This document describes the instrument cluster for various Hyster lift truck models, including internal combustion and electric lift trucks. The instrument cluster provides operators with essential information about the lift truck's condition and systems through a series of gauges, indicator lights, and in some cases, a digital display.

General Function Description:

The instrument cluster is typically installed around the steering column housing. It features gauges for fuel level, engine coolant temperature, and engine oil pressure (for internal combustion models), along with an hourmeter. Various warning and indicator lights alert the operator to specific conditions such as low brake fluid, low coolant level, alternator issues, transmission oil temperature, engine oil pressure, low fuel levels (LPG or diesel), water in fuel filter (diesel only), cold start (diesel only), malfunction indicator (GM gas only), air filter restriction, and seat belt status. Electric lift truck models feature a battery charge indicator and may include a digital display for status codes and performance levels.

Important Technical Specifications and Usage Features (Internal Combustion Models):

Fuel Gauge: Indicates the amount of fuel in the tank. The sending unit is in the fuel tank. Troubleshooting involves checking wiring or replacing the sending unit/gauge.
Coolant Temperature Gauge: Displays engine coolant temperature when the key is in the ON position. Normal operation shows the needle in the green area. A red zone indicates overheating, requiring immediate shutdown. The sending unit is in the cylinder head.
Hourmeter: Operates when the key is in the ON position, tracking hours for periodic maintenance.
Left/Right-Hand Turn Indicators (Optional): Lights up when the turn indicator lever is in the respective turn position.
Warning Light, Alternator: ON when the key is ON and engine is not running; must go OFF when the engine is running. If it stays ON, check the alternator and wiring.
Warning Light, Transmission Oil Temperature: ON when the key is in START; must go OFF when the engine is running. If it stays ON, the transmission oil is too hot. The sending unit is at the bottom of the transmission housing.
Warning Light, Engine Oil Pressure: ON when the key is ON and engine is not running; must go OFF when the engine is running. If it stays ON while running, stop the engine immediately. The sending unit is in the engine block.
Warning Light, Brake Fluid Level: ON when the key is in START; must go OFF during operation. If it stays ON during operation, brake fluid is low. A float in the master cylinder actuates this light.
Warning Light, Coolant Level in the Radiator: ON when the key is in START; must go OFF when the engine is running. Flashes if coolant level is too low. The sending unit is at the top of the radiator.
Coolant Level/Hot Warning Light (Later Models H/S2.00-3.20XM): Similar to the coolant level warning, but also illuminates if coolant temperature reaches 121°C (250°F).
Warning Light, Fasten Seat Belt: ON for 10 seconds when the key is ON. Activated by a switch in the seat.
Warning Light, Water in Fuel Filter (Diesel Only): ON when the key is in START; must go OFF when the engine is running. If it stays ON during operation, there is water in the fuel filter. The sending unit is in the fuel filter.
Indicator Light, Cold Start (Diesel Only): ON when the key is ON and glow plugs are activated. Stays ON until the engine can be started.
Malfunction Indicator Lamp (GM Gas Only): ON when the key is ON and engine is not running. Illuminates if the ECM computer senses an engine fault. Requires service if ON while the engine is running.
Indicator Light, Low LPG Fuel Level: ON when the key is in START; must go OFF when the engine is running. If it stays ON during operation, fuel level is low. The sending unit is in the fuel line at the fuel filter.
Indicator Light, Air Filter Restriction: ON when the key is in START; must go OFF when the engine is running. If it stays ON during operation, the air cleaner has a restriction. The sending unit is in the air filter canister.
Engine Oil Pressure Gauge: Indicates engine oil pressure. Normal operation shows the needle in the green area. A red area indicates low oil pressure, requiring immediate shutdown. The sending unit is in the engine block.
Voltmeter: Indicates the output of the alternator. Normal operation shows the needle in the green area.
Key Switch: Has three positions: OFF (all circuits except horn de-energized), ON (energizes all electric circuits except starter), and START (energizes starter motor).

Important Technical Specifications and Usage Features (Electric Lift Truck Models):

Battery Charge Indicator: Standard models use a meter movement with colored bands. Enhanced models use an LED bar graph (four green, four orange, two red bars). Decreases sequentially as the battery discharges. Red bars illuminate at 70-75% discharge, triggering a lift interrupt.
Digital Display (Enhanced Panel Only): A four-digit LED display, blank during normal operation. Shows status codes and hourmeter values. A dash (-) and three numbers indicate a problem status code. Illuminates for service interval (-99) and motor indicators (traction/hydraulic) to show operating hours. Displays traction circuit operating time for 4 seconds after key OFF, then pump motor operating time for another 4 seconds (if SCR control card is present).
Warning LED, Fasten Seat Belt: ON for 8-10 seconds after key ON.
Warning LED, Brake Fluid Reservoir Is Low: ON for 1 second at START; must go OFF during operation. Stays ON if fluid is low.
Warning LED, Parking Brake Indicator: ON when parking brake is applied and seat switch is closed; goes OFF when released. A buzzer sounds for 8-10 seconds if the parking brake is NOT applied and the seat switch opens or key is OFF.
LED Indicator, Steering Pump Motor: Illuminates with a warning LED if steering pump motor brushes are worn.
Warning LED, Motor Brushes are Worn: Illuminates with the relevant motor LED (traction, hydraulic, or steering) if brush wear sensor closes. Stays ON until key OFF.
LED Indicator, Traction Motor: Illuminates with a warning LED if the traction motor is too hot or brushes are worn.
LED Indicator, Hydraulic Motor: Illuminates with a warning LED if the hydraulic pump motor is too hot or brushes are worn.
Warning LED, Motor Temperature Over Limit: Illuminates if traction or hydraulic motor thermal switches close due to overheating. Reduces travel speed to limit 1.
Warning LED, Service Interval: Illuminates with status code -99 when periodic maintenance is due. Requires reset by service person.
LED Indicator, Hourmeter: Illuminates with another indicator when operating hours are shown on the digital display.
Push Button, Status Codes: With key OFF, pressing this button displays status codes for detected problems (most recent first). Cycles through 16 traction codes, then 16 pump motor codes. A handset or PC is needed for additional information and to clear codes.
Push Button, Set Lift Truck Performance: Allows operator to select one of four performance levels (Turtle, Mid, Rabbit) affecting acceleration, top speed, and battery energy consumption. Levels can be adjusted by a service technician.
LED Indicators, Performance Level: Four LEDs show the selected performance level, illuminating in sequence from low (turtle) to maximum (rabbit).

