ELECTRICAL SYSTEM

E4.0-5.5XN, E5.0XNS   (E80-120XN,
E100XNS)  [A099];
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. 1688880   2200 SRM 1369

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

• The Service Manuals are updated on a regular basis, but may not reflect recent design
changes to the product. Updated technical service information may be available from your
local authorizedHyster® dealer. Service Manuals provide general guidelines for
 
maintenance and service and are intended for use by trained and experienced technicians.
Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• 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
background. The CAUTION symbol and word are on yellow background.

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
©2014  HYSTER COMPANY
TABLE OF CONTENTS
General
Discharging the Capacitors
Display Panel and Key or Keyless Switch Replacement
Display Panel, Replace
Remove
Install
Electronic and Manual Hydraulic Controls
General
Manual Hydraulic Controls
Upper Front Cover
Direction Control Switch
Remove
Install
Clamp Button
 TABLE OF CONTENTS
Remove
Install
Emergency Disconnect Switch
Remove
Install
E-Hydraulic Controls - Test
Mini-Levers
Full Stroke Test
Function Returns to Neutral Test
Push Button Switch
E-Hydraulic Controls
Mini-levers, Remove and Install
Armrest Assembly
Remove
Install
Horn Button
Remove
Install
Direction Control Switch
Remove
Install
Emergency Disconnect Switch
Remove
Install
Momentary Switches and Function Selection Button
Remove
Install
Sensors and Switches
General
Synchronous Steering Valve
Steering Axle Sensor
Remove
Install
Hydraulic Motor Speed Sensor
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
Remove
Install
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
 TABLE OF CONTENTS
Remove
Install
Hydraulic Motor Temperature Sensor
Hydraulic Tank Level Sensor
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
Remove
Install
Lift Truck Models E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove
Install
Hydraulic Filter Sensor
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models and E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269)
Remove
Install
Hydraulic Oil Temperature Sensor
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Traction Speed Sensor
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove
Install
Traction Motor Temperature Sensor
Tilt Position Sensor , and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Tilt Position Sensor E1.6-2.0XN (E30-40XN) (A269)
Remove
Install
 TABLE OF CONTENTS
Tilt Position Sensor E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove
Install
Low Level Brake Fluid Switch for Lift Truck Models , , and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Low Level Brake Fluid Switch for Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
Remove
Install
Service Brake Pressure Sensor for Lift Truck Models , , and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Service Brake Pressure Sensor for Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
Remove
Install
Accelerator Pedal Position Sensor
Remove
Install
Seat Sensor (Operator Presence System)
Non-Suspension Seat
Remove
Install
Full Suspension and Swivel Seats
Remove
Install
Steering Direction Sensor
Remove
Install
Load Weight Sensor
Remove
Install
Battery Gate Switch
Lift Truck Models and E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269),
Remove
Install
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Horn Switch
Fixed Steering Column
Remove
Install
 TABLE OF CONTENTS
Telescopic Steering Column
Remove
Install
Impact Sensor
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Remove
Install
Lift Truck Models and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove
Install
Rear and Hood Horn Button Switches
Rear Horn Button Switch
Remove
Install
Hood Horn Button Switch
Remove
Install
Motor Controllers Replacement
General
Lift Truck Models and E2.2-3.5XN (E45-70XN) (A268)
Traction Motor and Hydraulic Pump and Motor Controllers
Remove
Install
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)
Hydraulic Pump and Motor Controller
Remove
Install
Traction Motor Controllers
Remove
Install
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Traction Motor and Hydraulic Pump and Motor Controllers
Remove
Install
Line Contactor
Remove
Install
Fans for Lift Truck Models , , and E2.2-3.5XN (E45-70XN) (A268)
Remove
Install
Fans for Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
 TABLE OF CONTENTS
Remove
Install
Vehicle System Manager
General
Remove
Install
Programming a New VSM and/or Display Panel
PC Service Tool Software
Fuses and Relays
Fuses
Relays
Backup Alarm
Battery Connection
Inspect
Replacing Cables
Cab Heater
Lights
General
Work Lights (Front and Rear)
Halogen Bulb Lights
Remove
Install
LED Lights
Remove
Install
Strobe Light
Remove
Install
LED Tail, Backup, and Brake Lights
Remove
Install
Front Marker/Turn Signal Lights
Remove
Install
Dome Light
Remove
Install
Converter
Remove
Install
  This section is for the following models:  
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)  [A099];
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]

General
The removal and replacement procedures for the following electrical components are
covered in this service manual:
•   Display panel
•   Electronic and manual hydraulic control components
•   Motor controllers
•   Sensors and switches
•   Lights
•   Fuses, alarm and horn
•   Battery
•   Vehicle System Manger (VSM)
For adjustment procedure for switches located on linkage for manual control valve,
See Main Control Valves 2000SRM1334 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Main Control Valves 2000SRM1439 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
If lift truck is equipped with an E-Hydraulic control valve, see section below for
replacement procedures for Electro-Hydraulic Valve Driver Module:
See Main Control Valves 2000SRM1334 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Main Control Valves 2000SRM1439 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
For information on servicing and maintaining AC hydraulic pump motor for all lift
truck models covered in this manual and for traction motor on lift truck models E2.2-
3.5XN (E45-70XN) (A268), see AC Motor Repair 0620SRM1385.
For information on battery for all lift truck models covered in this manual
see Industrial Battery 2240SRM0001.
For information on servicing and maintaining transaxle motors:
See Transaxle 1300SRM1370 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Transaxle 1300SRM1539 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
See Drive Axle, Speed Reducer, and Differential 1300SRM1366 for lift truck
models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
If any of wire harnesses need to be repaired, see Wire Harness
Repair 2200SRM1128 for repair procedures.
Some components used are made of plastic. When using screws to replace and install
plastic components, screws should be rotated counterclockwise until screw thread
turns over the last thread in the plastic part. The screw can then be turned clockwise to
make a connection. This prevents "cutting" new threads and damaging existing thread
in plastic components.
If any welding must be done, obtain proper authorization from a Resident Service
Engineer. If authorization is given, be sure to follow procedures
in WARNING and CAUTIONS below.

  WARNING 
Forklift frames and components may be painted with a catalyzed paint
such as polyurethane or a two-part primer. Welding, burning, or other
heat sufficient to cause thermal decomposition of the paint may release
isocyanates. These chemicals are allergic sensitizers to the skin and
respiratory tract and overexposure may occur without odor warning.
Should work be performed, utilize good industrial hygiene practices
including removal of all paint (prime and finish coats) to the metal
around the area to be welded, local ventilation, and/or supplied-air
respiratory protection.

  CAUTION
When an arc welder is used, always disconnect the battery connector on
the lift truck. This action will prevent damage to the motor controllers.
Connect the ground clamp for the arc welder as close as possible to the
weld area. This action will prevent damage to a bearing from the large
current from the welder.
Before performing arc welding repairs, disconnect motor controller and VSM
connections to prevent damage to motor controllers and VSM. See sections Motor
Controllers Replacement and Vehicle Systems Manager for procedures.
DISCHARGING THE CAPACITORS

  WARNING 
DO NOT make repairs or adjustments unless you have been properly
trained and authorized to do so. Improper repairs and adjustments can
create dangerous operating conditions. DO NOT operate a lift truck that
needs repairs. Report the need for repairs to your supervisor
immediately. If repair is necessary, attach a DO NOT OPERATE tag on
the steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to discharge before
opening any compartment covers or inspecting or repairing the
electrical system. DO NOT place tool on top of the battery. If a tool
causes a short circuit, the high current flow from the battery can cause
personal injury and property damage.
Some checks and adjustments are performed with the battery
connected. DO NOT connect the battery until the procedure instructs
you to do so. Never wear any metallic items on your fingers, arms, or
neck. Metal items can accidentally make an electrical connection and
cause injury.
Before performing any tests or adjustment, block the lift truck to prevent
unexpected movement.
The capacitor in the transistor controller(s) can hold an electrical charge
for about 10 seconds after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge the capacitor(s) before
inspecting or repairing any component in the drive unit compartment.
Make certain that the battery has been disconnected.
DO NOT short across the motor controller terminals with a screwdriver
or jumper wire.
Make certain the Emergency-Disconnect switch has not been activated.
This will isolate the controllers and prevent the capacitors from
discharging properly. The proper way to disconnect the battery is by
separating the battery connectors.
1.   
Ensure capacitors are discharged by performing Step 2 through Step 6 below.
2.   
Turn key or keyless switch to OFF position.
3.   
Disconnect battery by separating connectors.
4.   
Block drive wheels to prevent lift truck from moving.
5.  Make sure Emergency-Disconnect switch HAS NOT been activated. If Emergency-
 
Disconnect switch is activated, rotate switch to the right until it pops up.
6.    Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.
If a torque value is not specified, go to Metric and Inch (SAE)
Fasteners 8000SRM0231 for torque values.

Display Panel and Key or Keyless Switch Replacement

DISPLAY PANEL, REPLACE
Remove

  WARNING 
Before replacing the display panel, fully lower all parts of the mast and
tilt it forward until the tips of the forks touch the ground. This action will
prevent the mast from lowering suddenly if the control lever is
accidently moved.

  WARNING 
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.
Discharge capacitors as directed in Discharging the Capacitors in
General section of this manual.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors do not touch the other meter terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.
NOTE:  The display panel cannot be repaired and must be replaced as a unit, if it has
a malfunction. See Parts Manual for replacement part number. The key or keyless
switch can be replaced without replacing the whole display panel.
The high mount display panel is mounted inside of a display panel cover. The display
panel cover is mounted to a bracket on upper right corner of overhead guard.
See Figure 1.
The optional low mount display panel is mounted inside of a display panel cover. The
display panel cover is mounted on a bracket which is mounted in the middle of the
right front leg of the overhead guard. See Figure 2.

NOTE: STANDARD KEY SWITCH SHOWN.

1.   OVERHEAD GUARD
2.   DISPLAY PANEL
3.   DISPLAY PANEL COVER
4.   KEY OR KEYLESS SWITCH
5.   SLOT
Figure 1. High Mount Display Panel Arrangement
1.   MOUNTING BRACKET
2.   OVERHEAD GUARD
3.   DISPLAY PANEL COVER
4.   DISPLAY PANEL
5.   KEY OR KEYLESS SWITCH
6.   SLOT
Figure 2. Low Mount Display Panel Arrangement
1.    Read and follow WARNING and CAUTION above.
2.    Insert a flat head screwdriver in slot on the bottom of display panel.
See Figure 1 for high mount display panel.
See Figure 2 for low mount display panel.
3.  Pull screwdriver down to loosen display panel from slot. When display panel is loose from
 
slot, pull display panel out of display panel cover. See Figure 3.
NOTE: HIGH MOUNT DISPLAY PANEL SHOWN. LOW MOUNT IS SIMILAR.
1.   TOP NOTCHES 4.   BOTTOM NOTCH
2.   TOP SLOTS 5.   BOTTOM SLOT
3.   DISPLAY PANEL COVER 6.   DISPLAY PANEL
Figure 3. Display Panel Removal
4.  When display panel is pulled from display panel cover, the warning buzzer will disconnect
 
from the rear of display panel. See Figure 4.
NOTE: REAR OF DISPLAY PANEL AND DISPLAY PANEL COVER SHOWN.
SOME ELECTRICAL COMPONENTS AND CONNECTIONS OMITTED FOR
CLARITY.
1.   WARNING BUZZER
2.   DISPLAY PANEL
3.   DISPLAY PANEL COVER
4.   DISPLAY WIRE HARNESS
5.   WARNING BUZZER ELECTRICAL CONNECTION
Figure 4. Warning Buzzer
5.  Disconnect display wire harness from pin connector on the back of display panel. Remove
 
display panel from lift truck. See Figure 5.

1.   PIN CONNECTOR
2.   KEY SWITCH
Figure 5. Disconnecting Display Panel
6.  Remove key or keyless switch from display panel by pinching in on the pinch points and
 
pulling key or keyless switch from display panel. See Figure 6.
NOTE: BACK SIDE OF DISPLAY PANEL SHOWN.
1.   PIN CONNECTOR
2.   PINCH POINTS
3.   KEY OR KEYLESS SWITCH COVER
Figure 6. Key or Keyless Switch Removal
Install

NOTE:  If switch being installed uses a key, insert key into switch first. This will help
install switch into display panel. If switch is keyless, use knob to help install switch
into display panel.
NOTE:  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with
Outdoor Protection/ Wash-down Package, apply dielectric grease to the key switch
terminals.
1.  Take new key or keyless switch and install into display panel. Match notches on the switch
 
with holes on the switch cover. See Figure 6 and Figure 7. Switch will snap into place.
NOTE: KEY SWITCH SHOWN.
1.   KEY SWITCH
2.   DISPLAY PANEL
3.   NOTCH
Figure 7. Key or Keyless Switch Installation
NOTE:  Perform Step 2 for lift truck models J2.2-3.5XN (J45-70XN) (A276),
equipped with Outdoor Protection/Wash-down Package.
2.    Apply dielectric grease to display wire harness connector.
3.    Connect display wire harness to pin connector on the back of display panel. See Figure 5.
4.    Connect warning buzzer to the back of display panel. See Figure 4.
5.    Insert notches on top of display panel into slots on top of display panel cover. See Figure 3.
6.  Push in bottom of display panel until notch on the bottom slides into slot on the bottom and
 
display panel locks into place inside cover. See Figure 3.
Electronic and Manual Hydraulic Controls
GENERAL

  WARNING 
Before replacing any part of the electronic or manual hydraulic control
assembly, fully lower all parts of the mast and tilt it forward until the tips
of the forks touch the ground. This action will prevent the mast from
lowering suddenly if the control lever is accidently moved.
   WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
General section of this manual.
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.

  WARNING 
Never wear any metallic items on your fingers, arms, or neck. Metal
items can accidently make an electrical connection and cause an injury.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors do not touch the other metal terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.
The lift trucks covered in this service manual come standard with manual hydraulic
control levers, but have the option of using electronic-hydraulic (E-Hydraulic) mini-
lever controls. In each hydraulic control arrangement, there are several electronic
component parts that can be replaced if they are no longer working properly. These
components are:
• Direction Control Switch - The direction control switch is an optional feature and is used
  to select the direction of travel when lift truck is equipped with a standard accelerator
pedal.
• Emergency Disconnect Switch - The emergency disconnect switch is used to disconnect
all electrical power to lift truck. The switch is operated by pushing the button down until it
 
clicks. To reset (re-connect) emergency disconnect switch and energize electrical circuits,
turn switch clockwise until button pops up.
• Horn Button
- These buttons are used to sound the horn. On lift trucks equipped with E-Hydraulic mini-
  levers, there is an optional horn button on the armrest.
To replace horn switch on steering wheel or optional rear horn button on rear right
overhead guard leg or on hood, see Sensors and Switches section in this manual.
•   Clamp Button - The lift trucks covered in this service manual may be equipped with a
clamp function. On lift trucks equipped with manual hydraulic control levers, if lift truck is
equipped with three levers, the button for clamp function is located on top of the third
lever. If lift truck has four levers, the clamp button is on top of the fourth lever.
For lift trucks equipped with E-Hydraulic mini-levers, if lift truck is equipped with three
mini-levers, the momentary switch for clamp function is located behind third lever on the
 palm rest. If lift truck has four levers, the momentary switch is located behind fourth lever
on the palm rest.
When removing and replacing sensors or switches, be sure to tag connectors to aid in
correct installation.
MANUAL HYDRAULIC CONTROLS
Upper Front Cover

NOTE:  To replace direction control switch, emergency disconnect switch, and the
clamp button, the upper front cover must be removed first from manual hydraulic
control lever assembly as described below.
1.    Read and follow WARNING and CAUTION section in General section above.
2.    Remove four capscrews and front cover from hydraulic lever assembly.
See Figure 8 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 9 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE: OPTIONAL DIRECTION CONTROL SWITCH AND CLAMP BUTTON
SHOWN. FOUR LEVERS SHOWN. IF LIFT TRUCK IS EQUIPPED WITH
THREE LEVERS, CLAMP BUTTON IS ON THE TOP OF THIRD LEVER.
1.   UPPER FRONT COVER
2.   CAPSCREWS
3.   LOWER COVER
4.   UPPER REAR COVER
5.   DIRECTION CONTROL SWITCH
6.   CLAMP BUTTON
7.   EMERGENCY DISCONNECT SWITCH
Figure 8. Manual Hydraulic Control Lever Assemble for Lift Truck
Models E2.2-3.5XN (E45-70XN) (A268), J2.2-3.5XN (J45-70XN) (A276),
J4.0-5.0XN (J80-100XN) (A970), and E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
NOTE: OPTIONAL DIRECTION CONTROL SWITCH AND CLAMP BUTTON
SHOWN. FOUR LEVERS SHOWN. IF LIFT TRUCK IS EQUIPPED WITH
THREE LEVERS, CLAMP BUTTON IS ON THE TOP OF THIRD LEVER.
1.   UPPER FRONT COVER
2.   CAPSCREWS
3.   LOWER COVER
4.   UPPER REAR COVER
5.   DIRECTION CONTROL SWITCH
6.   CLAMP BUTTON
7.   EMERGENCY DISCONNECT SWITCH
Figure 9. Manual Hydraulic Control Lever Assembly for Lift Truck
Model E1.6-2.0XN (E30-40XN) (A269)
3.    Using four capscrews, install front cover on hydraulic lever assembly.
See Figure 8 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 9 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
Direction Control Switch
Remove
1.    Read and follow WARNING and CAUTION section in General section above.
2.  Remove upper front cover. See section Upper Front Cover for procedures. Disconnect
 
manual control valve wire harness from direction control switch. See Figure 10.

1.   CLAMP BUTTON CONNECTOR

2.   EMERGENCY DISCONNECT SWITCH CONNECTOR
3.   DIRECTION CONTROL SWITCH CONNECTOR
4.   MANUAL CONTROL VALVE WIRE HARNESS
Figure 10. Manual Control Levers Assembly Electrical Components
3.  Remove two outer capscrews and lift/lower with direction control switch handle from
 
manual lift/lower lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
A. AUX HANDLE WITH DUAL B. LIFT/LOWER WITH DIRECTION CONTROL
  FUNCTION   SWITCH
1.   PALM SIDE GRIP HANDLE 9.   OUTER CAPSCREW
2.   CLAMP SWITCH HANDLE 10.   CABLE TRACK
3. LIFT/LOWER WITH DIRECTION CONTROL 11.   SCREW
  SWITCH HANDLE
12. DIRECTION CONTROL SWITCH
4.   MANUAL AUX 2 LEVER   RETAINER
5.   MANUAL LIFT LEVER 13. DIRECTION CONTROL SWITCH
  CUP
6.   DIRECTION CONTROL SWITCH
14.   PUSH-BUTTON CABLE
7.   CLAMPING PUSH-BUTTON
15. DIRECTION CONTROL SWITCH
8.   INNER CAPSCREW   CABLE
Figure 11. Manual Hydraulic Control Handles for Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268)J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-
100XN) (A970), and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
A.   AUX HANDLE WITH DUAL FUNCTION C.   DTR HANDLE WITH DUAL
B. LIFT/LOWER WITH DIRECTION CONTROL FUNCTION
  SWITCH
1.   PALM SIDE GRIP HANDLE 10.   CABLE TRACK
2.   CLAMP SWITCH HANDLE 11.   SCREW
3. LIFT/LOWER WITH DIRECTION CONTROL 12. DIRECTION CONTROL SWITCH
  SWITCH HANDLE   RETAINER
4.   MANUAL AUX 2 LEVER 13.   DIRECTION CONTROL SWITCH CUP
5.   MANUAL LIFT LEVER 14.   PUSH-BUTTON CABLE
6.   DIRECTION CONTROL SWITCH 15. DIRECTION CONTROL SWITCH
  CABLE
7.   CLAMPING PUSH-BUTTON
16. DRIVE-THRU RACK (DTR)
8.   INNER CAPSCREW   CLAMPING HANDLE
9.   OUTER CAPSCREW 17. DRIVE-THRU RACK (DTR)
  PALMSIDE HANDLE
18.   LEVER ASSEMBLY
Figure 12. Manual Hydraulic Control Lever Assembly for Lift Truck
Models E1.6-2.0XN (E30-40XN) (A269)
4.    Remove one inner capscrew and palm side grip handle from manual lift lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
5.    Remove direction control switch cable from cable track.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
6.  Remove two screws, direction control switch retainer, direction control switch cup, and
  direction control switch from lift/lower lever with direction control switch handle.
See Figure 13.
1.   SCREW
2.   DIRECTION CONTROL SWITCH RETAINER
3.   DIRECTION CONTROL SWITCH CUP
4.   DIRECTION CONTROL SWITCH CABLE
Figure 13. Direction Control Switch
Install

1.    Install direction control switch into direction control switch cup. See Figure 13.
2.  Install direction control switch cup and direction control switch into lift/lower direction
 
control switch handle. See Figure 13.
3.  Install direction control switch retainer onto back side of direction control switch cup,
 
inside lift/lower with direction control switch handle. See Figure 13.
4.  Install two screws through retainer and direction control switch cup into direction control
 
switch. See Figure 13.
5.    Route direction control switch cable through cable track on manual lift/lower lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
6.    Install palm side handle and one capscrew on manual lift/lower lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
7.  Install lift/lower with direction control switch handle and two outer capscrews on manual
 
lift/lower lever. Tighten outer capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
8.    Install upper front cover. See section Upper Front Cover for procedures.
Clamp Button
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove upper front cover. See section Upper Front Cover for procedures. Disconnect
 
manual control valve wire harness from clamp button. See Figure 10.
3.    Remove two outer capscrews and clamp switch handle from manual aux 2 lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Remove one inner capscrew and palm side grip handle from manual aux 2 lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
NOTE:  Perform Step 5 and Step 6 for lift truck models E1.6-2.0XN (E30-40XN)
(A269).
5.  Remove one outer capscrew and Drive-Thru Rack (DTR) clamping handle from lever
 
assembly. See Figure 12.
6.  Remove one inner capscrew and DTR Palmside handle from lever assembly.
 
