FRAME

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

E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
J4.0-5.0XN (J80-100XN) [A970]

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........................................................................................................................... 6
Overhead Guard Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 7
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 9
Overhead Guard Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) .................................. 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 10
Overhead Guard Replacement for Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) ................................ 12
Remove ........................................................................................................................................................... 12
Install ............................................................................................................................................................. 12
Battery Restraint and Seat Assembly Repair .................................................................................................. 14
Operator Restraint System and Seat Assembly .......................................................................................... 20
Operator Restraint System....................................................................................................................... 20
Emergency Locking Retractor (ELR) ................................................................................................... 22
Armrest Assembly Repair......................................................................................................................... 22
Remove .................................................................................................................................................. 22
Disassemble........................................................................................................................................... 25
Clean...................................................................................................................................................... 26
Inspect ................................................................................................................................................... 26
Assemble................................................................................................................................................ 26
Install..................................................................................................................................................... 26
Hood and Seat Latches ............................................................................................................................. 26
Hood and Seat Assembly Replacement for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)......................................................................................................................... 27
General....................................................................................................................................................... 27
Remove ........................................................................................................................................................... 32
Install ............................................................................................................................................................. 37
Ground Test ................................................................................................................................................... 38
Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) ................... 38
General ........................................................................................................................................................... 38
Opening and Closing the Hood ................................................................................................................. 41
Manual Hydraulic Control Levers ....................................................................................................... 41
E-Hydraulic Mini-Levers ...................................................................................................................... 42
Remove ........................................................................................................................................................... 44
Install ............................................................................................................................................................. 44
Ground Test ................................................................................................................................................... 45
Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) ................. 46
General ........................................................................................................................................................... 46
Opening and Closing the Hood ................................................................................................................. 49
Manual Hydraulic Control Levers ....................................................................................................... 49
E-Hydraulic Mini-Levers ...................................................................................................................... 50
Remove ........................................................................................................................................................... 51
Install ............................................................................................................................................................. 51
Ground Test ................................................................................................................................................... 53
Master Cylinder Repair and Adjustment ......................................................................................................... 54
Brake Pedal Components .................................................................................................................................. 54
Brake System Air Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A276) .................................................... 55

©2012 HYSTER COMPANY i

Table of Contents Frame

TABLE OF CONTENTS (Continued)

Brake System Air Removal ........................................................................................................................... 55
Using Pressure Bleed System ....................................................................................................................... 55
Using Brake Pedal Pressure ......................................................................................................................... 55
Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN)
(A269), and J4.0-5.0XN (J80-100XN) (A970).................................................................................................... 55
Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 56
Remove ........................................................................................................................................................... 56
Install ............................................................................................................................................................. 58
Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN
(J80-100XN) (A970) ........................................................................................................................................... 59
Remove ........................................................................................................................................................... 59
Install ............................................................................................................................................................. 63
Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269) ............................................................................................................................................. 64
Remove ........................................................................................................................................................... 64
Install ............................................................................................................................................................. 69
Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN (J45-70XN) (A276) and
J4.0-5.0XN (J80-100XN) (A970)........................................................................................................................ 69
Hydraulic Tank Inspection ................................................................................................................................ 70
Inspect ............................................................................................................................................................ 70
Clean .............................................................................................................................................................. 73
Painting Instructions ......................................................................................................................................... 73
Safety Label Replacement ................................................................................................................................. 75
Battery Specifications........................................................................................................................................ 83
Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269).................................................................................................................................................................. 86
Overhead Guard ............................................................................................................................................ 86
Counterweight ............................................................................................................................................... 86
Traction Motor ............................................................................................................................................... 86
Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276).............................................................. 86
Overhead Guard ............................................................................................................................................ 86
Counterweight ............................................................................................................................................... 86
Torque Specifications for Lift Truck J4.0-5.0XN (J80-100XN) (A970)............................................................ 86
Overhead Guard ............................................................................................................................................ 86
Counterweight ............................................................................................................................................... 86

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];
J4.0-5.0XN (J80-100XN) [A970]

ii
100 SRM 1342 General

General
GENERAL See Figure 3 for lift truck models:
• E1.6-2.0XN (E30-40XN) (A269)
This section contains a description and service proce-
dures for the parts of the frame. These parts include See Figure 4 for lift truck models:
the frame, counterweight assembly, overhead guard, • J2.2-3.5XN (J45-70XN) (A276)
hood and seat assembly, access panels, and labels.
See Figure 5 for lift truck models:
Throughout this section, forward will refer to travel • J4.0-5.0XN (J80-100XN) (A970)
in the direction of the forks and left and right will be
determined by an operator sitting in the seat facing
forward. See Figure 1.

If a torque value is not specified, go to Metric and

Inch (SAE) Fasteners 8000 SRM 231 for torque val-
ues.

FRAME
The frame is a single weldment with mounts for:
• Counterweight
• Overhead guard
• Tilt cylinders
• Drive axle, or if equipped, transaxle
• Floor plate and pedals
• Side step and fender weldments A. LEFT SIDE
• Hood and seat assembly B. RIGHT SIDE
C. FORWARD TRAVEL
See Figure 2 for lift truck models:
• E2.2-3.5XN (E45-70XN) (A268) 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
100 SRM 1342 General

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 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
5. COUNTERWEIGHT MOUNTING PLATE 12. SIDE STEP MOUNTING BRACKET
6. LEFT FENDER

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

4
100 SRM 1342 General

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
5. COUNTERWEIGHT MOUNTING PLATE 12. SIDE STEP MOUNTING BRACKET
6. LEFT FENDER

Figure 5. Frame Weldment for Lift Truck J4.0-5.0XN (J80-100XN) (A970)

5
General 100 SRM 1342

The hydraulic and traction motor electronic con- accidentally make an electrical connection
trollers and contactors are located in the counter- and cause injury.
weight cavity for the following lift truck models:
• E2.2-3.5XN (E45-70XN) (A268) Before performing any tests or adjustments,
• E1.6-2.0XN (E30-40XN) (A269) block the lift truck to prevent unexpected
movement.
The hydraulic motor electronic controller and con-
tactor are located in the counterweight cavity and The capacitor in the transistor controller(s)
the traction motor controller is attached to the front can hold an electrical charge for about 10
bulkhead for the following lift truck models: seconds after the battery is disconnected.
• J2.2-3.5XN (J45-70XN) (A276) To prevent an electrical shock and personal
• J4.0-5.0XN (J80-100XN) (A970) injury, discharge the capacitor(s) before in-
specting or repairing any component in the
For all lift truck models covered in this Service drive unit compartment. Make certain that
Manual, the Vehicle Systems Manager (VSM) is the battery has been disconnected.
either mounted on or near the front bulkhead under-
neath the floor mat and floor plate. DO NOT short across the motor controller ter-
minals with a screwdriver or jumper wire.
DISCHARGING THE CAPACITORS
Make certain the Emergency-Disconnect
switch has not been activated. This will iso-
WARNING late the controller and prevent the capacitors
DO NOT make repairs or adjustments unless from discharging properly. The proper way
you have been properly trained and authorized to disconnect the battery is by separating the
to do so. Improper repairs and adjustments battery connectors.
can create dangerous operating conditions.
DO NOT operate a lift truck that needs re- 1. Ensure the capacitors are discharged by perform-
pairs. Report the need for repairs to your ing Step 2 through Step 6 below.
supervisor immediately. If repair is necessary,
attach a DO NOT OPERATE tag on the steering 2. Turn the key or keyless switch to the OFF posi-
wheel and disconnect the battery. tion.

Disconnect the battery and allow the capaci- 3. Disconnect the battery by separating the connec-
tors to discharge before opening any compart- tors.
ment covers or inspecting or repairing the elec- 4. Block the drive wheels to prevent the lift truck
trical system. DO NOT place tools on top of the from moving.
battery. If a tool causes a short circuit, the high
current flow from the battery can cause per- 5. Make sure the Emergency-Disconnect switch
sonal injury or property damage. HAS NOT been activated. If the Emer-
gency-Disconnect switch is activated, rotate
Some checks and adjustments are performed the switch to the right until it pops up.
with the battery connected. DO NOT connect
the battery until the procedure instructs you 6. Press horn button. Wait 30 seconds to be sure
to do so. Never wear any metallic items on capacitors are fully discharged.
your fingers, arms, or neck. Metal items can

6
100 SRM 1342 Overhead Guard Replacement

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.
See Periodic Maintenance 8000 SRM 1442 for
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 6.
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 6.
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 6.
See Periodic Maintenance 8000 SRM 1364 for
lift truck models: 7. Remove capscrews and handle from overhead
• E2.2-3.5XN (E45-70XN) (A268) guard. See Figure 6.

7
Overhead Guard Replacement 100 SRM 1342

Figure 6. Overhead Guard and Counterweight for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)

8
100 SRM 1342 Overhead Guard Replacement

Legend for Figure 6

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.
See Periodic Maintenance 8000 SRM 1442 for
3. Install front capscrews into front overhead guard lift truck models:
legs and the right and left plates. See Figure 6. • 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 6. Tighten rear cap-
screws to 270 N•m (199 lbf ft).

Overhead Guard Replacement for Lift Truck Models

J2.2-3.5XN (J45-70XN) (A276)
REMOVE If the mast and drive axle are removed, put
blocks under the counterweight so the lift
WARNING truck cannot fall backward.
If the counterweight is removed, put blocks
DO NOT operate lift truck without overhead
under the mast so that the lift truck cannot
guard correctly fastened to the lift truck frame.
fall forward.

WARNING Put the lift truck on blocks on a solid, even, and

DO NOT weld, drill, grind, or cut the overhead level surface. Verify the blocks or stands have
guard for mounts of lights or accessories. The enough capacity to hold the lift truck. Use ad-
strength of the overhead guard can be reduced. ditional blocks next to the tires as necessary to
prevent movement of the lift truck.

WARNING Verify the lifting devices used during repairs

PUTTING THE LIFT TRUCK ON BLOCKS can lift the weight of the parts and assemblies.

The lift truck must be put on blocks for some See the Operating Manual or Periodic Mainte-
types of maintenance and repair. The removal nance 8000 SRM 1372, for procedure to put lift
of the mast, drive axle, battery, or counter- truck on blocks.
weight assemblies will cause large changes
in the center of gravity. When the lift truck 1. Remove tow pin, capscrews, washers, and coun-
is put on blocks, put additional blocks in the terweight cover from counterweight. See Fig-
following positions: ure 7.

9
Overhead Guard Replacement 100 SRM 1342

2. Remove rear capscrews from rear overhead INSTALL

guard legs and counterweight. See Figure 7.
NOTE: Make sure electrical wires are routed as noted
3. Remove nuts and capscrews from hood cross- during removal to assure wires do not get pinched.
member and rear overhead guards legs. See
Figure 7. 1. Using a lifting device, install overhead guard
onto frame. See Figure 7.
4. Remove capscrews and hose cover from cowl to
allow access to front capscrews on left overhead 2. Connect electrical wires, as tagged during re-
guard leg. See Figure 7. moval.

5. Remove color-coated screws and overhead guard 3. Install front capscrews into front overhead
leg covers from front overhead guard legs. See guard legs and cowl. Tighten front capscrews to
Figure 7. 66 N•m (49 lbf ft). See Figure 7.

6. Remove front capscrews from front overhead 4. Install overhead guard leg covers and color-
guard legs and cowl. See Figure 7. coated screws onto front overhead guard legs.
See Figure 7.
NOTE: Note routing of electrical wires prior to dis-
connecting. 5. Install hose cover and capscrews onto cowl. See
Figure 7.
7. Tag and disconnect electrical wires that go
through the legs of overhead guard. 6. Install capscrews and nuts on rear overhead
guard legs and hood crossmember. See Figure 7.
NOTE: When overhead guard is lifted from fame,
make sure electrical wires move through the holes 7. Install rear capscrews into rear overhead guard
in the frame at the front and rear so they are not legs and counterweight. See Figure 7. Tighten
damaged. rear capscrews to 270 N•m (199 lbf ft).

