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Hyster E2.2-3.5XN (E45-70XN) (A268) Forklift Service Manual

2,806 pages · Publication A268

$289.75
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Models
E2.2-3.5XN (E45-70XN) (A268)
Manual type
Service Manual
Pages
2,806
Publication
A268
Condition
Brand new
Hyster E2.2-3.5XN (E45-70XN) (A268) Forklift Service Manual, publication A268

What's inside

From the manual's own table of contents: 199 sections, 441 entries. See sample pages (PDF, 362 KB)

Frame
Safety Precautions Maintenance and Repair
General2 topics
  • Frame
  • Discharging the Capacitors
Overhead Guard Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)2 topics
  • Remove
  • Install
Overhead Guard Replacement for Lift Truck Models J2.2-3.5XN (J45
Battery Restraint and Seat Assembly Repair1 topic
  • Operator Restraint System and Seat Assembly
Hood and Seat Assembly Replacement for Lift Truck Models E2.2-31 topic
  • Ground Test
Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3
Master Cylinder Repair and Adjustment for Lift Truck E2.2-3.5XN
Master Cylinder Repair and Adjustment for Lift Truck J2.2-3.5XN6 topics
  • Disassemble
  • Clean
  • Inspect
  • Assemble
  • Bench Bleed Master Cylinder
  • Install and Adjust
Brake Pedal Components for Lift Trucks E2.2-3.5XN (E45-70XN) (A2
Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A271 topic
  • Pedal Adjust
Brake System Air Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A3 topics
  • Brake System Air Removal
  • Using Pressure Bleed System
  • Using Brake Pedal Pressure
Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN) (
Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)
Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN)
Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)
Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN (
Hydraulic Tank Inspection
Painting Instructions
Safety Label Replacement
Battery Specifications
Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A2683 topics
  • Overhead Guard
  • Counterweight
  • Traction Motor
Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276
Show all 199 sections
Table 1. Counterweights for Lift Truck E2.2-3.5XN (E45-70XN) (A2
Table 2. Counterweights for Lift Truck E1.6-2.0XN (E30-40XN) (A2
Table 3. Counterweights for Lift Truck J2.2-3.5XN (J45-70XN) (A2
Drive Axle, Speed Reducer, and Differential
Drive Axle Repair
Differential Repair1 topic
  • Clean and Inspect
Torque Specifications
Table 1. Pinion Variation Numbers Examples
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. Correct Tooth Contact
Table 4. Incorrect Tooth Contact
Steering Axle
Steering Axle Assembly Repair
Tie Rod Replacement
Spindle Repair
Steering Cylinder Repair
Steering System
Steering Control Unit (SCU) Repair
Steering Wheel and Fixed Steering Column Assembly Repair1 topic
  • Gear Replacement for Lift Trucks Built Prior to October, 2008
Steering Wheel and Telescopic Column Assembly Repair2 topics
  • Steering Control Unit
  • Steering Column
Brake System1 topic
  • Dry Brake System
Service Brakes Repair (Dry Brake)3 topics
  • Remove and Disassemble
  • Assemble and Install
  • Adjust
Parking Brake Repair
Master Cylinder Repair
Brake Pedal Components
Automatic Park Brake1 topic
  • Adjustments
Service Brakes Adjustment (Dry Brake)1 topic
  • Brake Adjust
Parking Brake Adjustment
Brake System Air Removal
Brake Pedal Adjustment
Master Cylinder Adjustment1 topic
  • Adjust Push Rod
Parking Brake Not Applied Switch Test
Hydraulic System
Hydraulic Pump and Motor
Hydraulic Tank4 topics
  • Hydraulic Filter Replacement
  • Breather Clean and Inspect
  • Hydraulic Oil Cooler for Lift Truck Models J4.0-5.0XN (J80-100XN
  • Add Hydraulic Oil