See Figure 12.
7.    Remove push-button cable from cable track.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
Install

1.    Route push-button cable through cable track on manual aux 2 lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
2.    Install palm side handle and one inner capscrew on manual aux 2 lever.
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE:  Ensure clamping push-button is in correct position on clamp switch handle
by aligning notches and flats during assembly.
3.  Install clamp switch handle and two outer capscrews on manual aux 2 lever. Tighten outer
 
capscrews 1.35 to 1.65 N•m (11.9 to 14.6 lbf in).
See Figure 11 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 12 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE:  Perform Step 4 and Step 5 for lift truck models E1.6-2.0XN (E30-40XN)
(A269).
4.    Install DTR palmside handle and one inner capscrew on lever assembly. See Figure 12.
5.    Install DTR clamping handle and one outer capscrew on lever assembly. See Figure 12.
6.    Install upper front cover. See section Upper Front Cover for procedures.
Emergency Disconnect Switch
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove upper front cover. See section Upper Front Cover above for procedures.
3.  Remove five socket head capscrews from upper rear cover. See Figure 14. Pull cover
  rearward to generate enough space to disconnect emergency disconnect switch wires.
See Figure 10.

1.   SOCKET HEAD SCREWS

2.   UPPER REAR COVER
3.   LEVER LINKAGE
4.   MANUAL HYDRAULICS WIRE HARNESS
 Figure 14. Upper Rear Cover Removal
4.  Disconnect clamp function and direction control switch if lift truck is equipped with these
 
features. See Figure 10.
5.  Insert screwdriver or other flat tipped tool into slot on side of switch. Pull tool up to
  remove emergency disconnect switch, switch adapter, and lock from upper rear cover.
See Figure 15.
6.  Remove nut from upper rear cover. Remove emergency disconnect button and bushing
 
from hole in upper rear cover. See Figure 15.

NOTE: THE EMERGENCY DISCONNECT SWITCH SHOWN

IN FIGURE 15 IS ALSO USED ON LIFT TRUCKS EQUIPPED WITH E-
HYDRAULIC CONTROLS.
A.   INSERT SCREWDRIVER HERE
1.   EMERGENCY DISCONNECT SWITCH
2.   SWITCH ADAPTER
3.   LOCK
4.   NUT
5.   EMERGENCY DISCONNECT BUTTON
6.   BUSHING
7.   UPPER REAR COVER HOLE
Figure 15. Emergency Disconnect Switch Replacement
Install

1.  Insert emergency disconnect button and bushing into hole in upper rear cover.
  See Figure 15. Place nut on button and turn it clockwise to secure emergency disconnect
button and bushing in hole. Tighten nut to 2 N•m (18 lbf in).
NOTE:  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with
Outdoor Protection/Wash-down Package, apply dielectric grease to emergency
disconnect switch terminals.
2.    Connect wires to emergency disconnect switch. Tighten screws to 0.8 to 1.2 N•m (8.55 to
 10.7 lbf in).
3.  Install switch adapter and lock onto emergency disconnect button assembly. Install
  switches, by pushing switches onto switch adapter until switch clicks into place. Connect
main wire harness to emergency disconnect switch. See Figure 10.
4.  Connect clamp function and direction control switch if lift truck is equipped with these
 
functions. See Figure 10.
5.  Install and tighten five socket head capscrews to secure upper rear cover to manual lever
 
assembly. See Figure 15.
6.    Install upper front cover. See section Upper Front Cover for procedures.
E-HYDRAULIC CONTROLS - TEST
Mini-Levers

Perform all of the following test procedures to be sure mini-levers operate properly.
See User Interface 2200SRM1336 instructions to view Lever output Value. With
Service Password, view Diagnostics – Hydraulic Data Display – Hydraulic Input.
Full Stroke Test

Check for full stroke of mini-lever. Use DSC or install the Service Tool to monitor
functions.
1.  Stroke each lever to full stroke, forward and backward, and allow lever to snap back to
 
center.
2.    Turn key switch to ON position.
3.  Display electro-hydraulic diagnostics menu on dash display panel. Operate each lever to
full stroke forward and read input.
•   Is lever output = -92%?
 
•   YES: Go to Step 4.
• NO: Mini-lever not working properly. See procedures for each generation of MLM
 
for repair or replacement. Upon completion, rerun test.
4.  Operate each lever to full stroke backward and read input.
•   Is lever output = +92%?
  •   YES: Mini-lever is supplying full stroke.
• NO: Mini-lever not working properly. See procedures for each generation of MLM
 
for repair or replacement. Upon completion, rerun test.
5.  If mini-lever continues to not function properly, contact your local HYSTER dealer or
 
see Hyster Hypass Online.
Function Returns to Neutral Test

Check to confirm function returns to neutral (0%). Use DSC or install Service Tool to
monitor functions.
1.  Stroke each lever to full stroke, forward and backward, and allow lever to snap back to
 
center.
2.    Turn key switch to ON position.
3.  Display electro-hydraulic diagnostics menu on dash display panel.
•   Is each lever output = 0%?
  •   YES: Go to Step 4.
• NO: Mini-lever is not working properly. See procedures for each generation of
 
MLM for repair or replacement. Upon completion, rerun test.
4.  Operate each lever to full stroke forward and slowly release (1-2 seconds from full stroke).
Read output when fully released.
•   Is each lever output = 0%?
 
•   YES: Go to Step 5.
• NO: Mini-lever is not working properly. See procedures for each generation of
 
MLM for repair or replacement. Upon completion, rerun test.
5.  Operate each lever to full stroke back and slowly release (1-2 seconds from full stroke).
Read output when fully released.
•   Is each lever output = 0%?
 
•   YES: Mini-lever function is returning to neutral.
• NO: Mini-lever is not working properly. See procedures for each generation of
 
MLM for repair or replacement. Upon completion, rerun test.
6.  If mini-lever continues to not function, contact your local HYSTER dealer or see Hyster
 
Hypass Online.
Push Button Switch

1.    Check that push button switch operates properly by operating applicable function.
2.  If system does not function, see procedures for each generation of MLM for repair or
 
replacement. Upon completion, rerun test.
3.  If push button switch continues to not function properly, contact your
 
local HYSTER dealer or see Hyster Hypass Online.
E-HYDRAULIC CONTROLS

The lift trucks covered in this service manual may be equipped with optional E-
Hydraulic control mini-levers (see Figure 16). Each mini-lever can be replaced
separately if one malfunctions. Like manual control levers, E-Hydraulic control mini-
levers can be equipped with an optional clamp function (either the third or fourth
mini-lever). There is a momentary switch behind the mini-lever (either the third or
fourth mini-lever) that engages and disengages clamp function. If clamping function
quits working, mini-lever and momentary switch may need to be replaced. See
sections Mini-levers, Remove and Install and Momentary Switches and Function
Selection Button for replacement procedures.
1.   ARMREST
2.   EMERGENCY DISCONNECT SWITCH
3.   HORN BUTTON
4.   DIRECTION CONTROL SWITCH
5.   MINI-LEVERS
6.   WIRE HARNESS
7.   MOMENTARY SWITCHES
Figure 16. E-Hydraulic Controls Arrangement
Mini-levers, Remove and Install

  CAUTION
The following procedure should only be performed by Hyster trained
certified technicians. The removal and replacement of the mini-levers
should be done in a clean environment whenever possible and on an
electrically grounded surface. DO NOT touch any printed circuit board
(PCB) surface to prevent damage from electrostatic voltage.
1.    Read and follow WARNING and CAUTION section in General section above.
2.  Remove two capscrews that secure mini-lever to armrest. Remove mini-lever from
 
armrest. See Figure 17.
1.   CAPSCREWS
2.   MINI-LEVER
3.   ARMREST
4.   MOMENTARY SWITCH
Figure 17. Mini-Lever Removal
NOTE:  Before installing new mini-lever, check Parts Manual for correct part
number to be sure correct mini-lever is being installed.
3.    Install new mini-lever onto armrest using two capscrews.
Armrest Assembly
Remove

1.    Read and follow WARNING and CAUTION in General section above.

2.  Remove two capscrews from seat box cover and remove cover from seat box. Disconnect
 
main E-Hydraulic control wire harness from E-Hydraulic armrest harness. See Figure 18.
NOTE: COMPONENTS PARTS AND ELECTRICAL CONNECTIONS
OMITTED OR MOVED FOR CLARITY.
1.   SEAT BOX COVER
2.   CAPSCREWS
3.   SEAT BOX
4.   E-HYDRAULIC ARMREST HARNESS
5.   OPERATOR PRESENCE SYSTEM HARNESS
6.   ARMREST
Figure 18. Seat Box Cover Removal
3.  Pull up on handle (see Figure 20) and slide armrest all the way forward and remove flange
capscrew from under armrest mounting bracket that attaches armrest to mounting bracket.
 
Pull up on handle and slide armrest all the way back and remove other flange capscrew.
See Figure 19.
1.   E-HYDRAULIC CONTROL WIRE HARNESS
2.   FLANGE CAPSCREWS
3.   ARMREST
4.   ARMREST MOUNTING BRACKET
5.   HOLES FOR FLANGE CAPSCREWS
Figure 19. E-Hydraulic Armrest and Mounting Bracket
4.    Remove armrest from armrest mounting bracket.

A.   HANDLE MOVES ARMREST FORWARD OR BACKWARD

B.   HANDLE MOVES ARMREST UP OR DOWN
Figure 20. Armrest Adjustment Handles
5.  Remove six socket head screws that fasten bottom and top armrest covers together.
 
See Figure 21.
1.   SOCKET HEAD SCREWS
2.   BOTTOM ARMREST COVER
Figure 21. Bottom Armrest Cover Removal
6.  Remove five socket head capscrews from bottom armrest cover and armrest. Remove
 
bottom armrest cover.
NOTE:  The momentary switches and function selection button are optional features.
If lift truck is not equipped with these features, there will be a plug covering electrical
connector on PCB cassette.
7.  Disconnect momentary switches/function selection button connector from PCB cassette.
 
See Figure 22.
8.  Remove three socket screws from PCB cassette and remove PCB cassette from armrest.
 
See Figure 22.

1.   TO E-HYDRAULIC CONTROL WIRE HARNESS

2.   SOCKET HEAD SCREWS
3.   PCB CASSETTE
4.   MOMENTARY SWITCHES/FUNCTION SELECTION BUTTON CONNECTOR
Figure 22. PCB Cassette Removal
Install

1.    Install PCB cassette to armrest with three socket head screws. See Figure 22.
2.  If lift truck is equipped, connect momentary switches/function selection button connector
 
to PCB cassette. See Figure 22.
3.    Install bottom armrest cover to armrest with five socket head screws. See Figure 21.
4.  Install new armrest onto mounting bracket with flange capscrews. Tighten flange
 
capscrews to 13 to 15 N•m (115 to 132 lbf in).
5.  Install six socket head screws that fasten bottom and top armrest covers together.
 
See Figure 21.
6.  Connect E-hydraulic wire harness to armrest. See Figure 19. Install seat box cover to seat
 
box with two capscrews. See Figure 18. Tighten capscrews to 1.2 N•m (10.6 lbf in).
7.    Connect the battery.
Horn Button
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove armrest from armrest mounting bracket. Remove bottom armrest and PCB
 
cassette. See section Armrest Assembly for removal procedures.
3.  Remove two Phillips head screws that attach horn button to armrest. See Figure 23.
 
Remove horn button from armrest.
NOTE: MOMENTARY SWITCHES AND FUNCTION SELECTION BUTTON
CONNECTIONS NOT SHOWN FOR CLARITY. SEE FIGURE 27 FOR
MOMENTARY SWITCHES AND FUNCTION SELECTION BUTTON
CONNECTIONS.
1.   PHILLIPS HEAD SCREWS 6.   LOCK
2.   DIRECTION CONTROL SWITCH ADAPTER 7.   HORN SWITCH
3.   EMERGENCY DISCONNECT SWITCH 8.   ARMREST
4. EMERGENCY DISCONNECT SWITCH 9. DIRECTION CONTROL SWITCH
  ADAPTER   CONNECTOR
5.   NUT
Figure 23. Switch Arrangement and Connections, E-Hydraulic Mini-
Levers
Install

1.  Insert new horn switch into armrest and secure switch to armrest with two Phillips head
 
screws. See Figure 23.
2.  Install armrest and PCB cassette to armrest and install armrest to armrest mounting
 
bracket. See section Armrest Assembly for installation procedures.
Direction Control Switch
Remove
1.    Read and follow WARNING and CAUTION section in General section above.
2.  Remove armrest from armrest mounting bracket. Remove bottom armrest cover. See
 
section Armrest Assembly for removal procedures.
3.  Remove direction control switch assembly from armrest by compressing clips on either
  side of bezel and carefully pulling assembly out. Disconnect E-Hydraulic control wiring
harness from direction control switch. See Figure 24.

1.   DIRECTION CONTROL SWITCH

2.   BEZEL
3.   ARMREST
4.   E-HYDRAULIC CONTROL VALVE WIRING HARNESS
Figure 24. Direction Control Switch Replacement
4.    Remove direction control switch from bezel. See Figure 24.
Install

1.    Insert new direction control switch into bezel. See Figure 24.

2.  Connect E-Hydraulic control valve wiring harness to direction control switch. Install
  direction control switch assembly into armrest by compressing clips on either side of bezel
and pushing assembly into armrest until clips latch. See Figure 24.
3.  Install armrest cover to armrest, and install armrest to armrest mounting bracket. See
 
section Armrest Assembly for installation procedures.
Emergency Disconnect Switch

Both E-Hydraulic controls and manual hydraulic controls use the same emergency
disconnect switch. See Figure 25.
1.   HORN BUTTON
2.   EMERGENCY DISCONNECT SWITCH
3.   DIRECTION CONTROL SWITCH
Figure 25. Emergency Disconnect Switch Location, E-Hydraulic
Controls
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove armrest from armrest mounting bracket. Remove bottom armrest and PCB
 
cassette. See section Armrest Assembly for removal procedures.
3.    Disconnect wires from emergency disconnect switch.
4.  Insert screwdriver or other flat tipped tool into slot on side of switch (see Figure 15). Pull
  tool up to remove emergency disconnect switch, switch adapter, and lock from underneath
armrest.
5.  Remove nut from underneath armrest. Remove emergency disconnect button and bushing
 
from top part of armrest. See Figure 23.
Install

1.    Insert emergency disconnect button and bushing into hole in top part of armrest.
2.    Place nut on button and turn it clockwise to secure emergency disconnect button and
 bushing to armrest. Tighten nut to 2 N•m (18 lbf in). See Figure 15 or Figure 23.
3.  Install switch adapter and lock onto emergency disconnect button assembly. Install
 
switches, by pushing switches onto switch adapter until switches clicks into place.
4.  Connect wires to emergency disconnect switch. Tighten screws to 0.8 to 1.2 N•m (8.55 to
 
10.7 lbf in).
5.  Install armrest and PCB cassette to armrest and install armrest to armrest mounting
 
bracket. See section Armrest Assembly for installation procedures.
Momentary Switches and Function Selection Button

On lift trucks equipped with E-Hydraulic controls, there may be two optional
momentary switches (green buttons) and a function selection button (yellow button)
located behind the second, third, or fourth mini-lever. See Figure 26. The momentary
switch located behind the second mini-lever is used to override the Return To Set Tilt
(RTST) function. By pressing this switch, the RTST parameters are overridden and
the mast is allowed to tilt unrestricted.
If the lift truck is equipped with three mini-levers and a four function control valve,
there will be a function selection button behind the third mini-lever. Pressing this
button allows the third mini-lever to switch between the third and fourth functions. If
the lift truck is equipped with four mini-levers and a five function control valve, the
function selection button will be located behind the fourth mini-lever. Pressing the
button allows the fourth mini-lever to switch between the fourth and fifth functions.
If the lift truck is equipped with a clamp attachment, the last mini-lever on the right
controls the clamp function. Behind this lever will be a momentary switch. To engage
the clamp, move the mini-lever backward. To disengage the clamp, push the
momentary switch behind the mini-lever and move mini-lever forward.
The different configurations of switches and buttons discussed in this section may not
be found on your lift truck.
NOTE: ALL POSSIBLE MOMENTARY SWITCHES AND FUNCTION
SELECTION BUTTON CONFIGURATIONS SHOWN. NOT ALL LIFT TRUCK
MAY HAVE ALL SWITCHES AND BUTTONS SHOWN.
1.   MINI-LEVERS
2.   MOMENTARY SWITCH (RTST)
3.   FUNCTION SELECTION BUTTON
4.   MOMENTARY SWITCH (CLAMP)
5.   ARMREST HOUSING
Figure 26. Momentary Switches and Function Selection Button Location
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove armrest from armrest mounting bracket. Remove bottom armrest and PCB
 
cassette. See procedures in Armrest Assembly section above.
NOTE:  Tag wires prior to disconnecting them to aid in reconnecting.
3.  Pull momentary switches or function selection button connectors apart to disconnect them
 
from wire harness. See Figure 27.
4.  If momentary switch is being replaced, remove lock nut from back of green, round, push
 
button. Remove push button switch from armrest. See Figure 27.
NOTE:  Note the position of the yellow, rectangular, function button before removal
to aid in installation. See Figure 26.
5.    If function selection button is being replaced:
a.    Remove knurl nut. See Figure 27.
b.  Rotate red screw to left stop. Remove blue connector by sliding it from black cylinder.
 
See Figure 27.
c.    Remove function button from armrest.
1.   CLAMP BUTTON CONNECTION 5.   LOCK NUT
2.   RTST CONNECTION 6.   BLUE CONNECTOR
3.   FUNCTION SELECTION BUTTON CONNECTION 7.   KNURL NUT
4.   RED SCREW 8.   BLACK CYLINDER
Figure 27. Momentary Switches and Function Selection Button
Replacement
Install

1.    If installing a new function selection button:

a.    Insert black cylinder portion of function selection button through armrest housing.
b.    Slide blue connector onto cylinder. See Figure 27.
c.    Rotate red screw to right stop.
d.  Adjust position of yellow, rectangular function selection button. See Figure 26. Install and
 
tighten knurl nut to secure function selection button to armrest.
e.  Apply Nye 760G grease (supplied in kit) to function selection button switch connector.
 
Push function selection button connector to wire harness. See Figure 27.
2.    If installing a momentary switch:
a.    Install new green, round momentary switch assembly through armrest housing.
b.    Install and tighten lock nut to secure momentary switch to armrest. See Figure 27.
c.    Push momentary switch connector to wire harness. See Figure 27.
3.  Install armrest and PCB cassette to armrest and install armrest to armrest mounting
 
bracket. See section Armrest Assembly for installation procedures.
4.    Connect E-hydraulic wire harness to armrest. See Figure 19.
Sensors and Switches
GENERAL

  WARNING 
Before replacing any sensor or switch, fully lower all parts of the mast
and tilt it forward until the tips of the forks touch the ground. This action
will prevent the mast from lowering suddenly if the control lever is
accidently moved.
Never have any metal on your fingers, arms, or neck. These metal items
can accidentally create an electrical connection and cause an injury.

  WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
General section of this manual.
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors DO NOT touch the other metal terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.
All sensors and switches used on these trucks are non-repairable parts. Replace with
new sensors or switches whenever a sensor or switch malfunctions and is not
operating correctly. See Parts Manual for replacement part numbers. Before
installing new sensors or switches, use a clean cloth and make sure area around sensor
or switch is clean and free of oils and contaminates.
Lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
Wash-down Package will have sealed wiring harnesses as well as light switches and
windshield wiper switches that are fully sealed.
When removing and replacing sensors or switches, be sure to tag connectors to aid in
correct reconnecting.
SYNCHRONOUS STEERING VALVE

On lift trucks equipped with E-Hydraulics and Synchronous Steering, refer

to Steering System 1600SRM1363 prior to removing Synchronous Steering Valve
Kit.
STEERING AXLE SENSOR

The steering axle sensor is located on right side of steering axle.