8. Using a lifting device, remove overhead guard 8. Install counterweight cover, capscrews, washers,
from frame. See Figure 7. and tow pin onto counterweight. See Figure 7.

9. Remove capscrews and handle from overhead 9. Install handle and capscrews onto overhead
guard. See Figure 7. guard. Tighten capscrews to 19.2 N•m
(169.9 lbf in).

Legend for Figure 7

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

10
100 SRM 1342 Overhead Guard Replacement

Figure 7. Overhead Guard for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

11
Overhead Guard Replacement 100 SRM 1342

Overhead Guard Replacement for Lift Truck Models

J4.0-5.0XN (J80-100XN) (A970)
REMOVE 3. Remove color-coated screws and overhead guard
leg covers from front overhead guard legs. See
WARNING Figure 8.
DO NOT operate lift truck without overhead 4. Remove front capscrews from front overhead
guard correctly fastened to the lift truck frame. guard legs and cowl. See Figure 8.

WARNING NOTE: Note routing of electrical wires prior to dis-

connecting.
DO NOT weld, drill, grind, or cut the overhead
guard for mounts for lights or accessories. The 5. Tag and disconnect electrical wires that go
strength of the overhead guard can be reduced. through the legs of overhead guard.

NOTE: When overhead guard is lifted from fame,

WARNING
make sure electrical wires move through the holes
PUTTING THE LIFT TRUCK ON BLOCKS in the frame at the front and rear so they are not
The lift truck must be put on blocks for some damaged.
types of maintenance and repair. The removal 6. Using a lifting device, remove overhead guard
of the mast, drive axle, battery, or counter- from frame. See Figure 8.
weight assemblies will cause large changes
in the center of gravity. When the lift truck 7. Remove capscrews and handle from overhead
is put on blocks, put additional blocks in the guard. See Figure 8.
following positions:
If the mast and drive axle are removed, put INSTALL
blocks under the counterweight so the lift
truck cannot fall backward. NOTE: Make sure electrical wires are routed as noted
If the counterweight is removed, put blocks during removal to assure wires do not get pinched.
under the mast so that the lift truck cannot
fall forward. 1. Using a lifting device, install overhead guard
onto frame. See Figure 8.
Put the lift truck on blocks on a solid, even, and
level surface. Verify the blocks or stands have 2. Connect electrical wires, as tagged during re-
enough capacity to hold the lift truck. Use ad- moval.
ditional blocks next to the tires as necessary to 3. Install front capscrews into front overhead
prevent movement of the lift truck. guard legs and cowl. Tighten front capscrews to
Verify the lifting devices used during repairs 66 N•m (49 lbf ft). See Figure 8.
can lift the weight of the parts and assemblies. 4. Install overhead guard leg covers and color-
See the Operating Manual or Periodic Mainte- coated screws onto front overhead guard legs.
nance 8000 SRM 1541 for procedure to put lift See Figure 8.
truck on blocks. 5. Install hose cover and capscrews onto cowl. See
1. Remove three rear capscrews from each rear Figure 8.
overhead guard legs and counterweight. See 6. Install rear capscrews into rear overhead guard
Figure 8. legs and counterweight. See Figure 8. Tighten
2. Remove capscrews and hose cover from cowl to rear capscrews to 297 to 303 N•m (219 to
allow access to front capscrews on left overhead 223 lbf ft).
guard leg. See Figure 8. 7. Install handle and capscrews onto overhead
guard. Tighten capscrews to 19.2 N•m
(169.9 lbf in).

12
100 SRM 1342 Overhead Guard Replacement

1. REAR OVERHEAD GUARD LEG 8. COWL

2. COUNTERWEIGHT 9. COUNTERWEIGHT COVER
3. CAPSCREW 10. OVERHEAD GUARD
4. COLOR-COATED SCREW 11. OVERHEAD GUARD LEG COVER
5. HANDLE 12. FRAME
6. HOSE COVER 13. FRONT CAPSCREW
7. FRONT OVERHEAD GUARD LEG

Figure 8. Overhead Guard for Lift Truck J4.0-5.0XN (J80-100XN) (A970)

13
Battery Restraint and Seat Assembly Repair 100 SRM 1342

Battery Restraint and Seat Assembly Repair

See Figure 9 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 10 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 11 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. See Figure 12 for lift truck models
• J4.0-5.0XN (J80-100XN) (A970)
1. Adjust spacer plate(s) to prevent battery from
moving more than 13 mm (0.5 in.).

Legend for Figure 9

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

14
100 SRM 1342 Battery Restraint and Seat Assembly Repair

Figure 9. Battery Compartment for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

15
Battery Restraint and Seat Assembly Repair 100 SRM 1342

Figure 10. Battery Compartment for Lift Truck E1.6-2.0XN (E30-40XN) (A269)

16
100 SRM 1342 Battery Restraint and Seat Assembly Repair

Legend for Figure 10

NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

A. STANDARD COMPONENTS - VERTICAL B. OPTIONAL COMPONENTS - HORIZONTAL
BATTERY REMOVAL BATTERY REMOVAL
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

17
Battery Restraint and Seat Assembly Repair 100 SRM 1342

Figure 11. Battery Compartment for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

18
100 SRM 1342 Battery Restraint and Seat Assembly Repair

Legend for Figure 11

NOTE: BOTH STANDARD AND OPTIONAL VERSIONS SHOWN.

A. STANDARD COMPONENTS - VERTICAL B. OPTIONAL COMPONENTS - HORIZONTAL
BATTERY REMOVAL BATTERY REMOVAL
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

1. FRONT BULKHEAD 7. FRONT BATTERY SPACER

2. CAPSCREW 8. SIDE BATTERY SPACER
3. BATTERY SPACER PLATE 9. LEFT FRAME CHANNEL
4. SPACERS 10. BATTERY TRAY
5. BATTERY SPACER TUBE 11. RIGHT FRAME CHANNEL
6. NUT

Figure 12. Battery Compartment for Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

19
Battery Restraint and Seat Assembly Repair 100 SRM 1342

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.

See Figure 13 for lift truck models

• E2.2-3.5XN (E45-70XN) (A268)

See Figure 14 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

See Figure 15 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

See Figure 16 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

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.

See Figure 13 for lift truck models

• E2.2-3.5XN (E45-70XN) (A268)

See Figure 14 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)
A. RELEASE DIRECTION
See Figure 15 for lift truck models B. FRONT VIEW
• E1.6-2.0XN (E30-40XN) (A269)
1. SEAT
See Figure 16 for lift truck models 2. HIP RESTRAINT
• J4.0-5.0XN (J80-100XN) (A970) 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. HOOD RELEASE HANDLE
11. STOP SCREWS

Figure 13. Hood and Seat Check for Lift Truck

E2.2-3.5XN (E45-70XN) (A268)

20
100 SRM 1342 Battery Restraint and Seat Assembly Repair

1. SEAT ASSEMBLY
2. HOOD
3. SEAT RAIL
4. CAPSCREW
5. FORWARD/BACKWARD LEVER
6. OPERATOR PRESENCE SYSTEM CONNECTOR
7. RIDE POSITION INDICATOR

1. SEAT Figure 15. Hood and Seat Check for Lift Trucks
2. HIP RESTRAINT E1.6-2.0XN (E30-40XN) (A269)
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 14. Hood and Seat Check for Lift Truck

J2.2-3.5XN (J45-70XN) (A276)

21
Battery Restraint and Seat Assembly Repair 100 SRM 1342

See Figure 14 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

See Figure 15 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

See Figure 16 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

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
on the seat belt and hold for a moment to remove
slack from the belt in the retractor. Release the
1. SEAT seat belt. Seat belt will retract and the internal
2. HIP RESTRAINT latch will unlock. If the seat belt cannot be pulled
3. SEAT BELT AND MOUNT from the retractor assembly or the belt will not re-
4. SEAT POSITION ADJUSTOR tract, replace the seat belt assembly.
5. OPERATOR WEIGHT ADJUSTOR
6. SEAT RAIL • With hood closed and in locked position, pull seat
7. OPERATOR PRESENCE SYSTEM CONNECTOR belt with a sudden jerk. Make sure seat belt will
8. HOOD not pull from retractor assembly. If seat belt can
9. HOOD LATCH ASSEMBLY be pulled from retractor, when it is pulled with a
10. STOP SCREWS sudden jerk, replace seat belt assembly.
Figure 16. Hood and Seat Check for Lift Trucks • With hood in open position, make sure seat belt
J4.0-5.0XN (J80-100XN) (A970) will not pull from the retractor assembly. If seat
belt can be pulled from retractor, with hood in open
Emergency Locking Retractor (ELR) position, replace seat belt assembly.

NOTE: The seat belt may be either black or red. Armrest Assembly Repair
When the ELR style seat belt is properly buckled Remove
across the operator, the belt will permit slight op-
erator repositioning without activating the locking 1. Remove two capscrews from cover on seat box
mechanism. If the truck tips, travels off a dock, or and remove cover from seat box. Disconnect
comes to a sudden stop, the locking mechanism will the main E-Hydraulic control wire harness from
be activated and hold the operator’s lower torso in E-Hydraulic armrest connector. See Figure 17.
the seat.
2. Remove three capscrews and bottom armrest
See Figure 13 for lift truck models cover from armrest assembly. See Figure 18.
• E2.2-3.5XN (E45-70XN) (A268)

22
100 SRM 1342 Battery Restraint and Seat Assembly Repair

Legend for Figure 17

NOTE: COMPONENTS PARTS AND ELECTRICAL

CONNECTIONS OMITTED OR MOVED FOR CLAR-
ITY.
1. COVER
2. CAPSCREWS
3. SEAT BOX
4. E-HYDRAULIC ARMREST HARNESS
5. OPERATOR PRESENCE SYSTEM HARNESS
6. ARMREST

Figure 17. Seat Box Cover Removal

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 18. Armrest and Covers

23
Battery Restraint and Seat Assembly Repair 100 SRM 1342

NOTE: Clips remain attached to MLM inner cover

during removal.

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

rest assembly. See Figure 18.

NOTE: Only outside nylon washer to be removed; ny-

lon washer between slide brackets and slide mount-
ing bracket should remain on slider pin.

4. Remove nut, washer, and nylon washer from

slider pin on slide mounting bracket. See Fig-
ure 18 and Figure 19.

5. Remove capscrew and washer from armrest

spacer on slide mounting bracket. See Figure 18.

6. Remove armrest with slide brackets from slide

mounting bracket. See Figure 20. 1. ARMREST
2. SLIDE BRACKET
3. SLIDE MOUNTING BRACKET

Figure 20. Armrest and Seat

NOTE: TOP VIEW, ARMREST NOT SHOWN FOR

CLARITY.
1. SLIDE MOUNTING BRACKET
2. NYLON WASHER
3. NUT
4. WASHER
5. SLIDER PIN

Figure 19. Slide Mount - Armrest

A. HANDLE MOVES ARMREST FORWARD OR
BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN

Figure 21. Armrest Adjustment Handles

24
100 SRM 1342 Battery Restraint and Seat Assembly Repair

Disassemble

1. Pull up on handle (see Figure 21) and slide arm-

rest all the way forward. Remove flange cap-
screw under armrest mounting bracket. See Fig-
ure 22.

2. Pull up on handle (see Figure 21) and slide arm-

rest all the way back. Remove flange capscrew
under armrest mounting bracket. See Figure 22.