Steer Accumulator Replacement
Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268)1 topic
  • Tank Capacity
Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
Specifications for Lift Truck J4.0-5.0XN (J80-100XN) (A970)
Specifications for Lift Truck E4.0-5.5XN, E5.0XNS (E80-120XN, E12 topics
  • Hydraulic Pump and Motor
  • Hydraulic Tank
Torque Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269
Torque Specifications for Lift Truck J4.0-5.0XN (J80-100XN) (A97
Torque Specifications for Lift Truck E4.0-5.5XN, E5.0XNS (E80-12
Table 1. Hydraulic Pump Motor
Table 2. Hydraulic Pump Motor
Table 3. Hydraulic Pump Motor
Table 4. Hydraulic Pump Motor
Table 5. Hydraulic Pump Motor
Main Control Valves
Manual Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT5 topics
  • Disassemble Handles and Levers
  • Disassemble Manual Control Valve
  • Spool Seal Replacement
  • Assemble Manual Control Valve
  • Assemble Handles and Levers
Manual Hydraulic Control Valve Repair E2.2-3.5XN (E45-70XN) (A26
Manual Hydraulic Control Valve Repair E4.0-5.5XN, E5.0XNS (E80-1
E-Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT (J301 topic
  • E-Hydraulic Controls
E-Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN (E45
E-Hydraulic Control Valve Repair for Lift Truck E4.0-5.5XN, E5.0
Checks and Adjustments for Lift Truck J1.5-2.0XNT (J30-40XNT) (K3 topics
  • Manual Control Valve
  • E-Hydraulic Control Valve
  • Hydraulic System Air Removal
Checks and Adjustments for Lift Truck E2.2-3.5XN (E45-70XN) (A26
Position Sensor and OPS Check and Adjustment3 topics
  • Position Sensor
  • (OPS) Operator Presence Solenoid
  • Manual Control Valve Re-Calibration
Calibration Procedure1 topic
  • Control Valve
Torque Specifications for Lift Truck J1.5-2.0XNT (J30-40XNT) (K13 topics
  • Manual Hydraulic Control Valve
  • Manual Control Valve Handles and Levers
  • Manual Control Valve Covers
Table 1. Handle Options
Table 2. Position Sensor Connector Pin Layout
Table 3. Position Sensor Electrical Connector Pin Layout
Table 4. Handle Options
Table 5. Position Sensor Electrical Connector Pin Layout
Table 6. Handle Options
Table 7. Lower Solenoid Connector Pin Layout
Table 8. Upper Solenoid Connector Pin Layout
Table 9. Lower Solenoid Connector Pin Layout
Table 10. Upper Solenoid Connector Pin Layout
Table 11. Lower Solenoid Connector Pin Layout
Table 12. Upper Solenoid Connector Pin Layout
Table 13. Pressure Specifications
Table 14. Test Specifications
Table 15. Service Tools
Table 16. Position Sensor Wiring
Table 17. Sensor Power Check
Periodic Maintenance4 topics
  • Serial Number Data
  • How to Move Disabled Lift Truck
  • How to Put Lift Truck on Blocks
  • How to Clean a Lift Truck
Safety Procedures When Working Near Mast1 topic
  • WHEN WORKING NEAR THE MAST ALWAYS
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily2 topics
  • How to Make Checks With Key or Keyless Switch OFF
  • How to Make Checks With Key or Keyless Switch ON
Maintenance Procedures Every 500 Hours or Three Months17 topics
  • Forks
  • Header Hose Checks
  • Mast Lubrication
  • Parking Brake Adjustment
  • Brake Fluid Check
  • Operator Presence System Check
  • Differential and Speed Reducer
  • Tilt Cylinder Rod End Pins
  • Lift Chains
  • Lift Chain Lubrication
  • Fork Pins and Guides
  • Check Upper and Lower Bearings, Integral Sideshift Carriage
  • Check Lower Mounting Hook, Integral Sideshift Carriage
  • Steering King Pins
  • Hydraulic Tank Breather, Check
  • Other Lubrication
  • Contactor
Maintenance Procedures Every 2000 Hours or Yearly6 topics
  • Hydraulic System
  • Differential and Speed Reducer Oil Change
  • Brake Fluid Replacement
  • Service Brakes
  • Integral Sideshift Carriage, Replace Upper and Lower Bearings
