INSTRUMENT PANEL

INDICATORS AND

SENDERS

H8.00-12.00XM (H170-280HD) [F007];

H13.00-16.00XM (H300-360HD) [E019];

H10.00-12.00XM-12EC (H360HD-EC) [E019]

PART NO. 1494143

2200 SRM 939

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 ...............................................................................................................................................................

Description .........................................................................................................................................................

General ...........................................................................................................................................................

Instrument Panel Meters, Indicators, and LCD Display ............................................................................

Error Code Display, Transmission ................................................................................................................

Error Code Display, Engine...........................................................................................................................

Connector .......................................................................................................................................................

Seat Switch Logic ......................................................................................................................................

Central Warning Light Output.................................................................................................................

Buzzer Output ...........................................................................................................................................

Engine Shutdown Output .........................................................................................................................

Instrument Panel Component Replacement ....................................................................................................

Instrument Panel...........................................................................................................................................

Remove.......................................................................................................................................................

Light ...............................................................................................................................................................

Replace .......................................................................................................................................................

Sender Replacement ..........................................................................................................................................

Fuel Level Sender ..........................................................................................................................................

Transmission Pressure and Temperature Sender, Tier 1 ............................................................................

Pressure Sender, Tier 2 .................................................................................................................................

Temperature Sender, Tier 2 ..........................................................................................................................

Low Coolant Sender.......................................................................................................................................

Vacuum Switch ..............................................................................................................................................

Crankshaft Position Sensor ..........................................................................................................................

Specifications......................................................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models:

H8.00-12.00XM (H170-280HD) [F007];

H13.00-16.00XM (H300-360HD) [E019];

H10.00-12.00XM-12EC (H360HD-EC) [E019]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

2200 SRM 939

Description

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

section only describes electrical meters, senders, and
instrument panel displays.

Meters and displays are used to provide operator
information on the status of many systems, includ-
ing engine oil pressure, fuel level, transmission oil
pressure, engine coolant temperature, transmission
oil temperature, and hour display, and transmission
fault codes. For further data, see Figure 1.

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.

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.

Figure 1. Instrument Panel and Indicators

Description

2200 SRM 939

Table 1. Instrument Panel and Indicators

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Battery Charging
Condition Warning
Light

The light will NOT come ON when the key is placed in
the ON position and the engine is not running. The light
must be OFF while the engine is running. If the light
comes ON during operation, there is a problem that must
be checked immediately.

CAUTION

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

Low Engine Oil
Pressure Warning
Light, Tier 1

The red light must be OFF when the engine is running.
If the engine oil pressure is less than or equal to 69 kPa
(10 psi), the red light will come ON, and a buzzer will
sound. The central warning light will also come ON, and
30 seconds later, the engine will shut down.

CAUTION

Stop the engine immediately if the red light is ON
while the engine is running.

Low Engine Oil
Pressure Warning
Light, Tier 2

The red light must be OFF, when the engine is
running. When the engine oil pressure gets below
200 kPa (29 psi)above 950 rpm, or gets below 150 kPa
(22 psi)below 950 rpm, the red light will be ON.

Coolant Temperature
Warning Light, Tier 1

The red light must be OFF when the engine is running.
If the engine coolant temperature is more than or equal
to 120 C (248 F), the red light will come ON, and a buzzer
will sound. The central warning light will also come ON,
and 30 seconds later, the engine will shut down.

CAUTION

Do not continue to operate the lift truck when the
light is ON. This indicates that the engine is too hot.

Coolant/Intake Air
Temperature Warning
Light, Tier 2

The red light must be OFF when the engine is running.
If the engine cooling is more than 110 C (230 F), or the
intake air temperature is more than 76 C (169 F), the
red light will come ON, and a buzzer will sound. The
central warning light will also come ON and the start
aid/diagnostic/engine warning light will flash. The engine
may be de-rated.

CAUTION

Do not continue to operate the lift truck when the
light is ON. This indicates that the engine is too hot.

2200 SRM 939

Description

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Transmission Oil
Pressure Warning
Light

The red light is ON when the key switch is in the START
position and must go OFF when the engine is running.
If the transmission oil pressure is less than or equal to
1000 kPa (145 psi), the red light will come ON, and a
buzzer will sound. The central warning light will also
come ON.

