1688870-0100SRM1342 - (01-2011) - UK-EN Frame Manual

FRAME
E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276]
PART NO. 1688870 100 SRM 1342

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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Frame Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
General ........................................................................................................................................................... 1
Frame ............................................................................................................................................................. 1
Discharging the Capacitors........................................................................................................................... 5
Overhead Guard Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Install ............................................................................................................................................................. 8
Overhead Guard Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) .................................. 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 11
Battery Restraint and Seat Assembly Repair .................................................................................................. 12
Operator Restraint System and Seat Assembly .......................................................................................... 17
Operator Restraint System....................................................................................................................... 17
Emergency Locking Retractor (ELR) ................................................................................................... 19
Armrest Assembly Repair......................................................................................................................... 20
Remove .................................................................................................................................................. 20
Disassemble........................................................................................................................................... 22
Clean...................................................................................................................................................... 23
Inspect ................................................................................................................................................... 23
Assemble................................................................................................................................................ 23
Install..................................................................................................................................................... 24
Hood and Seat Latches ............................................................................................................................. 24
Hood and Seat Assembly Replacement for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)......................................................................................................................... 25
General....................................................................................................................................................... 25
Remove ........................................................................................................................................................... 29
Install ............................................................................................................................................................. 34
Ground Test ................................................................................................................................................... 35
Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) .................... 35
General ........................................................................................................................................................... 35
Opening and Closing the Hood ................................................................................................................. 38
Remove ........................................................................................................................................................... 39
Install ............................................................................................................................................................. 41
Ground Test ................................................................................................................................................... 42
Master Cylinder Repair and Adjustment for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)......................................................................................................................... 43
Master Cylinder Repair and Adjustment for Lift Truck J2.2-3.5XN (J45-70XN) (A276).............................. 43
Remove ........................................................................................................................................................... 43
Disassemble ................................................................................................................................................... 43
Clean .............................................................................................................................................................. 46
Inspect ............................................................................................................................................................ 46
Assemble ........................................................................................................................................................ 46
Bench Bleed Master Cylinder ....................................................................................................................... 46
Install and Adjust .......................................................................................................................................... 46
Brake Pedal Components for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 47
Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A276) ....................................................... 47
Remove ........................................................................................................................................................... 47
Disassemble ................................................................................................................................................... 49
Inspect ............................................................................................................................................................ 49
©2011 HYSTER COMPANY i

Table of Contents Frame
TABLE OF CONTENTS (Continued)

Assemble ........................................................................................................................................................ 49
Install ............................................................................................................................................................. 50
Pedal Adjust ................................................................................................................................................... 50
Brake System Air Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A276) .................................................... 51
Brake System Air Removal ........................................................................................................................... 51
Using Pressure Bleed System ....................................................................................................................... 51
Using Brake Pedal Pressure ......................................................................................................................... 51
Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 51
Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 52
Remove ........................................................................................................................................................... 53
Install ............................................................................................................................................................. 54
Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN) (A276) ................................................ 54
Remove ........................................................................................................................................................... 56
Install ............................................................................................................................................................. 56
Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 58
Remove ........................................................................................................................................................... 58
Install ............................................................................................................................................................. 63
Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN (J45-70XN) (A276) ................................. 64
Hydraulic Tank Inspection ................................................................................................................................ 64
Inspect ............................................................................................................................................................ 64
Clean .............................................................................................................................................................. 65
Painting Instructions ......................................................................................................................................... 67
Safety Label Replacement ................................................................................................................................. 69
Battery Specifications........................................................................................................................................ 76
Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269).................................................................................................................................................................. 78
Overhead Guard ............................................................................................................................................ 78
Counterweight ............................................................................................................................................... 78
Traction Motor ............................................................................................................................................... 78
Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276).............................................................. 78
Overhead Guard ............................................................................................................................................ 78
Counterweight ............................................................................................................................................... 78
This section is for the following models:
E2.2-3.5XN (E45-70XN) [A268];

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276]
ii
100 SRM 1342 General
General
GENERAL If a torque value is not specified, go to Metric and
Inch (SAE) Fasteners 8000 SRM 231 for torque val-
This section contains a description and service proce- ues.
dures for the parts of the frame. These parts include
the frame, counterweight assembly, overhead guard, FRAME
hood and seat assembly, access panels, and labels.
The frame is a single weldment with mounts for:
Throughout this section, forward will refer to travel • Counterweight
in the direction of the forks and left and right will be • Overhead guard
determined by an operator sitting in the seat facing • Tilt cylinders
forward. See Figure 1. • Drive axle
• Floor plate and pedals
• Side step and fender weldments
Electronic controllers and contactors are attached to

the counterweight and the Vehicle Systems Manager
(VSM) is attached to frame for lift truck models indi-
cated below:
See Figure 2 for lift truck models:

• E2.2-3.5XN (E45-70XN) (A268)
See Figure 3 for lift truck models:

• E1.6-2.0XN (E30-40XN) (A269)
On lift truck J2.2-3.5XN (J45-70XN) (A276) the hy-

draulic motor controller and contactor are attached
to the counterweight and the traction motor con-
A. LEFT SIDE C. FORWARD
B. RIGHT SIDE TRAVEL troller is attached to the frame. See Figure 4.
Figure 1. Truck Orientation
1
General 100 SRM 1342
1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

BRACKET 6. LEFT FRAME CHANNEL
2. REAR OVERHEAD GUARD MOUNTING 7. REAR BULKHEAD
BRACKET 8. TILT ANCHOR PLATE
3. COUNTERWEIGHT MOUNTING PLATE 9. SIDE STEP MOUNTING BRACKET
4. FRONT BULKHEAD
Figure 2. Frame Weldment for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
2
1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

BRACKET 6. LEFT FRAME CHANNEL
2. REAR OVERHEAD GUARD MOUNTING 7. REAR BULKHEAD
BRACKET 8. TILT ANCHOR PLATE
4. FRONT BULKHEAD
Figure 3. Frame Weldment for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
3
General 100 SRM 1342
1. FRONT OVERHEAD GUARD MOUNTING 7. RIGHT FENDER

BRACKET 8. RIGHT FRAME CHANNEL
2. OPERATOR MODULE PLATE 9. LEFT FRAME CHANNEL
3. FRONT BULKHEAD 10. TILT ANCHOR PION
4. REAR BULKHEAD 11. DRIVE AXLE MOUNTS
6. LEFT FENDER
Figure 4. Frame Weldment for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
4
DISCHARGING THE CAPACITORS seconds after the battery is disconnected.

To prevent an electrical shock and personal
WARNING injury, discharge the capacitor(s) before in-
specting or repairing any component in the
DO NOT make repairs or adjustments unless
drive unit compartment. Make certain that
you have been properly trained and authorized
the battery has been disconnected.
to do so. Improper repairs and adjustments
can create dangerous operating conditions. DO NOT short across the motor controller ter-
DO NOT operate a lift truck that needs re- minals with a screwdriver or jumper wire.
pairs. Report the need for repairs to your
supervisor immediately. If repair is necessary, Make certain the Emergency-Disconnect
attach a DO NOT OPERATE tag on the steering switch has not been activated. This will iso-
wheel and disconnect the battery. late the controller and prevent the capacitors
from discharging properly. The proper way
Disconnect the battery and allow the capaci- to disconnect the battery is by separating the
tors to discharge before opening any compart- battery connectors.
ment covers or inspecting or repairing the elec-
trical system. DO NOT place tools on top of the 1. Ensure the capacitors are discharged by perform-
battery. If a tool causes a short circuit, the high ing Step 2 through Step 6 below.
current flow from the battery can cause per-
sonal injury or property damage. 2. Turn the key or keyless switch to the OFF posi-
tion.
Some checks and adjustments are performed
with the battery connected. DO NOT connect 3. Disconnect the battery by separating the connec-
the battery until the procedure instructs you tors.
to do so. Never wear any metallic items on
4. Block the drive wheels to prevent the lift truck
your fingers, arms, or neck. Metal items can
from moving.
accidentally make an electrical connection
and cause injury. 5. Make sure the Emergency-Disconnect switch
HAS NOT been activated. If the Emer-
Before performing any tests or adjustments,
gency-Disconnect switch is activated, rotate
block the lift truck to prevent unexpected
the switch to the right until it pops up.
movement.
6. Wait at least 10 seconds to be sure that the ca-
The capacitor in the transistor controller(s)
pacitors are fully discharged.
can hold an electrical charge for about 10
5
Overhead Guard Replacement 100 SRM 1342
Overhead Guard Replacement for Lift Trucks E2.2-3.5XN

(E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
REMOVE See Periodic Maintenance 8000 SRM 1442 for
lift truck models:
WARNING • E1.6-2.0XN (E30-40XN) (A269)
DO NOT operate lift truck without overhead 1. Remove battery from lift truck. See How to
guard correctly fastened to the lift truck frame. Change Battery in the Operating Manual or
one of the following service manuals
WARNING
See Periodic Maintenance 8000 SRM 1364 for
DO NOT weld, drill, grind, or cut the overhead
lift truck models
guard for mounts of lights or accessories. The
• E2.2-3.5XN (E45-70XN) (A268)
strength of the overhead guard can be reduced.
WARNING lift truck models:
PUTTING THE LIFT TRUCK ON BLOCKS • E1.6-2.0XN (E30-40XN) (A269)
The lift truck must be put on blocks for some 2. Remove hood and seat assembly from lift truck.
types of maintenance and repair. The removal See the Remove procedures in the section Hood
of the mast, drive axle, battery, or counter- and Seat Assembly Repair.
weight assemblies will cause large changes 3. Access to rear capscrews is from the battery
in the center of gravity. When the lift truck compartment. Remove rear capscrews from rear
is put on blocks, put additional blocks in the overhead guard legs and plates. See Figure 5.
following positions:
If the mast and drive axle are removed, put 4. Remove front capscrews from front overhead
blocks under the counterweight so the lift guard legs and from the right and left plates.
truck cannot fall backward. See Figure 5.
If the counterweight is removed, put blocks
under the mast so that the lift truck cannot NOTE: Note routing of electrical wires prior to dis-
fall forward. connecting.
Put the lift truck on blocks on a solid, even, and NOTE: Tag electrical connectors during removal to
level surface. Verify the blocks or stands have aid in installation.
enough capacity to hold the lift truck. Use ad-
ditional blocks next to the tires as necessary to 5. Tag and disconnect electrical wires that go
prevent movement of the lift truck. through the legs of overhead guard.
Verify the lifting devices used during repairs NOTE: When overhead guard is lifted from frame
can lift the weight of the parts and assemblies. assembly, make sure electrical wires move through
holes in frame at the front and rear so that they are
See the Operating Manual or one of the follow- not damaged.
ing service manuals for the procedure to put
the lift truck on blocks. 6. Using a lifting device, remove overhead guard
from frame assembly. See Figure 5.
lift truck models: 7. Remove capscrews and handle from overhead
• E2.2-3.5XN (E45-70XN) (A268) guard. See Figure 5.
6
100 SRM 1342 Overhead Guard Replacement
Figure 5. Overhead Guard and Counterweight for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)
7
Legend for Figure 5

1. OVERHEAD GUARD 7. CAPSCREW
2. REAR CAPSCREW 8. REAR OVERHEAD GUARD LEG
3. COUNTERWEIGHT 9. FRONT OVERHEAD GUARD LEG
4. FRAME ASSEMBLY 10. RIGHT PLATE
5. FRONT CAPSCREW 11. LEFT PLATE
6. HANDLE 12. PLATE
INSTALL 5. Install hood and seat assembly onto lift truck.