The steering axle sensor is an optional feature on lift truck model
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 28 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 29 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 30 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Put lift truck on jacks or blocks and remove right steer tire and wheel.
See Periodic Maintenance 8000SRM1364 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
See Periodic Maintenance 8000SRM1577 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
3.    Disconnect steering wire harness from steering axle sensor.
See Figure 28 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 29 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 30 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Remove flange capscrew and protective cover from steering axle.
5.    Remove two socket head screws and sensor from steering axle.
See Figure 28 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 29 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 30 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
1.   PROTECTIVE COVER 4.   STEERING AXLE SENSOR
2.   FLANGE CAPSCREW 5.   STEERING WIRE HARNESS CONNECTOR
3.   SOCKET HEAD SCREWS
Figure 28. Steering Axle Sensor Replacement, Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268)
1.   PROTECTIVE COVER 4.   STEERING AXLE SENSOR
2.   FLANGE CAPSCREW 5.   STEERING AXLE SENSOR CONNECTOR
3.   SOCKET HEAD SCREWS
Figure 29. Steering Axle Sensor Replacement, Lift Truck Models J2.2-
3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
1.   PROTECTIVE COVER 4.   STEERING AXLE SENSOR
2.   FLANGE CAPSCREW 5.   STEERING AXLE SENSOR CONNECTOR
3.   SOCKET HEAD SCREWS
Figure 30. Steering Axle Sensor Replacement, Lift Truck Model E4.0-
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Install

1.    Using two socket head screws, install new sensor onto steering axle.
See Figure 28 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 29 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 30 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
2.  Connect steering wire harness to steering axle sensor. Install protective cover to steering
 
axle with flange capscrew.
3.    Install wheel and tire to steering axle and remove lift truck from blocks.
See Periodic Maintenance 8000SRM1364 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
See Periodic Maintenance 8000SRM1577 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Connect the battery.
HYDRAULIC MOTOR SPEED SENSOR
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    For lift trucks manufactured before June 2012:
a.    Remove floor mat. Remove rear floor plate.
b.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
  to disconnect accelerator pedal or MONOTROL® pedal. Remove front floor plate with
accelerator orMONOTROL® pedal still attached. See Figure 31.
3.    For lift trucks manufactures after June 2012:
a.    Remove floor mat. Remove rear floor plate.
b.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
  Remove front floor plate with accelerator or MONOTROL® pedal still attached.
See Figure 32.
Figure 31. Removing Floor Plate and Accelerator or MONOTROL® Pedal,
Manufactured Before June 2012
 Legend for Figure 31
A.   STANDARD ACCELERATOR PEDAL B.   MONOTROL® PEDAL
1.   FRONT FLOOR PLATE 5. CAPSCREW, WASHER, NUT (FRONT FLOOR
  PLATE)
2.   CAPSCREW AND NUT (PEDAL BASE)
6.   REAR FLOOR PLATE
3.   PEDAL BASE
7.   MONOTROL® PEDAL CONNECTOR
4. ACCELERATOR PEDAL POSITION
  SENSOR
A.   STANDARD ACCELERATOR PEDAL B.   MONOTROL® PEDAL
1.   FRONT FLOOR PLATE 4.   ACCELERATOR PEDAL POSITION SENSOR
2.   CAPSCREW AND NUT (PEDAL BASE) 5.   REAR FLOOR PLATE
3.   PEDAL BASE 6.   MONOTROL® PEDAL CONNECTOR
Figure 32. Removing Floor Plate and Accelerator or MONOTROL® Pedal,
Manufactured After June 2012
4.    Disconnect main wire harness from hydraulic motor speed sensor.
5.  If lift truck is equipped with an 80 volt hydraulic pump motor, there is a shroud that covers
  hydraulic motor speed sensor that must be removed first. To remove shroud, perform the
following:
a.  Remove three hex nut and hex bolts from mounting bracket. Remove mounting bracket
 
from shroud. See Figure 33.
b.  Remove two Allen head screws from each side of shroud. Remove shroud from hydraulic
 
pump motor. See Figure 33.

1.   HEX BOLT
2.   HEX NUT
3.   MOUNTING BRACKET
4.   SHROUD
5.   ALLEN HEAD SCREW
6.   HYDRAULIC MOTOR SPEED SENSOR WIRE
Figure 33. Shroud Removal
6.  Remove socket head screw, hydraulic motor speed sensor, and hydraulic motor speed
 
sensor connector from hydraulic motor. See Figure 34.
1. HYDRAULIC MOTOR SPEED 3. HYDRAULIC MOTOR TEMPERATURE SENSOR
  SENSOR   CONNECTOR
2.   SOCKET HEAD SCREW 4.   HYDRAULIC MOTOR SPEED SENSOR CONNECTOR
Figure 34. Hydraulic Motor Speed Sensor, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268)
Install

1.  Install new hydraulic motor speed sensor and hydraulic motor speed sensor connector into
 
hydraulic motor. See Figure 34.
2.    Attach hydraulic motor speed sensor to hydraulic motor with socket head screw.
3.    Connect main wire harness to hydraulic motor speed sensor.
4.  If lift truck is equipped with an 80 volt hydraulic pump motor, install shroud over the
 
hydraulic motor speed sensor. To install shroud, perform the following:
a.    Install shroud to hydraulic pump motor using two Allen head screws. See Figure 33.
b.    Install mounting bracket to bottom of shroud using three hex bolts and hex nuts.
 See Figure 33. Tighten hex nuts and bolts to 60 to 70 N•m (44 to 52 lbf ft).
5.    Connect accelerator pedal or MONOTROL® pedal, (see Figure 31).
Install front floor plate using capscrews and washers for lift truck models E2.2-3.5XN
(E45-70XN) (A268) manufactured before June 2012.
No hardware is required to install front floor plate for lift truck models E2.2-3.5XN
(E45-70XN) (A268) manufactured after June 2012.
6.    Install rear floor plate. Install floor mat and connect the battery.
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove tow pin and counterweight cover from counterweight. See Figure 35.

1.   COUNTERWEIGHT
2.   COUNTERWEIGHT COVER
3.   WASHER
4.   CAPSCREW
5.   TOW PIN
 Figure 35. Tow Pin and Counterweight Cover Removal, Lift Truck
Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
3.    Disconnect hydraulic motor speed sensor wire harness. See Figure 36.
4.  Remove socket head screw and hydraulic motor speed sensor from hydraulic motor.
 
See Figure 36.

NOTE:  J2.2-3.5XN (J45-70XN) (A276) SHOWN. J4.0-5.0XN (J80-100XN)

(A970) IS SIMILAR.
1. HYDRAULIC MOTOR SPEED 3. HYDRAULIC MOTOR TEMPERATURE SENSOR
  SENSOR   CONNECTOR
2.   SOCKET HEAD SCREW 4.   HYDRAULIC MOTOR SPEED SENSOR CONNECTOR
Figure 36. Hydraulic Motor Speed Sensor, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Install

1.  Install new hydraulic motor speed sensor and connector into hydraulic motor.
 
See Figure 36.
2.    Attach hydraulic motor speed sensor to hydraulic motor with socket head screw.
3.    Connect main wire harness to hydraulic motor speed sensor.
4.    Install counterweight cover and tow pin. See Figure 35.
5.    Connect the battery.
Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Disconnect and remove battery. See Periodic Maintenance 8000SRM1442 for
 
procedures.
3.    Remove battery tray with rollers. See Frame 0100SRM1342 for procedures.
4.    Disconnect hydraulic motor speed sensor wire harness. See Figure 37.

1. HYDRAULIC MOTOR SPEED 3. HYDRAULIC MOTOR TEMPERATURE SENSOR

  SENSOR   CONNECTOR
2.   SOCKET HEAD SCREW 4.   HYDRAULIC MOTOR SPEED SENSOR CONNECTOR
Figure 37. Hydraulic Motor Speed Sensor for Lift Truck Model E1.6-
2.0XN (E30-40XN) (A269)
5.  Remove socket head screw and hydraulic motor speed sensor from hydraulic motor.
 
See Figure 37.
Install

1.    Install new hydraulic motor speed sensor and socket head screw. See Figure 37.
2.    Connect hydraulic motor speed sensor wire harness. See Figure 37.
3.    Install battery tray with rollers. See Frame 0100SRM1342 for procedures.
4.    Install and connect battery. See Periodic Maintenance 8000SRM1442 for procedures.
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove floor mat. Remove rear floor plate.
Lift front floor plate up enough to disconnect accelerator pedal or Monotrol® pedal.
See Figure 38. Remove front floor plate with accelerator or Monotrol® pedal still
attached.
A.   STANDARD ACCELERATOR PEDAL
B.   MONOTROL® PEDAL
1.   FRONT FLOOR PLATE
2.   CAPSCREW AND NUT (PEDAL BASE)
3.   PEDAL BASE
4.   ACCELERATOR PEDAL POSITION SENSOR
5.   REAR FLOOR PLATE
6.   MONOTROL® PEDAL CONNECTOR
Figure 38. Removing Floor Plate and Accelerator or Monotrol® Pedal
3.    Disconnect main wire harness from hydraulic motor speed sensor. See Figure 39.
4.  Remove socket head screw, hydraulic motor speed sensor, and hydraulic motor speed
 
sensor connector from hydraulic motor. See Figure 39.

1.   HYDRAULIC MOTOR SPEED SENSOR

2.   SOCKET HEAD SCREW
3.   HYDRAULIC MOTOR TEMPERATURE SENSOR CONNECTOR
4.   HYDRAULIC MOTOR SPEED SENSOR CONNECTOR
Figure 39. Hydraulic Motor Speed Sensor, Lift Truck Models E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Install

1.  Install new hydraulic motor speed sensor and hydraulic motor speed sensor connector into
 
hydraulic motor. See Figure 39.
2.    Attach hydraulic motor speed sensor to hydraulic motor with socket head screw.
3.    Connect main wire harness to hydraulic motor speed sensor.
4.  Connect accelerator pedal or Monotrol® pedal (see Figure 38), and install front plate.
 
Install rear floor plate. Install floor mat and connect the battery.
HYDRAULIC MOTOR TEMPERATURE SENSOR

The hydraulic motor temperature sensor is heat welded and sealed onto winding coils
in stator housing in hydraulic motor. It is a non-replaceable part and cannot be
replaced separately from hydraulic motor.
See Figure 34 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 36 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 37 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 39 for lift truck models
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
HYDRAULIC TANK LEVEL SENSOR
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove tow pin and counterweight cover from counterweight. See Figure 35.
3.    Disconnect main wire harness from hydraulic tank level sensor.
NOTE:   DO NOT twist wires on hydraulic tank level sensor during removal.
4.  Turn hydraulic tank level sensor counterclockwise to unscrew and remove hydraulic tank
 
level sensor from hydraulic tank. See Figure 40.

1.   HYDRAULIC PUMP MOTOR

2.   HYDRAULIC TANK
3.   COUNTERWEIGHT
4.   HYDRAULIC TANK LEVEL SENSOR
5.   SENSOR CONNECTOR
6.   HYDRAULIC OIL TEMPERATURE SENSOR
Figure 40. Hydraulic Tank Level and Hydraulic Oil Temperature Sensors,
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-
100XN) (A970)
Install

NOTE:   DO NOT twist wires on hydraulic tank level sensor during installation.

1.  Install new hydraulic tank level sensor by turning it clockwise to screw it into hydraulic
 
tank. Tighten hydraulic tank level sensor to 4 to 7 N•m (35 to 62 lbf in).
2.    Connect main wire harness to hydraulic tank level sensor. See Figure 40.
3.    Install counterweight cover and tow pin onto counterweight. See Figure 35.
4.    Connect the battery.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove three socket head capscrews and foldover nuts and remove step plate from frame
 
channel. See Figure 41
1.   SOCKET HEAD CAPSCREW
2.   LEFT STEP PLATE
3.   FOLDOVER NUT
4.   SENSOR CONNECTOR
5.   HYDRAULIC TANK LEVEL SENSOR
6.   LEFT FRAME CHANNEL
Figure 41. Hydraulic Tank Level Sensor, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
3.    Disconnect main wire harness from hydraulic tank level sensor.
NOTE:   DO NOT twist wires on hydraulic tank level sensor during removal.
4.    Remove hydraulic tank level sensor by turning sensor counterclockwise. See Figure 41.
Install

NOTE:   DO NOT twist wires on hydraulic tank level sensor during installation

1.  Install new hydraulic tank level sensor by turning it clockwise to screw it into hydraulic
 
tank. Tighten hydraulic tank level sensor 4 to 7 N•m (35 to 62 lbf in).
2.    Connect main wire harness to hydraulic tank level sensor. See Figure 41.
3.  Install step plate to frame channel using three socket head capscrews and foldover nuts.
 
See Figure 41.
4.    Connect the battery.
Lift Truck Models E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Lift hood to UP position and remove the battery. See the Operating Manual or Periodic
 
Maintenance 8000SRM1577 for procedures.
3.    Disconnect main wire harness from hydraulic tank level sensor.
NOTE:   DO NOT twist wires on hydraulic tank level sensor during removal.
4.    Remove connector from mounting bracket by pulling mounting clip up. See Figure 42.
5.  Remove hydraulic tank level sensor from hydraulic tank by turning sensor
 
counterclockwise. See Figure 42.
1.   HYDRAULIC TANK LEVEL SENSOR 6.   FRONT BULKHEAD
2.   HYDRAULIC TANK LEVEL SENSOR CONNECTOR 7.   HYDRAULIC OIL FILTER
3.   MOUNTING CLIP 8.   HYDRAULIC TANK BREATHER
4.   MOUNTING BRACKET 9.   SUCTION STRAINER
5.   HYDRAULIC TANK
Figure 42. Hydraulic Tank Level Sensor, Lift Truck Models E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Install

NOTE:   DO NOT twist wires on hydraulic tank level sensor during removal.

1.  Install new hydraulic tank level sensor by turning it clockwise to screw it into hydraulic
 
tank. See Figure 42. Tighten hydraulic tank level sensor 4 to 7 N•m (35 to 62 lbf in).
2.  Install connector to mounting bracket by pushing mounting clip into hole in mounting
 
bracket.
3.    Connect main wire harness to hydraulic tank level sensor. See Figure 42.
4.  Install battery into lift truck. Connect battery and close hood. See the Operating
 
Manual or Periodic Maintenance 8000SRM1577 for procedures.
HYDRAULIC FILTER SENSOR
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove
1.    Read and follow WARNING and CAUTION section in General section above.
2.    Remove tow pin and counterweight cover from counterweight. See Figure 35.
3.    Disconnect main wire harness from hydraulic filter sensor.
4.  Remove hydraulic filter sensor from hydraulic filter by loosening nut on hydraulic filter
 
sensor. See Figure 43.

NOTE: SOME HYDRAULIC SYSTEM COMPONENTS OMITTED FOR

CLARITY.
1.   COUNTERWEIGHT
2.   HYDRAULIC FILTER
3.   NUT
4.   HYDRAULIC FILTER SENSOR
5.   HYDRAULIC TANK
Figure 43. Hydraulic Filter Sensor, Lift Truck Models J2.2-3.5XN (J45-
70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Install

1.  Install new hydraulic filter sensor into hydraulic filter by tightening nut on hydraulic filter
 
sensor to 4 to 7 N•m (3 to 5 lbf in). See Figure 43.
2.    Connect main wire harness to hydraulic filter sensor.
3.    Install tow pin and counterweight cover to counterweight. See Figure 35.
4.    Connect the battery.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269) and E4.0-
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove
1.    Read and follow WARNING and CAUTION in General section above.
NOTE:  Perform Step 2 and Step 3 for lift truck models E1.6-2.0XN (E30-40XN)
(A269) and E2.2-3.5XN (E45-70XN) (A268) manufactured before June 2012
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
  to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31. Remove front floor
plate with the accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 4 and Step 5 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012, and lift truck models E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099).
4.    Remove the floor mat and floor plate.
5.  Lift front floor plate up enough to disconnect the accelerator pedal
  or MONOTROL® pedal. See Figure 32. Remove front floor plate with the accelerator
or MONOTROL® pedal still attached.
6.    Disconnect main wire harness from hydraulic filter sensor.
7.  Remove hydraulic filter sensor from hydraulic filter adapter and hydraulic filter by
 
loosening nut on hydraulic filter sensor.
See Figure 44 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 45 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 46 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)

NOTE: SOME HYDRAULIC SYSTEM COMPONENTS OMITTED FOR

CLARITY.
1.   HYDRAULIC PUMP AND MOTOR
2.   HYDRAULIC FILTER
3.   HYDRAULIC FILTER ADAPTER
4.   NUT
5.   HYDRAULIC FILTER SENSOR
Figure 44. Hydraulic Filter Sensor, Lift Truck Models E2.2-3.5XN (E45-
70XN) (A268)

1.   HYDRAULIC PUMP AND MOTOR

2.   HYDRAULIC FILTER
3.   HYDRAULIC FILTER ADAPTER
4.   NUT
5.   HYDRAULIC FILTER SENSOR
Figure 45. Hydraulic Filter Sensor for Lift Truck Model E1.6-2.0XN (E30-
40XN) (A269)
1.   RIGHT STEP PLATE
2.   HYDRAULIC FILTER
3.   HYDRAULIC FILTER ADAPTER
4.   HYDRAULIC FILTER SENSOR
Figure 46. Hydraulic Filter Sensor for Lift Truck Model E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Install

1.  Install new hydraulic filter sensor into hydraulic filter adapter by tightening nut on
 
hydraulic filter sensor to 25 N•m (18 lbf ft).
See Figure 44 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 45 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 46 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
2.    Connect main wire harness to hydraulic filter sensor.
3.    Connect accelerator pedal or MONOTROL® pedal, (see Figure 31).
NOTE:  Perform Step 4 for lift truck models E1.6-2.0XN (E30-40XN)
(A269) and E2.2-3.5XN (E45-70XN) (A268) manufactured before June 2012.
4.    Install front floor plate using capscrews and washers.
NOTE:  Perform Step 5 for lift truck models E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099) and E2.2-3.5XN (E45-70XN) (A268) manufactured after June
2012.
5.    No hardware is required to install the front floor plate.
6.    Install rear floor plate. Install floor mat and connect the battery.
HYDRAULIC OIL TEMPERATURE SENSOR
NOTE:  Lift truck models E1.6-2.0XN (E30-40XN) (A269) and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099) are not equipped with a Hydraulic Oil
Temperature Sensor.
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove tow pin and counterweight cover from counterweight. See Figure 35.
3.    Disconnect main wire harness from hydraulic oil temperature sensor.
4.    Unscrew and remove hydraulic oil temperature sensor from hydraulic tank. See Figure 40.
Install

1.  Install new hydraulic oil temperature sensor to hydraulic tank. Tighten hydraulic oil
 
temperature sensor to 20 N•m (177 lbf in).
2.    Connect main wire harness to hydraulic oil temperature sensor.
3.    Install tow pin and counterweight cover to counterweight. See Figure 35.
4.    Connect the battery.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

NOTE:  Perform Step 2 to Step 4 for lift trucks manufactured before June 2012.
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift trucks manufactured after June 2012.
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.    Disconnect main wire harness from hydraulic oil temperature sensor.
9.  Loosen nut on hydraulic oil temperature sensor and remove sensor from hydraulic tank.
 
See Figure 47.
NOTE: SOME HYDRAULIC SYSTEM COMPONENTS OMITTED FOR
CLARITY
1.   HYDRAULIC OIL TEMPERATURE SENSOR
2.   HYDRAULIC MOTOR
3.   HYDRAULIC TANK
Figure 47. Hydraulic Oil Temperature Sensor, Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268)
Install

1.  Install new hydraulic oil temperature sensor to hydraulic tank. Tighten hydraulic oil
 
temperature sensor to 20 N•m (177 lbf in).
2.    Connect main wire harness to hydraulic oil temperature sensor.
3.    Connect accelerator pedal or MONOTROL® pedal.
See Figure 31 for lift trucks manufactured before June 2012.
See Figure 32 for lift trucks manufactured after June 2012.
NOTE:  Perform Step 4 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured before June 2012.
4.    Install front floor plate using capscrews and washers.
NOTE:  Perform Step 5 and Step 6 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    No hardware is required to install front floor plate.
6.    Install rear floor plate.
7.    Install floor mat and connect the battery.
TRACTION SPEED SENSOR
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove

NOTE:  There are two speed sensors. The procedures below describe how to replace
one sensor. The procedures are the same for both sensors.
1.    Read and follow WARNING and CAUTION section in General section above.
2.    Put lift truck on blocks and remove tire and wheel. See Operating Manual or section
Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
3.    Disconnect main wire harness from speed sensor.
4.  Remove socket head screw securing speed sensor to traction motor. Remove speed sensor
 
and sensor connector from traction motor.
See Figure 48 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 49 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY. RIGHT
SIDE SPEED SENSOR SHOWN. LEFT SIDE IS THE SAME.
1.   SOCKET HEAD SCREW 3.   TRANSAXLE ASSEMBLY
2.   TRACTION SPEED SENSOR
Figure 48. Speed Sensor Removal, Lift Truck Models J2.2-3.5XN (J45-
70XN) (A276)

NOTE: SOME COMPONENT PARTS OMITTED FOR CLARITY. RIGHT

SIDE SPEED SENSOR SHOWN. LEFT SIDE IS THE SAME.
1.   SOCKET HEAD SCREW 3.   TRANSAXLE ASSEMBLY
2.   TRACTION SPEED SENSOR
Figure 49. Speed Sensor Removal, Lift Truck Models J4.0-5.0XN (J80-
100XN) (A970)
Install

1.  Install new speed sensor and sensor connector onto traction motor. Secure speed sensor to
 
traction motor with socket head screws.
See Figure 48 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 49 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
2.    Connect main wire harness to speed sensor.
3.    Install tire and wheel. Remove lift truck from blocks. See Operating Manual or section
Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
4.    Connect the battery.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Put lift truck on blocks. See Operating Manual or section
Periodic Maintenance 8000SRM1364 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
Periodic Maintenance 8000SRM1442 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
3.    Remove drip shield for access to speed sensor.
4.    Disconnect main wire harness from speed sensor connector.
See Figure 50 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 51 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
5.  Remove socket head screw securing speed sensor to traction motor. Remove speed sensor
 
connector from sensor wiring connector mounting bracket.
NOTE: BOTTOM VIEW SHOWN.
1.   TRACTION MOTOR 3.   SPEED SENSOR
2.   SENSOR MOUNTING BRACKET 4.   SPEED SENSOR CONNECTOR
Figure 50. Speed Sensor Removal Lift Truck Models E2.2-3.5XN (E45-
70XN) (A268)
1.   TRACTION MOTOR 4.   SPEED SENSOR CONNECTOR
2. SENSOR WIRING 5. TRACTION MOTOR TEMPERATURE SENSOR
  BRACKET   CONNECTOR
3.   SPEED SENSOR
Figure 51. Speed Sensor Removal Lift Truck Model E1.6-2.0XN (E30-
40XN) (A269)
Install

1.    Install new speed sensor to traction motor.

See Figure 50 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 51 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
2.    Connect main wire harness to speed sensor.
3.    Install drip shield.
4.    Remove lift truck from blocks.
5.    Connect the battery.
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Raise hood and seat assembly and remove batteries and floor plates.
 