CAUTION

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

Transmission Oil
Temperature Warning
Light, Tier 1

The red light must be OFF when the engine is running.
If the transmission oil temperature is more than or equal
to 132 C (270 F), the red light will come ON, and a buzzer
will sound. The central warning light will also come ON,
and 30 seconds later, the engine will shut down.

CAUTION

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

Transmission Oil
Temperature Warning
Light, Tier 2

CAUTION

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

Park Brake Warning
Light

The light is ON when the park brake is applied or when
there is not enough pressure to release the parking brake.

Cold Start Warning
Light, Tier 1

The cold start warning light is ON when the cold start
button (Perkins Engine Only) is depressed to aid in
starting the engine.

Description

2200 SRM 939

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Start Aid/Diagnostic/
Engine Warning
Light, Tier 2

The start aid/diagnostic/engine warning light is ON
before the engine is cranked and the cold start aid
is activated. The start aid/diagnostic/engine warning
light flashes when the coolant temperature is over
110 C (230 F), or the intake air temperature is over
76 C (169 F). The engine may be derated. If the start
aid/diagnostic/engine warning light is ON when the
engine is running, or has been shut down, an electrical
fault has been detected.

Engine Air Filter
Warning Light

The red light must be OFF when the engine is running.
The engine air filter warning light is ON when the engine
air filter is dirty or has an obstruction. If the light is ON,
replace the air filter element.

CAUTION

Do not operate the lift truck when the light is ON.
Stop the truck immediately.

Coolant Level
Warning Light

The red light must be OFF when the engine is running.
If the engine coolant is low, the red light will come on.
The central warning light will also come on.

CAUTION

Do not continue to operate the lift truck when the
light is ON. This indicates that the engine is too hot.

Seat Belt Warning
Light

This orange light is ON for 10 seconds after the key is
placed in the ON position.

WARNING

Before driving the lift truck, always fasten your
safety belt.

Fuel Filter Warning
Light

The orange light must be OFF when the engine is
running. The orange fuel filter warning light is ON when
the fuel filter is dirty or has an obstruction.

CAUTION

Clean or replace the fuel filter immediately.

Fuel Reserve Warning
Light

The orange light must be OFF when the engine is
running. The orange fuel reserve warning light is ON
when the fuel level is below 10% of the fuel tank capacity.
The central warning light will also come ON.

2200 SRM 939

Description

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

STOP Engine Warning
Light, Tier 1

The red light must be OFF when the engine is running.
When either the engine coolant temperature, the
transmission oil temperature, or the engine oil pressure
reaches the alarm values, the STOP light, the central
light, and buzzer will be activated. After 30 seconds, the
truck will automatically shut down. This can be reset by
turning the key switch to OFF and back ON, which will
allow the driver 30 seconds to move the truck.

CAUTION

When the light is ON, immediately STOP the lift
truck.

STOP Engine Warning
Light, Tier 2

The red light must be OFF when the engine is running.
When the transmission oil temperature gets above 132 C
(270 F) the STOP light flashes, the central light and
buzzer will be activated, and the engine may be derated.
When the engine oil pressure, above 950 rpm, gets below
200 kPa (29 psi) but above 150 kPa (22 psi) the STOP
light will be ON Below 150 kPa (22 psi) the STOP light
will Flash, the central light and buzzer will be activated,
and the engine may be derated. When the engine oil
pressure, below 950 rpm, gets below 150 kPa (22 psi), the
STOP light will flash, the central light and buzzer will be
activated, and the engine may be derated.

Low Brake Pressure
Warning Light

The red light must be OFF when the engine is running.
The red light is ON when the pressure in the brake
system is too low. The central warning light will also
come ON.

WARNING

Do not operate the lift truck when the light is ON.

High Brake
Temperature Warning
Light

The red light must be OFF when the engine is running.
This red light is ON when the temperature in the brake
system is higher than normal operating temperature for
brake system. The central warning light will also come
on.

WARNING

Do not operate the lift truck when the light is ON.

Description

2200 SRM 939

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Transmission Failure
Warning Light

The red light must be OFF when the engine is running.
This red light comes ON (solid or flashes) when a
transmission error occurs. At the same time, an error
code is displayed in the hourmeter display. The central
warning light will also come ON, when the red light is
ON (solid). Sometimes a buzzer will sound. For further
reference see Error Code Display, Transmission.