3. Remove armrest from armrest mounting

bracket. See Figure 22.

4. For replacement of mini-levers and switches at-

NOTE: HANDLES NOT SHOWN IN THIS VIEW FOR
tached to armrest, see Electrical System 2200
CLARITY.
SRM 1369.
1. ARMREST MOUNTING BRACKET
5. Remove two nuts and upper armrest handle slide 2. FLANGE CAPSCREW
assembly from slide mounting bracket. See Fig- 3. ARMREST
ure 23.
Figure 22. Armrest Slide

1. UPPER ARMREST HANDLE SLIDE ASSEMBLY 4. NUT

2. LOWER ARMREST HANDLE SLIDE ASSEMBLY 5. CAPSCREW
3. SLIDE MOUNTING BRACKET

Figure 23. Slider Assemblies

25
Battery Restraint and Seat Assembly Repair 100 SRM 1342

6. Remove two spaced screws and slider handle 5. Place armrest onto armrest mounting bracket at
from upper armrest slide. See Figure 24. the back position. Install flanged capscrew un-
der armrest mounting bracket. See Figure 22.
7. Remove two nuts, two capscrews and lower arm- Tighten flanged capscrew to 12 N•m (106 lbf in).
rest handle slide assembly from slide mounting
bracket. See Figure 23. 6. Move armrest into forward position. Install
flanged capscrew under armrest mounting
8. Remove two spaced screws and slider handle bracket. See Figure 22. Tighten flanged cap-
from lower armrest handle slide. See Figure 24. screw to 12 N•m (106 lbf in).
Clean Install
1. Clean plastic or rubber components using warm NOTE: Ensure one nylon washer is still in place on
soapy water and wipe dry with a lint free cloth. slide pin as noted during removal.
Inspect 1. Install slide brackets with armrest onto slide
mounting bracket. See Figure 20.
1. Check all components for damage. Replace dam-
aged components. 2. Install washer and capscrew into armrest spacer
on slide mounting bracket. See Figure 18.
Assemble
3. Install nylon washer, washer, and nut onto slide
1. Install slider handle and two spaced screws onto
pin on slide mounting bracket. See Figure 18 and
lower armrest slide. See Figure 24.
Figure 19.
2. Install lower armrest handle slide assembly, two
NOTE: Ensure clips are attached to MLM inner cover
capscrews, and two nuts onto slide mounting
prior to installation.
bracket. See Figure 23.
4. Install MLM inner cover onto seat side of armrest
3. Install slider handle and two spaced screws onto
assembly. See Figure 18.
upper armrest slide. See Figure 24.
5. Install bottom armrest cover and three cap-
4. Install upper armrest handle slide assembly and
screws onto armrest assembly. See Figure 18.
two nuts onto slide mounting bracket. See Fig-
ure 24. 6. Connect the main E-Hydraulic control wire
harness to E-Hydraulic armrest connector. In-
stall cover to seat box with two capscrews.
See Figure 17. Tighten capscrews to 1.2 N•m
(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 25.
A. UPPER HANDLE SLIDE ASSEMBLY 2. Seat rails must be correctly fastened to hood and
B. LOWER HANDLE SLIDE ASSEMBLY
hood fastened to hinges on frame. Lift hood to
1. UPPER ARMREST SLIDE make sure it is fastened correctly and will not
2. SLIDER HANDLE move side to side.
3. SPACED SCREW
4. LOWER ARMREST SLIDE

Figure 24. Slider Handles

26
100 SRM 1342 Hood and Seat Assembly Replacement

Legend for Figure 25

NOTE: SWIVEL SEAT NOT USED ON E1.6-2.0XN

(E30-40XN) (A269) LIFT TRUCKS.
1. SEAT BELT
2. OPERATOR PRESENCE SYSTEM CONNECTOR
3. SEAT RAIL
4. SWIVEL LATCH RELEASE LEVER
5. OPERATOR WEIGHT ADJUSTOR
6. RIDE POSITION INDICATOR
7. SEAT POSITION ADJUSTOR
8. BACK REST ANGLE
9. ARM REST

Figure 25. Swivel Seat Option

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 When correctly locked to the frame, it will hold the
battery in the battery compartment if an accident
The hood is the platform for the seat assembly and causes the lift truck to tip over. The hood is a welded
is located above the battery. It functions as a battery steel assembly. Two hood hinges at the back attach
restraint that completely covers the battery compart- to the overhead guard. A latch assembly on the front
ment. bulkhead, locks the hood closed during operation.
Gas-controlled struts hold the hood in the open
See Figure 26 for lift truck models
position.
• E2.2-3.5XN (E45-70XN) (A268)

See Figure 27 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

27
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 6. BATTERY STOPPER

Figure 26. Hood and Latch Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)

28
100 SRM 1342 Hood and Seat Assembly Replacement

Opening the hood latch assembly unlocks the hood See Figure 29 for lift truck models
from the frame so the hood can be raised for access • E1.6-2.0XN (E30-40XN) (A269)
to the battery. The hood latch assembly must be in
good condition and properly secured before the lift The seat assembly slides on seat rails that are fas-
truck can be operated. If the hood latch assembly tened to the hood by four capscrews. A forward/back-
does not lock the hood in the closed position the lift ward lever at the left front side of the base adjusts
truck must not be operated. the seat either forward or backward.

See Figure 26 for lift truck models See Figure 30 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) • E2.2-3.5XN (E45-70XN) (A268)

See Figure 27 for lift truck models See Figure 31 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) • E1.6-2.0XN (E30-40XN) (A269)

To open the hood latch assembly in lift trucks with NOTE: Swivel seat not used on E1.6-2.0XN
manual hydraulic control levers, the manual hy- (E30-40XN) (A269) lift trucks.
draulic control levers and linkage assembly must
Optional seats are available in cloth or vinyl with fea-
be moved: pull latch handle up and allow manual
tures such as full suspension and with the ability to
hydraulic lever assembly to move forward and away
swivel. All seats have a seat sensor installed in the
from mounting plate on front bulkhead.
bottom cushion that senses operator presence. When
See Figure 28 for lift truck models the operator is not on the seat, the seat sensor opens
• E2.2-3.5XN (E45-70XN) (A268) and interrupts the controller and stops lift truck op-
eration.

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 27. Hood and Latch Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)

29
Hood and Seat Assembly Replacement 100 SRM 1342

1. FRONT BULKHEAD
2. MANUAL HYDRAULIC LEVER ASSEMBLY
1. MANUAL HYDRAULIC LEVER ASSEMBLY 3. LATCH HANDLE
2. LATCH HANDLE
3. FRONT BULKHEAD Figure 29. Latch Handle, Manual Hydraulic
Control Levers, Lift Trucks E1.6-2.0XN
Figure 28. Latch Handle, Manual Hydraulic (E30-40XN) (A269)
Control Levers, Lift Trucks E2.2-3.5XN
(E45-70XN) (A268)

Legend for Figure 30

NOTE: FULL-SUSPENSION SWIVEL SEAT SHOWN.

1. SEAT ASSEMBLY 5. CAPSCREW
2. HOOD 6. FORWARD/BACKWARD LEVER
3. SEAT RAIL 7. OPERATOR PRESENCE SYSTEM CONNECTOR
4. WASHER 8. RIDE POSITION INDICATOR

30
100 SRM 1342 Hood and Seat Assembly Replacement

Figure 30. Seat, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)

31
Hood and Seat Assembly Replacement 100 SRM 1342

The hood, seat belt, hip restraint brackets, seat, and 2. Slide the seat all the way back, and if necessary,
seat rails are all parts of the operator restraint sys- move the armrest all the way back if lift truck
tem. Checks and adjustments for the operator re- is equipped with E-Hydraulic control levers. See
straint system are described in the Operating Man- Figure 21.
ual or
3. If lift truck is equipped with manual hydraulic
Periodic Maintenance 8000 SRM 1364 for lift levers, pull the latch handle for the manual hy-
truck models draulic lever assembly and move the manual hy-
• E2.2-3.5XN (E45-70XN) (A268) draulic lever assembly tot he forward position be-
fore raising the hood.
Periodic Maintenance 8000 SRM 1442 for lift
truck models See Figure 28) for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) • E2.2-3.5XN (E45-70XN) (A268)

REMOVE See Figure 29 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)
To raise the hood, perform the following:

1. Use the tilt memory lever (see Figure 32) and tilt
the steering column all the way up.

1. SEAT ASSEMBLY NOTE: OPTIONAL TELESCOPIC STEERING COL-

2. HOOD UMN SHOWN.
3. SEAT RAIL
4. CAPSCREW 1. TILT POSITION LEVER
5. FORWARD/BACKWARD LEVER 2. TILT MEMORY LEVER
6. OPERATOR PRESENCE SYSTEM CONNECTOR 3. TELESCOPIC COLUMN LOCKING HANDLE
7. RIDE POSITION INDICATOR
Figure 32. Steering Column Tilt Memory Lever
Figure 31. Seat, Lift Trucks E1.6-2.0XN
(E30-40XN) (A269)

32
100 SRM 1342 Hood and Seat Assembly Replacement

NOTE: Perform Step 4 for lift truck models 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 17.

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 Electrical System
from right side of truck, pull hood release lever 2200 SRM 1369 for procedures.
towards the right side of the truck to unlatch
13. Remove emergency battery disconnect switch if
the hood. Place hand in plastic pocket provided
necessary. See Electrical System 2200 SRM
(above item 2 in Figure 26) and raise hood to the
1369 for procedures.
up position.
NOTE: Perform Step 14 through Step 16 if removing
NOTE: Perform Step 5 for lift truck models
seat assembly from hood.
E1.6-2.0XN (E30-40XN) (A269).
14. Remove four capscrews and washers from hood
NOTE: The hood can be raised from either side of the
and rails.
lift truck. Pull or push the hood release lever. The
hood release lever is spring loaded. Use a sling and See Figure 30 for lift truck models
crane to hold the hood in the up position. • E2.2-3.5XN (E45-70XN) (A268)
5. To raise the hood, lift the hood release handle up- See Figure 31 for lift truck models
wards to unlatch the hood. See Figure 27. Place • E1.6-2.0XN (E30-40XN) (A269)
hands in plastic handle provided and raise hood
to the UP position. 15. Tag and disconnect operator presence system
connector from main wire harness.
6. Remove the counterweight cover. See the Re-
move procedures in the section Counterweight See Figure 30 for lift truck models
Replacement. • E2.2-3.5XN (E45-70XN) (A268)

7. Remove screws and latch cover from latch assem- See Figure 31 for lift truck models
bly. • E1.6-2.0XN (E30-40XN) (A269)

See Figure 33 for lift truck models 16. Remove seat assembly from hood.
• E2.2-3.5XN (E45-70XN) (A268)
NOTE: To remove seat from seat rails, perform
See Figure 34 for lift truck models Step 17.
• E1.6-2.0XN (E30-40XN) (A269)
17. Remove stop screws from seat rails, hold ride po-
NOTE: Perform Step 8 for lift truck models sition indicator in the open position, and slide
E2.2-3.5XN (E45-70XN) (A268). seat from seat rails. See Figure 13.

8. Remove nuts, capscrews and latch assembly from 18. Remove locking clip from gas-controlled strut
front bulkhead. See Figure 33. front end. Remove gas-controlled strut front end
from ball stud on strut bracket. Remove ball
NOTE: Perform Step 9 for lift truck models stud, spacer, and O-ring from strut bracket.
E1.6-2.0XN (E30-40XN) (A269).
See Figure 33 for lift truck models
9. Remove latch assembly from front bulkhead. See • E2.2-3.5XN (E45-70XN) (A268)
Figure 34.
See Figure 34 for lift truck models
NOTE: Tag electrical connectors during removal to • E1.6-2.0XN (E30-40XN) (A269)
aid in installation.

