Sender Description

Item Function
Engine Oil Pressure The engine oil pressure sender is located on the side of the
Sender engine block and senses the engine oil pressure. If the oil
pressure drops lower than specifications, the sender transmits
a signal to the control panel and lights the engine oil pressure
indicator. The engine oil pressure sender signal also drives
the engine oil pressure gauge.

CAUTION
Do not continue to operate the lift truck if the red light
is ON at engine speeds above idle.
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 orange
light is ON during operation.

7
Description 2200 SRM 1234

Table 3. Sender Description (Continued)

Item Function
Fuel Level Sender The fuel level sender is installed in the fuel tank and indicates
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 orange
light is ON during operation.
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 8
ON when the air intake pressure drops below 6.4 kPa (0.9 psi).

Low Pressure Sender
CAUTION
Lift truck performance will be limited when the red light
is ON.
The low pressure sender is mounted in the manifold on the
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 14.

WARNING
Never operate a truck with a brake malfunction.
Brake Temperature The brake temperature senders are mounted in the wheel
Sender hubs and sense the brake fluid temperature. If the fluid
temperature exceeds 110 C (230 F), the senders send a signal
to the instrument panel and lights warning light 15.

WARNING
Never operate a truck with a brake malfunction.
Intake Manifold This is an active sensor with and output between 0 and 5 volts.
Pressure Sensor The ECM will recognize the output to be valid if it is between
0.5 volt representing 52 kPa (8 psi) and 4.5 volts representing
306 kPa (44 psi).

8
2200 SRM 1234 Instrument Panel Component Replacement

Table 3. Sender Description (Continued)

Item Function
Intake Manifold This is a thermistor-type sensor with an output between 0
Temperature Sensor and 5 volts. The ECM will recognize the output to be valid
if it is between 0.2 volt at 40 C ( 40 F) and 4.9 volts at
150 C (302 F). Sensor diagnostics will detect a fault if the
input voltage is outside this range for more than 2 seconds
continuously.
Crankshaft Position This is a magnetic-type sensor that measures both crankshaft
Sensor speed and position. The sensor will measure speeds above
246 rpm when the output will be greater than 0.4 volt peak
to peak. The sensor detects the passing of teeth on a wheel.
These teeth are spaced at 1/36 intervals of the wheel. One
tooth is missing to facilitate the position measurement. There
are a total of 36 teeth.

Instrument Panel Component Replacement

3. Check that the wiring and connections to meter,
WARNING indicator, or sender are tight and in good condi-
Before replacing any components, fully lower tion.
all parts of the mast and tilt it forward until the
tips of the forks touch the ground. This action INSTRUMENT PANEL
will prevent the mast from lowering suddenly
if the control lever is accidently moved. Remove
ALWAYS disconnect the battery and remove op- NOTE: The only replaceable parts of the instrument
erator key before replacing components. panel are the lights.

Never have any metal on your fingers, arms, or 1. Locate the fuse panel. See Figure 3.
neck. These metal items can accidentally make
an electrical connection and may cause an in- 2. Disconnect ground lead of battery.
jury.

Meters, display panels, most indicators, and senders

are not repairable items. The most accurate and usu-
ally easiest check for proper operation of individual
meters, indicators, or senders is direct replacement.
The most common causes of failure are 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 following
checks.

1. Check that other meters and electrical circuits

operate correctly.
1. FUSE PANEL
2. Check that the battery is fully charged and has a
good ground, and cable terminals are clean and Figure 3. Fuse Panel Location
tight.

9
Sender Replacement
3. Loosen four retaining screws and remove the fuse
panel cover. See Figure 4.
1. RETAINING SCREWS
2. FUSE PANEL COVER
Figure 4. Fuse Panel Screws
4. From the fuse panel side, using a flat blade
screwdriver, depress clips holding instrument
panel in place. Left side first, then right side.
See Figure 5.
1. PANEL CLIPS
Figure 5. Fuse Panel Clips
Sender Replacement
FUEL LEVEL SENDER
WARNING
Before replacing any components, fully lower
all parts of the mast and tilt it forward until the
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.
10
2200 SRM 1234
5. Pull instrument panel away from the console.
See Figure 6.
Figure 6. Instrument Panel Removal
6. Disconnect plug from socket.
7. Loosen 12 screws at rear of instrument panel.
8. Remove rear cover from instrument panel.
LIGHT
Replace
1. Turn light holder counterclockwise and remove.
2. Insert replacement light holder.
3. Turn replacement light holder clockwise and
tighten.
4. Mount cover.
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:
2200 SRM 1234 Sender Replacement

WARNING
All fuel vapors are extremely explosive. Do not
have sparks or flames around vehicles or fuel
storage and service areas. Verify there is no
source of open flame or sparks in the vicinity.
Use caution to prevent sparks from tools.
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.
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.
4. Install new pressure sender.

3. Remove screws that fasten sender plate to tank.

4. Remove sender.

5. Carefully install new sender. Use a new gasket.

6. Verify screw holes are aligned and install screws.

Tighten screws enough to partially compress gas-
ket to prevent leaks.

7. Remove tape from wire connector and install con-

nector on sender terminal.

Figure 8. Pressure Sender

TEMPERATURE SENDER
NOTE: If applicable, replace O-ring when replacing
sender.

1. Turn key switch to OFF position.

2. Disconnect electrical connector.

3. Remove temperature sender. See Figure 9.

4. Install new temperature sender.

1. ELECTRICAL 3. SENDER UNIT

TERMINAL 4. FLOAT ARM
2. PLATE 5. FLOAT

Figure 7. Fuel Level Sender

Figure 9. Temperature Sender

11
Sender Replacement 2200 SRM 1234

LOW COOLANT SENDER

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

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. 1. AMP CONNECTOR

Figure 11. Vacuum Switch

CRANKSHAFT POSITION SENSOR

NOTE: If applicable, replace O-ring when replacing
sensor.

1. Turn key switch to OFF position.

Figure 10. Low Coolant Sender
3. Turn sender counterclockwise and remove.
4. Install a new sender. Use Teflon tape. Turn
clockwise and tighten. Torque 5.6 ±0.6 N•m (50
±5 lbf in).
2. Disconnect electrical connector.
3. Remove crankshaft position sensor. See Fig-
ure 12.
4. Install new crankshaft position sensor.

5. Connect sender wire.

VACUUM SWITCH
1. Turn key switch to OFF position.

2. Disconnect amp connector. See Figure 11.

3. Remove vacuum switch.

4. Install a new vacuum switch.

Figure 12. Crankshaft Position Sensor

12
 TECHNICAL PUBLICATIONS

2200 SRM 1234 7/07 (1/07)(7/06)(5/06)(8/05) Printed in United Kingdom