See the Install procedures in the section Hood
NOTE: Make sure electrical wires are routed as and Seat Assembly Repair.
noted during removal to assure that wires do not get
pinched. 6. Install battery into lift truck. See How to
Change Battery in the Operating Manual or
1. Using a lifting device, install overhead guard
onto frame assembly. See Periodic Maintenance 8000 SRM 1364 for
lift truck models
2. Connect electrical wires, as tagged during re- • E2.2-3.5XN (E45-70XN) (A268)
moval.
3. Install front capscrews into front overhead guard lift truck models
legs and the right and left plates. See Figure 5. • E1.6-2.0XN (E30-40XN) (A269)
Tighten front capscrews to 66 N•m (49 lbf ft).
7. Install handle and capscrews on overhead guard.
4. Install rear capscrews into rear overhead guard Tighten capscrews to 25.2 N•m (18.5 lbf ft).
legs and plates. See Figure 5. Tighten rear cap-
screws to 270 N•m (199 lbf ft).
8
Overhead Guard Replacement for Lift Truck Models

J2.2-3.5XN (J45-70XN) (A276)
REMOVE 1. Remove tow pin, capscrews, washers, and coun-
terweight cover from counterweight. See Fig-
WARNING ure 6.
DO NOT operate lift truck without overhead 2. Remove rear capscrews from rear overhead
guard correctly fastened to the lift truck frame. guard legs and counterweight. See Figure 6.
WARNING 3. Remove nuts and capscrews from hood cross-

member and rear overhead guards legs. See
DO NOT weld, drill, grind, or cut the overhead
Figure 6.
guard for mounts of lights or accessories. The
strength of the overhead guard can be reduced. 4. Remove capscrews and hose cover from cowl to
allow access to front capscrews on left overhead
WARNING guard leg. See Figure 6.
PUTTING THE LIFT TRUCK ON BLOCKS 5. Remove color-coated screws and overhead guard
The lift truck must be put on blocks for some leg covers from front overhead guard legs. See
types of maintenance and repair. The removal Figure 6.
of the mast, drive axle, battery, or counter- 6. Remove front capscrews from front overhead
weight assemblies will cause large changes guard legs and cowl. See Figure 6.
in the center of gravity. When the lift truck
is put on blocks, put additional blocks in the NOTE: Note routing of electrical wires prior to dis-
following positions: connecting.
If the mast and drive axle are removed, put
blocks under the counterweight so the lift 7. Tag and disconnect electrical wires that go
truck cannot fall backward. through the legs of overhead guard.
If the counterweight is removed, put blocks
under the mast so that the lift truck cannot NOTE: When overhead guard is lifted from fame,
fall forward. make sure electrical wires move through the holes
in the frame at the front and rear so they are not
Put the lift truck on blocks on a solid, even, and damaged.
level surface. Verify the blocks or stands have
enough capacity to hold the lift truck. Use ad- 8. Using a lifting device, remove overhead guard
ditional blocks next to the tires as necessary to from frame. See Figure 6.
prevent movement of the lift truck. 9. Remove capscrews and handle from overhead
Verify the lifting devices used during repairs guard. See Figure 6.
can lift the weight of the parts and assemblies.
See the Operating Manual or Periodic Mainte-

nance 8000 SRM 1372, for procedure to put lift
truck on blocks.
9
Figure 6. Overhead Guard for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
10
Legend for Figure 6

1. REAR OVERHEAD GUARD LEG 11. FRAME
2. COUNTERWEIGHT 12. OVERHEAD GUARD
3. REAR CAPSCREW 13. HANDLE
4. HOSE COVER 14. COUNTERWEIGHT COVER
5. CAPSCREW 15. WASHER
6. COLOR-COATED SCREW 16. TOW PIN
7. OVERHEAD GUARD LEG COVER 17. HOOD CROSSMEMBER
8. FRONT OVERHEAD GUARD LEG 18. NUT
9. COWL 19. OVERHEAD GUARD MOUNTING PLATE
10. FRONT CAPSCREW
INSTALL 5. Install hose cover and capscrews onto cowl. See

Figure 6.
NOTE: Make sure electrical wires are routed as noted
during removal to assure wires do not get pinched. 6. Install capscrews and nuts on rear overhead
guard legs and hood crossmember. See Figure 6.
1. Using a lifting device, install overhead guard
onto frame. See Figure 6. 7. Install rear capscrews into rear overhead guard
legs and counterweight. See Figure 6. Tighten
2. Connect electrical wires, as tagged during re- rear capscrews to 270 N•m (199 lbf ft).
moval.
8. Install counterweight cover, capscrews, washers,
3. Install front capscrews into front overhead and tow pin onto counterweight. See Figure 6.
guard legs and cowl. Tighten front capscrews to
66 N•m (49 lbf ft). See Figure 6. 9. Install handle and capscrews onto overhead
guard. Tighten capscrews to 19.2 N•m
4. Install overhead guard leg covers and color- (169.9 lbf in).
coated screws onto front overhead guard legs.
See Figure 6.
11
Battery Restraint and Seat Assembly Repair 100 SRM 1342
Battery Restraint and Seat Assembly Repair

See Figure 7 for lift truck models
WARNING • E2.2-3.5XN (E45-70XN) (A268)
The battery must fit the battery compartment
so that the battery restraint will operate cor- See Figure 8 for lift truck models
rectly. A lose battery can cause serious injury • E1.6-2.0XN (E30-40XN) (A269)
and property damage if the lift truck over-
turns. See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
NOTE: Lift trucks are equipped with adjustable
spacer plate(s) in the battery compartment.
1. Adjust spacer plate(s) to prevent battery from

moving more than 13 mm (0.5 in.).
Legend for Figure 7
NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

A. STANDARD COMPONENTS - VERTICAL B. OPTIONAL COMPONENTS - HORIZONTAL
BATTERY REMOVAL BATTERY REMOVAL
1. RIGHT FRAME CHANNEL 13. NUT
2. LATCH ROD 14. FRONT BULKHEAD
3. SPRING 15. WASHER
4. SLOTTED PIN 16. PLATE
5. LATCH PLATE 17. BATTERY SLIDE PAD
6. RIGHT PLATE 18. ROLLER
7. HOOD LATCH ASSEMBLY 19. PLATE
8. REAR BULKHEAD 20. COVER
9. BRACKET 21. POWER CABLE COVER
10. CAPSCREW 22. LEFT PLATE
11. BATTERY SPACER PLATE 23. INSERT
12. SPACER
12
100 SRM 1342 Battery Restraint and Seat Assembly Repair
Figure 7. Battery Compartment for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
13
Figure 8. Battery Compartment for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
14
Legend for Figure 8

1. RIGHT FRAME CHANNEL 12. WASHER
2. LATCH ROD 13. NUT
3. SPRING 14. BRACKET
4. SLOTTED PIN 15. FRONT BULKHEAD
5. LATCH PLATE 16. BATTERY SLIDE PLATE
6. RIGHT PLATE 17. PLATE
7. REAR BULKHEAD 18. ROLLER
8. INSERT 19. PLATE
9. SPACER 20. COVER
10. BATTERY SPACER PLATE 21. POWER CABLE COVER
11. CAPSCREW
15
Figure 9. Battery Compartment for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
16
Legend for Figure 9

1. NUT 13. BRACKET
2. SPACER 14. PIN
3. BATTERY SPACER PLATE 15. LEVER
4. CAPSCREW 16. BATTERY GATE
5. FRONT BULKHEAD 17. BULLET ISOLATOR
6. INSERT 18. LEFT FRAME CHANNEL
7. SIDE STEP MOUNTING BRACKET 19. INNER FRAME CHANNEL
8. REAR BULKHEAD 20. RIGHT FRAME CHANNEL
9. BATTERY ROLLERS 21. BATTERY SPACER PLATE MOUNTING
10. MAGNET BRACKET
11. BATTERY GATE SWITCH 22. SPRING
12. BATTERY RETENTION PLATE
OPERATOR RESTRAINT SYSTEM AND

SEAT ASSEMBLY
Operator Restraint System
The seat belt, hip restraint, seat, hood, and hood
latch are all part of the operator restraint system.
Each item must be checked to make sure it is fas-
tened correctly, functions correctly, and is in good
condition. The operator restraint system helps the
operator stay within the lift truck in case of a tip over.
1. Make sure seat is not loose on seat rails.

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• E1.6-2.0XN (E30-40XN) (A269)
Legend for Figure 10

A. RELEASE B. FRONT VIEW
DIRECTION
1. SEAT 7. OPERATOR
2. HIP RESTRAINT PRESENCE
3. SEAT BELT AND SYSTEM
MOUNT CONNECTOR
4. SEAT POSITION 8. HOOD
ADJUSTOR 9. HOOD LATCH
5. OPERATOR ASSEMBLY
WEIGHT 10. HOOD RELEASE
ADJUSTOR HANDLE
6. SEAT RAIL 11. STOP SCREWS
Figure 10. Hood and Seat Check for Lift Truck
E2.2-3.5XN (E45-70XN) (A268)
17
2. Make sure seat rails are securely attached to

the mounting surface. The seat rail must lock
securely in position, but move freely when un-
locked.

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• E1.6-2.0XN (E30-40XN) (A269)
1. SEAT
2. HIP RESTRAINT
3. SEAT BELT AND MOUNT
4. SEAT POSITION ADJUSTOR
5. OPERATOR WEIGHT ADJUSTOR
6. SEAT RAIL
7. OPERATOR PRESENCE SYSTEM CONNECTOR
8. HOOD
9. HOOD LATCH ASSEMBLY
10. STOP SCREWS
Figure 11. Hood and Seat Check for Lift Truck

J2.2-3.5XN (J45-70XN) (A276)
18
comes to a sudden stop, the locking mechanism will

be activated and hold the operator’s lower torso in
the seat.

• E2.2-3.5XN (E45-70XN) (A268)

• J2.2-3.5XN (J45-70XN) (A276)

• E1.6-2.0XN (E30-40XN) (A269)
A seat belt that is damaged, worn, or does not op-

erate properly will not provide protection when it is
needed. The end of the belt must fasten correctly in
the latch. The seat belt must be in good condition.
Replace the seat belt if it is damaged or worn.
NOTE: The following seat belt operation checks must

be performed three times before replacing the seat
belt assembly:
• With hood closed and in the locked position, pull

seat belt slowly from retractor assembly. Make
sure seat belt pulls out and retracts smoothly. If
seat belt does not pull out of the retractor assem-
bly the internal latch may be locked. Pull firmly
1. SEAT ASSEMBLY on the seat belt and hold for a moment to remove
2. HOOD
3. SEAT RAIL slack from the belt in the retractor. Release the
4. CAPSCREW seat belt. Seat belt will retract and the internal
5. FORWARD/BACKWARD LEVER latch will unlock. If the seat belt cannot be pulled
6. OPERATOR PRESENCE SYSTEM CONNECTOR from the retractor assembly or the belt will not re-
7. RIDE POSITION INDICATOR tract, replace the seat belt assembly.
Figure 12. Hood and Seat Check for Lift Trucks • With hood closed and in locked position, pull seat
E1.6-2.0XN (E30-40XN) (A269) belt with a sudden jerk. Make sure seat belt will
not pull from retractor assembly. If seat belt can
Emergency Locking Retractor (ELR) be pulled from retractor, when it is pulled with a
sudden jerk, replace seat belt assembly.
NOTE: The seat belt may be either black or red. • With hood in open position, make sure seat belt
will not pull from the retractor assembly. If seat
When the ELR style seat belt is properly buckled belt can be pulled from retractor, with hood in open
across the operator, the belt will permit slight op- position, replace seat belt assembly.
erator repositioning without activating the locking
mechanism. If the truck tips, travels off a dock, or
19
Armrest Assembly Repair

Remove
1. Remove two capscrews from cover on seat box

and remove cover from seat box. Disconnect
the main E-Hydraulic control wire harness from
E-Hydraulic armrest connector. See Figure 13.
2. Remove three capscrews and bottom armrest

cover from armrest assembly. See Figure 14.
NOTE: Clips remain attached to MLM inner cover

during removal.
3. Remove MLM inner cover from seat side of arm-

rest assembly. See Figure 14.
NOTE: Only outside nylon washer to be removed; ny-

lon washer between slide brackets and slide mount-
ing bracket should remain on slider pin.
NOTE: COMPONENTS PARTS AND ELECTRICAL
4. Remove nut, washer, and nylon washer from CONNECTIONS OMITTED OR MOVED FOR CLAR-
slider pin on slide mounting bracket. See Fig- ITY.
ure 14 and Figure 15. 1. COVER
2. CAPSCREWS
5. Remove capscrew and washer from armrest 3. SEAT BOX
spacer on slide mounting bracket. See Figure 14. 4. E-HYDRAULIC ARMREST HARNESS
5. OPERATOR PRESENCE SYSTEM HARNESS
6. Remove armrest with slide brackets from slide 6. ARMREST
mounting bracket. See Figure 16.
Figure 13. Seat Box Cover Removal
20
A. RIGHT SIDE VIEW B. FRONT VIEW

1. BOTTOM ARMREST COVER 7. ARMREST
2. CAPSCREW 8. SEAT
3. MLM INNER COVER 9. NUT
4. CLIP 10. NYLON WASHER
5. SLIDE MOUNTING BRACKET 11. SLIDER PIN
6. WASHER 12. ARMREST SPACER
Figure 14. Armrest and Covers

NOTE: TOP VIEW, ARMREST NOT SHOWN FOR

CLARITY.
1. SLIDE MOUNTING BRACKET
2. NYLON WASHER
3. NUT
4. WASHER
5. SLIDER PIN
Figure 15. Slide Mount - Armrest
21
NOTE: HANDLES NOT SHOWN IN THIS VIEW FOR