CAUTION

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

Engine Oil Pressure
Gauge, Tier 1

Gauge indicates normal engine oil pressure when the
needle is approximately in the middle of the scale. If the
engine oil pressure drops to less than or equal to 69 kPa
(10 psi), the red light will come ON and a buzzer will
sound. The central warning light will also come ON, and
30 seconds later, the engine will shut down. The engine
shutdown can be reset by turning the key switch to OFF
and back ON, which will allow the driver 30 seconds to
move the truck.

CAUTION

Stop the engine immediately if the red light is ON
while the engine is running.

Engine Oil Pressure
Gauge, Tier 2

When the engine is running the gauge indicates normal
engine oil pressure when the needle is approximately in
the middle of the scale. When the engine oil pressure,
above 950 rpm, gets below 200 kPa (29 psi) but above
150 kPa (22 psi) the STOP light will be ON. Below
150 kPa (22 psi) the STOP light will flash, the central
light and buzzer will be activated, and the engine may be
derated. When the engine oil pressure, below 950 rpm,
gets below 150 kPa (22 psi), the STOP light will flash,
the central light and buzzer will be activated, and the
engine may be derated.

Fuel Level Gauge

This gauge indicates the level of fuel in the fuel tank.
When the fuel level is 10% or less of the tank capacity,
the orange warning light will come ON and the central
warning light also will come ON.

2200 SRM 939

Description

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Transmission Oil
Pressure Gauge

Gauge indicates the transmission oil pressure while the
engine is running. During normal operation, the gauge
needle is approximately in the middle of the scale. If
the pressure drops to 1000 kPa (145 psi) or less, the red
warning light will come ON, the buzzer will sound, and
the central warning light will come ON.

CAUTION

Do not continue to operate the lift truck when the
gauge indicates that the transmission oil pressure
is too low.

Transmission Oil
Temperature Gauge

Gauge indicates the transmission oil temperature while
the engine is running. During normal operation, the
gauge needle will be in the green zone. If the temperature
is 132 C (270 F) or greater, the red warning light will
come ON, the buzzer will sound, the central warning light
will come ON, and the engine will shut down 30 seconds
later. The engine shutdown can be reset by turning the
key switch to OFF and back ON, which will allow the
driver 30 seconds to move the truck.

CAUTION

Do not continue to operate the lift truck when the
gauge indicates that the transmission oil tempera-
ture is too high (needle in the red zone).

Coolant Temperature
Gauge, Tier 1

Gauge indicates engine coolant temperature when key
switch is ON. During normal operation, the gauge needle
will be in the green zone. If the temperature is 120 C
(248 F) or greater, the red warning light will come ON,
the buzzer will sound, the central warning light will come
ON, and the engine will shut down 30 seconds later. The
engine shutdown can be reset by turning the key switch
to OFF and back ON, which will allow the driver 30
seconds to move the truck.

CAUTION

Do not continue to operate the lift truck when the
gauge indicates that the engine is too hot (needle in
the red zone).

Description

2200 SRM 939

Table 1. Instrument Panel and Indicators (Continued)

Item

No.

Item

Function

NOTE: For all warning lights, except the battery warning light and the cold start warning
light, there is a light check after power-up.

Coolant Temperature
Gauge, Tier 2

When the coolant Temperature gets above 110 C (230 F),
the start aid/diagnostic/engine warning light flashes,
red warning light will be ON, the buzzer will sound, the
central warning light will come ON, and the engine will
be derated.

Hourmeter and Error
Code Indicator

The hourmeter operates while the engine is running.
Periodic Maintenance recommendations are based on
these hours. It also displays transmission error codes to
alert the driver of any problems with the transmission.

ERROR CODE DISPLAY, TRANSMISSION

Transmission system error codes take precedence
over hourmeter and will display error codes listed
below as required. If multiple errors occur simul-
taneously, error codes will continually scroll every
3 seconds until error condition is resolved. When
multiple errors exist, truck functionality responds
to worst case error condition. Transmission system
exceeded parameters (error codes 1 through 6) are

self-correcting error conditions and will return truck
to normal functionality when parameter require-
ments are satisfied. Error codes 30 through 41 occur
when equipment failure creates a condition that
could lead to possible safety issues and/or equip-
ment damage and requires component repair or
replacement and a system reset to resume normal
truck functionality. Normal hourmeter display will
return when error conditions are corrected and truck
functionality restored.