See Frame 0100SRM1342 for procedures.
3.    Disconnect wire harness from speed sensor connector. See Figure 52.
4.  Remove socket head screw securing speed sensor to sensor mounting bracket on traction
 
motor. See Figure 52.
5.    Remove sensor mounting bracket. See Figure 52.
6.    Remove socket head screw securing speed sensor to traction motor. See Figure 52.
7.    Remove speed sensor and speed sensor connector from traction motor. See Figure 52.

1.   TRACTION MOTOR 4.   SOCKET HEAD CAPSCREW

2.   SPEED SENSOR CONNECTOR 5.   SPEED SENSOR
3. TRACTION MOTOR TEMPERATURE SENSOR 6. SENSOR MOUNTING
  CONNECTOR   BRACKET
Figure 52. Speed Sensor Removal Lift Truck Models E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Install
1.    Install new speed sensor and speed sensor connector. See Figure 52.
2.    Install socket head capscrew securing speed sensor to traction motor. See Figure 52.
3.    Install sensor mounting bracket and two socket head capscrews. See Figure 52.
4.    Connect wire harness to speed sensor connector. See Figure 52.
5.    Install floor plates and batteries. See Frame 0100SRM1342 for procedures.
6.    Lower hood and seat assembly.
TRACTION MOTOR TEMPERATURE SENSOR

The traction motor temperature sensor is heat welded and sealed onto winding coils in
stator housing in traction motor. It is a non-replaceable part and cannot be replaced
separately from traction motor.
TILT POSITION SENSOR E2.2-3.5XN (E45-70XN) (A268), J2.2-3.5XN (J45-70XN)
(A276) AND J4.0-5.0XN (J80-100XN) (A970)

  WARNING 
Before replacing any components installed on the mast, fully lower all
parts of the mast and tilt it forward until the tips of the forks touch the
ground. This action will prevent the mast from lowering suddenly if the
control lever is accidently moved.
The tilt position sensor is located on left side of mast. It is mounted on a bracket on
left tilt cylinder rod end. See Figure 53. The tilt position sensor is an optional feature
on lift trucks covered in this service manual.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Disconnect main wire harness from tilt position sensor. Remove two grommets and wire
 
harness from tilt position sensor bracket.
3.    Remove two torx capscrews from tilt position sensor. See Figure 53.
4.    Remove tilt position sensor from tilt position sensor bracket.
NOTE: COMPONENTS OF COWL AND MAST OMITTED FOR CLARITY.
LEFT SIDE SHOWN.
1.   TILT CYLINDER 5.   GROMMET
2. TILT POSITION SENSOR MOUNTING 6. TILT POSITION SENSOR WIRE AND
  BRACKET   CONNECTOR
3.   TILT POSITION SENSOR 7.   TILT CYLINDER ROD END
4.   TORX CAPSCREWS
Figure 53. Tilt Position Sensor Removal for E2.2-3.5XN (E45-70XN)
(A268), J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Install

1.  Install new tilt position sensor on tilt position sensor bracket using two torx head
 
capscrews. See Figure 53.
2.    Install grommets and wire harness to tilt position sensor bracket.
3.    Connect main wire harness to tilt position sensor connector. See Figure 53.
4.    Connect the battery.
TILT POSITION SENSOR E1.6-2.0XN (E30-40XN) (A269)

  WARNING 
Before replacing any components installed on the mast, fully lower all
parts of the mast and tilt it forward until the tips of the forks touch the
ground. This action will prevent the mast from lowering suddenly if the
control lever is accidently moved.
The tilt position sensor is located on left side of mast. It is mounted on a bracket on
left tilt cylinder rod end. See Figure 54. The tilt position sensor is an optional feature
on lift trucks covered in this service manual. Perform the following procedures if lift
truck is equipped with tilt position sensor.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Disconnect mast harness from cowl harness.
3.  Remove two torx capscrews, nuts, and tilt sensor from sensor bracket on mast.
 
See Figure 54.
4.    Remove mast harness from sensor and mast brackets.

1.   TORX CAPSCREWS
2.   RETURN TO SET TILT (TILT ANGLE) SENSOR
3.   SENSOR BRACKET
4.   COWL
5.   MAST HARNESS (TO COWL HARNESS)
6.   HARNESS BRACKET
Figure 54. Tilt Position Sensor for Lift Truck Model E1.6-2.0XN (E30-
40XN) (A269)
Install

1.  Install new tilt position sensor on sensor bracket using two torx head capscrews and two
 
nuts. See Figure 54.
2.    Install mast harness to harness bracket.
3.    Connect mast harness to cowl harness. See Figure 54.
4.  Tilt mast completely forward and backward to ensure tilt sensor is installed and connected
 
correctly.
TILT POSITION SENSOR E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)

  WARNING 
Before replacing any components installed on the mast, fully lower all
parts of the mast and tilt it forward until the tips of the forks touch the
ground. This action will prevent the mast from lowering suddenly if the
control lever is accidently moved.
The tilt position sensor is located on left side of mast. It is mounted on a bracket on
left tilt cylinder rod end. See Figure 55. The tilt position sensor is an optional feature
on lift trucks covered in this service manual.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Disconnect main wire harness from tilt position sensor wire connector. Remove tilt sensor
  wire, grommets and other tilt sensor wire retainers from chassis and set aside.
See Figure 55.
3.  Remove anchor capscrews from anchor, sensor bracket and tilt cylinder rod end.
 
See Figure 55.
4.    Remove anchor. See Figure 55.
5.    Remove sensor bracket from tilt cylinder rod end. See Figure 55.
6.    Remove two nuts and two torx head capscrews from tilt position sensor. See Figure 55.
7.    Remove tilt position sensor from sensor bracket. See Figure 55.
8.    Remove tilt position sensor and tilt position sensor wire. See Figure 55.
1.   ANCHOR CAPSCREW 7.   TILT CYLINDER
2.   WASHER 8.   TILT POSITION SENSOR WIRE CONNECTOR
3.   ANCHOR 9.   SENSOR BRACKET
4.   TILT POSITION SENSOR WIRE 10.   TORX CAPSCREW
5.   TILT CYLINDER ROD END 11.   TILT POSITION SENSOR
6.   GROMMET 12.   NUT
Figure 55. Tilt Position Sensor Removal for E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099)
Install

1.  Install tilt position sensor in sensor bracket using two nuts and two torx head capscrews.
 
See Figure 55.
2.    Install sensor bracket onto tilt cylinder rod end. See Figure 55.
3.  Install anchor, washer, and anchor capscrew. Tighten anchor capscrew
 
to 68 N•m (50 lbf ft). See Figure 55.
4.  Install tilt position wire, grommets and other sensor wire retainers into chassis as shown
 
in Figure 55.
5.    Connect main wire harness to tilt position sensor wire connector. See Figure 55.
6.    Connect the battery.
LOW LEVEL BRAKE FLUID SWITCH FOR LIFT TRUCK MODELS E2.2-3.5XN (E45-
70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), J2.2-3.5XN (J45-70XN)
(A276) ANDJ4.0-5.0XN (J80-100XN) (A970)

NOTE:  The low level brake fluid switch is a component of the master brake cylinder
reservoir and is located on bottom of reservoir.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

NOTE:  Perform Step 2 to Step 4 for lift truck models E1.6-2.0XN (E30-40XN)
(A269), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970) and E2.2-
3.5XN (E45-70XN) (A268)manufactured before June 2012:
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.    Disconnect main wire harness from low brake fluid level switch connector. See Figure 56.
NOTE: SOME COMPONENTS OMITTED FOR CLARITY
1.   BRAKE MASTER CYLINDER 4.   BRAKE FLUID RESERVOIR
2.   BRAKE PRESSURE SENSOR 5.   LOW LEVEL BRAKE FLUID SWITCH CONNECTOR
3.   COWL HARNESS CONNECTOR
Figure 56. Brake System Switches and SensorsE2.2-3.5XN (E45-70XN)
(A268), E1.6-2.0XN (E30-40XN) (A269), J2.2-3.5XN (J45-70XN)
(A276) and J4.0-5.0XN (J80-100XN) (A970)
9.  Press retaining clip on low level brake fluid switch and pop low level brake fluid switch
 
out. Remove switch from brake fluid reservoir. See Figure 57.
1.   RETAINING CLIP 4.   BRAKE FLUID RESERVOIR
2.   BRAKE MASTER CYLINDER 5.   LOW LEVEL BRAKE FLUID SWITCH
3.   BRAKE PRESSURE SENSOR
Figure 57. Low Level Brake Fluid Switch Replacement
Install

1.  Install new low level brake fluid switch into brake fluid reservoir. Switch will snap into
 
position. See Figure 57.
2.    Connect main wire harness to low brake fluid level switch connector.
3.    Connect accelerator pedal or MONOTROL® pedal. See Figure 31.
NOTE:  Perform Step 4 for lift truck models E1.6-2.0XN (E30-40XN) (A269), J2.2-
3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-3.5XN (E45-
70XN) (A268)manufactured before June 2012.
4.    Install front floor plate using capscrews and washers
NOTE:  Perform Step 5 for lift truck model E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    No hardware is required to install the front floor plate.
6.    Install rear floor plate. Install floor mat and connect the battery.
LOW LEVEL BRAKE FLUID SWITCH FOR LIFT TRUCK MODEL E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)

NOTE:  The low level brake fluid switch is a non-serviceable component of brake

fluid reservoir. If low level brake fluid switch needs to be replaced, the brake fluid
reservoir will need to be replaced as well.
NOTE:  Drain fluid from master cylinder prior to performing this repair procedure.
See Drive Axle Repair 1300SRM1575.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove three button head capscrews from brake fluid reservoir cover. See Figure 58.
3.    Remove brake fluid reservoir cover. See Figure 58.
4.  Disconnect main wire harness from low brake fluid reservoir electrical connector.
 
See Figure 58.
5.  Loosen clamp on brake fluid reservoir and press retaining clip holding brake fluid reservoir
 
to cowl to remove brake fluid reservoir from lift truck. See Figure 58.
NOTE: SOME COMPONENTS OMITTED FOR CLARITY.
1.   BRAKE FLUID RESERVOIR 5. BRAKE FLUID RESERVOIR
  COVER
2.   RETAINING CLIP
6.   BUTTON HEAD CAPSCREWS
3. LOW LEVEL BRAKE FLUID SWITCH
  CONNECTOR 7.   BRAKE PRESSURE SENSOR
4.   CLAMP 8.   COWL
Figure 58. Brake System Switches and Sensors E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099)
Install

1.    Install new brake fluid reservoir onto hose and tighten clamp. See Figure 58.
2.  Add correct amount of fluid to reach operating level. See Operating Manual or Periodic
 
Maintenance 8000SRM1577 for proper fluid type and amount.
3.    Press brake fluid reservoir into retaining clip.
4.  Connect main wire harness to low level brake fluid reservoir electrical connector.
 
See Figure 58.
5.    Bleed brake system as described in Drive Axle Repair 1300SRM1575.
6.    Install brake fluid reservoir cover. See Figure 55.
7.    Install three button head capscrews into brake fluid reservoir cover. See Figure 58.
SERVICE BRAKE PRESSURE SENSOR FOR LIFT TRUCK MODELS E2.2-3.5XN
(E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), J2.2-3.5XN (J45-70XN)
(A276) ANDJ4.0-5.0XN (J80-100XN) (A970)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

NOTE:  Perform Step 2 to Step 4 for lift truck models E1.6-2.0XN (E30-40XN)
(A269), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-
3.5XN (E45-70XN) (A268)manufactured before June 2012:
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.  Disconnect main wire harness from brake pressure sensor and remove it from master
 
cylinder. See Figure 56.
Install

1.  Install a new brake pressure sensor on master cylinder. Tighten brake pressure sensor to 23
 
to 28 N•m (204 to 248 lbf in).
2.    Connect main wire harness to new brake pressure sensor. See Figure 56.
3.    Connect accelerator pedal or MONOTROL® pedal, (see Figure 31).
NOTE:  Perform Step 4 for lift truck models E1.6-2.0XN (E30-40XN) (A269), J2.2-
3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-3.5XN (E45-
70XN) (A268)manufactured before June 2012.
4.    Install the front floor plate using capscrews and washers.
NOTE:  Perform Step 5 and Step 6 for lift truck model E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    No hardware is required to install front floor plate.
6.    Install rear floor plate. Install floor mat and connect the battery.
7.    Bleed brake system as described in the section
Brake System 1800SRM1359 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
Brake System 1800SRM1438 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
Transaxle 1300SRM1539 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
SERVICE BRAKE PRESSURE SENSOR FOR LIFT TRUCK MODEL E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove floor mat. Remove rear floor plate. Lift front floor plate up enough to disconnect
  the accelerator pedal or MONOTROL® pedal. See Figure 32. Remove front floor plate
with accelerator orMONOTROL® pedal still attached.
3.  Install container beneath service brake pressure sensor to catch any fluid. Container should
 
have a capacity of at least 0.35 liter (0.37 qt).
4.  Disconnect main wire harness from brake pressure sensor and remove it from master
 
cylinder. See Figure 58.
5.    Remove container.
Install

1.  Install a new brake pressure sensor on master cylinder. Tighten brake pressure sensor to 23
 
to 28 N•m (204 to 248 lbf in).
2.    Connect main wire harness to new brake pressure sensor. See Figure 58.
3.    Connect accelerator pedal or MONOTROL® pedal, (see Figure 38).
Install the front floor plate. Install rear floor plate. Install floor mat and connect the
battery.
4.  Add brake fluid. See Operating Manual or Periodic Maintenance 8000SRM1577 for
 
proper fluid type and amount.
5.    Bleed brake system as described in Drive Axle Repair 1300SRM1575.
ACCELERATOR PEDAL POSITION SENSOR
Remove

NOTE:  The accelerator pedal position sensor cannot be replaced separately from

accelerator pedal. If accelerator pedal position sensor malfunctions, accelerator pedal
assembly must be replaced.
NOTE:  In the steps and illustrations below, the standard accelerator pedal is used.
The procedures to replace a MONOTROL® pedal are the same.
1.    Read and follow WARNING and CAUTION section in General section above.
NOTE:  Perform Step 2 to Step 4 for lift truck models E1.6-2.0XN (E30-40XN)
(A269), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970) and E2.2-
3.5XN (E45-70XN) (A268)manufactured before June 2012:
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.  Remove three capscrews and nuts that attach the accelerator pedal and pedal base to
 
accelerator pedal mounting plate. See Figure 31. Remove accelerator pedal mounting plate.
Install

1.  Install new accelerator pedal, pedal base and accelerator pedal mounting plate to front
 
floor plate with capscrews and nuts. See Figure 31.
NOTE:  Perform Step 2 for lift truck models E1.6-2.0XN (E30-40XN) (A269), J2.2-
3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-3.5XN (E45-
70XN) (A268)manufactured before June 2012.
2.    Install front floor plate using capscrews and washers
NOTE:  Perform Step 3 for lift truck model E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
3.    No hardware is required to install the front floor plate.
4.    Install rear floor plate. Install floor mat and connect the battery.
SEAT SENSOR (OPERATOR PRESENCE SYSTEM)
Non-Suspension Seat
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Tilt steering column all the way up.
NOTE:  Before removing seat from hood, tag or mark holes that mount the seat to
hood. This will aid in correctly installing seat to hood.
See Figure 59 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 60 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 61 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
3.  Disconnect chassis harness from seat harness. Remove four capscrews and washers
 
holding seat to hood. Remove seat from hood. Remove spacer bars.
See Figure 59 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 60 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 61 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)

NOTE: BOTTOM VIEW OF HOOD SHOWN.

1.   HOOD LATCH ASSEMBLY
2.   MOUNTING HOLES, NON-SUSPENSION SEAT
3.   GAS SPRING
4.   HOOD HINGE ASSEMBLY
5.   SEAT HARNESS
Figure 59. Seat Removal, Non-Suspension Seat, Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268)
NOTE: BOTTOM VIEW OF HOOD SHOWN.
1.   HOOD LATCH ASSEMBLY
2.   MOUNTING HOLES, NON-SUSPENSION SEAT
3.   GAS SPRING
4.   HOOD HINGE ASSEMBLY
5.   SEAT HARNESS
Figure 60. Seat Removal, Non-Suspension Seat, Lift Truck Models J2.2-
3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
NOTE: BOTTOM VIEW OF HOOD SHOWN.
1.   HOOD LATCH ASSEMBLY
2.   MOUNTING HOLES, NON-SUSPENSION SEAT
3.   GAS SPRING
4.   HOOD HINGE ASSEMBLY
5.   SEAT HARNESS
Figure 61. Seat Removal, Non-Suspension Seat, Lift Truck Model E4.0-
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Disconnect seat harness from seat sensor. See Figure 62.
5.    Remove two capscrews, washers, and seat sensor from seat.
1.   CAPSCREWS
2.   SEAT SENSOR
3.   SEAT SENSOR ELECTRICAL CONNECTOR
4.   SEAT GROUND WIRE
5.   SEAT HARNESS
Figure 62. Seat Sensor, Non- and Semi-Suspension Seat
Install

1.    Using two capscrews and washers, install sensor to seat. See Figure 62.
2.    Connect seat harness to seat sensor.
See Figure 59 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 60 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 61 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
3.  Install seat onto hood using four capscrews, spacer bars, and washers in correct holes, as
 
marked during removal. Tighten capscrews to 18 N•m (156 lbf in).
See Figure 59 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 60 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 61 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Connect chassis harness to seat harness.
5.    Connect battery and close hood.
Full Suspension and Swivel Seats
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Pull out two pins that secure bottom seat cushion to seat base.
3.    Lift bottom seat cushion up and disconnect seat harness from seat sensor.
4.    Use a small, flat-bladed screwdriver and remove seat sensor from seat base. See Figure 63.

1.   SEAT SENSOR
2.   CUSHION PINS
3.   SEAT HARNESS
4.   SEAT BASE
5.   TO CHASSIS HARNESS
Figure 63. Seat Sensor, Full Suspension Seat
Install

1.    Install new seat sensor into seat base.

2.    Connect seat harness to seat sensor. See Figure 63.
3.    Place bottom seat cushion onto seat base and attach cushion to base with pins.
4.    Connect the battery.
STEERING DIRECTION SENSOR
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove upper steering column cover by pressing from both sides and pulling cover up and
 
out. See Figure 68.
3.  Disconnect steering wire harness from steering direction sensor electrical connector.
 
See Figure 64.
4.  Remove two capscrews from steering direction sensor and remove steering direction
 
sensor from sensor mounting plate. See Figure 64.