CLARITY.
1. ARMREST 2. FLANGE
1. ARMREST 3. SLIDE MOUNTING MOUNTING CAPSCREW
2. SLIDE BRACKET BRACKET BRACKET 3. ARMREST
Figure 16. Armrest and Seat Figure 18. Armrest Slide
Disassemble 2. Pull up on handle (see Figure 17) and slide arm-
rest all the way back. Remove flange capscrew
1. Pull up on handle (see Figure 17) and slide arm-
under armrest mounting bracket. See Figure 18.
rest all the way forward. Remove flange cap-
screw under armrest mounting bracket. See Fig- 3. Remove armrest from armrest mounting
ure 18. bracket. See Figure 18.
4. For replacement of mini-levers and switches at-

tached to armrest, see Electrical System 2200
SRM 1369.
5. Remove two nuts and upper armrest handle slide

assembly from slide mounting bracket. See Fig-
ure 19.
6. Remove two spaced screws and slider handle

from upper armrest slide. See Figure 20.
7. Remove two nuts, two capscrews and lower arm-

rest handle slide assembly from slide mounting
bracket. See Figure 19.
8. Remove two spaced screws and slider handle

from lower armrest handle slide. See Figure 20.
A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN
Figure 17. Armrest Adjustment Handles
22
1. UPPER ARMREST HANDLE SLIDE ASSEMBLY 4. NUT

2. LOWER ARMREST HANDLE SLIDE ASSEMBLY 5. CAPSCREW
3. SLIDE MOUNTING BRACKET
Figure 19. Slider Assemblies

Clean
1. Clean plastic or rubber components using warm

soapy water and wipe dry with a lint free cloth.
Inspect
1. Check all components for damage. Replace dam-

aged components.
Assemble
A. UPPER HANDLE B. LOWER HANDLE
SLIDE ASSEMBLY SLIDE ASSEMBLY 1. Install slider handle and two spaced screws onto
lower armrest slide. See Figure 20.
1. UPPER ARMREST 3. SPACED SCREW
SLIDE 4. LOWER ARMREST
2. SLIDER HANDLE SLIDE 2. Install lower armrest handle slide assembly, two
capscrews, and two nuts onto slide mounting
Figure 20. Slider Handles bracket. See Figure 19.
23
3. Install slider handle and two spaced screws onto 2. Seat rails must be correctly fastened to hood and
upper armrest slide. See Figure 20. hood fastened to hinges on frame. Lift hood to
make sure it is fastened correctly and will not
4. Install upper armrest handle slide assembly and move side to side.
two nuts onto slide mounting bracket. See Fig-
ure 20.
5. Place armrest onto armrest mounting bracket at

the back position. Install flanged capscrew un-
der armrest mounting bracket. See Figure 18.
Tighten flanged capscrew to 12 N•m (106 lbf in).
6. Move armrest into forward position. Install

flanged capscrew under armrest mounting
bracket. See Figure 18. Tighten flanged cap-
screw to 12 N•m (106 lbf in).
Install
NOTE: Ensure one nylon washer is still in place on

slide pin as noted during removal.
1. Install slide brackets with armrest onto slide

mounting bracket. See Figure 16.
2. Install washer and capscrew into armrest spacer

on slide mounting bracket. See Figure 14.
3. Install nylon washer, washer, and nut onto slide

pin on slide mounting bracket. See Figure 14 and
Figure 15.
NOTE: Ensure clips are attached to MLM inner cover NOTE: SWIVEL SEAT NOT USED ON E1.6-2.0XN
prior to installation. (E30-40XN) (A269) LIFT TRUCKS.
4. Install MLM inner cover onto seat side of armrest 1. SEAT BELT
2. OPERATOR PRESENCE SYSTEM CONNECTOR
assembly. See Figure 14. 3. SEAT RAIL
4. SWIVEL LATCH RELEASE LEVER
5. Install bottom armrest cover and three cap- 5. OPERATOR WEIGHT ADJUSTOR
screws onto armrest assembly. See Figure 14. 6. RIDE POSITION INDICATOR
7. SEAT POSITION ADJUSTOR
6. Connect the main E-Hydraulic control wire 8. BACK REST ANGLE
harness to E-Hydraulic armrest connector. In- 9. ARM REST
stall cover to seat box with two capscrews.
See Figure 13. Tighten capscrews to 1.2 N•m Figure 21. Swivel Seat Option
(10.6 lbf in).
Hood and Seat Latches

1. Make sure seat rails are not loose. Seat rails
must lock tightly in position, but move freely
when unlocked. See Figure 21.
24
100 SRM 1342 Hood and Seat Assembly Replacement
Hood and Seat Assembly Replacement for Lift Truck Models

E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
General See Figure 23 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
The hood is the platform for the seat assembly and
is located above the battery. It functions as a battery When correctly locked to the frame, it will hold the
restraint that completely covers the battery compart- battery in the battery compartment if an accident
ment. causes the lift truck to tip over. The hood is a welded
steel assembly. Two hood hinges at the back attach
See Figure 22 for lift truck models to the overhead guard. A latch assembly on the front
• E2.2-3.5XN (E45-70XN) (A268) bulkhead, locks the hood closed during operation.
Gas-controlled struts hold the hood in the open
position.
NOTE: SEAT NOT SHOWN FOR CLARITY.

A. RELEASE DIRECTION C. BOTTOM VIEW
B. FRONT VIEW
1. HOOD LATCH ASSEMBLY 4. GAS SPRING
2. HOOD 5. HOOD HINGE
3. HOOD RELEASE LEVER 6. BATTERY STOPPER
Figure 22. Hood and Latch Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
25
Hood and Seat Assembly Replacement 100 SRM 1342
NOTE: SEAT NOT SHOWN FOR CLARITY.

A. RELEASE DIRECTION C. BOTTOM VIEW
B. FRONT VIEW
1. HOOD LATCH ASSEMBLY 4. GAS SPRING
2. HOOD 5. HOOD HINGE
3. HOOD RELEASE LEVER
Figure 23. Hood and Latch Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
Opening the hood latch assembly unlocks the hood To open the hood latch assembly in lift trucks with
from the frame so the hood can be raised for access manual hydraulic control levers, the manual hy-
to the battery. The hood latch assembly must be in draulic control levers and linkage assembly must
good condition and properly secured before the lift be moved: pull latch handle up and allow manual
truck can be operated. If the hood latch assembly hydraulic lever assembly to move forward and away
does not lock the hood in the closed position the lift from mounting plate on front bulkhead.
truck must not be operated.
See Figure 22 for lift truck models • E2.2-3.5XN (E45-70XN) (A268)
• E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)
26
NOTE: Swivel seat not used on E1.6-2.0XN

(E30-40XN) (A269) lift trucks.
Optional seats are available in cloth or vinyl with fea-

tures such as full suspension and with the ability to
swivel. All seats have a seat sensor installed in the
bottom cushion that senses operator presence. When
the operator is not on the seat, the seat sensor opens
and interrupts the controller and stops lift truck op-
eration.
1. MANUAL HYDRAULIC LEVER ASSEMBLY

2. LATCH HANDLE
3. FRONT BULKHEAD
Figure 24. Latch Handle, Manual Hydraulic

Control Levers, Lift Trucks E2.2-3.5XN
(E45-70XN) (A268)
The seat assembly slides on seat rails that are fas-

tened to the hood by four capscrews. A forward/back-
1. FRONT BULKHEAD
ward lever at the left front side of the base adjusts 2. MANUAL HYDRAULIC LEVER ASSEMBLY
the seat either forward or backward. 3. LATCH HANDLE
See Figure 26 for lift truck models Figure 25. Latch Handle, Manual Hydraulic
• E2.2-3.5XN (E45-70XN) (A268) Control Levers, Lift Trucks E1.6-2.0XN
(E30-40XN) (A269)
• E1.6-2.0XN (E30-40XN) (A269)
27
Figure 26. Seat, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)
28
NOTE: FULL-SUSPENSION SWIVEL SEAT SHOWN.

1. SEAT ASSEMBLY 5. CAPSCREW 7. OPERATOR PRESENCE
2. HOOD 6. FORWARD/BACKWARD SYSTEM CONNECTOR
3. SEAT RAIL LEVER 8. RIDE POSITION INDICATOR
4. WASHER
Periodic Maintenance 8000 SRM 1442 for lift
truck models
• E1.6-2.0XN (E30-40XN) (A269)
REMOVE
To raise the hood, perform the following:
1. Use the tilt memory lever (see Figure 28) and tilt
the steering column all the way up.
1. SEAT ASSEMBLY 6. OPERATOR

2. HOOD PRESENCE
3. SEAT RAIL SYSTEM
4. CAPSCREW CONNECTOR
5. FORWARD/BACKWARD 7. RIDE POSITION
LEVER INDICATOR
Figure 27. Seat, Lift Trucks E1.6-2.0XN

(E30-40XN) (A269)
The hood, seat belt, hip restraint brackets, seat, and

seat rails are all parts of the operator restraint sys-
tem. Checks and adjustments for the operator re-
straint system are described in the Operating Man-
ual or NOTE: OPTIONAL TELESCOPIC STEERING COL-
UMN SHOWN.
truck models 1. TILT POSITION LEVER
• E2.2-3.5XN (E45-70XN) (A268) 2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 28. Steering Column Tilt Memory Lever
29
2. Slide the seat all the way back, and if necessary, See Figure 30 for lift truck models
move the armrest all the way back if lift truck • E1.6-2.0XN (E30-40XN) (A269)
is equipped with E-Hydraulic control levers. See
Figure 17. NOTE: Perform Step 8 for lift truck models
E2.2-3.5XN (E45-70XN) (A268).
3. If lift truck is equipped with manual hydraulic
levers, pull the latch handle for the manual hy- 8. Remove nuts, capscrews and latch assembly from
draulic lever assembly and move the manual hy- front bulkhead. See Figure 29.
draulic lever assembly tot he forward position be-
NOTE: Perform Step 9 for lift truck models
fore raising the hood.
E1.6-2.0XN (E30-40XN) (A269).
See Figure 24) for lift truck models
9. Remove latch assembly from front bulkhead. See
• E2.2-3.5XN (E45-70XN) (A268)
Figure 30.
NOTE: Tag electrical connectors during removal to
• E1.6-2.0XN (E30-40XN) (A269)
aid in installation.
10. Disconnect battery connector.
E2.2-3.5XN (E45-70XN) (A268).
NOTE: Perform Step 11 if lift truck is equipped with
NOTE: The hood can be raised from either side of the
E-Hydraulics.
lift truck. Pull or push the hood release lever. The
hood release lever is spring loaded. Use a sling and 11. Tag and disconnect electrical connector for E-Hy-
crane to hold the hood in the up position. draulic controller. See Figure 13.
4. From the left side of the lift truck, push the hood 12. Tag and disconnect electrical connectors from
release lever out towards the right side of the emergency battery disconnect and hood and
truck to unlatch the hood. If hood is opened latch position switches. See service manual
from right side of truck, pull hood release lever section Electrical System 2200 SRM 1369 for
towards the right side of the truck to unlatch procedures.
the hood. Place hand in plastic pocket provided
(above item 2 in Figure 22) and raise hood to the 13. Remove emergency battery disconnect switch if
up position. necessary. See service manual section Electri-
cal System 2200 SRM 1369 for procedures.
E1.6-2.0XN (E30-40XN) (A269). NOTE: Perform Step 14 through Step 16 if removing
seat assembly from hood.
NOTE: The hood can be raised from either side of the
lift truck. Pull or push the hood release lever. The 14. Remove four capscrews and washers from hood
hood release lever is spring loaded. Use a sling and and rails.
crane to hold the hood in the up position.
5. To raise the hood, lift the hood release handle up- • E2.2-3.5XN (E45-70XN) (A268)
wards to unlatch the hood. See Figure 23. Place
hands in plastic handle provided and raise hood See Figure 27 for lift truck models
to the UP position. • E1.6-2.0XN (E30-40XN) (A269)
6. Remove the counterweight cover. See the Re- 15. Tag and disconnect operator presence system
move procedures in the section Counterweight connector from main wire harness.
Replacement.
7. Remove screws and latch cover from latch assem- • E2.2-3.5XN (E45-70XN) (A268)
bly.
• E2.2-3.5XN (E45-70XN) (A268)
16. Remove seat assembly from hood.
30
Figure 29. Hood and Latch, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)
31