33
Hood and Seat Assembly Replacement 100 SRM 1342

19. Remove locking clip from gas-controlled strut See Figure 33 for lift truck models
back end. Remove gas-controlled strut back end • E2.2-3.5XN (E45-70XN) (A268)
from ball stud on hood hinge. Remove gas-con-
trolled strut. Remove ball stud, spacer, and See Figure 34 for lift truck models
O-ring from hood hinge. • E1.6-2.0XN (E30-40XN) (A269)

See Figure 33 for lift truck models 23. Remove capscrews and flange nuts from hood
• E2.2-3.5XN (E45-70XN) (A268) hinge base plate and remove hood hinge base
plate.
See Figure 34 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) See Figure 33 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268)
20. Repeat Step 18 and Step 19 for opposite gas-con-
trolled strut. See Figure 34 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
21. Remove lifting device and close hood.
24. Using a lifting device, remove hood from battery
NOTE: Note placement of washers prior to removal compartment.
to aid in installation.

22. Remove nuts, shoulder bolts, and washers from

hood hinges and hood hinge arms.

Legend for Figure 33

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

34
100 SRM 1342 Hood and Seat Assembly Replacement

Figure 33. Hood and Latch, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)

35
Hood and Seat Assembly Replacement 100 SRM 1342

Figure 34. Hood and Latch, Lift Trucks E1.6-2.0XN (E30-40XN) (A269)

36
100 SRM 1342 Hood and Seat Assembly Replacement

Legend for Figure 34

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

INSTALL See Figure 33 for lift truck models

• E2.2-3.5XN (E45-70XN) (A268)
1. Using a lifting device, position hood onto hinges
and install washers, shoulder bolts, nuts, cap- See Figure 34 for lift truck models
screws, and flange nuts as noted during removal. • E1.6-2.0XN (E30-40XN) (A269)
a. Tighten nuts.
b. Nuts must be fully engaged with shoulder 5. Repeat Step 3 and Step 4 for opposite gas-con-
bolt and hood hinge arm assembly must be trolled strut. Close hood.
free to move.
6. If seat rails were removed from seat assembly,
c. Add or subtract washers, if necessary, to al-
hold ride position indicator in the open position
low hood hinge arm assembly to move freely
and slide seat onto seat rails. Install stop screws.
when opening and closing hood.
See Figure 13.
See Figure 33 for lift truck models
7. If seat assembly has been removed from hood,
• E2.2-3.5XN (E45-70XN) (A268)
position seat onto hood and install washers and
See Figure 34 for lift truck models capscrews into hood and seat rails.
• E1.6-2.0XN (E30-40XN) (A269)
See Figure 30 for lift truck models
2. Open and close hood to check for proper clear- • E2.2-3.5XN (E45-70XN) (A268)
ance.
See Figure 31 for lift truck models
3. Raise hood; use a lifting device to support hood in • E1.6-2.0XN (E30-40XN) (A269)
the open position. Install ball stud, spacer, and
NOTE: Remove tags as electrical connections are
O-ring onto hood hinge. Install gas-controlled
made.
strut back end onto ball stud on hood hinge. In-
stall locking clip on gas-controlled strut back end 8. Connect operator presence system connector to
and ball stud. main wire harness.
See Figure 33 for lift truck models See Figure 30 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) • E2.2-3.5XN (E45-70XN) (A268)
See Figure 34 for lift truck models See Figure 31 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) • E1.6-2.0XN (E30-40XN) (A269)
4. Install ball stud, spacer, and O-ring onto strut 9. Install hood and latch switches and emergency
bracket. Install gas-controlled strut front end battery disconnect switch, if removed, and adjust
onto ball stud on strut bracket. Install locking as necessary. See Electrical System 2200 SRM
clip on gas-controlled strut front end and ball 1369 for procedures.
stud.

37
Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342

10. Connect electrical wires, as tagged during re- 2. Using an ohm meter, place a test lead at the
moval, to emergency battery disconnect and armrest mounting bolt and another at the truck
hood and latch position switches. See Electri- frame. The resistance needs to read 5 Ohms or
cal System 2200 SRM 1369 for procedures. less. See Figure 35.

11. If equipped, connect electrical connector for 3. If the resistance is greater than 5 Ohms, double
E-Hydraulic controller. See Figure 17. check installation of seat assembly, both ends of
seat wiring harness, and wiring harness ground
12. Install nuts, capscrews, and latch assembly to strap.
front bulkhead. Install screws and latch cover to
latch assembly.

13. Connect battery connector.

14. Close hood and remove lifting device.

15. Install counterweight cover. See the Install

procedures in the section Counterweight Re-
placement.

16. If lift truck is equipped with manual hydraulic

control levers, push manual hydraulic control
lever assembly until it clicks into place.

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 1. ARMREST BOLT 2. FRAME

and associated bracketing, perform continuity
test. Figure 35. Ground Test

Hood and Seat Assembly Replacement For Lift Truck

Models J2.2-3.5XN (J45-70XN) (A276)
GENERAL and properly secured before the lift truck can be op-
erated. If the hood latch assembly does not lock the
The hood is the platform for the seat assembly and hood in the closed position, the lift truck must not be
is located above the battery. It functions as a bat- operated. See Figure 36.
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 release lever
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 36. 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- The seat assembly slides on seat rails that are fas-
tery. The latch assembly must be in good condition tened to the hood by four capscrews. A lever at the

38
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)

left front side of the seat base controls the adjust- The hood, seat belt, hip restraint brackets, seat, and
ment of the seat to the forward and backward posi- seat rails are all parts of the operator restraint sys-
tions. Optional seats are available in cloth or vinyl tem. Checks and adjustments for the operator re-
with features such as full suspension and with the straint system are described in the Operating Man-
ability to swivel. All seats have a seat switch (Opera- ual and Periodic Maintenance 8000 SRM 1372.
tor Presence System) installed in the bottom cushion
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
interrupts the motor controller and stops lift truck
operation. See Figure 37.

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 36. Hood and Hood Latch Arrangement, Lift Trucks J2.2-3.5XN (J45-70XN) (A276)

39
Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342

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

Figure 37. Seat Assembly

40
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)

Opening and Closing the Hood Manual Hydraulic Control Levers

1. Use the tilt memory lever (see Figure 38) and tilt NOTE: The hood must be raised from the left side of
the steering column all the way up. the lift truck.

2. Slide the seat all the way back. Move the arm- 1. If lift truck is equipped with manual hydraulic
rest all the way back if lift truck is equipped with control levers, open the hood as follows:
E-Hydraulic control levers. See Figure 21.
a. Place hand under hood release lever and
3. If lift truck is equipped with manual hydraulic push hood release lever up to release hood
levers, release the latch for the manual hydraulic latch assembly. See Figure 39.
lever assembly and move the assembly to the for-
ward position. See Figure 28. b. Place hand in hood handle and raise hood all
the way up.

c. To close the hood, lower hood until the latch

assembly touches the latch striker. Push
down on hood until it clicks once to lock. Try
to lift hood up using the hood handle to make
sure hood is securely latched. See Figure 39.

A. OPEN POSITION
B. FRONT VIEW
1. HOOD RELEASE LEVER
2. HOOD LATCH ASSEMBLY
3. HOOD
4. HOOD HORN BUTTON
5. HOOD HANDLE

Figure 39. Hood and Hood Handle Components

NOTE: OPTIONAL TELESCOPIC STEERING COL-
UMN SHOWN.
1. TILT POSITION SENSOR
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE

Figure 38. Steering Column Levers

41
Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342

E-Hydraulic Mini-Levers Figure 40. Raise hood to full upright posi-

tion.
There are two ways to open and close the hood as
described in Step 1 and Step 2 below. c. To close hood, lower hood to first stop point.
Turn lever to left and close hood until bolt
1. To open and close the hood, perform the follow- touches the striker. Push down on hood until
ing: it clicks once to lock. Try to lift hood up using
hood handle to make sure hood is securely
a. Place hand in hood handle (see Figure 39)
latched. See Figure 41.
and raise hood to the first stop point. See
Figure 40.

b. Turn lever to the right to the second stop.

Lever will be horizontal to slot in plate. See

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 40. Opening The Hood

Legend for Figure 41

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

42
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)

Figure 41. Hood and Latch, Lift Trucks J2.2-3.5XN (J45-70XN) (A276)

43
Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) 100 SRM 1342

2. To open and close the hood, perform the follow- 9. Remove seat assembly from hood.
ing:
NOTE: To remove seat from seat rails, perform
a. Place hand in hood handle (see Figure 39) Step 10.
and raise hood to the first stop point. See
Figure 40. 10. Remove stop screws from seat rails, hold ride po-
sition indicator in the open position, and slide
b. Turn lever to the right to the third stop. seat from seat rails. See Figure 14.
Lever will be vertical to slot in plate. See
Figure 40. Raise hood to full upright posi- 11. Remove locking clip from gas-controlled strut
tion. front end. Remove gas-controlled strut front
end from ball stud and hood hinge arm. See
c. To close hood, lower hood down until the bolt Figure 41.
touches the striker (see Figure 41). Push
down on hood until it clicks once to lock. Try 12. Remove locking clip from gas-controlled strut
to lift hood up using hood handle to make back end. Remove gas-controlled strut back end
sure hood is securely latched. from ball stud and hood hinge. See Figure 41.

13. Repeat Step 11 and Step 12 for opposite gas-con-

REMOVE
trolled strut.
1. Open and raise the hood to full upright position.
14. Close hood. See the section Opening and Closing
See the section Opening and Closing the Hood for
the Hood for procedures.
procedures.
15. Remove counterweight cover. See the section
2. Remove capscrews and latch assembly from latch
Counterweight Replacement for procedures.
plate on front bulkhead. See Figure 41.
NOTE: Note placement of washers prior to removal
NOTE: Tag electrical connectors during removal to
to aid in installation.
aid in installation.
16. Remove nuts, shoulder bolts, washers, and plates
3. Disconnect battery connector.
from hood hinges and hood hinge arms. See Fig-
NOTE: Perform Step 4 if lift truck is equipped with ure 41.
E-Hydraulics.
17. On left hood hinge, remove washers and snap
4. Tag and disconnect electrical connector for E-Hy- ring from bottom of link plate. Remove bottom
draulic controller. See Figure 17. of link plate from pin. See Figure 41.

5. Tag and disconnect electrical connectors from 18. Using a lifting device, remove hood from battery
emergency battery disconnect and hood and compartment.
latch position switches. See Electrical System
2200 SRM 1369 for procedures. INSTALL

6. Remove emergency battery disconnect switch if 1. Using a lifting device, position hood onto hinges
necessary. See Electrical System 2200 SRM and install washers, shoulder bolts, nuts, and
1369 for procedures. plates as noted during removal.
a. Tighten nuts.
NOTE: Perform Step 7 through Step 9 if removing b. Nuts must be fully engaged with shoulder
seat assembly from hood. bolt and hood hinge arm assembly must be
free to move.
7. Remove four capscrews and washers from hood c. Add or subtract washers, if necessary, to al-
and seat rails. See Figure 37. low hood hinge arm assembly to move freely
when opening and closing hood.
8. Tag and disconnect operator presence system
connector from main wire harness. See Fig- See Figure 41.
ure 37.