1.   CAPSCREWS
2.   STEERING DIRECTION SENSOR
3.   LOWER STEERING COLUMN COVER
4.   SENSOR MOUNTING PLATE
5.   STEERING DIRECTION SENSOR ELECTRICAL CONNECTOR
Figure 64. Steering Direction Sensor
Install

1.  Install new steering direction sensor onto sensor mounting plate. Secure steering direction
 
sensor to sensor mounting plate with two capscrews. See Figure 64.
2.    Connect steering wire harness to steering direction sensor.
3.  Install steering column upper cover by pressing from both sides and pushing against
  steering column lower cover until steering column upper cover snaps into place.
See Figure 68.
4.    Connect battery. Adjust steering column for operator comfort.
LOAD WEIGHT SENSOR

NOTE:  The lift trucks covered in this manual may be equipped with an optional load
weight sensor. See Operating Manual for a more detailed description on how load
weight sensor works.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

NOTE:  Perform Step 2 to Step 4 for lift truck models E1.6-2.0XN (E30-40XN)
(A269), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-
3.5XN (E45-70XN) (A268)manufactured before June 2012.
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift truck models E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099) and E2.2-3.5XN (E45-70XN) (A268) manufactured after
June 2012.
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.    Disconnect harness connector from load weight sensor.
9.    Remove load weight sensor from T-Fitting on hydraulic control valve. See Figure 65.
NOTE: E-HYDRAULIC CONTROL VALVE SHOWN. RIGHT SIDE SHOWN.
LOAD WEIGHT SENSOR IS IN SAME POSITION ON MANUAL HYDRAULIC
CONTROL VALVE.
1.   HYDRAULIC CONTROL VALVE 4.   HARNESS CONNECTOR
2.   T-FITTING 5.   FRONT BULKHEAD
3.   LOAD WEIGHT SENSOR
Figure 65. Load Weight Sensor
Install

1.  Insert new load weight sensor into T-Fitting. Tighten sensor by hand, and then torque
 
sensor to 25 N•m (221 lbf in).
2.    Connect harness connector to load weight sensor. See Figure 65.
3.    Connect accelerator pedal or MONOTROL® pedal. See Figure 31.
NOTE:  Perform Step 4 for lift truck models E1.6-2.0XN (E30-40XN) (A269), J2.2-
3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), and E2.2-3.5XN (E45-
70XN) (A268)manufactured before June 2012.
4.    Install front floor plate using capscrews and washers.
NOTE:  Perform Step 5 and Step 6 for lift truck model E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099) and E2.2-3.5XN (E45-70XN) (A268) manufactured after
June 2012.
5.    No hardware is required to install front floor plate.
6.    Install rear floor plate. Install floor mat and connect the battery.
7.  Re-calibrate load weight sensor. See section User Interface 2200SRM1336 for calibration
 
procedures.
BATTERY GATE SWITCH

NOTE:  The lift truck models covered in this manual, except J4.5-5.0XN (J80-

100XN) (A970), may be equipped with an optional battery restraint system that
includes rollers and a side battery gate for horizontal removal of the battery. There is a
switch for the side battery gate, located on right side of lift truck. This switch can be
replaced if it malfunctions.
NOTE:  Read and follow WARNING and CAUTION section in General section
above.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), and E4.0-
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.  Lift up hood and remove battery for access to battery gate switch. See Operating
 
Manual or service manual Frame 0100SRM1342 for procedures.
2.  Remove battery plate that is closest to battery gate on right side of lift truck frame.
 
See Figure 66.
Figure 66. Battery Gate Switch Replacement
 Legend for Figure 66
NOTE: LIFT TRUCK MODEL E2.2-3.5XN (E45-70XN) (A268) SHOWN, LIFT
TRUCK MODEL E1.6-2.0XN (E30-40XN) (A269) AND E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099) SIMILAR.
A.   REMOVE BATTERY PLATE B.   REPLACE BATTERY GATE SWITCH
1.   BATTERY GATE 5.   CAPSCREWS
2.   BATTERY PLATE 6. BATTERY GATE
  SWITCH
3.   BATTERY ROLLER
7.   BRACKET
4.   BATTERY GATE SWITCH CONNECTOR AND WIRE HARNESS
3.  Disconnect main wire
harness from battery gate
switch connector and wire
  harness. See Figure 66.
Remove two capscrews and
battery gate switch from
bracket.
Install

1.  Install new battery gate switch and two capscrews on bracket. See Figure 66. Connect
 
main wire harness to battery gate connector and wire harness.
2.    Install battery plate into battery compartment.
3.  Install battery and close hood. See Operating Manual or service
 
manual Frame 0100SRM1342 for procedures.
4.    Connect the battery.
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)
Remove

1.  Lift up hood and remove right side panel. See Operating Manual or service
 
manual Frame 0100SRM1342 for procedures.
2.    Disconnect main wire harness from battery gate switch. See Figure 67.
1.   CAPSCREWS 5.   BRACKET
2.   BATTERY GATE 6. BATTERY GATE SWITCH CONNECTOR AND WIRE
  HARNESS
3. BATTERY RETENTION
  ROD 7.   GROMMET
4.   BATTERY GATE SWITCH
Figure 67. Battery Gate Switch Replace, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276)
3.  Remove two capscrews from battery gate switch. Remove battery gate switch from
 
bracket. See Figure 67.
Install

1.    Install new battery gate switch to bracket with two capscrews. See Figure 67.
2.    Connect main wire harness to battery gate switch connector.
3.  Install right side panel and close hood. See Operating Manual or service
 
manual Frame 0100SRM1342 for procedures.
4.    Connect the battery.
HORN SWITCH

NOTE:  The procedures below are for replacing horn switch and horn switch
mechanism located on steering column. If your lift truck is equipped with E-Hydraulic
mini-levers, there is an option for a horn button on the armrest. See section Electronic
and Manual Hydraulic Controls for procedures to replace horn sensor on the E-
Hydraulic armrest.
Fixed Steering Column
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Remove upper steering column cover by pressing from both sides and pulling cover up and
 
out. See Figure 68.

1.   STEERING COLUMN UPPER COVER

2.   CLIP
3.   STEERING COLUMN LOWER COVER
4.   CAPSCREW
5.   STEERING COLUMN TOP COVER
6.   DASH PANEL
7.   TILT POSITION LEVER
Figure 68. Steering Column Covers
3.  Disconnect steering wire harness from horn switch. Remove capscrews, washers, and
 
tapped plate from horn switch. Remove horn switch from horn switch plate. See Figure 69.
NOTE: FIXED STEERING COLUMN SHOWN. HORN SWITCH ON
OPTIONAL TELESCOPIC STEERING COLUMN IS THE SAME.
1.   FIXED STEERING COLUMN
2.   HORN SWITCH PLATE
3.   PIN
4.   RETAINING RING
5.   SPRING
6.   SWITCH CONTACT WASHER
7.   SNAP RING
8.   CAPSCREW
9.   WASHER
10.   HORN SWITCH
11.   TAPPED PLATE
 Figure 69. Horn Switch
Install

1.  Install new horn switch, tapped plate, washers, and capscrews to horn switch plate.
 
See Figure 69.
NOTE:  Perform Step 2 for lift truck models J2.2-3.5XN (J45-70XN) (A276),
equipped with Outdoor Protection/ Wash-down Package.
2.    Apply dielectric grease to horn switch terminal.
3.    Connect steering wire harness to horn switch.
4.  Install steering column upper cover by pressing from both sides and pushing against
  steering column lower cover until steering column upper cover snaps into place.
See Figure 68.
5.    Connect the battery.
Telescopic Steering Column
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove horn button, nut, and rod from steering wheel. See Figure 70.

1.   HORN BUTTON
2.   NUT
3.   ROD
4.   STEERING WHEEL
Figure 70. Horn Button Assembly and Electrical Connections
3.  Remove hex nut and steering wheel from steering column. If necessary, use a puller tool to
 
remove steering wheel. See Figure 71.
1.   HEX NUT
2.   STEERING WHEEL
3.   STEERING COLUMN UPPER COVER
4.   STEERING COLUMN LOWER COVER
5.   STEERING COLUMN TOP COVER
Figure 71. Steering Wheel
4.  Remove upper steering column cover by pressing from both sides and pulling cover up and
 
out. See Figure 68.
5.  Remove four mounting capscrews and steering column top cover from steering column
 
plate. See Figure 71.
6.  Disconnect steering wire harness from horn switch. Remove capscrews, washers, and
 
tapped plate from horn switch. Remove horn switch from horn switch plate. See Figure 69.
Install

1.  Install new horn switch, tapped plate, washers, and capscrews to horn switch plate.
 
See Figure 69.
NOTE:  Perform Step 2 for lift truck models J2.2-3.5XN (J45-70XN) (A276),
equipped with Outdoor Protection/ Wash-down Package.
2.    Apply dielectric grease to horn switch terminal.
3.    Connect steering wire harness to horn switch.
4.  Install steering column top cover and four mounting capscrews on steering column plate.
 
See Figure 71.
5.  Install steering column upper cover by pressing from both sides and pushing against
  steering column lower cover until steering column upper cover snaps into place.
See Figure 68.
6.  Install steering wheel and hex nut on steering column. Tighten nut 40 to 54 N•m (30 to
 
40 lbf ft). See Figure 71.
7.    Install rod, nut, and horn button in steering wheel. See Figure 70.
8.    Connect the battery.
IMPACT SENSOR
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Remove

NOTE:  The impact sensor is located on right side of lift truck between right tilt
anchor plate and right front overhead guard mounting plate. See Figure 72.

1.   RIGHT FRONT OVERHEAD GUARD MOUNTING PLATE

2.   RIGHT TILT ANCHOR PLATE
3.   PLATE
4.   IMPACT SENSOR
Figure 72. Impact Sensor Location, Lift Truck Models J2.2-3.5XN (J45-
70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
NOTE:  Read and follow WARNING and CAUTION section in General section
above.
1.    Remove floor mat. Remove rear floor plate.
2.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
  to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31. Remove front floor
plate with accelerator or MONOTROL® pedal still attached.
3.  Going through the opening in right tilt anchor plate (see Figure 72), disconnect main wire
 
harness from impact sensor.
NOTE:  Note placement and orientation of impact sensor prior to removal to aid in
installation.
4.  Remove two impact sensor mounting capscrews and impact sensor from impact sensor
 
mounting bracket. See Figure 73.
NOTE: RIGHT ANCHOR TILT PLATE AND OTHER FRAME COMPONENTS
OMITTED FOR CLARITY.
1. RIGHT FRONT OVERHEAD GUARD 4. IMPACT SENSOR MOUNTING
  MOUNTING PLATE   CAPSCREW
2.   PLATE 5.   IMPACT SENSOR
3.   IMPACT SENSOR MOUNTING BRACKET 6.   IMPACT SENSOR CONNECTOR
Figure 73. Impact Sensor Replace, Lift Truck Models J2.2-3.5XN (J45-
70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Install

1.  Install new impact sensor and two impact sensor mounting capscrews on impact sensor
 
mounting bracket as noted during removal. See Figure 73.
2.    Connect main wiring harness to impact sensor as tagged during removal.
3.  Connect accelerator pedal or MONOTROL® pedal, and install front floor plate using
 
capscrews and washers.
4.    Install rear floor plate and floor mat. See Figure 31.
5.    Connect the battery.
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)

NOTE:  The impact sensor is located on right side of lift truck on a mounting plate
that is mounted to the inside of the right frame channel.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

NOTE:  Perform Step 2 to Step 4 for lift trucks models E1.6-2.0XN (E30-40XN)
(A269) and E2.2-3.5XN (E45-70XN) (A268) manufactured before June 2012.
2.    Remove floor mat. Remove rear floor plate.
3.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 31.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Perform Step 5 to Step 7 for lift truck models E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012:
5.    Remove floor mat. Remove rear floor plate.
6.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
7.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
8.    Disconnect main wire harness from impact sensor. See Figure 74.
NOTE:  Note placement and orientation of impact sensor prior to removal to aid in
installation.
9.  Remove three mounting plate capscrews and mounting plate with impact sensor from lift
 
truck.
10.  Remove two impact sensor capscrews and impact sensor from mounting plate.
 
See Figure 74.
NOTE: LIFT TRUCK MODEL E2.2-3.5XN (E45-70XN) (A268) SHOWN, LIFT
TRUCK MODEL E1.6-2.0XN (E30-40XN) (A269) SIMILAR.
1.   TILT ANCHOR PLATE 5.   MOUNTING PLATE
2.   MOUNTING PLATE CAPSCREWS 6.   IMPACT SENSOR CONNECTOR
3.   IMPACT SENSOR CAPSCREWS 7.   MAIN WIRING HARNESS CONNECTOR
4.   IMPACT SENSOR
Figure 74. Impact Sensor Replace, Lift Truck Models E2.2-3.5XN (E45-
70XN) (A268)
Install

1.  Install new impact sensor and two impact sensor capscrew on mounting plate.
 
See Figure 74.
2.  Install mounting plate, with new impact sensor attached, and three mounting plate
 
capscrews on right frame channel.
3.    Connect main wiring harness to impact sensor as tagged during removal.
4.    Connect accelerator pedal or MONOTROL® pedal. See Figure 31.
NOTE:  Perform Step 5 for lift truck models E1.6-2.0XN (E30-40XN)
(A269) and E2.2-3.5XN (E45-70XN) (A268) manufactured before June 2012.
5.    Install front floor plate using capscrews and washers.
NOTE:  Perform Step 6 and Step 7 for lift truck model E2.2-3.5XN (E45-70XN)
(A268) manufactured after June 2012.
6.    No hardware is required to install front floor plate.
7.    Install rear floor plate. Install floor mat.
8.    Connect the battery.
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

NOTE:  The impact sensor is located on the left side of lift truck between the left tilt
anchor plate and left front overhead guard mounting plate. See Figure 75.

1.   LEFT TILT ANCHOR PLATE 5.   IMPACT SENSOR CONNECTOR

2.   MOUNTING PLATE 6.   IMPACT SENSOR CAPSCREW
3.   MOUNTING PLATE CAPSCREW 7.   IMPACT SENSOR
4.   MAIN WIRING HARNESS CONNECTOR
Figure 75. Impact Sensor Location, Lift Truck Model E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
1.    Read and follow WARNING and CAUTION section in General section above.
2.    Remove floor mat. Remove rear floor plate.
3.  Lift front floor plate up enough to disconnect accelerator pedal or MONOTROL® pedal.
 
See Figure 32.
4.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
5.    Disconnect main wire harness from impact sensor. See Figure 75.
NOTE:  Note placement and orientation of impact sensor prior to removal to aid in
installation.
6.  Remove two impact sensor capscrews and remove impact sensor from mounting plate.
 
See Figure 75.
Install

1.  Install new impact sensor to mounting plate with two impact sensor capscrews.
 
See Figure 75.
2.    Connect main wiring harness to impact sensor as tagged during removal.
3.    Connect accelerator pedal or MONOTROL® pedal, and install front floor plate.
4.    Install rear floor plate.
5.    Install floor mat. See Figure 38.
6.    Connect the battery.
REAR AND HOOD HORN BUTTON SWITCHES

NOTE:  The procedures below are for replacing the optional horn switch located in
the rear handle on rear right overhead guard leg or in the handle located on right side
of hood. Lift truck models E3.2-3.5XN (E65-70XN) (A268) and J4.0-5.0XN (J80-
100XN) (A970) are the only trucks that may be equipped with a horn button on hood.
If your lift tucks is equipped with E-Hydraulic mini-levers, there is an optional horn
button on armrest. See section Electronic and Manual Hydraulic Controls for
procedures to replace horn sensor on E-Hydraulic armrest.
Rear Horn Button Switch
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.  Raise hood, and reach underneath right hood mounting bracket to disconnect main wiring
 
harness from rear horn button switch. See Figure 76.
NOTE: RIGHT HOOD MOUNTING BRACKET OMITTED FOR CLARITY.
1.   CAPSCREWS
2.   REAR HORN BUTTON
3.   RIGHT REAR OVERHEAD GUARD LEG
4.   REAR HANDLE
5.   REAR HORN SWITCH CONNECTOR
6.   HOOD
7.   LEFT HOOD MOUNTING BRACKET
Figure 76. Rear Horn Button Switch Arrangement
3.  Remove two capscrews that attach rear handle to right rear overhead guard leg.
 
See Figure 76. Remove handle from right rear overhead guard leg.
4.  Remove rear horn button switch and horn harness from the back of rear handle.
 
See Figure 77.
1.   RIGHT REAR OVERHEAD GUARD LEG
2.   REAR HORN BUTTON SWITCH AND HORN HARNESS
3.   REAR HANDLE
Figure 77. Rear Horn Button Switch Replace
Install

1.    Install new rear horn button switch and horn harness into rear handle.
2.  Thread horn harness and connector end through right overhead guard leg so that connector
 
end comes out the hole and into right hood mounting bracket. See Figure 76.
3.  Using two capscrews, attach rear handle and new horn button switch to right rear overhead
 
guard leg. See Figure 77.
4.    Connect main wire harness to rear horn switch connector. Close and secure hood.
5.    Connect the battery.
Hood Horn Button Switch

NOTE:  The hood horn button switch is an option found only on lift truck
models E3.2-3.5XN (E65-70XN) (A268) and E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099).
Remove
1.    Read and follow WARNING and CAUTION in General section above.
2.  Raise hood and disconnect main wire harness from hood horn switch connector.
 
See Figure 78.
3.  Close hood and remove two capscrews from rear handle. See Figure 78. Remove rear
 
handle from hood.

1.   HOOD HORN SWITCH CONNECTOR 4.   HOOD HORN BUTTON SWITCH

2.   CAPSCREWS 5.   HOOD
3.   REAR HANDLE
Figure 78. Hood Horn Button Switch Arrangement
4.    Remove hood horn button switch and horn harness from rear handle. See Figure 77.
Install

1.    Install new hood horn button switch and horn harness into rear handle. See Figure 77.
2.  Thread hood horn switch connector and horn harness through the hole in hood and using
 
two capscrews, install rear handle to hood. See Figure 78.
3.    Raise hood and connect hood horn switch connector to main wiring harness.
4.    Close hood after connecting the hood horn switch to main wiring harness.
5.    Connect the battery.
Motor Controllers Replacement
GENERAL

  WARNING 
Before replacing any of the motor controllers, fully lower all parts of the
mast and tilt it forward until the tips of the forks touch the ground. This
action will prevent the mast from lowering suddenly if the control lever
is accidently moved.

  WARNING 
Discharge capacitors as directed in Discharging the
Capacitors in General section at the beginning of this manual.
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors do not touch the other metal terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.

  CAUTION
DO NOT remove the small screws that fasten the cover of the motor
controller.
Make sure there is no dirt between the plate of the motor controller and
the mount surface of the lift truck frame.
The hydraulic pump and motor controller and traction motor controller, control and
monitor the electrical function for their respective components.
See Figure 79 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012.
See Figure 80 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012.
See Figure 81 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 82 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 83
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 84 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 85 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Before replacing any motor controllers, follow capacitor discharge procedure outlined
in Discharging the Capacitors in the General section of this manual. Attach a tag to
truck battery connector stating DO NOT CONNECT BATTERY. Remove the key
or turn the keyless switch OFF.
Make an identification for correct connection of the power cables on the power
terminals of the motor controller and all electrical connections that are disconnected
prior to removing the controller. This will aid in reconnecting during installation.
1.   FANS 6. HYDRAULIC PUMP AND MOTOR POWER
  CABLES
2. HYDRAULIC PUMP AND MOTOR
  CONTROLLER 7.   VEHICLE SYSTEM MANAGER
3.   LINE CONTACTOR 8.   TRACTION MOTOR
4.   TRACTION MOTOR CONTROLLER 9.   HYDRAULIC PUMP AND MOTOR
5.   TRACTION MOTOR POWER CABLES 10.   HYDRAULIC TANK
Figure 79. Motor Controllers and Electrical Components Arrangement,
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268), Manufactured Before
September, 2012
1.   FANS 6. HYDRAULIC PUMP AND MOTOR POWER
  CABLES
2. HYDRAULIC PUMP AND MOTOR
  CONTROLLER 7.   VEHICLE SYSTEM MANAGER
3.   LINE CONTACTOR 8.   TRACTION MOTOR
4.   TRACTION MOTOR CONTROLLER 9.   HYDRAULIC PUMP AND MOTOR
5.   TRACTION MOTOR POWER CABLES 10.   HYDRAULIC TANK
Figure 80. Motor Controllers and Electrical Components Arrangement,
Lift Truck Models E2.2-3.5XN (E45-70XN) (A268), Manufactured After
September, 2012
1. VEHICLE SYSTEM MANAGER MOUNTING 6.   HYDRAULIC PUMP AND MOTOR
  PLATE
7.   LINE CONTACTOR
2.   TRACTION MOTOR CONTROLLERS 8.   HYDRAULIC TANK
3.   HEATSINK 9. HYDRAULIC PUMP AND MOTOR
4.   FANS   CONTROLLER
5.   DRIVE AXLE ASSEMBLY 10.   POWER CABLES
Figure 81. Motor Controllers and Electrical Components Arrangement,
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), Manufactured Before
February, 2009
A. ELECTRICAL COMPONENTS FOR LIFT
TRUCK MODELS J2.2-3.5XN (J45-70XN)
(A276), EQUIPPED WITH OUTDOOR
  PROTECTION/WASH-DOWN PACKAGE,
MANUFACTURED AFTER OCTOBER,
2013
1.   VEHICLE SYSTEM MANAGER MOUNTING PLATE 6.   HYDRAULIC PUMP AND MOTOR
2.   TRACTION MOTOR CONTROLLERS 7.   LINE CONTACTOR
3.   HEATSINK 8.   HYDRAULIC TANK
4.   FANS 9. HYDRAULIC PUMP AND MOTOR
  CONTROLLER
5.   DRIVE AXLE ASSEMBLY
10.   POWER CABLES
Figure 82. Motor Controllers and Electrical Components Arrangement,
Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), Manufactured After
February, 2009
1.   DRIVE AXLE ASSEMBLY 6.   POWER CABLES
2.   TRACTION MOTOR CONTROLLER 7.   LINE CONTACTOR
3.   HEAT SINK 8. HYDRAULIC PUMP AND MOTOR
  CONTROLLER
4.   FANS
9.   HYDRAULIC TANK
5. VEHICLE SYSTEM MANAGER MOUNTING
  PLATE 10.   HYDRAULIC PUMP AND MOTOR
Figure 83. Motor Controllers and Electrical Components Arrangement,
Lift Truck Models, J4.0-5.0XN (J80-100XN) (A970)
1.   VEHICLE SYSTEM MANAGER 6.   FANS
2.   HYDRAULIC PUMP AND MOTOR CONTROLLER 7.   LINE CONTACTOR
3.   HYDRAULIC PUMP AND MOTOR 8.   TRACTION MOTOR CONTROLLER
4. HYDRAULIC PUMP AND MOTOR POWER 9. TRACTION MOTOR POWER
  CABLES   CABLES
5.   HYDRAULIC TANK 10.   TRACTION MOTOR
Figure 84. Motor Controllers and Electrical Components Arrangement
for Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
NOTE: BULKHEAD REMOVED FOR CLARITY.
1.   LINE CONTACTOR 6. HYDRAULIC PUMP AND MOTOR POWER
  CABLES
2.   FANS
7.   HYDRAULIC TANK
3.   TRACTION MOTOR CONTROLLER
8.   VEHICLE SYSTEM MANAGER
4. HYDRAULIC PUMP AND MOTOR
  CONTROLLER 9.   HYDRAULIC PUMP AND MOTOR
5.   TRACTION MOTOR POWER CABLES 10.   TRACTION MOTOR
Figure 85. Motor Controllers and Electrical Components Arrangement,
Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268) AND E1.6-2.0XN (E30-40XN)
(A269)
Traction Motor and Hydraulic Pump and Motor Controllers
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.  Remove the battery for access to the motor controllers. See the Operating Manual or
 
service manual
Periodic Maintenance 8000SRM1364 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
Periodic Maintenance 8000SRM1442 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
3.    Remove the plate that is in front of the motor controllers.
NOTE:  Make sure all power cables and electrical connections are clearly marked
before disconnecting them to help in reconnecting.
4.    Disconnect the power cables and all electrical connections from the motor controllers.
See Figure 86 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012.
See Figure 87 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012.
See Figure 88 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE:  Perform Step 5 for lift truck models E2.2-3.5XN (E45-70XN) (A268),
manufactured before September, 2012, and lift truck models E1.6-2.0XN (E30-40XN)
(A269).
5.  Remove eight flange capscrews from motor controllers. Remove motor controllers from
 
heatsink.
See Figure 86 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
See Figure 88 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE:  Perform Step 6 for lift truck models E2.2-3.5XN (E45-70XN) (A268),
manufactured after September, 2012.
6.  Remove eight flange capscrews from motor controllers and heatsink. Remove motor
 
controllers and heatsink from mounting bracket. See Figure 87.
NOTE: STANDARD PERFORMANCE MOTOR CONTROLLER PANELS
SHOWN. ENHANCED PERFORMANCE MOTOR CONTROLLER PANELS
ARE SIMILAR.
1.   FLANGE CAPSCREW 8.   FAN CONNECTORS
2. HYDRAULIC PUMP DRIVE MOTOR 9.   CONTACTOR
  CONTROLLER 10.   FUSE COVER
3.   TRACTION MOTOR CONTROLLER
11. CONTROLLER ELECTRICAL
4.   POWER CABLE U   CONNECTORS
5.   POWER CABLE V 12.   AIR DUCT
6.   POWER CABLE W 13.   FAN TO AIR DUCT
7.   FANS
Figure 86. Motor Controllers Replace for Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268), Manufactured Before September, 2012