A. FRONT VIEW B. BOTTOM VIEW
1. LATCH ASSEMBLY 11. GAS-CONTROLLED STRUT BACK END
2. FRONT BULKHEAD 12. SHOULDER BOLT
3. LATCH COVER 13. WASHER
4. SCREW 14. HOOD HINGE
5. CAPSCREW 15. HOOD HINGE ARM
6. NUT 16. STRUT BRACKET
7. HOOD 17. SPACER
8. LOCKING CLIP 18. O-RING
9. GAS-CONTROLLED STRUT FRONT END 19. FLANGE NUT
10. BALL STUD 20. HOOD HINGE BASE PLATE
NOTE: To remove seat from seat rails, perform 20. Repeat Step 18 and Step 19 for opposite gas-con-
Step 17. trolled strut.
17. Remove stop screws from seat rails, hold ride po- 21. Remove lifting device and close hood.
sition indicator in the open position, and slide
seat from seat rails. See Figure 10. NOTE: Note placement of washers prior to removal
to aid in installation.
18. Remove locking clip from gas-controlled strut
front end. Remove gas-controlled strut front end 22. Remove nuts, shoulder bolts, and washers from
from ball stud on strut bracket. Remove ball hood hinges and hood hinge arms.
stud, spacer, and O-ring from strut bracket.
See Figure 29 for lift truck model • E2.2-3.5XN (E45-70XN) (A268)
• E2.2-3.5XN (E45-70XN) (A268)
See Figure 30 for lift truck model • E1.6-2.0XN (E30-40XN) (A269)
• E1.6-2.0XN (E30-40XN) (A269)
23. Remove capscrews and flange nuts from hood
19. Remove locking clip from gas-controlled strut hinge base plate and remove hood hinge base
back end. Remove gas-controlled strut back end plate.
from ball stud on hood hinge. Remove gas-con-
trolled strut. Remove ball stud, spacer, and
• E2.2-3.5XN (E45-70XN) (A268)
O-ring from hood hinge.
• E1.6-2.0XN (E30-40XN) (A269)
• E2.2-3.5XN (E45-70XN) (A268)
24. Using a lifting device, remove hood from battery
compartment.
• E1.6-2.0XN (E30-40XN) (A269)

A. FRONT VIEW B. BOTTOM VIEW
1. LATCH ASSEMBLY 9. NUT
2. FRONT BULKHEAD 10. WASHER
3. CAPSCREW 11. HOOD HINGE
4. HOOD 12. SHOULDER BOLT
5. SPACER 13. HOOD HINGE ARM
6. BALL STUD 14. HOOD HINGE BASE PLATE
7. GAS CONTROLLED STRUT 15. FLANGE NUT
8. LOCKING CLIP
32
Figure 30. Hood and Latch, Lift Trucks E1.6-2.0XN (E30-40XN) (A269)
33
INSTALL 7. If seat assembly has been removed from hood,

position seat onto hood and install washers and
1. Using a lifting device, position hood onto hinges capscrews into hood and seat rails.
and install washers, shoulder bolts, nuts, cap-
screws, and flange nuts as noted during removal. See Figure 26 for lift truck models
a. Tighten nuts. • E2.2-3.5XN (E45-70XN) (A268)
b. Nuts must be fully engaged with shoulder
bolt and hood hinge arm assembly must be See Figure 27 for lift truck models
free to move. • E1.6-2.0XN (E30-40XN) (A269)
c. Add or subtract washers, if necessary, to al-
NOTE: Remove tags as electrical connections are
low hood hinge arm assembly to move freely
made.
when opening and closing hood.
8. Connect operator presence system connector to
main wire harness.
• E2.2-3.5XN (E45-70XN) (A268)
• E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)
2. Open and close hood to check for proper clear-
• E1.6-2.0XN (E30-40XN) (A269)
ance.
9. Install hood and latch switches and emergency
3. Raise hood; use a lifting device to support hood in
battery disconnect switch, if removed, and adjust
the open position. Install ball stud, spacer, and
as necessary. See service manual section Elec-
O-ring onto hood hinge. Install gas-controlled
trical System 2200 SRM 1369 for procedures.
strut back end onto ball stud on hood hinge. In-
stall locking clip on gas-controlled strut back end 10. Connect electrical wires, as tagged during re-
and ball stud. moval, to emergency battery disconnect and
hood and latch position switches. See service
manual section Electrical System 2200 SRM
• E2.2-3.5XN (E45-70XN) (A268)
1369 for procedures.
11. If equipped, connect electrical connector for
• E1.6-2.0XN (E30-40XN) (A269)
E-Hydraulic controller. See Figure 13.
4. Install ball stud, spacer, and O-ring onto strut
12. Install nuts, capscrews, and latch assembly to
bracket. Install gas-controlled strut front end
front bulkhead. Install screws and latch cover to
onto ball stud on strut bracket. Install locking
latch assembly.
clip on gas-controlled strut front end and ball
stud. 13. Connect battery connector.
See Figure 29 for lift truck models 14. Close hood and remove lifting device.
• E2.2-3.5XN (E45-70XN) (A268)
15. Install counterweight cover. See the Install
See Figure 30 for lift truck models procedures in the section Counterweight Re-
• E1.6-2.0XN (E30-40XN) (A269) placement.
5. Repeat Step 3 and Step 4 for opposite gas-con- 16. If lift truck is equipped with manual hydraulic
trolled strut. Close hood. control levers, push manual hydraulic control
lever assembly until it clicks into place.
6. If seat rails were removed from seat assembly,
hold ride position indicator in the open position
and slide seat onto seat rails. Install stop screws.
See Figure 10.
34
100 SRM 1342 Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)
GROUND TEST
NOTE: If the static discharge ground connection is
not secured properly it could lead to the possible fail-
ure of the traction and/or pump motor controllers.
1. To ensure proper installation of seat assembly

and associated bracketing, perform continuity
test.
2. Using an ohm meter, place a test lead at the

armrest mounting bolt and another at the truck
frame. The resistance needs to read 5 Ohms or
less. See Figure 31.
3. If the resistance is greater than 5 Ohms, double

check installation of seat assembly, both ends of
seat wiring harness, and wiring harness ground
strap.
1. ARMREST BOLT
2. FRAME
Figure 31. Ground Test
Hood and Seat Assembly Replacement for Lift Truck

Models J2.2-3.5XN (J45-70XN) (A276)
GENERAL good condition and properly secured before the lift
truck can be operated. If the hood latch assembly
The hood is the platform for the seat assembly and does not lock the hood in the closed position, the lift
is located above the battery. It functions as a bat- truck must not be operated.
tery restraint that completely covers the battery com-
partment. When correctly locked to the frame, it will To open the hood on lift truck with manual hy-
hold the battery in the battery compartment if an ac- draulics, the manual hydraulic control levers and
cident causes the lift truck to tip over. The hood is a linkage assembly must be moved: pull latch handle
welded, steel assembly. Two hood hinges at the back up and allow manual hydraulic linkage and handles
attach to the counterweight. A latch assembly on the to move forward and away from mounting plate
front bulkhead, locks the hood closed during opera- on front bulkhead. If the latch assembly does not
tion. Gas-controlled struts hold the hood in the open lock the hood in the closed position, the manual
position. See Figure 32. hydraulic levers and linkage assembly will not lock
into position and the lift truck will not operate.
Opening the latch assembly unlocks the hood from
the frame so the hood can be raised to access the bat-
tery. See Figure 32. The latch assembly must be in
35
Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342
A. OPEN POSITION C. BOTTOM VIEW

B. FRONT VIEW
1. HOOD 5. HOOD HINGE PLATE
2. HOOD RELEASE HANDLE 6. HOOD HINGE ARM
3. HOOD LATCH ASSEMBLY 7. LEVER
4. GAS SPRING
Figure 32. Hood and Hood Latch Arrangement
The seat assembly slides on seat rails that are fas- interrupts the motor controller and stops lift truck
tened to the hood by four capscrews. A lever at the operation. See Figure 33.
left front side of the seat base controls the adjust-
ment of the seat to the forward and backward posi- The hood, seat belt, hip restraint brackets, seat, and
tions. Optional seats are available in cloth or vinyl seat rails are all parts of the operator restraint sys-
with features such as full suspension and with the tem. Checks and adjustments for the operator re-
ability to swivel. All seats have a seat switch (Opera- straint system are described in the Operating Man-
tor Presence System) installed in the bottom cushion ual and Periodic Maintenance 8000 SRM 1372.
that senses the presence of the operator. When the
NOTE: The seat belt may be either black or red.
operator is not on the seat, the seat switch opens and
NOTE: FULL SUSPENSION SEAT WITH MANUAL HYDRAULIC HIP RESTRAINTS SHOWN.
1. SEAT MOUNTING CAPSCREW 6. WEIGHT ADJUSTMENT KNOB
2. HOOD 7. RIDE POSITION INDICATOR
3. OPERATOR PRESENCE SYSTEM CONNECTOR 8. FORWARD/BACKWARD LEVER
4. SEAT MOUNTING NUT 9. HIP RESTRAINT
5. SEAT RAIL
36
Figure 33. Seat Assembly
37
Opening and Closing the Hood NOTE: The hood must be raised from the left side of
the lift truck.
1. Use the tilt memory lever (see Figure 34) and tilt
the steering column all the way up. 4. Place hand under hood release lever and push
hood release lever up to release hood latch assem-
bly. See Figure 35.
There are two ways to open and close the hood as

described in Step 5 and Step 6 below.
5. To open and close the hood, perform the follow-

ing:
a. Place hand in hood handle (see Figure 35)

and raise hood to the first stop point. See
Figure 36.
b. Turn lever to the right to the second stop.

Lever will be horizontal to slot in plate. See
Figure 36. Raise hood to full upright posi-
tion.
c. To close hood, lower hood to first stop point.

Turn lever to left and close hood until bolt
touches the striker (see Figure 37). Push
down on hood until it clicks once to lock. Try
to lift hood up using hood handle to make
sure hood is securely latched.
NOTE: OPTIONAL TELESCOPIC STEERING COL-

UMN SHOWN.
1. TILT POSITION SENSOR
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 34. Steering Column Levers
2. Slide the seat all the way back. Move the arm- A. OPEN POSITION B. FRONT VIEW
rest all the way back if lift truck is equipped with
E-Hydraulic control levers. See Figure 17. 1. HOOD RELEASE LEVER
2. HOOD LATCH ASSEMBLY
3. If lift truck is equipped with manual hydraulic 3. HOOD
4. HOOD HORN BUTTON
levers, release the latch for the manual hydraulic 5. HOOD HANDLE
lever assembly and move the assembly to the for-
ward position. See Figure 24. Figure 35. Hood and Hood Handle Components
38
NOTE: NON-SUSPENSION SEAT AND RAISED HOOD SHOWN.

A. HOOD RAISED TO FIRST STOP POINT C. HOOD RAISED TO FULL UPRIGHT POSITION,
B. HOOD RAISED TO FULL UPRIGHT POSITION, LEVER TURNED TO THIRD STOP POINT
LEVER TURNED TO SECOND STOP POINT (VERTICAL TO SLOT)
(HORIZONTAL TO SLOT)
1. LEVER 4. SEAT
2. PLATE 5. SLOT
3. HOOD 6. LINK PLATE
Figure 36. Opening The Hood
6. To open and close the hood, perform the follow- 2. Remove capscrews and latch assembly from latch
ing: plate on front bulkhead. See Figure 37.
a. Place hand in hood handle (see Figure 35) NOTE: Tag electrical connectors during removal to
and raise hood to the first stop point. See aid in installation.
Figure 36.
b. Turn lever to the right to the third stop.
Lever will be vertical to slot in plate. See NOTE: Perform Step 4 if lift truck is equipped with
Figure 36. Raise hood to full upright posi- E-Hydraulics.
tion.
4. Tag and disconnect electrical connector for E-Hy-
c. To close hood, lower hood down until the bolt draulic controller. See Figure 13.
touches the striker (see Figure 37). Push
5. Tag and disconnect electrical connectors from
down on hood until it clicks once to lock. Try
emergency battery disconnect and hood and
to lift hood up using hood handle to make
latch position switches. See service manual
sure hood is securely latched.
section Electrical System 2200 SRM 1369 for
procedures.
REMOVE
6. Remove emergency battery disconnect switch if
1. Open and raise the hood to full upright position.
necessary. See service manual section Electri-
See the section Opening and Closing the Hood for
cal System 2200 SRM 1369 for procedures.
procedures.
39
Figure 37. Hood and Latch
40