44
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)

2. On left side of hood hinge, install washer and 16. Close hood. See procedures in Opening and Clos-
bottom of link plate to pin. Install other washer ing the Hood. Make certain locking mechanism
and snap ring to secure bottom of link plate to for hood is properly engaged.
pin. See Figure 41.
17. If lift truck is equipped with manual hydraulic
3. Open and close hood to check for proper clear- control levers, push manual hydraulic control
ance. See Opening and Closing the Hood for pro- lever assembly until it clicks into place.
cedures.
GROUND TEST
4. Install counterweight cover. See the section
Counterweight Replacement for procedures. NOTE: If the static discharge ground connection is
not secured properly it could lead to the possible fail-
5. Raise hood. Install gas-controlled strut back end ure of the traction and/or pump motor controllers.
onto ball stud on hood hinge. Install locking clip
on gas-controlled strut back end and ball stud. 1. To ensure proper installation of seat assembly
See Figure 41. and associated bracketing, perform continuity
test.
6. Install gas-controlled strut front end onto ball
stud on hood hinge arm. Install locking clip on 2. Using an ohm meter, place a test lead at the
gas-controlled strut front end and ball stud. See armrest mounting bolt and another at the truck
Figure 41. frame. The resistance needs to read 5 Ohms or
less. See Figure 42.
7. Repeat Step 5 and Step 6 for opposite gas-con-
trolled strut. 3. If the resistance is greater than 5 Ohms, double
check installation of seat assembly, both ends of
8. If seat rails were removed from seat assembly, seat wiring harness, and wiring harness ground
hold ride position indicator in the open position strap.
and slide seat onto seat rails. Install stop screws.
See Figure 14.

9. If seat assembly has been removed from hood,

position seat onto hood and install capscrews and
washers into hood and seat rails. See Figure 37.

NOTE: Remove tags as electrical connections are

made.

10. Connect operator presence system connector to

main wire harness. See Figure 37.

11. Install hood and latch switches and emergency

battery disconnect switch, if removed, and adjust
as necessary. See Electrical 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 Electri-
cal System 2200 SRM 1369 for procedures. 1. ARMREST BOLT
2. FRAME
13. If equipped, connect electrical connector for
E-Hydraulic controller. See Figure 17. Figure 42. Ground Test

14. Connect battery connector.

15. Install capscrews and latch assembly to latch

plate on front bulkhead. See Figure 41.

45
Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) 100 SRM 1342

Hood and Seat Assembly Replacement For Lift Truck

Models J4.0-5.0XN (J80-100XN) (A970)
GENERAL to move forward and away from mounting plate
on front bulkhead. If the latch assembly does not
The hood is the platform for the seat assembly and lock the hood in the closed position, the manual
is located above the battery. It functions as a bat- hydraulic levers and linkage assembly will not lock
tery restraint that completely covers the battery com- into position and the lift truck will not operate.
partment. When correctly locked to the frame, it will
hold the battery in the battery compartment if an ac- The seat assembly slides on seat rails that are fas-
cident causes the lift truck to tip over. The hood is a tened to the hood by four capscrews. A lever at the
welded, steel assembly. Two hood hinges at the back left front side of the seat base controls the adjust-
attach to the counterweight. A latch assembly on the ment of the seat to the forward and backward posi-
front bulkhead, locks the hood closed during opera- tions. Optional seats are available in cloth or vinyl
tion. Gas-controlled struts hold the hood in the open with features such as full suspension and with the
position. See Figure 43 ability to swivel. All seats have a seat switch (Opera-
tor Presence System) installed in the bottom cushion
Opening the latch assembly unlocks the hood from that senses the presence of the operator. When the
the frame so the hood can be raised to access the bat- operator is not on the seat, the seat switch opens and
tery. The latch assembly must be in good condition interrupts the motor controller and stops lift truck
and properly secured before the lift truck can be op- operation. See Figure 44.
erated. If the hood latch assembly does not lock the
hood in the closed position, the lift truck must not be The hood, seat belt, hip restraint brackets, seat, and
operated. See Figure 43 seat rails are all parts of the operator restraint sys-
tem. Checks and adjustments for the operator re-
To open the hood on lift truck with manual hy- straint system are described in the Operating Man-
draulics, the manual hydraulic control levers and ual and Periodic Maintenance 8000 SRM 1541
linkage assembly must be moved: pull release lever
up and allow manual hydraulic linkage and handles NOTE: The seat belt may be either black or red.

46
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

A. OPEN POSITION C. BOTTOM VIEW

B. FRONT VIEW
1. HOOD 6. LEFT HINGE ARM
2. HOOD RELEASE HANDLE 7. HOOD HINGE
3. HOOD LATCH ASSEMBLY 8. SPACER
4. GAS SPRING 9. PIN
5. RIGHT HINGE ARM 10. LEVER

Figure 43. Hood and Hood Latch Arrangement, Lift Trucks J4.0-5.0XN (J80-100XN) (A970)

47
Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) 100 SRM 1342

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

Figure 44. Seat Assembly

48
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

Opening and Closing the Hood Manual Hydraulic Control Levers

1. Use the tilt memory lever (see Figure 45) and tilt NOTE: The hood can be raised from either of the lift
the steering column all the way up. truck. In the examples given below, the hood is raised
from the left side of the lift truck. If hood is raised
2. Slide the seat all the way back. Move the arm- from the right side of the lift truck, push the hood
rest all the way back if lift truck is equipped with release handle out toward the left side of the lift truck
E-Hydraulic control levers. See Figure 21. to unlatch the hood.
3. If lift truck is equipped with manual hydraulic 1. If lift truck is equipped with manual hydraulic
levers, release the latch for the manual hydraulic control levers, open the hood as follows:
lever assembly and move the assembly to the for-
ward position. See Figure 28. a. Place hand under hood release handle and
pull hood release lever toward the left side of
lift truck to release hood latch assembly. See
Figure 46.

b. Place hand in hood handle and raise hood all

the way up.

c. To close the hood, lower hood until the latch

assembly touches the latch striker. Push
down on hood until it clicks once to lock.
Try to lift hood up using the hood handle
to make sure hood is securely latched. The
hood must be locked in the down position
during lift truck operation. See Figure 46.

NOTE: OPTIONAL TELESCOPIC STEERING COL-

UMN SHOWN. A. OPEN POSITION B. FRONT VIEW
1. TILT POSITION SENSOR 1. HOOD RELEASE HANDLE
2. TILT MEMORY LEVER 2. HOOD LATCH ASSEMBLY
3. TELESCOPIC COLUMN LOCKING HANDLE 3. HOOD
4. HOOD HORN BUTTON
Figure 45. Steering Column Levers 5. HOOD HANDLE

Figure 46. Hood and Hood Handle Components

49
Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) 100 SRM 1342

E-Hydraulic Mini-Levers b. Place hand in hood handle (see Figure 46)

and raise hood to the intermediate stop point.
NOTE: The hood can be raised from either of the lift
truck. In the examples given below, the hood is raised c. Turn lever until it clicks. Lever will be verti-
from the left side of the lift truck. If hood is raised cally oriented. See Figure 47. Raise hood to
from the right side of the lift truck, push the hood full upright position.
release handle out toward the left side of the lift truck
to unlatch the hood. NOTE: The intermediate stop can alternately be
temporarily disabled by rotating its lever 90 degrees
NOTE: Trucks equipped with E-hydraulics feature and holding it in this position with one hand while
an intermediate hood opening position. There are controlling the hood opening/closing with the other
two lever positions that disable the intermediate hand.
stop. See Figure 47.
2. To close hood, lower hood until latch touches the
1. To open and close the hood, perform the follow- striker. Push down on hood until it clicks to lock.
ing: Try to lift hood up using hood handle to make
sure hood is securely latched. The hood must
a. Place hand under hood release handle and be locked in the down position during lift truck
pull hood release lever toward the left side of operation.
lift truck to release hood latch assembly. See
Figure 46.

NOTE: FULL SUSPENSION SEAT AND RAISED HOOD SHOWN.

A. HOOD RAISED TO FULL UPRIGHT POSITION, LEVER TURNED TO TEMPORARY DISABLING POSITION
(HORIZONTAL TO SLOT)
B. HOOD RAISED TO INTERMEDIATE STOP POINT.
C. HOOD RAISED TO FULL UPRIGHT POSITION, LEVER TURNED TO PERMANENT DISABLING POSITION
(VERTICAL SLOT)
1. LEVER 4. SEAT
2. PLATE 5. SLOT
3. HOOD 6. LINK PLATE

Figure 47. Opening The Hood

50
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

REMOVE 13. Repeat Step 11 and Step 12 for opposite gas-con-

trolled strut.
1. Open and raise the hood to full upright position.
See the section Opening and Closing the Hood for 14. Close hood. See the section Opening and Closing
procedures. the Hood for procedures.

2. Remove spacers, nuts, and capscrews and re- 15. Remove counterweight cover. See the section
move latch assembly from front bulkhead. See Counterweight Replacement for procedures.
Figure 48.
NOTE: Note placement of washers prior to removal
NOTE: Tag electrical connectors during removal to to aid in installation.
aid in installation.
16. Remove nuts, shoulder bolts, washers, and plates
3. Disconnect battery connector. from hood hinges and hood hinge arms. See Fig-
ure 48.
NOTE: Perform Step 4 if lift truck is equipped with
E-Hydraulics. 17. On left hood hinge, remove washers and snap
ring from bottom of link plate. Remove bottom
4. Tag and disconnect electrical connector for E-Hy- of link plate from pin. See Figure 48.
draulic controller. See Figure 17.
18. Using a lifting device, remove hood from battery
5. Tag and disconnect electrical connectors from compartment.
emergency battery disconnect and hood and
latch position switches. See Electrical System INSTALL
2200 SRM 1369 for procedures.
1. Using a lifting device, position hood onto hinges
6. Remove emergency battery disconnect switch if and install washers, shoulder bolts, nuts, and
necessary. See Electrical System 2200 SRM plates as noted during removal.
1369 for procedures. a. Tighten nuts.
b. Nuts must be fully engaged with shoulder
NOTE: Perform Step 7 through Step 9 if removing
bolt and hood hinge arm assembly must be
seat assembly from hood.
free to move.
7. Remove four capscrews and washers from hood c. Add or subtract washers, if necessary, to al-
and seat rails. See Figure 44. low hood hinge arm assembly to move freely
when opening and closing hood.
8. Tag and disconnect operator presence system
connector from main wire harness. See Fig- See Figure 48.
ure 44.
2. On left side of hood hinge, install washer and
9. Remove seat assembly from hood. bottom of link plate to pin. Install other washer
and snap ring to secure bottom of link plate to
NOTE: To remove seat from seat rails, perform pin. See Figure 48.
Step 10.
3. Open and close hood to check for proper clear-
10. Remove stop screws from seat rails, hold ride po- ance. See Opening and Closing the Hood for pro-
sition indicator in the open position, and slide cedures.
seat from seat rails. See Figure 14.
4. Install counterweight cover. See the section
11. Remove locking clip from gas-controlled strut Counterweight Replacement for procedures.
front end. Remove gas-controlled strut front
end from ball stud and hood hinge arm. See 5. Raise hood. Install gas-controlled strut back end
Figure 48. onto ball stud on hood hinge. Install locking clip
on gas-controlled strut back end and ball stud.
12. Remove locking clip from gas-controlled strut See Figure 48.
back end. Remove gas-controlled strut back end
from ball stud and hood hinge. See Figure 48.