Display Output

Error

Code

Description

Transmission

Warning

Light

Central

Warning

Light

Buzzer

ERR01

Reversal speed exceeded

Flash

ERR02

Downshift speed exceeded

Flash

ERR03

High engine. rpm. Prevents transmission
engage

Flash

ERR04

Open

Flash

ERR05

Lift height exceeded (factory setting)

Solid

ERR06

Lift height exceeded

Solid

ERR07

Controller communication failure

Flash

ERR08

Transmission speed sensor-downshift inhibit

Flash

ERR09

Open

Flash

ERR10

Open

Flash

ERR11

Open

Solid

2200 SRM 939

Description

Display Output

Error

Code

Description

Transmission

Warning

Light

Central

Warning

Light

Buzzer

ERR12

Open

Flash

ERR30

Transmission low oil pressure

Solid

ERR31

Transmission high oil temperature

Solid

ERR32

Transmission speed sensor

Solid

ERR33

Engine speed sensor

Solid

ERR34

Throttle position switch

Solid

ERR35

Forward solenoid

Solid

ERR36

Reverse solenoid

Solid

ERR37

First gear solenoid

Solid

ERR38

Second gear solenoid

Solid

ERR39

Fwd/Rev selected at the same time

Solid

ERR40

Multiple range shifter positions

Solid

ERR41

Transmission controller failure

Solid

ERR42

Open

Solid

ERR43

Open

Solid

ERROR CODE DISPLAY, ENGINE

The start aid/diagnostic/engine warning light can
be used to identify a diagnostic code. The code will
identify the component, but cannot identify the fault
within the component.

After the code has been

flashed there will be a delay of five seconds before
the next code is flashed. The sequence of flashing
may be restarted at any time by reactivating the
cycling of the key switch.

To identify the fault codes, proceed as follows:

NOTE: The start aid/diagnostic/engine warning light
will flash in a sequence that will identify the diag-
nostic code. For example, flash code 517 will be five
flashes, a delay, one flash, a delay, and seven flashes.
Each flash will be 0.5 seconds long and the delay be-
tween flashes is 0.3 seconds. The delay between each
digit of the code will be 2 seconds. See Table 2 for
identification of fault codes.

For more in-depth fault finding, use diagnostic code
reader (hand held service tool).

Cycle the key switch OFFand ON twice within 3
seconds.

Wait for 2 seconds.

Count the number of flashes and write down the
code.

NOTE: Future changes to the diagnostic software are
as follows:
• The stop engine warning light will flash once to

indicate the start of the active fault codes.

• The start aid/diagnostic/engine warning light will

flash repeatedly indicating the active fault codes in
the same manner as current.

• If there are no active fault codes, then the start

aid/diagnostic/engine warning light will give code
111. If there is more than one active code, the stop
engine warning light will flash once to indicate the
end of one code and the start of another.

Description

2200 SRM 939

• After all of the active fault codes have flashed, the

stop engine warning light will flash twice to indi-
cate the start of logged fault codes. The flash se-
quence of logged codes is the same for that of active
codes. Once all the logged fault codes have flashed,

the start aid/diagnostic/engine warning light will
flash three times. Cycling the key switch twice
within three seconds will start the process again.

• All fault codes will flash in chronological order,

rather than numerical order.

Table 2. Engine Error Code Descriptions

CID Number

Description

Flash Code

0041

8 volt power supply

517

0091

Throttle position sensor

154

0100

Engine oil pressure sensor

157

0102

Intake manifold pressure sensor

135

0105

Intake manifold air temperature
sensor

133

0110

Engine coolant temperature
sensor

168

0174

Fuel temperature sensor

165

0247

J1939 data link

514

0253

Personality module

416

0262

5 volt power supply

516

0320

Engine speed/Timing sensor

141

0342

Secondary engine speed sensor

142

0774

Secondary throttle position sensor

155

1684

Fuel injection pump

158

1743

Mode selector switch for engine
operation

144

1894

Cruise control status switch

427

1895

Toggle switch for cruise control
speed

428

CONNECTOR

Instrument panel is connected to the system by
means of one connector. Connector is located at rear
of instrument panel. See Figure 2 and Table 3.

Seat Switch Logic

This function warns the operator when leaving the
seat without applying park brake. Two and one-half

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.