A. SIDE VIEW B. BOTTOM VIEW
1. LATCH ASSEMBLY 11. GAS CONTROLLED STRUT, BACK END
2. FRONT BULKHEAD 12. NUT
3. LATCH PLATE 13. LOCKING CLIP
4. LATCH STRIKER 14. SNAP RING
5. HOOD 15. LEVER
6. CAPSCREW 16. LINK PLATE
7. SHOULDER BOLT 17. HOOD HINGE ARM
8. WASHER 18. HOOD HINGE
9. BALL STUD 19. PIN
10. GAS CONTROLLED STRUT, FRONT END 20. PLATE
NOTE: Perform Step 7 through Step 9 if removing 17. On left hood hinge, remove washers and snap
seat assembly from hood. ring from bottom of link plate. Remove bottom
of link plate from pin. See Figure 37.
7. Remove four capscrews and washers from hood
and seat rails. See Figure 33. 18. Using a lifting device, remove hood from battery
compartment.
8. Tag and disconnect operator presence system
connector from main wire harness. See Fig- INSTALL
ure 33.
1. Using a lifting device, position hood onto hinges
9. Remove seat assembly from hood. and install washers, shoulder bolts, nuts, and
plates as noted during removal. See Figure 37.
NOTE: To remove seat from seat rails, perform
a. Tighten nuts.
Step 10.
b. Nuts must be fully engaged with shoulder
10. Remove stop screws from seat rails, hold ride po- bolt and hood hinge arm assembly must be
sition indicator in the open position, and slide free to move.
seat from seat rails. See Figure 11. c. Add or subtract washers, if necessary, to al-
low hood hinge arm assembly to move freely
11. Remove locking clip from gas-controlled strut when opening and closing hood.
front end. Remove gas-controlled strut front
end from ball stud and hood hinge arm. See 2. On left side of hood hinge, install washer and
Figure 37. bottom of link plate to pin. Install other washer
and snap ring to secure bottom of link plate to
12. Remove locking clip from gas-controlled strut pin. See Figure 37.
back end. Remove gas-controlled strut back end
from ball stud and hood hinge. See Figure 37. 3. Open and close hood to check for proper clear-
ance. See Opening and Closing the Hood for pro-
13. Repeat Step 11 and Step 12 for opposite gas-con- cedures.
trolled strut.
4. Install counterweight cover. See the section
14. Close hood. See the section Opening and Closing Counterweight Replacement for procedures.
the Hood for procedures.
5. Raise hood. Install gas-controlled strut back end
15. Remove counterweight cover. See the section onto ball stud on hood hinge. Install locking clip
Counterweight Replacement for procedures. on gas-controlled strut back end and ball stud.
See Figure 37.
NOTE: Note placement of washers prior to removal
to aid in installation. 6. Install gas-controlled strut front end onto ball
stud on hood hinge arm. Install locking clip on
16. Remove nuts, shoulder bolts, washers, and plates gas-controlled strut front end and ball stud. See
from hood hinges and hood hinge arms. See Fig- Figure 37.
ure 37.
41
7. Repeat Step 5 and Step 6 for opposite gas-con- GROUND TEST

trolled strut.
NOTE: If the static discharge ground connection is
8. If seat rails were removed from seat assembly, not secured properly it could lead to the possible fail-
hold ride position indicator in the open position ure of the traction and/or pump motor controllers.
and slide seat onto seat rails. Install stop screws.
See Figure 11. 1. To ensure proper installation of seat assembly
and associated bracketing, perform continuity
9. If seat assembly has been removed from hood, test.
position seat onto hood and install capscrews and
washers into hood and seat rails. See Figure 33. 2. Using an ohm meter, place a test lead at the
armrest mounting bolt and another at the truck
NOTE: Remove tags as electrical connections are frame. The resistance needs to read 5 Ohms or
made. less. See Figure 38.
10. Connect operator presence system connector to 3. If the resistance is greater than 5 Ohms, double
main wire harness. See Figure 33. check installation of seat assembly, both ends of
seat wiring harness, and wiring harness ground
11. Install hood and latch switches and emergency strap.
battery disconnect switch, if removed, and adjust
as necessary. See service manual section Elec-
trical System 2200 SRM 1369 for procedures.
12. Connect electrical wires, as tagged during re-

moval, to emergency battery disconnect and
hood and latch position switches. See service
manual section Electrical System 2200 SRM
1369 for procedures.
13. If equipped, connect electrical connector for

E-Hydraulic controller. See Figure 13.
14. Connect battery connector.
15. Install capscrews and latch assembly to latch

plate on front bulkhead. See Figure 37.
16. Close hood. See procedures in Opening and Clos-

ing the Hood. Make certain locking mechanism
for hood is properly engaged.
1. ARMREST BOLT 2. FRAME
17. If lift truck is equipped with manual hydraulic
control levers, push manual hydraulic control Figure 38. Ground Test
lever assembly until it clicks into place.
42
100 SRM 1342 Master Cylinder Repair and Adjustment
Master Cylinder Repair and Adjustment for Lift Truck E2.2-3.5XN

(E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
For procedures on adjusting and repairing the mas- Brake System 1800 SRM 1359 for lift truck models:
ter cylinder, see one of the following service manuals: • E2.2-3.5XN (E45-70XN) (A268)
Brake System 1800 SRM 1438 for lift truck models:

• E1.6-2.0XN (E30-40XN) (A269)
Master Cylinder Repair and Adjustment for Lift Truck

J2.2-3.5XN (J45-70XN) (A276)
REMOVE DISASSEMBLE
1. Block front and rear sides of wheels to make sure
lift truck cannot move. CAUTION
Disposal of lubricants and fluids must meed lo-
2. Remove floor mat and floor plates from lift truck cal environmental regulations.
to access master cylinder.
1. Drain master cylinder into drain pan. Dispose of
3. Disconnect wire at brake sensor and bottom of brake fluid.
master cylinder. Remove brake sensor. See Fig-
ure 39. 2. Remove push rod and boot from cylinder. See
Figure 40.
4. Disconnect reservoir level sensor switch from
cowl harness.
WARNING
5. Remove tube assembly from master cylinder. Use care when removing snap ring to avoid
Plug master cylinder and tube to prevent foreign possible injury.
material from entering the brake system. See
Figure 39. 3. Remove snap ring from cylinder. See Figure 40.
NOTE: Perform the following step only if the tube is CAUTION

damaged.
When the piston is removed, make sure the
6. Remove tube assembly from brake fitting. Plug cylinder bore and piston are not scratched or
fitting to prevent foreign material from entering damaged.
the brake system. Lay tube assembly aside until
4. Remove piston assembly from cylinder. See Fig-
ready for bench bleed. See Figure 39.
ure 40.
7. Remove cotter pin, washer, and pin from plate at
5. Remove gasket and cap from reservoir. See Fig-
bottom of brake pedal assembly. See Figure 39.
ure 40.
8. Remove two nuts, two capscrews, and master
cylinder from mounting plate. See Figure 39.
43
Master Cylinder Repair and Adjustment 100 SRM 1342
Figure 39. Master Cylinder and Brake Pedal
44
100 SRM 1342 Master Cylinder Repair and Adjustment
NOTE: MAIN CONTROL VALVE NOT SHOWN FOR CLARITY.

1. TUBE ASSEMBLY 10. CLEVIS
2. BRAKE FITTING 11. WASHER
3. MASTER CYLINDER 12. PIN
4. NUT 13. COTTER PIN
5. CAPSCREW 14. MOUNTING PLATE
6. BRACKET 15. BULKHEAD
7. BRAKE PEDAL ASSEMBLY 16. PLATE
8. PLATE 17. STEER ACCUMULATOR HOSE
9. COWL 18. BRAKE SENSOR
NOTE: ITEM 12, PISTON ASSEMBLY (INCLUDED ITEMS 1 THROUGH 6), SHOULD NOT BE DISASSEMBLED.
ILLUSTRATION CREATED FROM MANUFACTURER’S DOCUMENTATION.
1. SECONDARY CUP 12. PISTON ASSEMBLY
2. PISTON 13. PIN
3. SPACER 14. WASHER
4. PRIMARY CUP 15. COTTER PIN
5. RETAINER 16. REPAIR KIT
6. SPRING 17. MASTER CYLINDER ASSEMBLY
7. SNAP RING 18. GASKET
8. BOOT 19. CAP
9. PUSH ROD 20. CYLINDER
10. NUT 21. CLAMP
11. CLEVIS 22. RESERVOIR
Figure 40. Master Cylinder Assembly
45
Master Cylinder Repair and Adjustment 100 SRM 1342
CLEAN 1. Install piston assembly into cylinder. See Fig-

ure 40.
CAUTION
DO NOT use an oil solvent to clean the master WARNING
cylinder. Use alcohol or DOT3 brake fluid only. Use care when installing snap ring to avoid
possible injury.
1. Clean components, paying particular attention to
those areas highlighted in Figure 41 with alcohol 2. Install snap ring into cylinder. See Figure 40.
or DOT3 brake fluid only.
3. Install boot and push rod into cylinder. See Fig-
ure 40.
BENCH BLEED MASTER CYLINDER

NOTE: Master cylinder must be bench bled before in-
stalling it on lift truck.
1. Place master cylinder, horizontally, in a

soft-jawed vise.
2. Remove plugs from tube assembly ends. Connect

tube assembly to master cylinder.
3. Place the other end of tube assembly in a clear

container of brake fluid.
4. Fill reservoir with (DOT3) brake fluid, as needed.
5. Stroke master cylinder until all air is purged

from master cylinder.
6. Install gasket and cap to reservoir. See Fig-

ure 40.
INSTALL AND ADJUST

1. Remove plugs from master cylinder and tube as-
Figure 41. Cleaning Components sembly. Install tube assembly to master cylinder.
See Figure 39.
INSPECT
2. Install master cylinder with tube asembly at-
1. Inspect exterior of master cylinder assembly for tached, two capscrews, and two nuts onto mount-
damage. Replace master cylinder assembly if ing plate. Tighten nuts to 19 N•m (168 lbf in).
damaged. See Figure 39.
2. Inspect bore of master cylinder for holes or 3. Install pin, washer, cotter pin, and the back of
scratches. Replace master cylinder assembly if master cylinder onto plate at the bottom of brake
damaged. pedal assembly. See Figure 39.
NOTE: DO NOT disassemble piston assembly. 4. Remove plug from brake fitting. Install tube as-
sembly into brake fitting. See Figure 39.
ASSEMBLE
5. Install brake sensor. Tighten to 23 to 28 N•m
(203 to 247 lbf in). Connect wire from sensor to
CAUTION
bottom of master cylinder. See Figure 39.
When piston is installed, make sure the cylin-
der bore and piston are not scratched or dam-
aged.
46
100 SRM 1342 Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
6. Connect reservoir level sensor switch to cowl har- 13. Check adjustment of brake pedal as described in
ness. section Pedal Adjust of this manual.
7. Adjust brake pedal height to 96 mm (3.78 in.)

by adjusting capscrew. Tighten locknuts. See
Figure 42.
8. Adjust master cylinder per following procedure:
a. Loosen locknut on master cylinder push rod

and adjust by turning push rod counterclock-
wise (as viewed from rear of lift truck) to re-
move all slack between master cylinder and
brake pedal. DO NOT allow rubber boot to be
twisted while adjusting the rod length. See
Figure 42.
b. Turn push rod one-eighth turn clockwise (as

viewed from rear of lift truck) allowing mas-
ter cylinder to fully return when brake pedal
is released. Tighten locknut to 15 to 17 N•m
(133 to 150 lbf in). See Figure 42.
9. Flush with (DOT3) brake fluid and air bleed sys-

tem. See BSAR section of this manual.
1. BRAKE PEDAL 4. PUSH ROD
10. Adjust fluid level until at MAX line on reservoir. 2. CAPSCREW 5. RUBBER BOOT
3. LOCKNUT
11. Verify all connections are leak free.
Figure 42. Brake Pedal and Master Cylinder
12. Install floor plates and floor mat into lift truck Adjustment
Brake Pedal Components for Lift Trucks E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
For procedures dealing with brake pedal compo- Brake System 1800 SRM 1438 for lift truck models:
nents, see one of the following service manuals: • E1.6-2.0XN (E30-40XN) (A269)

• E2.2-3.5XN (E45-70XN) (A268)
Brake Pedal Components for Lift Truck J2.2-3.5XN

(J45-70XN) (A276)
REMOVE prevent foreign material from entering brake
system. See Figure 43.
1. Block front and rear sides of wheels to make sure
lift truck cannot move. 4. Disconnect wire at brake sensor and bottom of
master cylinder. See Figure 43.
2. Remove floor mat and floor plates from lift truck.
5. Disconnect reservoir level sensor switch from
3. Remove tube assembly from master cylinder. cowl harness.
Plug master cylinder and tube assembly to
47
Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342
Figure 43. Master Cylinder and Brake Pedal
48
100 SRM 1342 Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

1. TUBE ASSEMBLY 10. CLEVIS
2. BRAKE FITTING 11. WASHER
3. MASTER CYLINDER 12. PIN
4. NUT 13. COTTER PIN
5. CAPSCREW 14. MOUNTING PLATE
6. BRACKET 15. BULKHEAD
7. BRAKE PEDAL ASSEMBLY 16. PLATE
8. PLATE 17. STEER ACCUMULATOR HOSE
9. COWL 18. BRAKE SENSOR
6. Disconnect steer accumulator hose from main 2. Assemble brake pedal, two bushings, tube,
control valve steer supply fitting. Plug hose and washer, capscrew, and nut onto mount bracket.
fitting to prevent foreign material from entering See Figure 44.
hydraulic system. See Figure 43.
3. Assembly two locknuts and one capscrew onto
7. Remove nut and capscrew from bracket and plate mount bracket. See Figure 44.
attached to bulkhead; remove two nuts and two
capscrews from bracket and plate attached to 4. Adjust brake pedal height to 9 mm (3 in.) by ad-
cowl. Remove bracket, with brake pedal assem- justing capscrew. Measurement between bottom
bly, master cylinder, and steering accumulator of brake pedal and top of bracket. After adjust-
attached, from lift truck. See Figure 43. ment, tighten locknuts.
8. Remove cotter pin, washer, and pin from plate at 5. Connect spring to brake pedal and mount
bottom of brake pedal assembly. See Figure 43. bracket. See Figure 44.
9. Remove two nuts, two capscrews, and master

cylinder from mounting plate. See Figure 43.
DISASSEMBLE
1. Disconnect spring from mount bracket and brake
pedal assembly. See Figure 44.
2. Remove capscrew and two lock nuts from mount

bracket. See Figure 44.
3. Remove nut, capscrew, washer, two bushings,

tube, and brake pedal from mount bracket. See
Figure 44.
4. Remove brake pad from brake pedal. See Fig-

ure 44.
INSPECT
1. Inspect components for damage; replace if dam-
aged. 1. SPRING 7. BUSHING
2. BRACKET 8. TUBE
2. Spring free length measurement should be 133 3. BRAKE PEDAL 9. LOCKNUT
to 160 mm (5 to 6 in.). Replace spring if length is 4. NUT 10. MOUNT BRACKET
5. CAPSCREW 11. BRAKE PAD
beyond specification. 6. WASHER
ASSEMBLE Figure 44. Brake Pedal Assembly
1. Assemble brake pedal and brake pad. See Fig-
ure 44.
49
Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342
INSTALL pedal to the top of the bracket. Tighten locknuts.