51
Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970) 100 SRM 1342

Figure 48. Hood and Latch, Lift Trucks J4.0-5.0XN (J80-100XN) (A970)

52
100 SRM 1342 Hood and Seat Assembly Replacement For Lift Truck Models J4.0-5.0XN (J80-100XN) (A970)

Legend for Figure 48

A. SIDE VIEW B. REAR VIEW
1. LATCH ASSEMBLY 12. NUT
2. FRONT BULKHEAD 13. LOCKING CLIP
3. SPACERS 14. SNAP RING
4. LATCH STRIKER 15. LEVER
5. HOOD 16. LINK PLATE
6. CAPSCREW 17. HOOD HINGE ARM
7. SHOULDER BOLT 18. HOOD HINGE
8. WASHER 19. PIN
9. BALL STUD 20. PLATE
10. GAS CONTROLLED STRUT, FRONT END 21. REAR BULKHEAD
11. GAS CONTROLLED STRUT, BACK END 22. MOUNTING PLATE

6. Install gas-controlled strut front end onto ball 14. Connect battery connector.
stud on hood hinge arm. Install locking clip on
gas-controlled strut front end and ball stud. See 15. Install capscrews, nuts, and spacers and latch
Figure 48. assembly to front bulkhead. See Figure 48.

7. Repeat Step 5 and Step 6 for opposite gas-con- 16. Close hood. See procedures in Opening and Clos-
trolled strut. ing the Hood. Make certain locking mechanism
for hood is properly engaged.
8. If seat rails were removed from seat assembly,
hold ride position indicator in the open position 17. If lift truck is equipped with manual hydraulic
and slide seat onto seat rails. Install stop screws. control levers, push manual hydraulic control
See Figure 16. lever assembly until it clicks into place.

9. If seat assembly has been removed from hood, GROUND TEST

position seat onto hood and install capscrews and
washers into hood and seat rails. See Figure 44. NOTE: If the static discharge ground connection is
not secured properly it could lead to the possible fail-
NOTE: Remove tags as electrical connections are ure of the traction and/or pump motor controllers.
made.
1. To ensure proper installation of seat assembly
10. Connect operator presence system connector to and associated bracketing, perform continuity
main wire harness. See Figure 44. test.

11. Install hood and latch switches and emergency 2. Using an ohm meter, place a test lead at the
battery disconnect switch, if removed, and adjust armrest mounting bolt and another at the truck
as necessary. See Electrical System 2200 SRM frame. The resistance needs to read 5 Ohms or
1369 for procedures. less. See Figure 49.

12. Connect electrical wires, as tagged during re- 3. If the resistance is greater than 5 Ohms, double
moval, to emergency battery disconnect and check installation of seat assembly, both ends of
hood and latch position switches. See Electri- seat wiring harness, and wiring harness ground
cal System 2200 SRM 1369 for procedures. strap.

13. If equipped, connect electrical connector for

E-Hydraulic controller. See Figure 17.

53
Brake Pedal Components 100 SRM 1342

Legend for Figure 49

1. ARMREST BOLT
2. FRAME

Figure 49. Ground Test

Master Cylinder Repair and Adjustment

For procedures on adjusting and repairing the mas- Transaxle 1300 SRM 1539 for lift truck models
ter cylinder, see one of the following service manuals: • J4.0-5.0XN (J80-100XN) (A970)

Brake System 1800 SRM 1359 for lift truck models Transaxle 1300 SRM 1370 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) • J2.2-3.5XN (J45-70XN) (A276)

Brake System 1800 SRM 1438 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

Brake Pedal Components

For procedures dealing with brake pedal compo- Transaxle 1300 SRM 1539 for lift truck models
nents, see one of the following service manuals: • J4.0-5.0XN (J80-100XN) (A970)

Brake System 1800 SRM 1359 for lift truck models Transaxle 1300 SRM 1370 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) • J2.2-3.5XN (J45-70XN) (A276)

Brake System 1800 SRM 1438 for lift truck models

• E1.6-2.0XN (E30-40XN) (A269)

54
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), E1.6-2.0XN (E30-40XN) (A269), and
J4.0-5.0XN (J80-100XN) (A970)
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)

Brake System 1800 SRM 1359 for lift truck models Transaxle 1300 SRM 1539 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) • J4.0-5.0XN (J80-100XN) (A970)

55
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- Periodic Maintenance 8000 SRM 1442 for lift
nance or repair, see How to Put Lift Truck on truck models
Blocks in the Operating Manual or one of the fol- • E1.6-2.0XN (E30-40XN) (A269)
lowing service manuals
3. Remove overhead guard. See the Remove proce-
Periodic Maintenance 8000 SRM 1364 for lift dures in the section Overhead Guard Replace-
truck models ment.
• E2.2-3.5XN (E45-70XN) (A268)
4. Remove top of counterweight cover from coun-
Periodic Maintenance 8000 SRM 1442 for lift terweight by removing two cover capscrews and
truck models cover nuts. See Figure 50.
• E1.6-2.0XN (E30-40XN) (A269)
5. Remove controller cover. Remove controller, con-
tactors, and other electronic components located
WARNING in the counterweight, see Electrical System
The counterweight is very heavy. Make sure 2200 SRM 1369.
that the crane and lifting devices have enough
lifting capacity to safely lift the counterweight.
WARNING
The weights of the counterweights are shown
in Make sure slings and crane have enough capac-
ity to lift and hold counterweight.
Table 1 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268) See Table 1 for lift truck models
• E2.2-3.5XN (E45-70XN) (A268)
Table 2 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) See Table 2 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
The counterweight normally is not removed for most
repairs. Replacement of controller and contactors is 6. Wrap two slings through slots in top of counter-
easier with counterweight installed. The counter- weight. See Figure 50. Attach slings to crane.
weight is fastened to the frame with four capscrews. 7. From inside the battery compartment, near the
The weights for counterweights are shown in bottom, remove upper capscrews and washers
Table 1 for lift truck models from counterweight and frame. See Figure 50.
• E2.2-3.5XN (E45-70XN) (A268) 8. Remove lower capscrews, lower nuts, lower
Table 2 for lift truck models washers, and tow pin from counterweight and
• E1.6-2.0XN (E30-40XN) (A269) frame. See Figure 50.

9. Using crane lift counterweight away from frame.

REMOVE
1. Disconnect battery connector.

2. Remove battery from lift truck. See How to

Change Battery in the Operating Manual or
one of the following service manuals

Periodic Maintenance 8000 SRM 1364 for lift

truck models
• E2.2-3.5XN (E45-70XN) (A268)

56
100 SRM 1342 Counterweight Replacement

Table 1. Counterweights for Lift Truck Table 2. Counterweights for Lift Truck
E2.2-3.5XN (E45-70XN) (A268) E1.6-2.0XN (E30-40XN) (A269)

Model (mm*) Weight + 50 kg Model (mm*) Weight + 50 kg

(110 lb) (110 lb)
0 kg 0 kg
(0 lb) (0 lb)
E2.2XN(E45XN) 786 E1.6XN(E30XN) 700 489 kg (1078 lb)
E2.2-2.5XN 847 571 kg (1258 lb) E1.8XN 700 605 kg (1334 lb)
(E45-50XN) (E35XN)
E2.2XN(E45XN) 700 E2.0XN 700
754 kg (1662 lb)
(E40XN)
E2.5XN(E50XN) 786
764 kg (1684 lb) *Approximate battery compartment lengths.
E2.75XN 847
(E55XN)
E3.2XN(E65XN) 1015
E2.5XN(E50XN) 700
E3.0XN(E60XN) 847
948 kg (2090 lb)
E3.2XN(E65XN) 933
E3.5XN(E70XN) 1015
*Approximate battery compartment lengths.

57
Counterweight Replacement 100 SRM 1342

INSTALL 4. Disconnect and remove slings from counter-

weight.
1. Using crane, lift counterweight into position on
frame. 5. Install controller, contactors, and other electronic
components located in the counterweight. Install
2. Install upper capscrews and washers, near bot- controller cover onto counterweight. see Electri-
tom of the battery compartment, into counter- cal System 2200 SRM 1369. Connect electrical
weight and frame. See Figure 50. Tighten upper connectors as tagged during removal.
capscrews to 755 N•m (557 lbf ft).
6. Install counterweight cover, washers, and cap-
3. Install lower capscrews, lower nuts, and lower screws on counterweight. See Figure 50.
washers in the tow pin area, into counterweight
and frame. Install tow pin into counterweight. 7. Install overhead guard. See the Install proce-
See Figure 50. Tighten lower capscrews to dures in the section Overhead Guard Replace-
90 N•m (66 lbf ft). ment.

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

Figure 50. Counterweight Assembly for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN
(E30-40XN) (A269)

58
100 SRM 1342 Counterweight Replacement

8. Install battery into lift truck. See How to Periodic Maintenance 8000 SRM 1442 for lift
Change Battery in the Operating Manual or truck models
one of the following service manuals • E1.6-2.0XN (E30-40XN) (A269)

Periodic Maintenance 8000 SRM 1364 for lift 9. Connect battery connector.
truck models
• E2.2-3.5XN (E45-70XN) (A268)

Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN)

(A276) and J4.0-5.0XN (J80-100XN) (A970)
Put lift truck on blocks, see How to Put Lift Truck Periodic Maintenance 8000 SRM 1372 for lift
on Blocks in the Operating Manual or in service truck models
manual: • J2.2-3.5XN (J45-70XN) (A276)

Periodic Maintenance 8000 SRM 1372 for lift Periodic Maintenance 8000 SRM 1541 for lift
truck models truck models
• J2.2-3.5XN (J45-70XN) (A276) • J4.0-5.0XN (J80-100XN) (A970)

Periodic Maintenance 8000 SRM 1541 for lift NOTE: Some lift trucks are equipped with cab pan-
truck models els. Be careful not to damage panels when removing
• J4.0-5.0XN (J80-100XN) (A970) overhead guard.

4. Remove overhead guard. See the Overhead

WARNING Guard Replacement section of this manual.
The counterweight is heavy. Make sure that
the crane and lifting devices have enough lift- 5. For lift truck models J2.2-3.5XN (J45-70XN)
ing capacity to safely lift the counterweight. (A276), remove tow pin, capscrews, washers, and
The weights of the counterweights are shown counterweight cover from counterweight. See
in Figure 51.

Table 3 for lift truck models 6. For lift truck models J4.0-5.0XN (J80-100XN)
• J2.2-3.5XN (J45-70XN) (A276) (A970), remove mounting spacers and capscrews
and remove counterweight cover from counter-
Table 4 for lift trucks weight. See Figure 16.
• J4.0-5.0XN (J80-100XN) (A970)
7. Remove hood and seat assembly. See the Hood
The counterweight normally is not removed for most and Seat Assembly Replacement For Lift Truck
repairs. Replacement of controller and hydraulic Models J4.0-5.0XN (J80-100XN) (A970) section
components is easier with the counterweight in- of this manual.
stalled. The counterweight is fastened to the rear
bulkhead with mounting bolts. 8. Remove controller, contactors, and other elec-
tronic components located in the counterweight,
REMOVE see Electrical System 2200 SRM 1369.

NOTE: Tag all electrical connectors during removal NOTE: Tag all hydraulic lines during removal to aid
to aid in installation. in installation.

1. Disconnect battery connector. 9. Remove hydraulic pump and motor assembly

and hydraulic tank from counterweight. See
2. Discharge capacitors as described in General sec- Hydraulic System 1900 SRM 1367.
tion of this manual.