2200 SRM 939

Description

Figure 2. Connector

Table 3. Pin Description

Pin

Description

Pin

Description

Battery positive input

Brake system pressure light input

Seat switch input

RS-232 Receive input

Battery charging light input

RS-232 Transmission output

Ground

RS-232 Ground

Engine coolant level light input

Buzzer output

Brake system temperature light input

Shutdown output

Park brake monitor input

Central light output

Start aid/Engine warning light input

Engine coolant temperature gauge input

Engine combustion air filter input

Engine oil pressure gauge input

Fuel filter light input

Transmission oil pressure gauge input

Neutral gear input

Transmission oil temperature gauge input

Stop engine light input, Tier 2 only

Fuel level gauge input

Description

2200 SRM 939

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 too low
• Engine coolant temperature is too high
• Transmission oil pressure is below 999 kPa

(145 psi)

• Transmission oil temperature is above 132 C

(269 F)

• Fuel level is below 10% of the capacity
• Brake system pressure warning light is ON
• Brake system temperature warning light is ON
• Engine coolant level warning light is ON
• Transmission errors activating the central warn-

ing light (refer to error code display in the LCD)

• Intake manifold air temperature is high

Buzzer Output

This output is at pin number 17 and switches to
ground when any of the following conditions occur:
• Low engine oil pressure
• High engine coolant temperature

• Transmission oil pressure is below 1000 kPa

(145 psi)

• Transmission oil temperature is above 132 C

(270 F)

• Transmission errors activating the buzzer (refer to

error code display in the LCD)

• When the operator is not present and park brake is

not applied, the buzzer will sound for 10 seconds.

• High intake manifold air temperature

Engine Shutdown Output

NOTE: For Tier 2 engines, light 13 flashes.

This output is at pin number 18 and switches to
ground after a shutdown condition occurs.

When

either the engine coolant temperature (Tier 1),
transmission oil temperature, or engine oil pressure
reaches the alarm values, light 13 and the central
warning light will turn ON, and the buzzer will
sound, indicating shutdown condition.

Shutdown

output switches to ground and after a delay, the
engine is stopped.

Table 4. Sender Description

Item

Function

Water Temperature
Sender, Tier 1

The water temperature sender is mounted in the engine block
and senses the water temperature. If the water temperature
exceeds the specified temperature, the sender sends a signal to
the control panel and lights the coolant temperature indicator.
This signal also drives the coolant temperature gauge.

Water Temperature
Sender, Tier 2

The water temperature sender used with a Tier 2 engine is a
thermistor type sensor with an output between 0 and 5 volts.
The ECM will detect a fault condition, if the voltage from the
sensor is not within the range of 0.2 volts at

40 C ( 40 F)

and 4.9 volts at 150 C (302 F), and the fault is present for more
than 8 seconds continuously.

Transmission Oil
Temperature Sender

The transmission oil temperature sender unit is mounted
in the transmission oil sump and senses the transmission
fluid temperature. When the transmission temperature
exceeds system specifications, the sender sends a signal to the
instrument panel and lights the transmission oil temperature
warning light. This signal also drives the transmission oil
temperature gauge.

CAUTION

Do not continue to operate the lift truck when the gauge
indication is in the red area of the gauge.

2200 SRM 939

Description

Table 4. Sender Description (Continued)

Item

Function

Engine Oil Pressure
Sender, Tier 1

The engine oil pressure sender is located on the side of the
engine block and senses the engine oil pressure. If the oil
pressure drops lower than specifications, the sender sends 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 at engine speeds
above idle if the red light is ON.

Engine Oil Pressure
Sender, Tier 2

The engine oil temperature sender used with a Tier 2 engine
is a active sensor with an output between 0 and 5 volts. The
ECM will detect a fault condition, if the voltage from the
sensor is not within the range of 0.5 volts representing 106 kPa
(15 psi)and 4.5 volts representing 795 kPa (115 psi), and the
fault is present for more than 8 seconds continuously

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.

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).

CAUTION

Lift truck performance will be limited when the red light
is ON.

Description

2200 SRM 939

Table 4. Sender Description (Continued)

Item

Function

Transmission Oil
Pressure Sender

The transmission oil pressure sender unit is mounted in the
transmission on the engine side and senses the transmission
fluid pressure. When the transmission oil pressure drops below
specifications, the sender sends a signal to the instrument
panel and lights the transmission oil pressure warning light
4. The transmission oil pressure sender also drives the
transmission oil pressure gauge.