  • Wheel Bearings
Maintenance Procedures Every 4000 Hours Or Two Years3 topics
  • Hydraulic Oil, Change
  • Steering Direction Sensor Inspection
  • Telescopic Steering Column Lubrication
Battery Maintenance2 topics
  • How to Charge Battery
  • How to Change Batteries
Lift and Tilt System Leak Check2 topics
  • Lift Cylinders Leak Check
  • Tilt Cylinder Leak Check
Lift Chain Adjustments
Welding Repairs
Overhead Guard Changes
Wheels and Tires2 topics
  • Remove Wheels From Lift Truck
  • Remove and Install Tire on Wheel
Adhesives and Sealants
Table 1. Maintenance Schedule
Table 2. Hook-Type Carriage Chain Adjustment
Capacities and Specifications
Counterweights2 topics
  • Specifications
  • Turning Radius
Capacities
Tilt Angles
Maximum Carriage and Tilt Creep Rates
Mast Speeds7 topics
  • Drive Axle
  • Brake System
  • Steering Axle
  • Masts
  • Tilt Cylinders
  • Hydraulic Control Valves
  • Electrical System
Table 1. Manual Hydraulic Control Valve
Table 2. E-Hydraulic Control Valve
Table 4. Lift/Lower Speed, Standard Performance, 36 Volts
Table 5. Lift/Lower Speed, Standard Performance, 48 Volts
Table 6. Lift/Lower Speed Enhanced Performance, 48 Volts
Table 7. Lift/Lower Speed, Enhanced Performance, 80 Volts
Diagnostic Troubleshooting Manual
Safety Precautions TROUBLESHOOTING PROCEDURES1 topic
  • Service Manual Lookup
How To Use This Troubleshooting Manual5 topics
  • General Instructions and Safety Information
  • How to Use Diagnostic Troubleshooting Manual
  • General Instructions
  • Conventional Battery Box (CBB) Units
  • Drop Battery Box (DBB) Units
Operational Diagnostic Procedures1 topic
  • Operational Checkout Procedures
Traction Motor1 topic
  • Poor Tractive Performance
Electrical System8 topics
  • Troubleshooting Guidelines and Procedures
  • Wiring Reference Data
  • Harness Assembly Data
  • None
  • DTC None
  • Horn Failure
  • Lights Inoperative
  • Icon Glossary
Drive Axle/Unit5 topics
  • One Drive Wheel Will Not Move
  • Noise During Operation That Is Not Normal
  • Oil Leaks
  • Park Brake Does Not Operate Properly
  • Motion Inhibited
Hydraulic Systems59 topics
  • Manual Hydraulic Main Control Valve
  • E-Hydraulic Main Control Valve
  • Steering System
  • Abnormal Hydraulic Noise and/or Vibration
  • Abnormal Smell/Discoloration/Foaming of Oil
  • Cycle Times Too Fast - Fast Actuation (E-Valve)
  • Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve
  • Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-V
  • Jump/Delay In Tilt Forward or Back Actuation (E-Valve)
  • Forks Drop Slightly Before Lifting (E-Valve)
  • Forks Lower Without Command (E-Valve)
  • Forks Raise or Actuate Without Command (E-Valve)
  • Hydraulic Oil Cooler Not Functioning Correctly
  • Intermittent Activation (E-Valve) While Commanding Function
  • Forks Tilt Forward Without Command (E-Valve)
  • Lift/Lower Function Maximum Speed Too Slow (E-Valve)
  • Lift Function Will Not Move With MLM Movement (E-Valve)
  • Lift/Lower Continues To Move For Awhile After MLM Is Released (E
  • Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke
  • Lower Function Will Not Move With MLM Movement (E-Valve)
  • Poor Metering on Lift or Lower Functions (E-Valve)
  • Auxiliary Function Continues to Move for Awhile After MLM Is Rel
  • Auxiliary Function Maximum Speed Too Slow (E-Valve)
  • Auxiliary Function or Tilt Back Moves Without Command (E-Valve)
  • Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move
  • Tilt Forward or Tilt Back Function Continues to Move for Awhile
  • Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Val
  • Too Much MLM Movement (Deadband) to Start Function Moving (E-Val
  • Wrong Actuation Operates or Actuation is Backward (E-Valve)