See Figure 45.
1. Install master cylinder, two capscrews, and
two nuts onto mounting plate. Tighten nuts to
19 N•m (124 lbf in). See Figure 43.
2. Install pin, washer, and cotter pin onto plate at

bottom of brake pedal assembly. See Figure 43.
3. Install bracket, assembly, master cylinder, two

capscrews, and two nuts onto plate attached to
cowl; install capscrew, nut, and bracket onto
plate attached to bulkhead. See Figure 43.
4. Connect steer accumulator hose to main control

valve steer supply fitting. See Figure 43.
5. Connect reservoir level sensor switch to cowl har-

ness.
6. Connect wire at brake sensor and bottom of mas-

ter cylinder. See Figure 43.
7. Install tube assembly onto master cylinder. See

Figure 43.
1. BRAKE PEDAL
8. Install floor plates and floor mat into lift truck. 2. CAPSCREW
3. LOCKNUT
9. Remove blocks from front and rear sides of 4. MASTER CYLINDER PUSH ROD
wheels. 5. ROBBER BOOT
PEDAL ADJUST Figure 45. Brake Pedal and Master Cylinder

Adjustment
1. Adjust pedal height to 96 mm (3.78 in.) by ad-
justing capscrews at the rear of the pedal assem-
bly. Measurement is from the bottom of the brake
50
100 SRM 1342 Brake System Air Removal
Brake System Air Removal for Lift Truck J2.2-3.5XN

(J45-70XN) (A276)
BRAKE SYSTEM AIR REMOVAL 8. Check level of brake fluid in master cylinder
reservoir. Fill reservoir to correct level.
There are two commonly used methods to remove air
from the brake system. The preferred method is us- USING BRAKE PEDAL PRESSURE
ing a pressure bleed system. The other method is by
applying pressure using brake pedal. 1. Fill master cylinder reservoir with (DOT 3) brake
fluid.
USING PRESSURE BLEED SYSTEM
2. Remove bleeder cap.
1. Fill master cylinder reservoir with (DOT 3) brake
fluid. 3. Place one end of a rubber hose on bleeder screw
of wheel cylinder furthest from master cylinder.
2. Remove bleeder cap. Place other end of hose into a clear container of
brake fluid.
3. Place one end of a rubber hose on bleeder screw
of each wheel cylinder. Place other end of each NOTE: Check level of brake fluid in master cylinder
hose into a clear container of brake fluid. reservoir during procedure. Make sure to maintain
brake fluid at correct level.
4. Connect a pressure bleeder to master cylinder
reservoir. 4. Loosen bleeder screw at wheel cylinder one turn
so that air can be removed from brake system.
5. Loosen bleeder screws at wheel cylinders one Slowly push brake pedal and hold it at the end of
turn. its stroke. Close the bleeder screw.
NOTE: While applying air pressure to pressure 5. Repeat Step 4 until there are no air bubbles in
bleeder, check level of brake fluid in master cylinder container.
reservoir. Make sure to maintain brake fluid at the
correct level to avoid forcing more air into brake 6. Install bleeder cap.
system.
7. Repeat Step 1 through Step 4 and Step 6 for re-
6. Apply 34.5 kPa (5 psi) of air pressure to pressure maining wheel cylinder.
bleeder, forcing fluid through lines until all air is
removed from system. Close bleeder screws. 8. Check level of brake fluid in master cylinder
reservoir. Fill reservoir to correct level.
7. Install bleeder cap.
Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
For procedures to remove air from the brake system, Brake System 1800 SRM 1438 for lift truck models:
see one of the following service manuals: • E1.6-2.0XN (E30-40XN) (A269)

• E2.2-3.5XN (E45-70XN) (A268)
51
Counterweight Replacement 100 SRM 1342
Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
If the lift truck must be put on blocks for mainte- Table 1 for lift truck models
nance or repair, see How to Put Lift Truck on • E2.2-3.5XN (E45-70XN) (A268)
Blocks in the Operating Manual or one of the fol-
lowing service manuals Table 2 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
truck models The counterweight normally is not removed for most
• E2.2-3.5XN (E45-70XN) (A268) repairs. Replacement of controller and contactors is
easier with counterweight installed. The counter-
Periodic Maintenance 8000 SRM 1442 for lift weight is fastened to the frame with four capscrews.
truck models: The weights for counterweights are shown in
• E1.6-2.0XN (E30-40XN) (A269)
Table 1 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268)
WARNING
The counterweight is very heavy. Make sure Table 2 for lift truck models
that the crane and lifting devices have enough • E1.6-2.0XN (E30-40XN) (A269)
lifting capacity to safely lift the counterweight.
The weights of the counterweights are shown
in
Figure 46. Counterweight Assembly for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269)
52
100 SRM 1342 Counterweight Replacement

A. BACK VIEW SHOWN B. FRONT VIEW SHOWN
1. LOWER CAPSCREW 6. COUNTERWEIGHT COVER
2. TOW PIN 7. COVER NUT
3. LOWER WASHER 8. COVER CAPSCREWS
4. LOWER NUT 9. COUNTERWEIGHT
5. UPPER CAPSCREW AND WASHER 10. SLOTS
Table 1. Counterweights for Lift Truck REMOVE

E2.2-3.5XN (E45-70XN) (A268)
Model (mm*) Weight + 50 kg
2. Remove battery from lift truck. See How to
(110 lb)
0 kg
one of the following service manuals
(0 lb)
E2.2XN(E45XN) 786 Periodic Maintenance 8000 SRM 1364 for lift
truck models
E2.2-2.5XN 847 571 kg (1258 lb)
• E2.2-3.5XN (E45-70XN) (A268)
(E45-50XN)
E2.2XN(E45XN) 700
truck models
E2.5XN(E50XN) 786 • E1.6-2.0XN (E30-40XN) (A269)
E2.75XN 847 764 kg (1684 lb)
3. Remove overhead guard. See the Remove proce-
(E55XN) dures in the section Overhead Guard Replace-
E3.2XN(E65XN) 1015 ment.
E2.5XN(E50XN) 700 4. Remove top of counterweight cover from coun-

terweight by removing two cover capscrews and
E3.0XN(E60XN) 847
948 kg (2090 lb) cover nuts. See Figure 46.
E3.2XN(E65XN) 933
5. Remove controller cover. Remove controller, con-
E3.5XN(E70XN) 1015 tactors, and other electronic components located
*Approximate battery compartment lengths. in the counterweight, see Electrical System
2200 SRM 1369.
Table 2. Counterweights for Lift Truck WARNING

E1.6-2.0XN (E30-40XN) (A269) Make sure slings and crane have enough capac-
ity to lift and hold counterweight.
Model (mm*) Weight + 50 kg
(110 lb) See Table 1 for lift truck models
0 kg • E2.2-3.5XN (E45-70XN) (A268)
(0 lb)
See Table 2 for lift truck models
E1.6XN(E30XN) 700 489 kg (1078 lb) • E1.6-2.0XN (E30-40XN) (A269)
E1.8XN 700 605 kg (1334 lb) 6. Wrap two slings through slots in top of counter-
(E35XN) weight. See Figure 46. Attach slings to crane.
E2.0XN 700
754 kg (1662 lb) 7. From inside the battery compartment, near the
(E40XN)
bottom, remove upper capscrews and washers
*Approximate battery compartment lengths. from counterweight and frame. See Figure 46.
53
8. Remove lower capscrews, lower nuts, lower controller cover onto counterweight. see Electri-
washers, and tow pin from counterweight and cal System 2200 SRM 1369. Connect electrical
frame. See Figure 46. connectors as tagged during removal.
9. Using crane lift counterweight away from frame. 6. Install counterweight cover, washers, and cap-
screws on counterweight. See Figure 46.
INSTALL
7. Install overhead guard. See the Install proce-
1. Using crane, lift counterweight into position on dures in the section Overhead Guard Replace-
frame. ment.
2. Install upper capscrews and washers, near bot- 8. Install battery into lift truck. See How to
tom of the battery compartment, into counter- Change Battery in the Operating Manual or
weight and frame. See Figure 46. Tighten upper one of the following service manuals
capscrews to 755 N•m (557 lbf ft).
3. Install lower capscrews, lower nuts, and lower truck models
washers in the tow pin area, into counterweight • E2.2-3.5XN (E45-70XN) (A268)
and frame. Install tow pin into counterweight.
See Figure 46. Tighten lower capscrews to Periodic Maintenance 8000 SRM 1442 for lift
90 N•m (66 lbf ft). truck models
• E1.6-2.0XN (E30-40XN) (A269)
4. Disconnect and remove slings from counter-
weight. 9. Connect battery connector.
5. Install controller, contactors, and other electronic

components located in the counterweight. Install
Counterweight Replacement for Lift Trucks J2.2-3.5XN

(J45-70XN) (A276)
Put lift truck on blocks, see How to Put Lift Truck The weights of the counterweights are shown
on Blocks in the Operating Manual or Periodic in Table 3.
Maintenance 8000 SRM 1372.
The counterweight normally is not removed for most
repairs. Replacement of controller and hydraulic
WARNING components is easier with the counterweight in-
The counterweight is heavy. Make sure that stalled. The counterweight is fastened to the rear
the crane and lifting devices have enough lift- bulkhead with mounting bolts.
ing capacity to safely lift the counterweight.
54
1. COUNTERWEIGHT 5. REAR BULKHEAD

2. COUNTERWEIGHT COVER 6. MOUNTING BOLT
3. TOW PIN 7. WASHER
4. CAPSCREW 8. FRAME
Figure 47. Counterweight Assembly for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
55
NOTE: Some lift trucks are equipped with cab pan-

els. Be careful not to damage panels when removing
overhead guard.
4. Remove overhead guard. See the Overhead

Guard Replacement section of this manual.
5. Remove tow pin, capscrews, washers, and coun-

terweight cover from counterweight. See Fig-
ure 47.
6. Remove hood and seat assembly. See the Hood

and Seat Assembly Replacement for Lift Truck
Models J2.2-3.5XN (J45-70XN) (A276) section of
this manual.
7. Remove controller, contactors, and other elec-

tronic components located in the counterweight,
see Electrical System 2200 SRM 1369.
NOTE: Tag all hydraulic lines during removal to aid

in installation.
1. COUNTERWEIGHT 2. EYEBOLT
8. Remove hydraulic pump and motor assembly
Figure 48. Counterweight Lift for Lift Truck and hydraulic tank from counterweight. See
J2.2-3.5XN (J45-70XN) (A276) Hydraulic System 1900 SRM 1367.
Table 3. Counterweights for Lift Truck
J2.2-3.5XN (J45-70XN) (A276) WARNING
Make sure lifting device has enough capacity
Model (mm*) Weight + 50 kg to hold and lift counterweight. See Table 3.
(110 lb)
0 kg 9. Install two eyebolts into sides of counterweight.
(0 lb) See Figure 48. Attach lifting device to eyebolts.
J2.2-2.5XN 717 10. Remove steering axle from counterweight. See