3. Remove battery from the truck. See How to

Change Battery in the Operating Manual or

59
Counterweight Replacement 100 SRM 1342

Table 3. Counterweights for Lift Truck

WARNING J2.2-3.5XN (J45-70XN) (A276)
Make sure lifting device has enough capacity
to hold and lift counterweight. Model (mm*) Weight + 50 kg
(110 lb)
See Table 3 for lift truck models
0 kg
• J2.2-3.5XN (J45-70XN) (A276)
(0 lb)
See Table 4 for lift truck models J2.2-2.5XN 717
• J4.0-5.0XN (J80-100XN) (A970) 725 kg (1598 lb)
(J45-50XN)
10. Install two eyebolts into the counterweight and J3.0XN(J60XN) 861 801 kg (1766 lb)
attach lifting device to eyebolts. 861
J3.5XN(J70XN) 1116 kg (2460 lb)
See Figure 53 for lift truck models *Approximate battery compartment lengths.
• J2.2-3.5XN (J45-70XN) (A276)

See Figure 54 for lift truck models Table 4. Counterweights for Lift Truck
• J4.0-5.0XN (J80-100XN) (A970) J4.0-5.0XN (J80-100XN) (A970)

11. Remove steering axle from counterweight. See Model (mm*) Weight + 50 kg
Steering Axle 1600 SRM 1360. (110 lb)
0 kg
12. For lift truck models J2.2-3.5XN (J45-70XN) (0 lb)
(A276), remove three mounting bolts and wash-
ers from rear bulkhead and counterweight. See J4.0-4.5XN 859
1453 kg (3203 lb)
Figure 51. (J80-90XN)
J4.0-5.0XN 1006
13. For lift truck models J4.0-5.0XN (J80-100XN) 2621 kg (5778 lb)
(J80-100XN)
(A970), remove four mounting bolts and washers
from rear bulkhead and counterweight. See *Approximate battery compartment lengths.
Figure 52.

14. Using approved lifting device, pull counter-

weight slightly away from frame. Install eyebolt
into center hole in counterweight and attach
lifting device. Lift counterweight completely
away from frame.

60
100 SRM 1342 Counterweight Replacement

1. COUNTERWEIGHT 5. REAR BULKHEAD

2. COUNTERWEIGHT COVER 6. MOUNTING BOLT
3. TOW PIN 7. WASHER
4. CAPSCREW 8. FRAME

Figure 51. Counterweight Assembly for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

61
Counterweight Replacement 100 SRM 1342

1. MOUNTING BOLT 4. REAR BULKHEAD

2. WASHER 5. FRAME
3. COUNTERWEIGHT

Figure 52. Counterweight Assembly for Lift Trucks J4.0-5.0XN (J80-100XN) (A970)

62
100 SRM 1342 Counterweight Replacement

INSTALL
NOTE: Make sure lifting mechanism has enough ca-
pacity to hold and lift counterweight.

1. Using approved lifting device, position counter-

weight to rear bulkhead. Detach lifting device
from center eyebolt and remove eyebolt from cen-
ter hole in counterweight.

See Figure 53 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

See Figure 54 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

2. For lift trucks J2.2-3.5XN (J45-70XN) (A276), in-

stall three washers and mounting bolts into rear
bulkhead and counterweight. See Figure 51.
Tighten mounting bolts to 755 N•m (557 lbf ft).

3. For lift trucks J4.0-5.0XN (J80-100XN) (A970),

1. COUNTERWEIGHT install four mounting bolts and washers into
2. EYEBOLT rear bulkhead and counterweight. See Fig-
ure 52. Tighten mounting bolts to 755 N•m
Figure 53. Counterweight Lift for Lift Truck
(557 lbf ft).
J2.2-3.5XN (J45-70XN) (A276)
4. Install steering axle onto counterweight. See
Steering Axle 1600 SRM 1360.

5. Detach lifting device and remove two eyebolts

from top of counterweight.

See Figure 53 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276)

See Figure 54 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

6. Install hydraulic tank and hydraulic pump and

motor assembly. See Hydraulic System 1900
SRM 1367. Connect hydraulic lines as tagged
during removal.

7. Install controller, contactors, and other electronic

components located in counterweight, see Elec-
trical System 2200 SRM 1369. Connect electri-
cal connectors as tagged during removal.
1. COUNTERWEIGHT
2. EYEBOLT 8. Install hood and seat assembly. See the Hood
and Seat Assembly Replacement For Lift Truck
Figure 54. Counterweight Lift for Lift Trucks Models J4.0-5.0XN (J80-100XN) (A970) section
J4.0-5.0XN (J80-100XN) (A970) of this manual.

9. For lift truck models J2.2-3.5XN (J45-70XN)

(A276), install counterweight cover, capscrews,
and tow pin onto counterweight. See Figure 51.

63
Traction Motor Replacement 100 SRM 1342

10. For lift truck models J4.0-5.0XN (J80-100XN) 12. Install battery into lift truck. See How to
(A970), install mounting spacers and capscrews Change Battery in the Operating Manual or
and install counterweight cover to counter-
weight. See Figure 52. Periodic Maintenance 8000 SRM 1372 for lift
truck models
NOTE: For lift truck equipped with cab panels, be • J2.2-3.5XN (J45-70XN) (A276)
careful to not damage the panels when installing
overhead guard. Periodic Maintenance 8000 SRM 1541 for lift
truck models
11. Install overhead guard. See the Overhead Guard • J4.0-5.0XN (J80-100XN) (A970)
Replacement section of this manual.
13. Connect battery connector.

Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)

(A268) and E1.6-2.0XN (E30-40XN) (A269)
REMOVE • If the counterweight is removed, put blocks
under the mast so that the lift truck cannot
This procedure is for removal of the traction motor fall forward.
from under lift truck with the use of a floor jack. The
traction motor can also be removed through the bat- Put the lift truck on blocks on a solid, even, and
tery compartment. The lift truck must be on blocks level surface. Verify the blocks or stands have
with clearance for the floor jack and traction motor, enough capacity to hold the lift truck. Use ad-
if traction motor is removed from under lift truck. ditional blocks next to the tires as necessary to
prevent movement of the lift truck. Verify the
See Figure 55 for lift truck models lifting devices used during repairs can lift the
• E2.2-3.5XN (E45-70XN) (A268) weight of the parts and assemblies.
See Figure 56 for lift truck models See Operating Manual or one of the following
• E1.6-2.0XN (E30-40XN) (A269) service manuals for the procedure to put the
lift truck on blocks.
WARNING
See Periodic Maintenance 8000 SRM 1364 for
PUTTING THE LIFT TRUCK ON BLOCKS
lift truck models
The lift truck must be put on blocks for many • E2.2-3.5XN (E45-70XN) (A268)
types of maintenance and repair. The removal
Periodic Maintenance 8000 SRM 1442 for lift
of the mast, drive axle, battery, or counter-
truck models
weight assemblies will cause large changes in
• E1.6-2.0XN (E30-40XN) (A269)
the center gravity. When the lift truck is put on
blocks, put additional blocks in the following NOTE: Some lift trucks have an automatic park
positions: brake on the armature shaft of the traction motor.
• If the mast and drive axle are removed, put See Figure 55. The automatic park brake must be
blocks under the counterweight so the lift disconnected before traction motor is removed.
truck cannot fall backward.

64
100 SRM 1342 Traction Motor Replacement

1. Remove battery from lift truck. See How to 4. Remove e-ring, at fitting "D" on cable; remove
Change Battery in the Operating Manual or cable from bracket plate. See Figure 57.

See Periodic Maintenance 8000 SRM 1364 for NOTE: Tag electrical connectors during removal to
lift truck models aid in installation.
• E2.2-3.5XN (E45-70XN) (A268)
5. Tag and disconnect speed and temperature sen-
See Periodic Maintenance 8000 SRM 1442 for sor connectors from the terminals.
lift truck models
• E1.6-2.0XN (E30-40XN) (A269) 6. Tag and disconnect power cables from traction
motor.
2. Remove covers or plates and optional rollers from
bottom of battery compartment. See the Battery NOTE: Perform Step 7 only if lift truck is equipped
Restraint and Seat Assembly Repair section of with optional drip shield.
this manual.
7. Remove capscrews and drip shield from frame,
NOTE: Perform Step 3 and Step 4 if lift truck is allowing access to traction motor. See Figure 58.
equipped with an automatic park brake.
8. Position a floor jack under traction motor.
3. Remove jam-nuts and cable from automatic park
brake. See Figure 57.

A. TRACTION MOTOR B. TRACTION MOTOR WITH OPTIONAL

AUTOMATIC PARK BRAKE
1. TRACTION MOTOR 3. DRIVE AXLE
2. AUTOMATIC PARKING BRAKE

Figure 55. Traction Motor, Lift Trucks E2.2-3.5XN (E45-70XN) (A268)

65
Traction Motor Replacement 100 SRM 1342

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 58.

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 58.

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: It is possible that traction motor will rotate

during removal and lowering. Use a suitable strap
to lock down traction motor when removing.

13. Slowly lower traction motor to level ground; ad-

just floor jack as needed for removal.

NOTE: Perform Step 14 and Step 15 if lift truck is

equipped with an automatic park brake.

14. Remove capscrews and bracket plate from trac-

tion motor. See Figure 57. NOTE: OPTIONAL AUTOMATIC PARK BRAKE NOT
SHOWN. SEE FIGURE 57.
15. Remove capscrews and automatic park brake
from traction motor. See Figure 57. 1. FRAME
2. TRACTION MOTOR
16. Remove and discard O-ring from traction motor. 3. HYDRAULIC PUMP MOTOR
See Figure 58.
Figure 56. Traction Motor, Lift Trucks
E1.6-2.0XN (E30-40XN) (A269)

66
100 SRM 1342 Traction Motor Replacement

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 57. Automatic Park Brake and Traction Motor for Lift Trucks E2.2-3.5XN (E45-70XN) (A268)
and E1.6-2.0XN (E30-40XN) (A269)

67
Traction Motor Replacement 100 SRM 1342

1. MOUNTING FLANGE FOR TRACTION MOTOR 5. TRACTION MOTOR

2. BRACKET 6. O-RING
3. DRIP SHIELD 7. CAPSCREWS
4. CAPSCREWS

Figure 58. Traction Motor and Mounting Flange

68
100 SRM 1342 Traction Motor Repair or Replacement

INSTALL 10. Remove lift truck from blocks.

1. Install new O-ring onto traction motor. 11. Connect power cables to traction motor as tagged
during removal.
NOTE: Perform Step 2 and Step 3 if lift truck is
equipped with an automatic park brake. 12. Connect speed and temperature sensor connec-
tions to terminals as tagged during removal.
2. Install automatic park brake and capscrews onto
traction motor. See Figure 57. 13. Connect any other hydraulic lines disconnected
from main control valve during removal.
3. Install bracket plate and capscrews on traction
motor. See Figure 57. NOTE: Perform Step 14 and Step 15 if lift truck is
equipped with an automatic park brake.
NOTE: It is possible that the traction motor will ro-
tate during installation and raising of floor jack. Use 14. Install cable through bracket plate. Install e-ring
a suitable strap to lock down the traction motor when on cable at fitting "D". See Figure 57.
raising of floor jack.
15. Install cable and jam-nuts onto automatic part
4. Position traction motor beneath lift truck and brake. See Figure 57.
slowly raise into frame. Adjust floor jack, as
needed, during installation. 16. Install covers or plates and optional rollers into
bottom of battery compartment. See the Battery
5. Align bolt holes in mounting flange and traction Restraint and Seat Assembly Repair section of
motor. Install three 76.2 mm (3 in.) threaded this manual.
dowels, placed at equally spaced intervals, into
mounting flange and traction motor for support. 17. Install battery into lift truck. See How to
Change Battery in the Operating Manual or
6. Install four capscrews holding traction motor on one of the following service manuals
mounting flange.
Periodic Maintenance 8000 SRM 1364 for lift
7. Remove threaded dowels and replace with three truck models
remaining capscrews. Tighten all capscrews to • E2.2-3.5XN (E45-70XN) (A268)
between 38 to 48 N•m (28 to 35 lbf ft).
Periodic Maintenance 8000 SRM 1442 for lift
8. Remove strap from traction motor. Remove floor truck models
jack from underneath lift truck. • E1.6-2.0XN (E30-40XN) (A269)

9. Install drip shield and capscrews onto frame.

Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN

(J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
For repair or replacement of traction motor see Transaxle 1300 SRM 1539 for lift truck models
• J4.0-5.0XN (J80-100XN) (A970)
Transaxle 1300 SRM 1370 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)

69
Hydraulic Tank Inspection 100 SRM 1342

Hydraulic Tank Inspection

INSPECT inspection mirror and a light that is approved for
locations with flammable vapors.
WARNING The hydraulic tank is a steel fabricated drop-in or
Special procedures must be followed when a molded nylon assembly, and can be removed from
large leaks or other repairs are needed. All the lift truck, if necessary, to check for leaks or for
work must be done by authorized personnel. If replacement. Repair or replace hydraulic tank if
the tank is cleaned inside of a building, make cracked or leaking. See Hydraulic System 1900
sure there is enough ventilation. SRM 1367 for repair or replacement procedure.