CAUTION

Do not continue to operate the lift truck when the red
light is ON at engine speeds above idle.

Low Pressure Sender
(Air Brakes Only)

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.

Low Pressure Sender
(Wet Brakes Only)

WARNING

Never operate a truck with a brake malfunction.

Brake Temperature
Sender (Wet Brakes
Only)

The brake temperature senders are mounted in the wheel
hubs (one on the left-side and one on the right-side hub) and
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 15.

WARNING

Never operate a truck with a brake malfunction.

Intake Manifold
Pressure Sensor, Tier 2

This is an active sensor with and output between 0 and 5 volts.
The ECM will recognize the output to be valid if it is between
0.5 volts representing 52 kPa (8 psi) and 4.5 volts representing
306 kPa (44 psi).

2200 SRM 939

Instrument Panel Component Replacement

Table 4. Sender Description (Continued)

Item

Function

Intake Manifold
Temperature Sensor,
Tier 2

This is a thermistor type sensor with an output between 0
and 5 volts. The ECM will recognize the output to be valid
if it is between 0.2 volts 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
Sensor, Tier 2

This is a magnetic type sensor that measures both crankshaft
speed and position. The sensor will measure speeds above
246 rpm when the output will be greater than 0.4 volts 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

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.

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.

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 cause of failure is poor connections
or damaged or improper wiring, and not the meter
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.

Check that other meters and electrical circuits
operate correctly.

Check that the battery is fully charged and has a
good ground, and cable terminals are clean and
tight.

Check that the wiring and connections to meter,
indicator, or sender are tight and in good condi-
tion.

INSTRUMENT PANEL

Remove

NOTE: The only replaceable parts of the instrument
panel are the lights.

Locate the fuse panel. See Figure 3.

Disconnect ground lead of battery.

FUSE PANEL

Figure 3. Fuse Panel Location

Sender Replacement

2200 SRM 939

Loosen four retaining screws and remove the fuse
panel cover. See Figure 4.

RETAINING SCREWS

FUSE PANEL COVER

Figure 4. Fuse Panel Screws

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.

PANEL CLIPS

Figure 5. Fuse Panel Clips

Pull instrument panel away from the console.
See Figure 6.

Figure 6. Instrument Panel Removal

Disconnect plug from socket.

Loosen 12 screws at rear of instrument panel.

Remove rear cover from instrument panel.

LIGHT

Replace

Turn light holder counterclockwise and remove.

Insert replacement light holder.

Turn replacement light holder clockwise and
tighten.

Mount cover.

Sender Replacement

FUEL LEVEL SENDER

WARNING

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:

2200 SRM 939

Sender Replacement

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
no source of open flame or sparks in the vicin-
ity. Use caution to prevent sparks from tools.

Turn key switch to OFF position. Disconnect
battery positive cable at battery. Install a lock
or tag on connector to prevent connection.

Disconnect sender wire at sender.

ELECTRICAL
TERMINAL

PLATE

SENDER UNIT

FLOAT ARM

FLOAT

Figure 7. Fuel Level Sender

Remove screws that fasten sender plate to tank.

Remove sender.

Carefully install new sender. Use a new gasket.

Verify screw holes are aligned and install screws.
Tighten screws enough to partially compress gas-
ket to prevent leaks.

Remove tape from wire connector and install con-
nector on sender terminal.

TRANSMISSION PRESSURE AND
TEMPERATURE SENDER, TIER 1

Some pressure senders have a hollow threaded fit-
ting fastened to the base. See Figure 8. This makes it
possible for sender to sense pressure and also to fas-
ten sender to the equipment. It is possible to tighten
or loosen sender using a wrench on flats of fitting.
The body of temperature sender has threads to fit a
threaded hole in the equipment. This sender also has
a hex shape for tightening or loosening sender. Re-
place senders as follows:

ELECTRICAL TERMINAL

SENDER

THREADED BODY

SENSOR ELEMENT

CASE OF ENGINE OR TRANSMISSION

ELECTRICAL TERMINAL

SENDER

HEX NUT

THREADED FITTING

10. HOLE TO SENSOR ELEMENT
11. CASE OF ENGINE OR TRANSMISSION

Figure 8. Typical Pressure and Temperature

Senders

Sender Replacement

2200 SRM 939

PRESSURE SENDER, TIER 2

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

Turn key switch to OFF position.