NOTE: STANDARD PERFORMANCE MOTOR CONTROLLER PANELS

SHOWN. ENHANCED PERFORMANCE MOTOR CONTROLLER PANELS
ARE SIMILAR.
1.   FLANGE CAPSCREW 8.   FAN CONNECTORS
2. HYDRAULIC PUMP DRIVE MOTOR 9.   CONTACTOR
  CONTROLLER
10.   FUSE COVER
3.   TRACTION MOTOR CONTROLLER 11. CONTROLLER ELECTRICAL
4.   POWER CABLE U   CONNECTORS
5.   POWER CABLE V 12.   HEATSINK
6.   POWER CABLE W 13.   FAN AIR DUCT
7.   FANS 14. MOTOR CONTROLLERS MOUNTING
  BRACKET
 Figure 87. Motor Controllers Replace for Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268), Manufactured After September, 2012

NOTE: STANDARD PERFORMANCE MOTOR CONTROLLER PANELS

SHOWN. ENHANCED PERFORMANCE MOTOR CONTROLLER PANELS
ARE SIMILAR.
1.   FLANGE CAPSCREW 8.   FAN CONNECTORS
2. HYDRAULIC PUMP AND MOTOR 9.   CONTACTOR
  CONTROLLER 10.   FUSE COVER
3.   TRACTION MOTOR CONTROLLER
11. CONTROLLER ELECTRICAL
4.   POWER CABLE U   CONNECTORS
5.   POWER CABLE V 12.   HEATSINK
6.   POWER CABLE W 13.   FAN SPACER
7.   FANS
 Figure 88. Motor Controllers Replace for Lift Truck Models E1.6-2.0XN
(E30-40XN) (A269)
Install

NOTE:  The information in Step 1 and Step 2 applies to lift truck models E2.2-3.5XN

(E45-70XN) (A268), manufactured before September, 2012, and lift truck
models E1.6-2.0XN (E30-40XN) (A269).
1.  Before installing new motor controllers to heatsink, clean motor controllers and heatsink
mating surfaces to ensure they are clean and free of any debris or paint.
  Apply 1.5 mm (0.06 in.) coat of silicon grease (Hyster Part No. 1636646) to baseplate of
motor controllers and heatsink mating surface. The silicon grease should cover at least
90% of controller baseplate.
2.  Install new motor controllers to heatsink using eight flange capscrews. Tighten flange
 
capscrews to 13.5 to 17.5 N•m (119. to 155 lbf in).
See Figure 86 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
See Figure 88 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE:  The information in Step 3 applies to lift truck models E2.2-3.5XN (E45-
70XN) (A268), manufactured after September, 2012.
3.  Install new motor controllers and heatsink to motor controllers mounting bracket using
  eight flange capscrews. Tighten flange capscrews to 5.5 to 8.5 N•m (49 to 75 lbf in).
See Figure 87.
4.  Connect the fans and other electrical connections as noted during removal. Connect power
  cables at the power terminals of the motor controllers as identified during removal. Tighten
power cables to18 to 21 N•m (159 to 186 lbf in).
5.    Install the plate in front of the motor controllers using four capscrews.
6.    Install the battery in lift truck. See the Operating Manual or service manual
Periodic Maintenance 8000SRM1364 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
Periodic Maintenance 8000SRM1442 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
7.    Connect the battery.
LIFT TRUCK MODELS J2.2-3.5XN (J45-70XN) (A276) AND J4.0-5.0XN (J80-100XN)
(A970)
Hydraulic Pump and Motor Controller
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.  Remove the battery for access to the hydraulic pump and motor controller. See
 
the Operating Manual or service manual below for battery removal procedures.
Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
3.  Remove the counterweight cover and tow pin for access to the hydraulic pump and motor
 
controller. See Figure 89.

1.   COUNTERWEIGHT
2.   COUNTERWEIGHT COVER
3.   WASHER
4.   CAPSCREWS
5.   TOW PIN
Figure 89. Counterweight Cover Removal
NOTE:  Make sure all power cables and electrical connections are clearly marked
before disconnecting them to help aid in reconnecting.
4.    Disconnect the power cables and all electrical connections from hydraulic pump and motor
 controller.
See Figure 90 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 91 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 92 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
5.  Remove four flange capscrews from motor controller. Remove motor controller from
 
heatsink and lift truck frame.
See Figure 90 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 91 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 92 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE: STANDARD PERFORMANCE HYDRAULIC PUMP AND MOTOR
CONTROLLER PANEL SHOWN. ENHANCED PERFORMANCE
HYDRAULIC PUMP AND MOTOR CONTROLLER PANEL IS SIMILAR.
1.   FANS 8.   POWER CABLE W
2.   FAN CONNECTORS 9.   HYDRAULIC PUMP AND MOTOR
3.   AIR DUCT 10.   CONTACTOR
4.   FLANGE CAPSCREW 11. CONTROLLER ELECTRICAL
  CONNECTORS
5. HYDRAULIC PUMP AND MOTOR
  CONTROLLER 12.   HYDRAULIC TANK
6.   POWER CABLE U 13.   FAN SPACER
7.   POWER CABLE V
Figure 90. Hydraulic Pump and Motor Controller Replace, Lift Truck
Models J2.2-3.5XN (J45-70XN) (A276), Manufactured Before February,
2009
NOTE: STANDARD PERFORMANCE HYDRAULIC PUMP AND MOTOR
CONTROLLER PANEL SHOWN. ENHANCED PERFORMANCE
HYDRAULIC PUMP AND MOTOR CONTROLLER PANEL IS SIMILAR.
A. ELECTRICAL COMPONENTS FOR LIFT
TRUCK MODELS J2.2-3.5XN (J45-70XN)
  (A276), EQUIPPED WITH OUTDOOR
PROTECTION/WASH-DOWN PACKAGE,
MANUFACTURED AFTER OCTOBER, 2013
1.   FANS 8.   POWER CABLE W
2.   FAN CONNECTORS 9.   HYDRAULIC PUMP AND MOTOR
3.   AIR DUCT 10.   LINE CONTACTOR
4.   FLANGE CAPSCREW 11. CONTROLLER ELECTRICAL
  CONNECTORS
5.   HYDRAULIC PUMP AND MOTOR CONTROLLER
12.   HYDRAULIC TANK
6.   POWER CABLE U
13.   FAN SPACER
7.   POWER CABLE V
Figure 91. Hydraulic Pump and Motor Controller Replace, Lift Truck
Models J2.2-3.5XN (J45-70XN) (A276), Manufactured After February,
2009
NOTE: STANDARD PERFORMANCE HYDRAULIC PUMP AND MOTOR
CONTROLLER PANEL SHOWN. ENHANCED PERFORMANCE
HYDRAULIC PUMP AND MOTOR CONTROLLER PANEL IS SIMILAR.
1.   CONTACTORS 7.   CONTROLLER ELECTRICAL CONNECTORS
2.   POWER CABLE W 8.   FLANGE CAPSCREW
3.   FANS 9.   AIR DUCT
4.   FAN CONNECTOR 10.   HYDRAULIC PUMP AND MOTOR CONTROLLER
5.   POWER CABLE V 11.   HYDRAULIC TANK
6.   POWER CABLEU
Figure 92. Hydraulic Pump and Motor Controller Replace, Lift Truck
Models J4.0-5.0XN (J80-100XN) (A970)
Install

1.  Before installing new motor controller to heatsink, clean motor controller and heatsink
mating surface to ensure it is clean and free of any debris or paint.
  Apply 1.5 mm (0.06 in.) coat of silicon grease(Hyster Part No. 1636646) to baseplate of
motor controller and heatsink mating surface. The silicon grease should cover at least 90%
of controller baseplate.
2.  Install new hydraulic pump and motor controller onto heatsink with four flange capscrews.
 
Tighten flange capscrews to 13.5 to 17.5 N•m (119 to 155 lbf in).
NOTE:  Apply dielectric grease to the controller wiring harness connector for lift
truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
Wash-down Package
3.  Connect the fans and other electrical connections as noted during removal. Connect power
  cables at the power terminals of the hydraulic pump and motor controller as identified
during removal. Tighten power cables to 18 to 21 N•m (159 to 186 lbf in).
4.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
  Wash-down Package, spray power cable terminals on controller with rust inhibitor-ignition
sealer.
5.  Install the battery into the lift truck. See the Operating Manual or service manual section
 
below for battery installation procedures.
Periodic Maintenance 8000SRM1372 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
Periodic Maintenance 8000SRM1541 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
6.    Install the tow pin and counterweight cover using two capscrews. See Figure 89.
7.    Connect the battery.
8.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
  Protection/Wash-down package, spray battery connectors terminals with rust inhibitor-
ignition sealer, after tightening terminals.
9.  After install complete, perform ground test. See Frame 0100SRM1342, Ground Test
 
section.
Traction Motor Controllers
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.    Remove two bolts and belly pan from underside of lift truck.
3.    Disconnect motor controller connector from main wiring harness.
4.  Remove the floor mat. Remove rear floor plate. Remove capscrews and washers from front
floor plate and lift front floor plate up enough to disconnect the accelerator pedal
 
or MONOTROL® pedal. See Figure 93. Remove front floor plate with the accelerator
or MONOTROL® pedal still attached.
A.   STANDARD ACCELERATOR PEDAL B.   MONOTROL® PEDAL
1.   FRONT FLOOR PLATE 5. CAPSCREW, WASHER, NUT (FRONT FLOOR
  PLATE)
2.   CAPSCREW AND NUT (PEDAL BASE)
6.   REAR FLOOR PLATE
3.   PEDAL BASE
7.   MONOTROL® PEDAL CONNECTOR
4. ACCELERATOR PEDAL POSITION
  SENSOR
Figure 93. Removing Floor Plate and Accelerator or MONOTROL® Pedal
5.    Remove the brake pedal assembly for access to the traction motor controllers.
See Transaxle 1300SRM1370 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Transaxle 1300SRM1539 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE:  Make sure all power cables and electrical connections are clearly marked
before disconnecting them to help aid in reconnecting.
6.    Disconnect the power cables and all electrical connections from traction motor controllers.
See Figure 94 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 95 for lift trucks models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 96 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
7.  Remove eight flange capscrews securing the traction motor controllers to the air duct and
 
remove traction motor controllers.
1. TRACTION MOTOR 8.   RIGHT POWER CABLE U
  CONTROLLER
9.   RIGHT POWER CABLE V
2.   FLANGE CAPSCREW 10.   LEFT POWER CABLE W
3.   AIR DUCT 11.   LEFT POWER CABLE U
4.   FRONT BULKHEAD 12.   LEFT POWER CABLE V
5.   FAN 13. TRACTION MOTOR CONTROLLER CONNECTORS TO
6.   FAN CONNECTORS   MAIN WIRE HARNESS
7.   RIGHT POWER CABLE W 14.   FAN SPACER
Figure 94. Traction Motor Controllers, Replace, Lift Truck Models J2.2-
3.5XN (J45-70XN) (A276), Manufactured Before February, 2009
1.   RIGHT TRACTION MOTOR CONTROLLER
2.   LEFT TRACTION MOTOR CONTROLLER
3.   FLANGE CAPSCREW
4.   FANS
5.   FAN CONNECTIONS
6.   TRACTION MOTOR CONTROLLER CONNECTORS TO MAIN WIRE HARNESS
7.   RIGHT POWER CABLE U TERMINAL
8.   LEFT POWER CABLE U TERMINAL
9.   RIGHT POWER CABLE V TERMINAL
10.   RIGHT POWER CABLE W TERMINAL
11.   LEFT POWER CABLE V TERMINAL
12.   LEFT POWER CABLE W TERMINAL
13.   FRONT BULKHEAD
Figure 95. Traction Motor Controllers, Replace, Lift Truck Models J2.2-
3.5XN (J45-70XN) (A276), Manufactured After, 2009
1.   FRONT BULKHEAD 7.   RIGHT POWER CABLE U
2.   FAN CONNECTORS 8. TRACTION MOTOR CONTROLLER CONNECTORS TO
  MAIN WIRE HARNESS
3.   FAN
9.   LEFT POWER CABLE W
4. TRACTION MOTOR
  CONTROLLER 10.   LEFT POWER CABLE V
5.   RIGHT POWER CABLE W 11.   LEFT POWER CABLE U
6.   RIGHT POWER CABLE V
Figure 96. Traction Motor Controller, Replace, J4.0-5.0XN (J80-100XN)
(A970)
Install

1.  Before installing new motor controllers to heatsink, clean motor controllers and heatsink
 
mating surface to ensure they are clean and free of any debris or paint.
2.    Install new traction motor controllers into air duct using eight flange capscrews.
NOTE:  Apply dielectric grease to the controller wiring harness connector for lift
truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
Wash-down Package.
3.  Connect the fans and other electrical connections as noted during removal. Connect power
  cables at the power terminals of the traction motor controllers as identified during removal.
Tighten power cables to 18 to 21 N•m (159 to 186 lbf in).
4.    For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
Wash-down Package, spray power cable terminals on controller with rust inhibitor-ignition
 sealer.
5.    Install the brake pedal assembly. For installation procedure
See Transaxle 1300SRM1370 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Transaxle 1300SRM1539 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
6.  Connect the accelerator pedal or MONOTROL® pedal, (see Figure 93) and install the front
 
floor plate using capscrews and washers. Install rear floor plate.
7.    Connect motor controller connector to main wiring harness.
8.    Install belly pan and two bolts onto underside of lift truck.
9.    Connect the battery.
10.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
  Protection/Wash-down Package, spray battery connector terminals with rust inhibitor-
ignition sealer, after tightening terminals.
11.  After install complete, perform ground test. See Frame 0100SRM1342, Ground Test
 
section.
LIFT TRUCK MODEL E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Traction Motor and Hydraulic Pump and Motor Controllers
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.  Remove the battery for access to the motor controllers. See the Operating Manual or
 
service manual Periodic Maintenance 8000SRM1577.
NOTE:  Make sure all power cables and electrical connections are clearly marked
before disconnecting them to help in reconnecting.
3.  Disconnect the power cables and all electrical connections from the motor controllers.
 
See Figure 97.
4.    Remove twelve flange capscrews from motor controllers. See Figure 97.
5.    Remove motor controllers and heatsink from air duct as an assembly. See Figure 97.
6.    Remove sixteen screws securing motor controllers to heatsink. See Figure 97.
NOTE: STANDARD PERFORMANCE MOTOR CONTROLLER PANELS
SHOWN. ENHANCED PERFORMANCE MOTOR CONTROLLER PANELS
ARE SIMILAR.
1.   FUSE COVER 9. HYDRAULIC PUMP AND MOTOR
  CONTROLLER
2.   CONTACTOR
10.   POWER CABLE U
3.   FAN
11.   POWER CABLE V
4.   AIR DUCT
12.   POWER CABLE W
5.   FLANGE CAPSCREW
13.   FAN CONNECTORS
6.   SCREW
14.   HEATSINK
7. CONTROLLER ELECTRICAL
  CONNECTORS 15.   LINE CONTACTOR BRACKET CAPSCREW
8.   TRACTION MOTOR CONTROLLER
Figure 97. Motor Controllers Replace for Lift Truck Model E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Install

1.    Before installing new motor controllers to heatsink, clean motor controllers and heatsink
mating surfaces to ensure they are clean and free of any debris or paint.
Apply 1.5 mm (0.06 in.) coat of silicon grease (Hyster Part No. 1636646) to baseplate of
 motor controllers and heatsink mating surface. The silicon grease should cover at least
90% of controller baseplate.
2.    Install sixteen screws into motor controller and heatsink. See Figure 97.
3.    Install motor controller and heat sink in air duct.
4.    Install twelve flange capscrews and tighten to 9 to 11 N•m (80 to 97 lbf in).
5.  Connect the fans and other electrical connections as noted during removal. Connect power
cables at the power terminals of the motor controllers as identified during removal. For the
 
traction motor controller, tighten power cables to 10 N•m (89 lbf in). For the hydraulic
pump and motor controller, tighten power cables to 16 N•m (142 lbf in).
6.  Install the battery in lift truck. See the Operating Manual or service manual Periodic
 
Maintenance 8000SRM1577.
7.    Connect the battery.
LINE CONTACTOR

NOTE:  The procedures to replace the line contactor are the same for all lift truck
models covered in this repair manual. The line contactor is located on the right side of
the counterweight, just above the traction motor controller for lift truck models E2.2-
3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099).
See Figure 79 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012.
See Figure 80 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012.
See Figure 84 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 85 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
The line contactor is located just above the hydraulic pump and motor for lift truck
models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970).
For lift truck model J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
Protection/Wash-down Package, the line contactor is enclosed and power fuse is
shrouded.
See Figure 81 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 82
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 83
•   J4.0-5.0XN (J80-100XN) (A970)
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.    Remove the counterweight cover for access to the line contactor.
See Figure 98 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 89 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)

1.   CAPSCREWS
2.   COUNTERWEIGHT COVER
3.   COUNTERWEIGHT
Figure 98. Counterweight Cover Removal, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
NOTE:  Tag or mark line contactor wire connections before disconnecting them to
aid in reconnecting during installation.
3.    Disconnect all wires from line contactor.
See Figure 99 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 100 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 101 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 102 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/Wash-down Package,
 
manufactured after October, 2013
See Figure 103 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 104 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)

NOTE: SEVERAL ELECTRICAL COMPONENTS AND CONNECTIONS

OMITTED FOR CLARITY.
1.   CAPSCREW
2.   MAIN WIRE HARNESS CONNECTIONS
3.   PTC THERMISTOR ASSEMBLY
4.   LINE CONTACTOR
5.   MOUNTING BRACKET
6.   FUSE COVER
Figure 99. Line Contactor Replacement, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268) Manufactured Before September, 2012 and E1.6-
2.0XN (E30-40XN) (A269)