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 59 for lift truck models below with metal

tank
• E2.2-3.5XN (E45-70XN) (A268)

See Figure 60 for lift truck models below with nylon

tank
• E2.2-3.5XN (E45-70XN) (A268)

See Figure 61 for lift truck models

• J2.2-3.5XN (J45-70XN) (A276) 1. FILL CAP
2. FILTER HOUSING
See Figure 62 for lift truck models 3. DIPSTICK
4. BREATHER FILTER
• E1.6-2.0XN (E30-40XN) (A269) 5. OPTIONAL LEVEL SENSOR
6. OPTIONAL FILTER PRESSURE SWITCH
See Figure 63 for lift truck models 7. RETAINING STRAP
• J4.0-5.0XN (J80-100XN) (A970) 8. SUCTION STRAINER W/O-RING
9. MAGNETIC PLUG W/O-RING
Inspect seams for cracks and leakage. Check for wet 10. HYDRAULIC TANK
areas, accumulation of dirt, and loose or missing
paint caused by leakage. Areas of hydraulic tank Figure 59. Metal Hydraulic Tank for Lift Truck
that are not easily seen can be checked with an E2.2-3.5XN (E45-70XN) (A268)

70
100 SRM 1342 Hydraulic Tank Inspection

1. FILL CAP 1. FILL CAP

2. FILTER HOUSING 2. FILTER HOUSING
3. DIPSTICK 3. DIPSTICK
4. BREATHER FILTER 4. BREATHER FILTER
5. OPTIONAL LEVEL SENSOR 5. LEVEL SENSOR
6. OPTIONAL FILTER PRESSURE SWITCH 6. PRESSURE SWITCH
7. TEMPERATURE SENSOR 7. TEMPERATURE SENSOR
8. SUCTION STRAINER W/O-RING 8. SUCTION STRAINER W/ O-RING
9. MAGNETIC PLUG W/O-RING 9. DRAIN VALVE
10. HYDRAULIC TANK 10. HYDRAULIC TANK
Figure 60. Nylon Hydraulic Tank for Lift Truck Figure 61. Hydraulic Tank for Lift Truck
E2.2-3.5XN (E45-70XN) (A268) J2.2-3.5XN (J45-70XN) (A276)

71
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 62. Hydraulic Tank for Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)

72
100 SRM 1342 Painting Instructions

CLEAN
See Hydraulic System 1900 SRM 1367 for hy-
draulic tank cleaning procedures.

Legend for Figure 63

1. FILL CAP
2. FILTER HOUSING
3. DIPSTICK
4. BREATHER FILTER
5. LEVEL SENSOR
6. PRESSURE SWITCH
7. TEMPERATURE SENSOR
8. SUCTION STRAINER W/ O-RING
9. DRAIN VALVE
10. HYDRAULIC TANK

Figure 63. Hydraulic Tank for Lift Trucks

J4.0-5.0XN (J80-100XN) (A970)

Painting Instructions
WARNING CAUTION
Always wear protection equipment (gloves, DO NOT paint the pads, plastic covers or
goggles, face shield, safety glasses, and a knobs, cables, labels, and information plates,
mask) if an electric sander is used or spraying or controls. Paint can make some assemblies
paint, using either an aerosol can or spray gun. not operate correctly.

4. Paint surfaces. Use the correct paint from your

WARNING dealer for Hyster lift trucks. Follow the direc-
Always use solvents and paints in an area with tions on the container. The correct arrangement
ventilation. DO NOT use solvents or paints of colors is shown in Figure 64.
near heat, fire, or electrical equipment that
can make sparks. Follow the manufacturer’s
instructions and cautions. WARNING
Make sure all labels are installed after painting
1. Remove all dirt from surface to be painted. Clean is complete. Safety labels are installed on the
the area to be painted. Use a solvent for painted lift truck to provide information about possible
surfaces to remove grease and oil before sanding. hazards. It is important that all safety labels
DO NOT use solvent on new paint. Make sure are installed on the lift truck and can be read.
all oil and grease is removed.
5. Check that all labels are installed in the correct
2. Use sandpaper to remove top surface of the paint locations on the lift truck. See Safety Label Re-
and rust from metal. All metal surfaces where placement. New labels are available from your
paint is completely removed, must be painted. dealer for Hyster lift trucks.
Use a primer. Apply primer before applying final
coat of paint.

3. Protect all surfaces that will not be painted. See

the list of items in Figure 64.

73
Painting Instructions 100 SRM 1342

Figure 64. Color Arrangement

74
100 SRM 1342 Safety Label Replacement

Legend for Figure 64

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

See Figure 69 for lift truck models
WARNING • E2.2-3.5XN (E45-70XN) (A268)
Labels that have WARNINGS or CAUTIONS • E1.6-2.0XN (E30-40XN) (A269)
must be replaced if they are damaged. If a
mast of a different size or an accessory car- See Figure 70 for lift truck models
riage is installed, the capacity rating can • J2.2-3.5XN (J45-70XN) (A276)
change. Changes in the kind of drive tires can • J4.0-5.0XN (J80-100XN) (A970)
change the capacity rating. See a dealer for
HYSTER lift trucks for a replacement Name- See Figure 71 for lift truck models
plate. The Nameplate information is a safety • J2.2-3.5XN (J45-70XN) (A276)
item and must be correct for the equipment • J4.0-5.0XN (J80-100XN) (A970)
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.

See Figure 65 for lift truck models 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-
See Figure 66 for lift truck models 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.
See Figure 67 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)

See Figure 68 for lift truck models

• J4.0-5.0XN (J80-100XN) (A970)

75
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 65. Interior Labels for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269)

76
100 SRM 1342 Safety Label Replacement

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 66. Exterior Labels for Lift Truck E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269)

77
Safety Label Replacement 100 SRM 1342

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 67. Safety Labels for Lift Truck J2.2-3.5XN (J45-70XN) (A276)

78
100 SRM 1342 Safety Label Replacement

1. MAST WARNING LABEL 9. LIFTING EYE***

2. OPERATOR RESTRAINT 10. MODEL LABEL
3. OVERHEAD GUARD TEST PLATE* 11. HYSTER LOGO
4. OPERATOR WARNING LABEL** 12. FIRE SAFETY LABEL*
5. AUTOMATIC PARKING BRAKE RELEASE 13. NO RIDERS
CAUTION 14. NO ONE ON OR UNDER FORKS
6. BATTERY SPACER 15. PINCH POINT
7. OPERATORS MANUAL WARNING 16. NAMEPLATE
8. HYSTER COUNTERWEIGHT LOGO (OPTIONAL) 17. VERTICAL HYSTER LOGO

*LEFT SIDE OF LIFT TRUCK

**RIGHT SIDE OF LIFT TRUCK

***EUROPE ONLY

****US ONLY

Figure 68. Safety Labels for Lift Trucks J4.0-5.0XN (J80-100XN) (A970)

79
Safety Label Replacement 100 SRM 1342

NOTE: SEAT AND LEVERS ONLY SHOWN FOR CLARITY.

1. LIFT/LOWER SYMBOL 3. AUX SYMBOLS
2. TILT SYMBOL

Figure 69. Labels - Mini and Manual Levers for Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and
E1.6-2.0XN (E30-40XN) (A269)

80
100 SRM 1342 Safety Label Replacement

NOTE: 3-FUNCTION AND 4-FUNCTION MANUAL LEVERS SHOWN.

1. LIFT 3. AUXILIARY
2. TILT

Figure 70. Labels - Manual Levers for Lift Truck J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN
(J80-100XN) (A970)

81
Safety Label Replacement 100 SRM 1342

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 71. Labels - Mini Levers for Lift Truck J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN
(J80-100XN) (A970)

82
100 SRM 1342 Battery Specifications

Battery Specifications
Table 5. 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)
E2.2XN-E2.5XN 781 x 987 mm 978/983 mm 739/777 mm 1150 kg 1600 kg
(E45XN-E50XN) (30.7 x 38.9 in.) (38.5/38.7 in.) (29.1/30.6 in.) (2535 lb) (3527 lb)
E2.2XN-E3.0XN 842 x 987 mm 978/983 mm 800/838 mm 1317 kg 1771 kg
(E45XN-E60XN) (33.1 x 38.9 in.) (38.5/38.7 in.) (31.5/32.9 in.) (2903 lb) (3904 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 1010 x 987 mm 978/983 mm 1001/1006 mm 1550 kg 2000 kg
(E65-70XN) (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.

83
Battery Specifications 100 SRM 1342

Table 6. J2.2-3.5XN (J45-70XN) (A276) Model Trucks

Minimum
Battery Size Min/Max Weight
Compartment
Model
Size
Length × Width Length Width Minimum Maximum

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: 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.

Table 7. E1.6-2.0XN (E30-40XN) (A269) Model Trucks

Minimum
Battery Size Min/Max Weight
Compartment
Model
Size
Length × Width Length Width Minimum Maximum

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: 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.

84
100 SRM 1342 Battery Specifications

Table 8. J80-100XN (A970) Model Trucks

Minimum
Battery Size Min/Max Weight
Compartment
Model
Size
Length × Width Length Width Minimum Maximum

J80-100XN 861/1034 mm 852/855 mm 1025/1028 mm 2021 kg 2233 kg

(34.0/40.7 in.) (33.5/33.6 in.) (40.4/40.5 in.) (4456 lb) (4923 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.

Table 9. J4.0-5.0XN (A970) Model Trucks

Minimum
Battery Size Min/Max Weight
Compartment
Model
Size
Length × Width Length Width Minimum Maximum

J4.0-5.0XN 861/1034 mm 852/855 mm 1025/1028 mm 1770 kg 1956 kg

(34.0/40.7 in.) (33.5/33.6 in.) (40.4/40.5 in.) (3902 lb) (4312 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.

85
Torque Specifications for Lift Truck J4.0-5.0XN (J80-100XN) (A970) 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 COUNTERWEIGHT
Front Overhead Guard Leg Capscrews Mounting Bolts
66 N•m (49 lbf ft) 755 N•m (557 lbf ft)

Rear Overhead Guard Leg Capscrews

270 N•m (199 lbf ft)

Handle Capscrews
12 N•m (106.2 lbf in)

Torque Specifications for Lift Truck J4.0-5.0XN (J80-100XN) (A970)

OVERHEAD GUARD Handle Capscrews
19.2 N•m (169.9 lbf in)
Front Overhead Guard Leg Capscrews
66 N•m (49 lbf ft) COUNTERWEIGHT
Rear Overhead Guard Leg Capscrews Mounting Bolts
297 to 303 N•m (219 to 223 lbf ft) 755 N•m (557 lbf ft)

86
 TECHNICAL PUBLICATIONS

100 SRM 1342 3/12 (1/11)(7/10)(9/09)(9/08) Printed in United Kingdom