Disconnect electrical connector.

Remove pressure sender. See Figure 9.

Install new pressure sender.

Figure 9. Pressure Sender, Tier 2

TEMPERATURE SENDER, TIER 2

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

Turn key switch to OFF position.

Disconnect electrical connector.

Remove temperature sender. See Figure 10.

Install new temperature sender.

Figure 10. Temperature Sender, Tier 2

LOW COOLANT SENDER

WARNING

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

NOTE: Verify system fluid is drained so that level
is below sender to prevent leakage when sender is
removed.

Turn key switch to OFF position.

Disconnect sender wire. See Figure 11.

Figure 11. Low Coolant Sender

Turn sender counterclockwise and remove.

Install a new sender.

Use Teflon tape.

Turn

clockwise and tighten. Torque 5.6 ±0.6 N•m (50
±5 lbf in).

Connect sender wire.

VACUUM SWITCH

Turn key switch to OFF position.

Disconnect amp connector. See Figure 12.

Remove vacuum switch.

Install a new vacuum switch.

AMP CONNECTOR

Figure 12. Vacuum Switch

2200 SRM 939

Specifications

CRANKSHAFT POSITION SENSOR

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

Turn key switch to OFF position.

Disconnect electrical connector.

Remove crankshaft position sensor.

See Fig-

ure 13.

Install new crankshaft position sensor.

Figure 13. Crankshaft Position Sensor

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

Warning lights (except battery charging)

24 Vdc 1.2W

Warning light battery charging

24 Vdc 2W

Gauges

Actuator: coil type or PWM coil type

Needle stroke: 90 degrees

Instrument panel gauges

Reading tolerances: ±4 degrees

Hourmeter/Error LCD Display

View angle

12 o’clock

Polarized

Transflective. Positive

Drive method

1/2 Duty

Driving voltage

5.0 Vdc

Engine running hours

Maximum 99,999 hours

Indication

Error codes indication

Specifications

2200 SRM 939

Item

Design Data

Senders

Operating voltage

24 Vdc

Water temperature sender, Tier 1

Body threads

5/8-18 UNF-2A

Hex (across flats)

20 mm (0.787 in.)

Water temperature sender, Tier 2

Body threads

M18x1.5

Transmission oil temperature sender

Body threads

1/2-14 NPTF

Hex (across flats)

22 mm (0.866 in.)

Engine oil pressure sender, Tier 1

Body threads

1/8-27 NPTF

Hex (across flats)

17 mm (0.670 in.)

Engine oil pressure sender, Tier 2

Body threads

M12x1.5

Transmission oil pressure

Body threads

1/8-27 NPTF

Hex (across flats)

22 mm (0.866 in.)

Low coolant sender

Body threads

1/8-27 NPTF

Hex (across flats)

22 mm (0.866 in.)

Sender terminal threads

Fits connector type Delphi P/N 121521193

Fuel sender plate

Number of holes

Hole size

5.1 mm

Low pressure sender (air brakes only)

Body threads

1/8-27 NPTF

Hex (across flats)

11 mm (0.44 in.)

Low pressure sender (wet brakes only)

Body threads

1/4" NPT

Hex (across flats)

27 mm (1.062 in.)

Brake temperature sender (wet brakes only)

Body threads

3/8" NPTF

Vacuum switch

Body threads

1/8-27 NPTF

2200 SRM 939

Troubleshooting

Item

Design Data

Intake manifold pressure sensor

Body threads

M14x1.5

Intake manifold temperature sensor

Body threads

M18x1.5

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-
tors not connected.

Fasten the connector or connectors.

No Indication - Only One
Meter

Meter wires damaged or not con-
nected.

Replace display connectors. Install
connectors on proper meter termi-
nals.

Separate sender wire damaged or
not connected.

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

Meter malfunction. Voltage is at ter-
minal.

Replace fault display.

Sender malfunction. No voltage is at
terminal.

Replace sender.

Incorrect Indication

Battery is discharged.

Charge battery.

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

Replace fault display.

Separate sender malfunction.

Replace sender.

Sender will not sense because sys-
tem has corrosion.

Clean and flush system. Check for
bent or cracked sensor tubing.

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

2200 SRM 939

12/04 (7/03)(2/03)(11/00) Printed in United Kingdom

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