NOTE: SEVERAL ELECTRICAL COMPONENTS AND CONNECTIONS

OMITTED FOR CLARITY.
A.   LINE CONTACTOR USED ON LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268)
B.   TWO POLE LINE CONTACTOR OPTION USED ON LIFT TRUCK MODELS E2.2-3.5XN (A268)
1.   CAPSCREW
2.   MAIN WIRE HARNESS CONNECTIONS
3.   PTC THERMISTOR ASSEMBLY
4.   LINE CONTACTOR
5.   MOUNTING BRACKET
6.   FUSE COVER
Figure 100. Line Contactor Replacement, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268) Manufactured After September, 2012
NOTE: SOME ELECTRICAL COMPONENTS AND CONNECTIONS
OMITTED FOR CLARITY.
A. LIFT TRUCK MODELS J2.2-3.5XN (J45- B. LIFT TRUCK MODLES J2.2-3.5XN (J45-
  70XN) (A276), MANUFACTURED BEFORE   70XN) (A276), MANUFACTURED AFTER
FEBRUARY, 2009 FEBRUARY, 2009
1.   CAPSCREWS 6.   MOUNTING BRACKET
2. MAIN WIRE HARNESS 7. HYDRAULIC PUMP AND MOTOR
  CONNECTIONS   CONTROLLER
3.   PTC THERMISTOR ASSEMBLY 8.   HYDRAULIC PUMP AND MOTOR
4.   FUSES 9.   LINE CONTACTOR FUSE
5.   LINE CONTACTOR
Figure 101. Line Contactor Replacement, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276)
1.   HYDRAULIC PUMP AND MOTOR CONTROLLER
2.   HYDRAULIC PUMP AND MOTOR
3.   LINE CONTACTOR POWER FUSE SHROUD
4.   LINE CONTACTOR POWER FUSE
5.   FUSES
6.   CAPSCREWS
7.   PTC THERMISTOR ASSEMBLY
8.   LINE CONTACTOR
9.   MAIN WIRE HARNESS CONNECTIONS
Figure 102. Line Contactor Replacement for Lift Truck Models J2.2-
3.5XN (J45-70XN) (A276), Equipped With Outdoor Protection/Wash-down
Package

NOTE: SOME ELECTRICAL COMPONENTS AND CONNECTIONS

OMITTED FOR CLARITY.
1.   CAPSCREWS
2.   MAIN WIRE HARNESS CONNECTIONS
3.   PTC THERMISTOR ASSEMBLY
4.   FUSES
5.   LINE CONTACTOR
6.   MOUNTING BRACKET
7.   HYDRAULIC PUMP AND MOTOR CONTROLLER
8.   HYDRAULIC PUMP AND MOTOR
Figure 103. Line Contactor Replacement, Lift Truck Models J4.0-5.0XN
(J80-100XN) (A970)
1.   LINE CONTACTOR
2.   PTC THERMISTOR
3.   FUSE COVER
4.   MAIN WIRE HARNESS CONNECTION
5.   MOUNTING BRACKET
6.   CAPSCREW
Figure 104. Line Contactor Replacement, Lift Truck Model E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
4.    Remove two capscrews and remove line contactor from mounting bracket.
See Figure 99 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 100 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 101 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 102 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/Wash-down Package
See Figure 103 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE:  Perform Step 5 and Step 6 for lift truck model E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099).
5.    Remove two line contactor bracket capscrews. See Figure 97.
6.  Remove four capscrews from back of mounting bracket securing line contactors to
 
mounting bracket. See Figure 104.
Install
1.  Before installing new line contactor, check to ensure the PTC thermistor assembly is on
 
contactor posts.
See Figure 99 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 100 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 101 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 102 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/Wash-down Package
See Figure 103 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE:  Perform Step 2 and Step 3 for lift truck model E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099).
2.    Install new line contactors to mounting bracket using four capscrews. See Figure 104.
3.  Install mounting bracket in lift truck using two line contactor bracket capscrews and
 
tighten to 66 to 83 N•m (49 to 61 lbf ft).
4.    Install new line contactor to mounting bracket using two capscrews.
See Figure 99 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 100 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 101 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 102 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/Wash-down Package
See Figure 103 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
5.    Connect all wires to line contactor in same positions as noted during removal.
6.    Install the counterweight cover using two capscrews.
See Figure 98 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 89 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 104 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
7.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor Protection/
  Wash-down Package, spray rust inhibitor-ignition sealer on line contactor fuse power cable
terminals, after tightening nuts retaining line contactor fuse. See Figure 101.
8.    Connect the battery.
9.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
  Protection/Wash-down Package, spray battery connector terminals with rust inhibitor-
ignition sealer, after tightening terminals.
FANS FOR LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-
40XN) (A269), J2.2-3.5XN (J450-70XN) (A276) AND J4.0-5.0XN (J80-100XN) (A970)

NOTE:  For all lift truck models except E2.2-3.5XN (E45-70XN)

(A268) manufactured after September, 2012, the same style of fan assembly is used
and the procedures to install a new fan assembly are the same.
For lift truck models E2.2-3.5XN (E45-70XN) (A268) manufactured before
September, 2012, and lift truck models E1.6-2.0XN (E30-40XN) (A269) the fan
assembly is located on two fan spacers mounted to the heatsink on the counterweight,
just above the hydraulic pump and motor controller.
See Figure 79 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
See Figure 84 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
(A970) there are two sets of fans. One set is located on the right side of the
counterweight mounted on two fan spacers, mounted to the heatsink, just above the
hydraulic pump and motor controller. The other fan set is located under the floor plate
and mounted to two fan spacers on the heatsink above the traction motor controller.
See Figure 81 for lift truck model
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 82
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 83
•   J4.0-5.0XN (J80-100XN) (A970)
For lift truck models E2.2-3.5XN (E45-70XN) (A268) manufactured after September,
2012 three fan assemblies are mounted to an air duct, which is mounted to the motor
controllers mounting bracket just above the traction motor controller and hydraulic
pump and motor controller. See Figure 106.
Remove

1.    Read and follow the WARNING and CAUTION in the General section above.

2.  Remove the counterweight cover for lift truck models E2.2-3.5XN (E45-70XN)
(A268), E1.6-2.0XN (E30-40XN) (A269), J2.2-3.5XN (J45-70XN) (A276), and J4.0-
 
5.0XN (J80-100XN) (A970) if the fans for the hydraulic pump and motor controller will be
replaced.
See Figure 98 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 89 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
3.  On lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
(A970), if the fans for the traction motor are being replaced, remove the floor mat. Remove
 
rear floor plate. Remove capscrew, washer, and nut from front floor plate. Remove front
floor plate with accelerator or MONOTROL® pedal still attached. See Figure 93.
4.    Disconnect main wire harness from fan assembly.
See Figure 86 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
See Figure 87 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 88 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 90, and Figure 94 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
NOTE:   DO NOT discard finger guard removed in Step 5 and Step 6. It will be used
with new fan assembly.
5.  For all lift truck models, except E2.2-3.5XN (E45-70XN) (A268) manufactured after
  September, 2012, remove four screws that attach fan assembly to fan spacer. Remove
finger guard and fan assembly from fan spacer. See Figure 105.
6.    For lift truck models E2.2-3.5XN (E45-70XN) (A268) manufactured after September,
 2012, remove four capscrews that attach fan assembly to air duct. Remove finger guard
and connector from clip. Remove fan assembly from air duct. See Figure 106.

NOTE: FAN FOR E1.6-2.0XN (E30-40XN) (A269) SHOWN. OTHER FANS

SIMILAR.
1.   FAN SPACER
2.   FAN ASSEMBLY
3.   FINGER GUARD
4.   SCREWS
Figure 105. Fan Assembly Replacement, All Lift Truck Models
Except E2.2-3.5XN (E45-70XN) (A268) Manufactured After September,
2012
1.   SCREWS 4.   AIR DUCT
2.   FINGER GUARD 5.   CONNECTOR
3.   FAN ASSEMBLY 6.   CONNECTOR CLIP
Figure 106. Fan Assembly Replacement, Lift Truck Models E2.2-3.5XN
(E45-70XN) (A268) Manufactured After September, 2012
Install

NOTE:  For all lift truck models, except E2.2-3.5XN (E45-70XN)

(A268) manufactured after September, 2012, when installing new fan assembly, fan
connector wire must be on right bottom of fan assembly when viewed from the motor
controller side.
For lift truck models E2.2-3.5XN (E45-70XN) (A268) manufactured after September,
2012, when installing new fan assembly, fan connector wire must be on center bottom
of fan assembly when viewed from the motor controller side.
See Figure 86 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured before September, 2012
See Figure 87 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268) manufactured after September, 2012
See Figure 88 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 90 and Figure 94 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured before February, 2009
See Figure 91 and Figure 95 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276), manufactured after February, 2009
See Figure 92 and Figure 96 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
1.  For all lift truck models, except E2.2-3.5XN (E45-70XN) (A268) manufactured after
  September, 2012, install new fan assembly and finger guard to fan spacer with four screws.
See Figure 105.
2.  For lift truck models E2.2-3.5XN (E45-70XN) (A268) manufactured after September,
 
2012, install new fan assembly and finger guard to air duct with four capscrews.
3.    Connect main wire harness to fan assembly.
4.  Install the counterweight cover, if the fans for the hydraulic pump and motor controller
 
were replaced.
See Figure 98 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 89 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
5.  For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
(A970), if the fans for the traction motor were replaced, connect the accelerator pedal
 
or MONOTROL®pedal, (see Figure 93) and install the front floor plate using capscrews,
washers, and nuts. Install rear floor plate. Install floor mat.
6.    Connect the battery.
FANS FOR LIFT TRUCK MODEL E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099)

NOTE:  The same style of fan assembly is used on all lift truck models covered in
this service manual. The procedures to install a new fan assembly are the same for all
trucks.
The fan assembly is mounted to the air duct on the counterweight, just above the
traction motor and hydraulic pump and motor controllers for lift truck model E4.0-
5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099). See Figure 97.
Remove

1.    Read and follow the WARNING and CAUTION in the General section above.

2.    Remove the counterweight cover. See Figure 98.
3.    Disconnect main wire harness from fan assembly. See Figure 97.
NOTE:   DO NOT discard finger guard. It will be used with new fan assembly.
4.  Remove four screws that attach fan assembly to air duct. Remove finger guard and fan
 
assembly from air duct. See Figure 105.
5.    Repeat Step 4 for three other fan assemblies.
Install

NOTE:  When installing new fan assembly, fan connector wire must be on left
bottom of fan assembly when viewed from the motor controller side. See Figure 97.
1.    Install new fan assembly and finger guard to air duct with four screws. See Figure 105.
2.    Repeat Step 1 for three other fan assemblies.
3.    Connect main wire harness to fan assembly. See Figure 97.
4.    Install the counterweight cover. See Figure 98.
5.    Connect the battery.
Vehicle System Manager
GENERAL

  WARNING 
Before replacing the Vehicle System Manager (VSM), fully lower all parts
of the mast and tilt it forward until the tips of the forks touch the ground.
This action will prevent the mast from lowering suddenly if the control
lever is accidently moved.
Never have any metal on your fingers, arms, or neck. These metal items
can accidentally create an electrical connection and cause an injury.

  WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
the General section at the beginning of this manual.
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors DO NOT touch the other metal terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.
   CAUTION
Make sure there is no dirt between the plate of the VSM and the mount
surface of the lift truck frame.
The Vehicle System Manager (VSM) is a microprocessor-powered controller which
controls or monitors directly or indirectly, every electrical device on the lift truck.
For lift truck models E2.2-3.5XN (E45-70XN) (A268), J2.2-3.5XN (J45-70XN)
(A276), J4.0-5.0XN (J80-100XN) (A970) and E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099) the VSM is located on a mounting bracket under the floor mat and
floor plate and to the left of the front bulkhead. See Figure 107.
For lift truck models E1.6-2.0XN (E30-40XN) (A269) the VSM is mounted to a
bracket that is attached to the center of the front bulkhead. See Figure 108.
REMOVE

NOTE:  The VSM is not a serviceable part. If it malfunctions, replace with a new

VSM. See Parts Manual for replacement part number.
1.    Read and follow WARNING and CAUTION section above in General section.
2.    Remove floor mat.
3.    Remove rear floor plate.
4.  Remove capscrews and washers from front floor plate and lift front floor plate up enough
 
to disconnect accelerator pedal or MONOTROL® pedal. See Figure 93.
5.    Remove front floor plate with accelerator or MONOTROL® pedal still attached.
NOTE:  Be sure to tag all connectors to aid correct installation.
6.    Disconnect two main harness electrical connectors from VSM.
7.  Remove bolts securing VSM to VSM mounting bracket on front bulkhead. Remove VSM
 
from lift truck.
See Figure 107 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 108 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE: VEHICLE SYSTEM MANAGER FOR LIFT TRUCK MODELS J2.2-
3.5XN (J45-70XN) (A276) WITH E-HYDRAULIC CONTROLS SHOWN.
1.   FRONT BULKHEAD 4.   VEHICLE SYSTEM MANAGER
2.   VSM MOUNTING BRACKET 5.   MAIN HARNESS ELECTRICAL CONNECTORS
3.   BOLTS
Figure 107. Vehicle System Manager Removal, Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-
100XN) (A970) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
1.   FRONT BULKHEAD 4.   VEHICLE SYSTEM MANAGER
2.   VSM MOUNTING BRACKET 5.   MAIN HARNESS ELECTRICAL CONNECTORS
3.   BOLTS
Figure 108. Vehicle Systems Manager Removal, Lift Truck Models E1.6-
2.0XN (E30-40XN) (A269)
INSTALL
1.    Install new VSM onto mounting bracket. Tighten bolts to 19 N•m (168 lbf in).
NOTE:  On lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
Protection/ Wash-down Package, apply dielectric grease to VSM electrical connectors
before performing Step 2.
2.    Connect all electrical connections, as noted, to VSM.
See Figure 107 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 108 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
3.    Connect accelerator pedal or MONOTROL® pedal, and install front floor plate using
 capscrews and washers.
4.    Install rear floor plate.
5.    Install floor mat and connect the battery. See Figure 93.
PROGRAMMING A NEW VSM AND/OR DISPLAY PANEL

NOTE:  See section Diagnostic Troubleshooting Manual 9000SRM1377 for

information on how delete and reset fault codes to the VSM, how to use the PC
Service Tool software, and for the procedures to troubleshoot the VSM, display panel,
and other electrical components used on these trucks.
NOTE:  When installing a new VSM or Display use PC Service Tool to upload
Application Code and the correct Configuration Data File.
Two file types are required to operate the VSM; Application Code File and
Configuration Data File (CDF). New VSMs will have the Application Code loaded
but you will need to upload a truck specific CDF.
•   Application Code File - These are operating files for the VSM and Display.
• Configuration Data File (CDF) - This file contains a unique set of data values that
represent how a truck is equipped, how systems are controlled, and what options are
enabled. The CDF is also linked and unique to the truck serial number. An example of a
lift truck serial number is K160V12345A001. The first 11 characters (K160V12345A)
represent the truck’s serial number and the last 3 digits (001) represent the CDF revision
loaded on the truck. The serial number of a lift truck is stored in the display panel.
 
See User Interface 2200SRM1336 for the procedures to find the serial number. The CDF
can be found online at Hypass Online® using the serial number.
The CDF revision will change every time a new version is ordered and transferred
to Hypass Online®. The CDF cannot be modified by a service technician. However, a
replacement file (with alternate options [SEF]) can be loaded into a truck VSM by a
service technician.
PC SERVICE TOOL SOFTWARE

The PC Service Tool software is not used to transfer backup copies whenever a new
VSM or display panel is installed on a lift truck. Backup copies are generated
automatically when the system detects that a blank (new) VSM or display panel has
been installed.
A non-blank VSM or display panel is one that has been used previously. A non-blank
VSM or display panel is not usable outside of the system it was originally connected
to. In other words, a VSM or display panel cannot be removed from one lift truck and
installed onto another lift truck. If a VSM or display panel must be replaced, a new
part (blank) must be used. See the Parts Manual for part numbers for replacement
parts.
To perform diagnostic service, the PC Service Tool software can be used. To connect
the PC Service Tool, remove the dust cover that covers the PC service tool diagnostic
connector on the right side of the steering column and connect the interface
cable (Hyster Part No. 1534010) to the PC service tool diagnostic connector.
See Figure 109. All transfers will create a transfer log on the PC's hard drive and can
be accessed by service personnel. The file transfer log will include all serial number
transfers and other configuration information related to a specific truck. For minimum
PC requirements to run the software, refer to the PC Service Tool Installation and Use
Guide, Systems Requirements section.

1.   DUST COVER
2.   TILT MEMORY LEVER
Figure 109. Connecting PC Service Tool
Fuses and Relays
Fuses

  WARNING 
Disconnect the battery and separate the connector before opening the
compartment cover or inspecting/repairing the electrical system. If a tool
causes a short circuit, the high-current flow from the battery can cause
an injury or parts damage.

  WARNING 
Use only fuses of the same type and rating as specified
in Figure 110, Figure 111, and Figure 112. Replacing fuses of a different
type or with higher or lower amperage ratings than specified may cause
injury or parts damage.

  WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
the General section at the beginning of this manual.
The fuse panel for lift trucks covered in this service manual are located in the
counterweight. For lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-
2.0XN (E30-40XN) (A269), fuses are located on back wall and right side of
counterweight, just above traction motor controller. See Figure 110.
For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
(A970), fuses are mounted on same bracket as line contactor. The fuses and line
contactor assembly bracket is mounted to a crossmember in the center of
counterweight.
See Figure 111 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
See Figure 112 for lift truck models
•   J4.0-5.0XN (J80-100XN) (A970)
The fuse panel for lift truck model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
(A099) is located under counterweight cover above and centered between motor
controllers. See Figure 112.
NOTE: STANDARD PERFORMANCE CONTROLLER SHOWN. ENHANCED
PERFORMANCE IS SIMILAR.
A. FUSE LOCATION FOR LIFT TRUCK MODELS E2.2-
  3.5XN (E45-70XN) (A268) MANUFACTURED BEFORE
SEPTEMBER, 2011
B. FUSE LOCATION FOR LIFT TRUCK MODELS E2.2-
  3.5XN (E45-70XN) (A268) MANUFACTURED AFTER
SEPTEMBER, 2011
C. FUSE LOCATION FOR LIFT TRUCK MODEL E1.6-2.0XN
  (E30-40XN) (A269)
1.   LINE CONTACTOR 5.   FUSE WIRES
2.   COUNTERWEIGHT 6.   FUSE COVER
3.   FUSES (5 AMPS AND 15 AMPS) 7.   HYDRAULIC PUMP AND MOTOR CONTROLLER
4.   TRACTION MOTOR CONTROLLER
 Figure 110. Fuse Location for Lift Truck Models E2.2-3.5XN (E45-70XN)
(A268) and E1.6-2.0XN (E30-40XN) (A269)

NOTE: STANDARD PERFORMANCE CONTROLLER SHOWN. ENHANCED

PERFORMANCE IS SIMILAR.
A. FUSE LOCATION ON LIFT TRUCK MODELS
  MANUFACTURED BEFORE SEPTEMBER, 2009 (STANDARD
APPLICATION)
B. FUSE LOCATION ON LIFT TRUCK MODELS
  MANUFACTURED AFTER NOVEMBER, 2013 (OUTDOOR
APPLICATION)
C. FUSE LOCATION ON LIFT TRUCK MODELS
  MANUFACTURED AFTER SEPTEMBER, 2009 (STANDARD
APPLICATION)
1.   LINE CONTACTOR 4.   FUSE WIRES
2.   COUNTERWEIGHT 5.   FUSE COVER
3.   FUSES (5 AMPS AND 15 AMPS) 6.   CROSSMEMBER
7.   HYDRAULIC PUMP AND MOTOR CONTROLLER
Figure 111. Fuse Locations for Lift Truck Models J2.2-3.5XN (J45-70XN)
(A276)
NOTE: STANDARD PERFORMANCE CONTROLLER SHOWN. ENHANCED
PERFORMANCE IS SIMILAR.
A. FUSE LOCATION ON LIFT TRUCK MODELS E4.0-5.5XN,
  E5.0XNS (E80-120XN, E100XNS) (A099)
B. FUSE LOCATION ON LIFT TRUCK MODELS J4.0-5.0XN (J80-
  100XN) (A970)
1.   LINE CONTACTOR 4.   FUSE WIRES
2.   COUNTERWEIGHT 5.   FUSE COVER
3.   FUSES (5 AMPS AND 15 AMPS) 6.   CROSSMEMBER
7.   HYDRAULIC PUMP AND MOTOR CONTROLLER
Figure 112. Fuse Locations for Lift Truck Models E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099) and J4.0-5.0XN (J80-100XN) (A970)
Remove the counterweight cover for access to the fuses.
See Figure 113 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 114 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
Fuses must be checked with a multimeter. Discharge capacitors as specified
in Discharging the Capacitors in General section at the beginning of this service
manual.
1.   CAPSCREWS
2.   COUNTERWEIGHT COVER
3.   COUNTERWEIGHT
Figure 113. Counterweight Cover Removal, Lift Truck Models E2.2-
3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN) (A269), and E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
1.   COUNTERWEIGHT
2.   COUNTERWEIGHT COVER
3.   WASHER
4.   CAPSCREWS
5.   TOW PIN
Figure 114. Counterweight Cover Removal, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276) and J4.0-5.0XN (J80-100XN) (A970)
Before replacing any failed fuses, check to see what caused the fuse to open before
connecting the battery. Make certain to replace any failed fuse with one of the same
type and amperage.
For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
Protection/Wash-down Package, spray fuse connection with rust inhibitor-ignition
sealer.
Relays

  WARNING 
Disconnect the battery and separate the connector before opening the
compartment cover or inspecting/repairing the electrical system. If a tool
causes a short circuit, the high-current flow from the battery can cause
an injury or parts damage.

  WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
the General section at the beginning of this manual.
NOTE:  When replacing relays, use only Hyster approved relays.
On lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269), relays and receptacles are mounted in the center of front bulkhead.
On lift truck models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN)
(A970), and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099), relays and
receptacles are mounted on left side of front bulkhead, near Vehicle Systems Manager
(VSM).
For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
Protection/Wash-down Package, control circuit relays are sealed relays with sealed
connectors or fitted with individual weatherproof covers.
See Figure 115 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 116 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
1.    Remove floor mat and floor plate for access to relays.
2.    Remove relay from receptacle.
See Figure 115 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 116 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
3.    For lift truck models J2.2-3.5XN (J45-70XN) (A276), equipped with Outdoor
Protection/Wash-down Package, apply dielectric grease to flasher relay terminal
 connections.
4.    Replace with new relay by aligning the relay with mounting holes in receptacle.
5.    Install floor plate and floor mat.

NOTE: RELAYS FOR LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN)

(A268) SHOWN. RELAYS FOR TRUCKS EQUIPPED WITH OPTIONAL E-
HYDRAULICS, OPTIONAL SYNCHRONOUS STEERING, AND OTHER
OPTIONS SHOWN.
1.   KEYSWITCH RELAY (12 VOLTS) 6. TURN SIGNAL RELAY (24
  VOLTS)
2.   E-HYDRAULIC RELAY (24 VOLTS)
7.   FRONT BULKHEAD
3. SYNCHRONOUS STEER VALVE RELAY (24
  VOLTS) 8.   RECEPTACLE
4.   BRAKE LIGHT RELAY (24 VOLTS) 9.   WIRE HARNESS
5.   REVERSE RELAY (24 VOLTS)
Figure 115. Relay Replacement for Lift Truck Models E2.2-3.5XN (E45-
70XN) (A268), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN)
(A970), and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
A.   MANUAL HYDRAULICS B.   E-HYDRAULICS
1.   KEY SWITCH RELAY 5.   RECEPTACLE
2.   FLASHER (TURN SIGNAL OPTION) RELAY 6.   WIRE HARNESS
3.   BRAKE LIGHT RELAY 7.   E-HYDRAULIC ENABLE RELAY
4.   REVERSE RELAY 8.   FRONT BULKHEAD
Figure 116. Relay Replacement for Lift Truck Model E1.6-2.0XN (E30-
40XN) (A269)

Backup Alarm

  WARNING 
DO NOT operate a truck if the backup alarm does not function properly.
Injury to personnel may occur.
A backup alarm is used to indicate backwards travel. When backing up, the operator
may be preoccupied with the position of the mast or carriage or have a restricted range
of visibility. The backup alarm sounds when the lift truck is moved backwards to alert
nearby traffic to pay close attention when near the lift truck. The alarm is located
inside of the counterweight.
See Figure 117 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 118 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 119 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
If backup alarm is not functioning properly, remove counterweight cover for access.
See Figure 113 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 114 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
Test voltage to backup alarm by sitting in seat and moving Direction Control Switch
(DCS) to reverse position. When proper voltage (12 to 48 volts) is reaching the
assembly yet no sound is produced, the assembly must be replaced. Disconnect alarm
connector from lighting wiring harness. Remove two capscrews attaching alarm to
mounting plate. Position new backup alarm as removed and secure using two
capscrews. Tighten capscrews to 3.5 to 4 N•m (31 to 35 lbf in). Connect alarm
connector as removed and test for proper operation. Install counterweight cover and
return to service.
NOTE: SEVERAL COMPONENTS OMITTED FOR CLARITY.
A. BACKUP ALARM LOCATION FOR B. BACKUP ALARM LOCATION FOR LIFT TRUCK
  LIFT TRUCK MODELS E2.2-3.5XN   MODELS J2.2-3.5XN (J45-70XN) (A276) AND J4.0-
(E45-70XN) (A268) 5.0XN (J80-100XN) (A970)
1.  MOUNTING PLATE 4.   BACKUP ALARM
2.   ALARM CONNECTOR 5.   COUNTERWEIGHT
3.   CAPSCREW 6.   CROSSMEMBER
Figure 117. Backup Alarm for Lift Truck Models E2.2-3.5XN (E45-70XN)
(A268), J2.2-3.5XN (J45-70XN) (A276), and J4.0-5.0XN (J80-100XN)
(A970)

1.   MOUNTING PLATE 4.   BACKUP ALARM

2.   ALARM CONNECTOR 5.   COUNTERWEIGHT
3.   CAPSCREW
Figure 118. Backup Alarm for Lift Truck Model E1.6-2.0XN (E30-40XN)
(A269)
1.   MOUNTING PLATE 4.   BACKUP ALARM
2.   ALARM CONNECTOR 5.   COUNTERWEIGHT
3.   CAPSCREW
Figure 119. Backup Alarm for Lift Truck Model E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099)
Battery Connection
The battery cables supply power from the battery terminals through the battery cable
connectors and then to the connections of the motor controllers and main contactor in
the truck.
INSPECT

Inspect battery cables for cuts or damage to insulation. Inspect for abrasions of
insulation or burned insulation or connector ends. Inspect battery connectors for worn
or damaged cable ends or cracked housings. Overheated cables or heat affected
terminal lug ends are signs of cable damage, loose connections, or improper battery
charging or maintenance. Replace any damaged cables and repair or replace damaged
battery connectors.
REPLACING CABLES

  WARNING 
Making repairs with the battery connected can cause a short circuit.
Disconnect the battery by separating the connectors before inspecting
or repairing the electrical system.
Be careful using tools near the battery terminals. Contact between
terminals can cause a short circuit. High current flow during a short
circuit can result in injury or parts damage.
1.  Move lift truck to a safe, level area and completely lower mast. Turn key switch
  to OFF position and attach a DO NOT OPERATE tag to control handle. Block drive
wheel to prevent unexpected movement.
2.  Pull connector (battery side) from fixed connector (truck side) to separate battery cable
 
connectors. See Figure 120.

Figure 120. Battery Connector and Cables

3.    If power cables or connector (battery side) are damaged, replace cables:
a.  Remove battery from lift truck. See Operating Manual or Periodic Maintenance for
 
procedures to remove battery from lift truck.
b.    Disconnect cables from battery terminals.
c.    Install new cables.
d.  Reinstall battery to lift truck. See Operating Manual or Periodic Maintenance for
 
procedures to install battery in lift truck.
e.    Connect battery connectors.
4.    If power cables or connector (truck side) are damaged, replace cables:
a.    For lift trucks manufactured before June 2012:
Remove floor mat. Remove rear floor plate. Remove capscrews and washers from
front floor plate and lift front floor plate up enough to disconnect accelerator pedal
or MONOTROL® pedal. SeeFigure 93. Remove front floor plate with accelerator
or MONOTROL® pedal still attached for access to main contactor.
For lift trucks manufactured after June 2012:
Remove floor mat. Remove rear floor plate. Lift front floor plate up enough to
disconnect accelerator pedal or MONOTROL® pedal. See Figure 32. Remove front
floor plate with accelerator orMONOTROL® pedal still attached for access to main
contactor.
b.  Discharge capacitors. See Discharging the Capacitors in General section of this manual for
 
procedures.
NOTE:  Make note of position of cables for proper reinstallation.
c.  Remove nuts securing cables to terminals of main contactor. Remove cables from
 
terminals.
d.  Remove two clamps securing cables to frame inside electrical compartment. One cable is
 
on top of hydraulic filter and the other is under hydraulic motor.
e.    Remove hardware securing connector (truck side) to mounting bracket.
f.    Remove power cables from lift truck.
g.    Route new cables into electrical compartment.
h.    Secure connector to mounting bracket using capscrews and attaching hardware.
i.  Position power cables onto terminals as removed. Secure cables to terminals of main
 
contactor and hoist controller using attaching hardware.
j.  Install two clamps securing power cables to frame inside electrical compartment as
 
removed.
k.  Connect accelerator pedal or MONOTROL® pedal, (see Figure 93) and install front floor
  plate using capscrews and washers. Install rear floor plate. Install floor mat and connect the
battery.
Cab Heater
For repair procedures on the cab heater refer to section Operator's
Cab 0100SRM1446.

Lights
GENERAL

  WARNING 
Before replacing any of the lights, fully lower all parts of the mast and tilt
it forward until the tips of the forks touch the ground. This action will
prevent the mast from lowering suddenly if the control lever is
accidently moved.
Never have any metal on your fingers, arms, or neck. These metal items
can accidentally create an electrical connection and cause an injury.

  WARNING 
Discharge capacitors as directed in Discharging the Capacitors in
General section of this manual.
Disconnect the battery before doing any work on the electrical system.
Serious injury to personnel and/or damage to lift truck components can
occur if battery is not disconnected.

  CAUTION
A short circuit and damage can occur if wires are not installed correctly.
Make sure wire connectors do not touch the other metal terminals or
wire connectors, metal brackets, or the bracket mounting nuts. Make
sure the wires are not pulled tight and are not touching other parts to
damage the insulation.
There are several different options for lights used on lift trucks covered in this service
manual. Your lift truck may not be equipped with all lights discussed in this section.
See Figure 121 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
See Figure 122 for lift truck models
•   E1.6-2.0XN (E30-40XN) (A269)
NOTE: LIFT TRUCK MODELS E2.2-3.5XN (E45-70XN) (A268) SHOWN.
LIGHTS ARRANGEMENT FOR LIFT TRUCK MODELS J2.2-3.5XN (J45-
70XN) (A276), J4.0-5.0XN (J80-100XN) (A970), AND E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099) IS THE SAME.
A.   FRONT VIEW C.   REAR VIEW AFTER JUNE 2012
B.   REAR VIEW BEFORE JUNE 2012
1.   FRONT WORK LIGHTS 4.   LED TAIL, BACKUP, AND BRAKE LIGHTS
2.   FRONT MARKER/TURN SIGNAL LIGHTS 5.   REAR WORK LIGHTS
3.   STROBE LIGHT
Figure 121. Lights Arrangement for Lift Truck Models E2.2-3.5XN (E45-
70XN) (A268), J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN)
(A970) and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
A.   FRONT VIEW C.   REAR VIEW AFTER JUNE 2012
B.   REAR VIEW BEFORE JUNE 2012
1.   FRONT WORKLIGHT 4.   STROBE LIGHT
2.   FRONT MARKER/TURN SIGNAL LIGHT 5.   TAIL, BACKUP, AND BRAKE LIGHT
3.   DOME LIGHT 6.   REAR WORK LIGHT
Figure 122. Lights Arrangement for Lift Truck Model E1.6-2.0XN (E30-
40XN) (A269)
WORK LIGHTS (FRONT AND REAR)
Halogen Bulb Lights
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Disconnect negative battery cable from terminal.

  CAUTION
DO NOT touch the Halogen bulb surface or inside reflectors with your
bare hands. Oils from skin can lead to breakage or shorten the life of the
lamp. Use clean gloves or lint free cloth for installation and removal.
Clean any dirt or oil, from the lamp surface with alcohol and a lint free
cloth or tissue. Any foreign particles or materials on the bulb surface
can cause hot spots on the bulb and result in lamp failure.
3.  To replace bulb, remove lens assembly by removing four capscrews. See Figure 123.
 
Replace bulb and reinstall lens assembly.
4.  To replace work light assembly, disconnect overhead guard harness from light and remove
  capscrew, washer, and nut attaching work light to overhead guard for front work lights, or
to mounting bracket for rear work lights.
Install

1.  Install work light on overhead guard using capscrew, washer, and nut. See Figure 123.
 
Tighten nut to 20 N•m (177 lbf in). Connect overhead guard harness to work light.
2.    Connect negative battery cable to terminal.
NOTE: REAR WORK LIGHT SHOWN, FRONT WORK LIGHT IS SIMILAR.
1.   CAPSCREWS (LENS ASSEMBLY)
2.   LENS ASSEMBLY
3.   NUT (ATTACHES LIGHT TO OVERHEAD GUARD)
Figure 123. Halogen Bulb Work Lights
LED Lights

NOTE:  LED work lights are an optional feature on lift trucks covered in this service
manual. If LED work light malfunctions, the whole LED work light assembly must be
replaced.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Disconnect negative battery cable from terminal.
3.    Disconnect overhead guard harness from work light.
4.  Remove locknut, washer, and capscrew and remove LED work light from overhead guard.
 
See Figure 124.
1.   LOCKNUT
2.   WASHER
3.   CAPSCREW
4.   MOUNTING BRACKET
5.   LED LIGHT ASSEMBLY
Figure 124. LED Work Lights
Install

1.  Install new LED work light assembly by using capscrew, washer, and locknut. Tighten nut
 
to 20 N•m (177 lbf in). See Figure 124.
2.    Connect overhead guard harness to work light.
3.    Connect negative battery cable to terminal.
STROBE LIGHT

NOTE:  The strobe light may either be mounted above the top of overhead guard
(high-mounted) or below the top of overhead guard (low-mounted). The removal and
installation procedures are the same for both options.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Disconnect negative battery cable from terminal.
3.    Disconnect overhead guard harness from strobe light electrical connector.
4.  Remove capscrews, washers, lockwasher, and nuts securing strobe light and light guard to
  strobe light mounting bracket. See Figure 125. Remove strobe light and guard from lift
truck.
NOTE:  If strobe light on your lift truck is equipped with a replaceable halogen bulb,
go to Step 5. If strobe light is equipped with LED lights, the whole light assembly
must be replaced. Go to Step 2 in theInstall section.
5.  If strobe light bulb needs to be replaced, remove strobe light lens from base and remove
 
bulb.
Install

1.  If bulb is being replaced, install new bulb into strobe light base. Install strobe light lens
 
onto base.
2.  Place strobe light assembly and strobe light guard onto mounting bracket. Secure assembly
 
to mounting bracket with capscrews, washers, lockwasher, and nuts. See Figure 125.
3.    Connect overhead guard harness to strobe light electrical connector.
4.    Connect negative battery cable to terminal.

1.   CAPSCREW
2.   MOUNTING BRACKET
3.   STROBE LIGHT BULB
4.   STROBE LIGHT GUARD
5.   NUT
6.   STROBE LIGHT LENS
7.   LIGHT BASE
Figure 125. Strobe Light Assembly
LED TAIL, BACKUP, AND BRAKE LIGHTS

NOTE:  These light assemblies are nonrepairable and must be replaced as an

assembly. See Parts Manual for replacement LED lights.
Remove

1.    Read and follow WARNING and CAUTION section in General section above.

2.    Remove key, or turn keyless switch OFF, if truck is equipped with this switch.
3.    Disconnect negative battery cable from terminal.
4.  Remove torx head screw securing LED light assembly to LED light housing.
 
See Figure 126.
5.    Disconnect chassis light harness from LED light assembly.
6.  If LED light housing must be removed from overhead guard leg, remove two capscrews
  and LED light housing from overhead guard leg. The inserts should remain attached to
housing. See Figure 126.

1.   TORX HEAD SCREW

2.   LED LIGHT ASSEMBLY
3.   CAPSCREW
4.   LED LIGHT HOUSING
5.   INSERT
Figure 126. LED Tail, Backup, and Brake Lights Replacement
Install

1.    If LED light housing was removed, install housing on overhead guard leg with two
 capscrews and inserts.
2.    Connect chassis light harness to LED light assembly.
3.  Insert torx head screw and install LED light assembly to LED light housing.
 
See Figure 126.
4.    Connect negative battery cable to terminal.
FRONT MARKER/TURN SIGNAL LIGHTS
Remove

1.    Read and follow WARNING and CAUTION in General section above.

2.    Disconnect negative battery cable from terminal.
3.    Disconnect light wire harness from front marker/turn signal light connector.
4.  Remove two bolts located at top of the front marker/turn signal light assembly and inside
 
corner of overhead guard. See Figure 127.
5.  Remove front marker/turn signal light assembly from overhead guard and trim.
 
See Figure 127.

NOTE: RIGHT FRONT MARKER/TURN SIGNAL LIGHT ASSEMBLY

SHOWN. PROCEDURES TO REMOVE AND REPLACE LEFT FRONT
MARKER/TURN SIGNAL LIGHT ASSEMBLY ARE THE SAME.
1.   FRONT MARKER/TURN SIGNAL LIGHT ASSEMBLY
2.   CONNECTOR
3.   BOLT
4.   OVERHEAD GUARD
5.   TRIM
Figure 127. Front Marker/Turn Signal Light Assembly Removal
Install

1.  Install new front marker/turn signal light assembly to overhead guard and trim using two
 
bolts. See Figure 127.
2.    Connect light wire harness to front marker/turn signal light connector.
3.    Connect negative battery cable to terminal.
DOME LIGHT
Remove

1.    Read and follow WARNING and CAUTION in General section above.

2.    Disconnect negative battery terminal.
3.    Disconnect light wire harness from dome light connector.
4.    Remove two screws and dome light from overhead guard. See Figure 128.

1.   SCREWS
2.   DOME LIGHT
3.   OVERHEAD GUARD
Figure 128. Dome Light
Install

1.    Install new dome light and two screws on overhead guard. See Figure 128.
2.    Connect light wire harness to dome light connector.
3.    Connect negative battery terminal.
CONVERTER

The LED tail, backup, and brake Lights operate at 12 volts with a DC/DC converter.
On lift truck models E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN (E30-40XN)
(A269), and E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099), the standard
converter is mounted to the front bulkhead, behind the hydraulic pump and motor. Lift
truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269) may also be equipped with an optional converter that is mounted on the right
wall of the frame.
On lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
(A970), the converter is mounted on the rear bulkhead, in front of the hydraulic tank.
See Figure 129 for lift truck models
•   E2.2-3.5XN (E45-70XN) (A268)
•   E1.6-2.0XN (E30-40XN) (A269)
See Figure 130 for lift truck models
•   J2.2-3.5XN (J45-70XN) (A276)
•   J4.0-5.0XN (J80-100XN) (A970)
See Figure 131 for lift truck model
•   E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
Remove

1.    Read and follow the WARNING and CAUTION section in the General section above.

2.    Disconnect negative battery cable from terminal.
3.  For lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269), remove the floor mat. Remove rear floor plate. Remove capscrews and washers
  from front floor plate and lift front floor plate up enough to disconnect the accelerator
pedal or MONOTROL® pedal. Remove front floor plate with the accelerator
or MONOTROL® pedal still attached for access to the converter. See Figure 93.
4.  For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
  (A970), remove the tow pin and counterweight cover for access to the converter.
See Figure 89.
5.    Disconnect main wire harness from electrical connector. See Figure 129.
6.  For lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269), remove four capscrews from converter and remove converter from front bulkhead.
 
If lift truck is equipped with an optional converter, remove two capscrews from converter
and remove converter from mounting plate. See Figure 129.
7.  For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
  (A970), remove four capscrews from converter and remove converter from rear bulkhead.
See Figure 130.
8.  For lift truck model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) remove two
 
capscrews from converter and remove converter from front bulkhead. See Figure 131.
A.   STANDARD CONVERTER LOCATION B.   OPTIONAL CONVERTER LOCATION
1.   CAPSCREW 5.   MOUNTING PLATE
2.   CONVERTER 6.   IMPACT SENSOR
3.   ELECTRICAL CONNECTION 7.   HYDRAULIC PUMP AND MOTOR
4.   FRONT BULKHEAD
 Figure 129. Converter, Lift Truck Models E2.2-3.5XN (E45-70XN)
(A268) and E1.6-2.0XN (E30-40XN) (A269)

1.   CAPSCREW 4.   HYDRAULIC TANK

2.   CONVERTER 5.   REAR BULKHEAD
3.   ELECTRICAL CONNECTION
Figure 130. Converter, Lift Truck Models J2.2-3.5XN (J45-70XN)
(A276) and J4.0-5.0XN (J80-100XN) (A970)
1.   FRONT BULKHEAD 4.   CONVERTER
2.   MOUNTING PLATE 5.   HYDRAULIC PUMP AND MOTOR
3.   CAPSCREW
Figure 131. Converter, Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-
120XN, E100XNS) (A099)
Install

1.  For lift truck model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099) install new
 
standard converter on front bulkhead using two capscrews. See Figure 131.
2.  For lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269), install new, standard converter on the front bulkhead using four capscrews. If lift
 
truck is equipped with optional converter, install new, optional converter to mounting plate
using two capscrews. See Figure 129.
3.  For lift truck models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN (J80-100XN)
 
(A970), install new converter on the rear bulkhead using four capscrews. See Figure 130.
4.  Apply 3 mm (0.12 in.) of lubricating grease, (Hyster P/N 1463849) to each terminal
 
opening on electrical connector plug on main wire harness.
5.    Connect converter to main wiring harness.
6.    Connect negative battery cable to terminal.
7.  For lift truck models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN (J80-100XN)
  (A970), E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099), install the tow pin and
counterweight cover. See Figure 89.
8.  For lift truck models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN)
(A269), connect the accelerator pedal or MONOTROL® pedal, and install the front floor
 
plate using capscrews and washers. Install rear floor plate. Install floor mat and connect the
battery. See Figure 93.