Curtis 1215 Display Panel (Specific to N30-45XMR, N25-30XMDR, N50XMA):

Function Description: A rectangular display unit with a 16-character, dot matrix, liquid crystal display (LCD) with green backlighting. Shows hourmeter readings, lift truck performance status, and warning/fault conditions. Warning messages blink yellow, fault messages blink red.
Technical Specifications: Available in standard (-25 to 70°C) and freezer models (-40 to 70°C).
Usage Features:
- Battery Indicator: 10-bar multicolor LED. Flashing red LED (second from bottom) indicates nearly discharged battery. Bottom red LED alternately flashes with LO-Battery LED (crossed battery symbol) indicating a discharged battery, which triggers a lift interrupt.
- Hourmeter Switch: Operator-controlled button (hourglass symbol) to display truck hours (1/10 hour), drive motor hours, or lift motor hours. Returns to normal display mode after 30 seconds.
- Drive Mode Display: Allows operator to select one of three performance levels (Turtle, Mid, Rabbit) for traction motor controller performance. Settings are retained when key is OFF but revert to Rabbit mode if battery is disconnected. These settings are programmable by a service technician.
- LED Function Selection Lights: Display the selected hydraulic function (lift, tilt, reach, sideshift), independent of the LCD display.
- Internal Backup Battery: Retains memory of battery indicator and hourmeter readings when the main battery is disconnected.

Maintenance Features:

General: Always disconnect the battery connector before maintenance. Use correct blocks to prevent rolling/falling. Keep the unit and work area clean. Use correct, clean, and good condition tools. Use HYSTER APPROVED parts. Ensure all fastening devices are removed before using force. Fasten a DO NOT OPERATE tag to controls. Follow WARNING and CAUTION notes.
Cluster-Type Display Panel (Internal Combustion): Newer clusters are non-repairable and must be replaced as a unit (except for the ignition switch). Older clusters may have replaceable parts.
- Removal: Disconnect negative battery cable. Remove steering control unit. Disconnect wiring harnesses (24-pin and 6-pin pig tail connections, ground wire). Remove screws holding the cluster to the steering housing.
- Assembly/Installation: Install parts as shown in diagrams. Ensure seals are correctly installed. Connect wiring harnesses. Install steering control unit and cover. Connect battery and check operation.
Cluster Display Panel (Electric Lift Truck): Standard and enhanced display panels are replaced as a unit.
- Standard Display Panel Parts: Key switch, housing, O-ring seal, light filter, battery indicator, hourmeter, gasket, buzzer, circuit board, jumper harness, and key switch wires are replaceable. LED indicators are part of the circuit board and cannot be replaced separately.
- Enhanced Display Panel Parts: Only the O-ring seal, key switch, key switch wires, and housing are replaceable. All other parts are replaced as a single unit.
- Replacement Procedure: Disconnect battery and remove key. Remove front steering column cover. Disconnect connectors (18-pin, key switch wires, two-pin for standard panel). Remove screws holding display panel to column cover. Install new display panel, connect wires, set DIP switches for correct voltage (standard panel only).
- Battery Indicators: Replaced as part of the display panel. Adjustment procedures are in the Battery Indicators 2260 SRM 138 section.
- Digital Display (Enhanced Panel Only): Cannot be replaced as a separate component; replaced as part of the enhanced display panel.
- Status Code or Performance Level Switches and LED Indicators (Enhanced Panel Only): Cannot be replaced as separate components; replaced as part of the enhanced display panel.
Curtis 1215 Display Panel: Cannot be repaired; replaced if faulty.
- Removal: Move lift truck to a safe, level area. Turn key OFF, remove key, apply DO NOT OPERATE tag, block drive wheels. Disconnect battery. Remove hydraulic tank dipstick. Remove battery compartment cover. Disconnect plugs X-4 and X-6 from display assembly. Remove nuts and brackets fastening display assembly.
- Installation: Adjust pots on rear of dash display. Connect plugs X-4 and X-6. Position display assembly, install nuts and brackets. Install battery cover, hydraulic tank dipstick. Remove blocks and DO NOT OPERATE tag. Connect battery and install key.

Hyster E40XMS - Page 24

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