725 kg (1598 lb)
(J45-50XN) Steering Axle 1600 SRM 1360.
J3.0XN(J60XN) 861 801 kg (1766 lb) 11. Remove three mounting bolts and washers from
J3.5XN(J70XN) 861 1116 kg (2460 lb) rear bulkhead and counterweight. See Figure 47.
*Approximate battery compartment lengths. 12. Using approved lifting device, pull counter-
weight slightly away from frame. Install eyebolt
into center hole in counterweight (see Figure 48)
REMOVE
and attach lifting device. Lift counterweight
NOTE: Tag all electrical connectors during removal completely away from frame.
to aid in installation.
INSTALL
NOTE: Make sure lifting mechanism has enough ca-
2. Discharge capacitors as described in General sec- pacity to hold and lift counterweight.
tion of this manual.
1. Using approved lifting device, position counter-
3. Remove battery from the truck. See How to weight to rear bulkhead. Detach lifting device
Change Battery in the Operating Manual or from center eyebolt and remove eyebolt from cen-
Periodic Maintenance 8000 SRM 1372. ter hole in counterweight. See Figure 48.
56
2. Install three washers and mounting bolts into Models J2.2-3.5XN (J45-70XN) (A276) section of
rear bulkhead and counterweight. See Figure 47. this manual.
Tighten mounting bolts to 755 N•m (557 lbf ft).
8. Install counterweight cover, capscrews, and tow
3. Install steering axle onto counterweight. See pin onto counterweight. See Figure 47.
Steering Axle 1600 SRM 1360.
NOTE: For lift truck equipped with cab panels, be
4. Detach lifting device and remove two eyebolts careful to not damage the panels when installing
from sides of counterweight. See Figure 48. overhead guard.
5. Install hydraulic tank and hydraulic pump and 9. Install overhead guard. See the Overhead Guard
motor assembly. See Hydraulic System 1900 Replacement section of this manual.
SRM 1367. Connect hydraulic lines as tagged
during removal. 10. Install battery into lift truck. See How to
6. Install controller, contactors, and other electronic Periodic Maintenance 8000 SRM 1372.
components located in counterweight, see Elec-
trical System 2200 SRM 1369. Connect electri- 11. Connect battery connector.
cal connectors as tagged during removal.
7. Install hood and seat assembly. See the Hood

and Seat Assembly Replacement for Lift Truck
57
Traction Motor Replacement 100 SRM 1342
Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
REMOVE See Operating Manual or one of the following
service manuals for the procedure to put the
This procedure is for removal of the traction motor lift truck on blocks.
from under lift truck with the use of a floor jack. The
traction motor can also be removed through the bat- See Periodic Maintenance 8000 SRM 1364 for
tery compartment. The lift truck must be on blocks lift truck models
with clearance for the floor jack and traction motor, • E2.2-3.5XN (E45-70XN) (A268)
if traction motor is removed from under lift truck.
See Figure 49 for lift truck models truck models
• E2.2-3.5XN (E45-70XN) (A268) • E1.6-2.0XN (E30-40XN) (A269)
See Figure 50 for lift truck models NOTE: Some lift trucks have an automatic park
• E1.6-2.0XN (E30-40XN) (A269) brake on the armature shaft of the traction motor.
See Figure 49. The automatic park brake must be
WARNING disconnected before traction motor is removed.
PUTTING THE LIFT TRUCK ON BLOCKS 1. Remove battery from lift truck. See How to
The lift truck must be put on blocks for many
types of maintenance and repair. The removal See Periodic Maintenance 8000 SRM 1364 for
of the mast, drive axle, battery, or counter- lift truck models
weight assemblies will cause large changes in • E2.2-3.5XN (E45-70XN) (A268)
the center gravity. When the lift truck is put on
blocks, put additional blocks in the following See Periodic Maintenance 8000 SRM 1442 for
positions: lift truck models
• If the mast and drive axle are removed, put • E1.6-2.0XN (E30-40XN) (A269)
blocks under the counterweight so the lift
truck cannot fall backward. 2. Remove covers or plates and optional rollers from
• If the counterweight is removed, put blocks bottom of battery compartment. See the Battery
under the mast so that the lift truck cannot Restraint and Seat Assembly Repair section of
fall forward. this manual.
Put the lift truck on blocks on a solid, even, and NOTE: Perform Step 3 and Step 4 if lift truck is
level surface. Verify the blocks or stands have equipped with an automatic park brake.
enough capacity to hold the lift truck. Use ad-
3. Remove jam-nuts and cable from automatic park
ditional blocks next to the tires as necessary to
brake. See Figure 51.
prevent movement of the lift truck. Verify the
lifting devices used during repairs can lift the
weight of the parts and assemblies.
58
100 SRM 1342 Traction Motor Replacement
A. TRACTION MOTOR
B. TRACTION MOTOR WITH OPTIONAL AUTOMATIC PARK BRAKE
1. TRACTION MOTOR 2. AUTOMATIC PARKING BRAKE 3. DRIVE AXLE
Figure 49. Traction Motor, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)
59
6. Tag and disconnect power cables from traction

motor.
NOTE: Perform Step 7 only if lift truck is equipped

with optional drip shield.
7. Remove capscrews and drip shield from frame,

allowing access to traction motor. See Figure 52.
8. Position a floor jack under traction motor.
NOTE: The traction motors are in different config-

urations for different applications of the lift trucks.
Traction motors weigh approximately 90 to 140 kg
(200 to 310 lb). Make sure floor jack has capacity to
hold traction motor.
9. Remove three capscrews, equally spaced around

mounting flange, from mounting flange and trac-
tion motor. See Figure 52.
10. Install three 76.2 mm (3 in.) threaded dowels

into mounting flange and traction motor bolt
holes at these positions.
11. Remove four remaining capscrews from mount-

ing flange and traction motor. See Figure 52.
12. Use pry bar, as necessary, to separate mounting

flange and traction motor. The dowels will sup-
port traction motor as it slides back, preventing
any pressure on motor input sleeve.
NOTE: OPTIONAL AUTOMATIC PARK BRAKE NOT NOTE: It is possible that traction motor will rotate
SHOWN. SEE FIGURE 51. during removal and lowering. Use a suitable strap
to lock down traction motor when removing.
1. FRAME 3. HYDRAULIC PUMP
2. TRACTION MOTOR MOTOR 13. Slowly lower traction motor to level ground; ad-
just floor jack as needed for removal.
Figure 50. Traction Motor, Lift Trucks
E1.6-2.0XN (E30-40XN) (A269) NOTE: Perform Step 14 and Step 15 if lift truck is
equipped with an automatic park brake.
4. Remove e-ring, at fitting "D" on cable; remove
cable from bracket plate. See Figure 51. 14. Remove capscrews and bracket plate from trac-
tion motor. See Figure 51.
NOTE: Tag electrical connectors during removal to
aid in installation.
5. Tag and disconnect speed and temperature sen-

sor connectors from the terminals.
60
1. TRACTION MOTOR 6. FITTING "D"

2. AUTOMATIC PARK BRAKE 7. BRACKET PLATE
3. JAM-NUT 8. CAPSCREW
4. CABLE 9. WASHER
5. E-RING
Figure 51. Automatic Park Brake and Traction Motor for Lift Trucks E2.2-3.5XN (E45-70XN) (A268)
and E1.6-2.0XN (E30-40XN) (A269)
61
Figure 52. Traction Motor and Mounting Flange
62

1. MOUNTING FLANGE FOR TRACTION MOTOR 5. TRACTION MOTOR
2. BRACKET 6. O-RING
3. DRIP SHIELD 7. CAPSCREWS
4. CAPSCREWS
15. Remove capscrews and automatic park brake 9. Install drip shield and capscrews onto frame.
from traction motor. See Figure 51.
10. Remove lift truck from blocks.
16. Remove and discard O-ring from traction motor.
See Figure 52. 11. Connect power cables to traction motor as tagged
during removal.
INSTALL
12. Connect speed and temperature sensor connec-
1. Install new O-ring onto traction motor. tions to terminals as tagged during removal.
NOTE: Perform Step 2 and Step 3 if lift truck is 13. Connect any other hydraulic lines disconnected
equipped with an automatic park brake. from main control valve during removal.
2. Install automatic park brake and capscrews onto NOTE: Perform Step 14 and Step 15 if lift truck is
traction motor. See Figure 51. equipped with an automatic park brake.
3. Install bracket plate and capscrews on traction 14. Install cable through bracket plate. Install e-ring
motor. See Figure 51. on cable at fitting "D". See Figure 51.
NOTE: It is possible that the traction motor will ro- 15. Install cable and jam-nuts onto automatic part
tate during installation and raising of floor jack. Use brake. See Figure 51.
a suitable strap to lock down the traction motor when
16. Install covers or plates and optional rollers into
raising of floor jack.
bottom of battery compartment. See the Battery
4. Position traction motor beneath lift truck and Restraint and Seat Assembly Repair section of
slowly raise into frame. Adjust floor jack, as this manual.
needed, during installation.
17. Install battery into lift truck. See How to
5. Align bolt holes in mounting flange and traction Change Battery in the Operating Manual or
motor. Install three 76.2 mm (3 in.) threaded one of the following service manuals
dowels, placed at equally spaced intervals, into
mounting flange and traction motor for support.
truck models
6. Install four capscrews holding traction motor on • E2.2-3.5XN (E45-70XN) (A268)
mounting flange.
7. Remove threaded dowels and replace with three truck models
remaining capscrews. Tighten all capscrews to • E1.6-2.0XN (E30-40XN) (A269)
between 38 to 48 N•m (28 to 35 lbf ft).
8. Remove strap from traction motor. Remove floor

jack from underneath lift truck.
63
Hydraulic Tank Inspection 100 SRM 1342
Traction Motor Repair or Replacement for Lift Truck

J2.2-3.5XN (J45-70XN) (A276)
For repair or replacement of traction motor see Transaxle 1300 SRM 1370.
Hydraulic Tank Inspection

INSPECT the lift truck, if necessary, to check for leaks or for
replacement. Repair or replace hydraulic tank if
WARNING cracked or leaking. See Hydraulic System 1900
SRM 1367 for repair or replacement procedure.
Special procedures must be followed when
large leaks or other repairs are needed. All
work must be done by authorized personnel. If
the tank is cleaned inside of a building, make
sure there is enough ventilation.
WARNING
DO NOT use tools that can make sparks, heat,
or static electricity. The vapors in the tank can
cause an explosion.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
Make a visual inspection of all sides of hydraulic

tank.
See Figure 54 for lift truck models indicated below

with nylon tank
• E2.2-3.5XN (E45-70XN) (A268)
See Figure 53 for lift truck models indicated below NOTE: FOR LIFT TRUCK MODEL E2.2-3.5XN (E45-
with metal tank 70XN) (A268) EQUIPPED WITH DROP-IN METAL HY-
• E2.2-3.5XN (E45-70XN) (A268) DRAULIC TANK.
See Figure 55 for lift truck models 1. FILL CAP

• J2.2-3.5XN (J45-70XN) (A276) 2. FILTER HOUSING
3. DIPSTICK
4. BREATHER FILTER
See Figure 56 for lift truck models 5. OPTIONAL LEVEL SENSOR
• E1.6-2.0XN (E30-40XN) (A269) 6. OPTIONAL FILTER PRESSURE SWITCH
7. RETAINING STRAP
Inspect seams for cracks and leakage. Check for wet 8. SUCTION STRAINER W/ O-RING
areas, accumulation of dirt, and loose or missing 9. MAGNETIC PLUG W/ O-RING
paint caused by leakage. Areas of hydraulic tank 10. HYDRAULIC TANK
that are not easily seen can be checked with an
Figure 53. Hydraulic Tank for Lift Truck
inspection mirror and a light that is approved for
E2.2-3.5XN (E45-70XN) (A268)
locations with flammable vapors.
The hydraulic tank is a steel fabricated drop-in or

a molded nylon assembly, and can be removed from
64
100 SRM 1342 Hydraulic Tank Inspection
CLEAN
See Hydraulic System 1900 SRM 1367 for hy-
draulic tank cleaning procedures.
1. FILL CAP 7. TEMPERATURE

2. FILTER HOUSING SENSOR
3. DIPSTICK 8. SUCTION
4. BREATHER FILTER STRAINER WITH
5. LEVEL SENSOR O-RING
NOTE: FOR LIFT TRUCK MODEL E2.2-3.5XN (E45- 6. PRESSURE 9. DRAIN VALVE
70XN) (A268) EQUIPPED WITH NYLON HYDRAULIC SWITCH 10. HYDRAULIC TANK
TANK. Figure 55. Hydraulic Tank for Lift Truck
1. FILL CAP J2.2-3.5XN (J45-70XN) (A276)
2. FILTER HOUSING
3. DIPSTICK
4. BREATHER FILTER
5. OPTIONAL LEVEL SENSOR
6. OPTIONAL FILTER PRESSURE SWITCH
7. TEMPERATURE SENSOR
8. SUCTION STRAINER W/ O-RING
9. MAGNETIC PLUG W/O-RING
10. HYDRAULIC TANK
Figure 54. Hydraulic Tank for Lift Truck

E2.2-3.5XN (E45-70XN) (A268)
65
Hydraulic Tank Inspection 100 SRM 1342
1. MOUNTING BRACKETS 8. O-RING SEAL

2. HYDRAULIC TANK 9. SPRING
3. MAGNETIC PLUG AND O-RING 10. FILL CAP
4. SUCTION STAINER AND O-RING 11. NUT
5. BREATHER FILTER 12. DIPSTICK
6. FILTER HOUSING 13. LEVEL SENSOR
7. FILTER PRESSURE SWITCH
Figure 56. Hydraulic Tank for Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
66
100 SRM 1342 Painting Instructions
Painting Instructions
3. Protect all surfaces that will not be painted. See
WARNING the list of items in Figure 57.
Always wear protection equipment (gloves,
goggles, face shield, safety glasses, and a
mask) if an electric sander is used or spraying CAUTION
paint, using either an aerosol can or spray gun. DO NOT paint the pads, plastic covers or
knobs, cables, labels, and information plates,
or controls. Paint can make some assemblies
WARNING not operate correctly.
Always use solvents and paints in an area with
ventilation. DO NOT use solvents or paints 4. Paint surfaces. Use the correct paint from your
near heat, fire, or electrical equipment that dealer for Hyster lift trucks. Follow the direc-
can make sparks. Follow the manufacturer’s tions on the container. The correct arrangement
instructions and cautions. of colors is shown in Figure 57.
1. Remove all dirt from surface to be painted. Clean

the area to be painted. Use a solvent for painted WARNING
surfaces to remove grease and oil before sanding. Make sure all labels are installed after painting
DO NOT use solvent on new paint. Make sure is complete. Safety labels are installed on the
all oil and grease is removed. lift truck to provide information about possible
hazards. It is important that all safety labels
2. Use sandpaper to remove top surface of the paint are installed on the lift truck and can be read.
and rust from metal. All metal surfaces where
paint is completely removed, must be painted. 5. Check that all labels are installed in the correct
Use a primer. Apply primer before applying final locations on the lift truck. See . New labels are
coat of paint. available from your dealer for Hyster lift trucks.
67
Painting Instructions 100 SRM 1342
Figure 57. Color Arrangement
68
100 SRM 1342 Safety Label Replacement
NOTE: USE COLORS APPROVED BY HYSTER COMPANY. DO NOT PAINT THE FOLLOWING ITEMS: PEDAL
PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY AND SEAT RAILS, INFORMA-
TION CASE AND COVER, TIRES, MAST CHAINS, AND HOSES, ALL LABELS AND INFORMATION PLATES,
BATTERY CONNECTOR, PARKING BRAKE HANDLE, KEY SWITCH, CYLINDER RODS, ALL PLASTIC COVERS,
AND STEERING COLUMN COVER.
NOTE: LIGHT AREAS = YELLOW; DARK AREAS = BLACK; AND FORKS = RED.
Safety Label Replacement

WARNING • J2.2-3.5XN (J45-70XN) (A276)
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a See Figure 61 for lift truck models
mast of a different size or an accessory car- • E2.2-3.5XN (E45-70XN) (A268)
riage is installed, the capacity rating can • E1.6-2.0XN (E30-40XN) (A269)
change. Changes in the kind of drive tires can
change the capacity rating. See a dealer for See Figure 62 for lift truck models
HYSTER lift trucks for a replacement Name- • J2.2-3.5XN (J45-70XN) (A276)
plate. The Nameplate information is a safety
item and must be correct for the equipment
• J2.2-3.5XN (J45-70XN) (A276)
and configuration of the lift truck.
NOTE: The Nameplate is installed using rivets. The
NOTE: If the labels or information plates are missing
old rivets must be removed when installing a new
or are damaged, they must be replaced.
Nameplate.
NOTE: Not all labels used on these lift truck models
1. Before installing a new label, make sure surface
are shown in the following illustrations. See Parts
is dry and has no oil or grease. DO NOT use
Manual for a complete listing of all labels used on
solvent on new paint. Clean surface of old paint
these lift trucks.
using a cleaning solvent.
2. Remove paper from back of label. DO NOT touch
• E2.2-3.5XN (E45-70XN) (A268)
adhesive surface.
• E1.6-2.0XN (E30-40XN) (A269)
3. Carefully hold label in correct position above sur-
face. The label cannot be moved after it touches
• E2.2-3.5XN (E45-70XN) (A268)
surface. Put label onto surface. Make sure all
• E1.6-2.0XN (E30-40XN) (A269)
air is removed from under label and corners and
edges are tight.
69
Safety Label Replacement 100 SRM 1342
1. OPERATOR RESTRAINT 5. RIVET

2. TILT COLUMN 6. PATENTS AND TRADEMARKS
3. NAMEPLATE TAG 7. PARKING BRAKE WARNING
4. INCOMPLETE TRUCK NAMEPLATE
Figure 58. Interior Labels for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269)
70
NOTE: SWIVEL SEAT NOT USED ON E1.6-2.0XN (E30-40XN) (A269) LIFT TRUCKS.
A. SIDE VIEW B. BACK VIEW
1. VERTICAL HYSTER LOGO 11. MODEL LABEL
2. UL PLATE 12. HYSTER LOGO
3. NO ONE ON OR UNDER FORKS 13. OPTIONAL UL (TYPE EE)
4. OPERATOR RESTRAINT 14. NO RIDERS
5. OVERHEAD GUARD* 15. PINCH POINT
6. OPERATOR WARNING 16. MAST WARNING
7. BATTERY SPACER 17. LIFTING EYE**
8. HYSTER COUNTERWEIGHT LOGO 18. NO ENTRY
9. OPERATING MANUAL WARNING 19. NO EXIT
10. SWIVEL SEAT WARNING
*RIGHT SIDE OF LIFT TRUCK
**EUROPE ONLY
Figure 59. Exterior Labels for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269)
71
1. MAST WARNING LABEL 11. LIFTING EYE***

2. OPERATOR RESTRAINT 12. MODEL LABEL
3. OVERHEAD GUARD TEST PLATE* 13. AC POWER LABEL***
4. OPERATOR WARNING LABEL** 14. HYSTER LOGO
5. PARK BRAKE WARNING 15. FIRE SAFETY LABEL*
6. PATENT PLATE 16. NO RIDERS
7. UL INSPECTION PLATE 17. NO ONE ON OR UNDER FORKS
8. BATTERY SPACER 18. PINCH POINT
9. OPERATORS MANUAL WARNING 19. NAMEPLATE
10. HYSTER COUNTERWEIGHT LOGO (OPTIONAL) 20. VERTICAL HYSTER LOGO
*LEFT SIDE OF LIFT TRUCK
**RIGHT SIDE OF LIFT TRUCK
***EUROPE ONLY
Figure 60. Safety Labels for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
72
NOTE: SEAT AND LEVERS ONLY SHOWN FOR CLARITY.

1. LIFT/LOWER SYMBOL 2. TILT SYMBOL 3. AUX SYMBOLS
Figure 61. Labels - Mini and Manual Levers for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)
73
NOTE: 3-FUNCTION AND 4-FUNCTION MANUAL LEVERS SHOWN.

1. LIFT 2. TILT 3. AUXILIARY
Figure 62. Labels - Manual Levers for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
74
NOTE: 4-FUNCTION MINI LEVERS SHOWN.

1. HOIST/TILT LABEL 5. BATTERY DISCONNECT
2. REACH LABEL 6. RADIAL TIRE WARNING
3. "CAUTION" LABEL 7. AUXILIARY LABEL
4. SWIVEL SEAT CAUTION
Figure 63. Labels - Mini Levers for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
75
Battery Specifications 100 SRM 1342
Battery Specifications
Table 4. E2.2-3.5XN (E45-70XN) (A268) Model Trucks
Minimum
Battery Size Min/Max Weight
Compartment
Model
Size
Length × Width Length Width Minimum Maximum
E2.2XN-E2.5XN 695 x 987 mm 978/983 mm 681/691 mm 1050 kg 1500 kg

(E45XN-E50XN) (27.4 x 38.9 in.) (38.5/38.7 in.) (26.8/27.2 in.) (2314 lb) (3307 lb)
E3.2XN(E65XN) 928 x 987 mm 978/983 mm 900/924 mm 1410 kg 1860 kg
(36.5 x 38.9 in.) (38.5/38.7 in.) (35.4/36.4 in.) (3108 lb) (4100 lb)
E3.2-3.5XN(E65- 1010 x 987 mm 978/983 mm 1001/1006 mm 1550 kg 2000 kg
70XN) (39.8 x 38.9 in.) (38.5/38.7 in.) (39.4/39.6 in.) (3417 lb) (4409 lb)
NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
NOTE: Battery compartment length is front to back. Width is side to side. The "length" dimension of the
battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to
0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side dimension.
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.
76
100 SRM 1342 Battery Specifications
Table 5. J2.2-3.5XN (J45-70XN) (A276) Model Trucks
Minimum
Compartment
Model
Size
J2.2-2.5XN 717/1034 mm 708/711 mm 1025/1028 mm 1687 kg 1879 kg

(J45-50XN) (28.2/40.7 in.) (27.8/27.9 in.) (40.4/40.5 in.) (3719 lb) (4142 lb)
J2.5-3.5XN
861/1034 mm 852/855 mm 1025/1028 mm 2021 kg 2233 kg
(J50-70XN)
(34.0/40.7 in.) (33.5/33.6 in.) (40.4/40.5 in.) (4456 lb) (4923 lb)
NOTE: Battery compartment length is front to back. Width is side to side. The "length" dimension of the
battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to
0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side dimension.
WARNING
Table 6. E1.6-2.0XN (E30-40XN) (A269) Model Trucks
Minimum
Compartment
Model
Size
E1.6-2.0XN 700 x 909 x

654/692 mm 784/907 mm 1132 kg
(E30-40XN) 585 mm (27.6 x 839 kg (1850 lb)
(25.7/27.2 in.) (30.9/35.7 in.) (2495 lb)
35.8 x 23.0 in.)
NOTE: Battery compartment length is front to back. Width is side to side. The length dimension of the battery
must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.)
maximum. Battery width must fit within the battery compartment side-to-side dimension.
WARNING
77
Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342
Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
OVERHEAD GUARD COUNTERWEIGHT
Front Overhead Guard Leg Capscrews Upper Capscrews
66 N•m (49 lbf ft) 755 N•m (557 lbf ft)
Rear Overhead Guard Leg Capscrews Lower Capscrews

270 N•m (199 lbf ft) 90 N•m (66 lbf ft)
Handle Capscrews TRACTION MOTOR

12 N•m (10.6 lbf in)
Traction Motor to Mounting Flange Capscrews
38 to 48 N•m (28 to 35 lbf ft)
Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

OVERHEAD GUARD Handle Capscrews
12 N•m (106.2 lbf in)
Front Overhead Guard Leg Capscrews
66 N•m (49 lbf ft) COUNTERWEIGHT
Rear Overhead Guard Leg Capscrews Mounting Bolts
270 N•m (199 lbf ft) 755 N•m (557 lbf ft)
78
TECHNICAL PUBLICATIONS
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FRAME

E2.2-3.5XN (E45-70XN) [A268];

PART NO. 1688870 100 SRM 1342

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2011 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

E2.2-3.5XN (E45-70XN) [A268];

Electronic controllers and contactors are attached to

See Figure 2 for lift truck models:

See Figure 3 for lift truck models:

On lift truck J2.2-3.5XN (J45-70XN) (A276) the hy-

Figure 1. Truck Orientation

1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

Figure 2. Frame Weldment for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

1. FRONT OVERHEAD GUARD MOUNTING 5. RIGHT FRAME CHANNEL

Figure 3. Frame Weldment for Lift Truck E1.6-2.0XN (E30-40XN) (A269)

1. FRONT OVERHEAD GUARD MOUNTING 7. RIGHT FENDER

Figure 4. Frame Weldment for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

DISCHARGING THE CAPACITORS seconds after the battery is disconnected.

Overhead Guard Replacement for Lift Trucks E2.2-3.5XN

Legend for Figure 5

INSTALL 5. Install hood and seat assembly onto lift truck.

Overhead Guard Replacement for Lift Truck Models

WARNING 3. Remove nuts and capscrews from hood cross-

See the Operating Manual or Periodic Mainte-

Figure 6. Overhead Guard for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

Legend for Figure 6

INSTALL 5. Install hose cover and capscrews onto cowl. See

Battery Restraint and Seat Assembly Repair

1. Adjust spacer plate(s) to prevent battery from

Legend for Figure 7

NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

Figure 7. Battery Compartment for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

Figure 8. Battery Compartment for Lift Truck E1.6-2.0XN (E30-40XN) (A269)

Legend for Figure 8

NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

Figure 9. Battery Compartment for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

Legend for Figure 9

NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

OPERATOR RESTRAINT SYSTEM AND

1. Make sure seat is not loose on seat rails.

See Figure 10 for lift truck models

See Figure 11 for lift truck models

See Figure 12 for lift truck models

Legend for Figure 10

2. Make sure seat rails are securely attached to

See Figure 10 for lift truck models

See Figure 11 for lift truck models

See Figure 12 for lift truck models

Figure 11. Hood and Seat Check for Lift Truck

comes to a sudden stop, the locking mechanism will

See Figure 10 for lift truck models

See Figure 11 for lift truck models