  • Actuation Exhibits Slight Movement in Opposite Direction Before
  • Auxiliary Function is Slow or Does Not Function (Manual Valve)
  • Cycle Times Too Fast - Fast Actuation (Manual Valve)
  • Function Continues to Activate After Returning to Neutral
  • Lift Function Is Slow or Does Not Function (Manual Valve)
  • Tilt Back Function Will Not Operate (Manual Valve)
  • Tilt Forward or Tilt Back Will Not Function When Activated (Manu
  • No Steering (All Other Hydraulic Functions OK)
  • Steering Is Slow or Difficult
  • Steering Operation Is Not Smooth
  • Steering Wheel End Lock Position Cannot Be Felt by Operator
  • Steering Wheel Turns By Itself or Does Not Return To Neutral
  • Steering Wheel Turns the Tires in the Wrong Direction
  • Actuations Do Not Act Simultaneously
  • Oil Leaking/Component Life Too Short
  • Abnormal Steer Axle Noise
  • Abnormal Steering Wheel Vibration
  • Back Lash/Kick Back in Steering Wheel
  • Hydraulic Warm-up Procedure
  • Primary Relief Valve Test and Adjustment
  • Secondary Relief Valve Test and Adjustment
  • Hydraulic Pump Flow Test
  • Main Control Valve LS Leakage Test (E-Valve)
  • Main Control Valve Unloader Margin Test
  • E-Hydraulic Valve Leakage Test
  • Steering Relief Pressure Test and Adjustment
  • Steering Control Unit LS Pressure Test
  • Lift Cylinder Leakage Test
  • Tilt Cylinder Leakage Test
  • Steering Cylinder Leakage Test
Operators Station8 topics
  • Operator Station General Description and Principles of Operation
  • Display Panel
  • Programming - Menus
  • Display Menu Flowchart
  • Manual Hydraulic Control Levers
  • E-Hydraulic System Interface
  • Lighting Control
  • Cab Panels
Front End (Mast) and Chassis35 topics
  • Front End, Mast
  • Carriages
  • Mast Mounts
  • Two-Stage Full Free-Lift (FFL) Mast
  • Two-Stage Limited Free-Lift (LFL) Mast
  • Three-Stage Full Free-Lift (FFL) Mast
  • Four-Stage Full Free-Lift (FFL) Mast
  • Cylinder Cushion During Lifting Sequence
  • Cylinder Cushion During Lowering Sequence
  • Tilt and Sideshift Cylinders
  • Lowering Control Valves
  • Chassis
  • Abnormal Channel Wear
  • Abnormal Hose Wear
  • Abnormal Mast Noise
  • Body Panels Making Noise
  • External Leakage From Free-Lift or Main Lift Cylinders
  • FFL Mast Banging During Phasing
  • High Tire Wear - Drive Axle
  • High Tire Wear - Steer Axle
  • Hoses Not Tracking Correctly
  • Integral Sideshift Moving Too Fast
  • Integral Sideshift Not Moving or Slow
  • Fork Positioner Not Moving or Slow
  • Mast is Loose
  • Mast Lift Chains Are Loose
  • Mast or Carriage Binding
  • Mast/Carriage Bounces or is Spongy
  • Misphasing of Full Free-Lift Mast
  • Overhead Guard Loose or Damaged
  • Racking During Lift
  • Racking During Tilt
  • Truck Feels Unstable
  • Truck Wanders, Does Not Track Straight or Steer Well
  • Wheel Studs Breaking
Supplementary Data1 topic
  • Abbreviations and Acronyms
Table 9030-03-1. Circuit Group Identification
Table 9030-03-2. Hyster Wiring Color Codes
Table 9030-10-1. VSM Connection
Table 9030-10-2. Motor Temperature Sensor
Table 9030-20-1. Main Schematic
Table 9030-20-2. Device Connectors
Table 9030-20-3. Main Schematic
Table 9030-20-4. Device Connectors
Table 9030-20-5. Main Schematic
Table 9030-20-6. Device Connectors
Table 9030-20-7. Main Schematic
Table 9030-20-8. Device Connectors
Table 9030-20-9. Display Internal Failure Fault DTCs
Table 9030-20-10. Motor Controller Temperature and Silicon Tempe
Table 9050-43-1. Test Specifications
Table 9050-43-2. Service Tools
Table 9050-43-3. Service Tools
Table 9050-43-4. Test Specifications
Table 9050-43-5. Test Specifications for Lift Trucks J1.5-2.0XNT
Table 9050-43-6. Test Specifications for Lift Trucks E2.2-3.5XN
Table 9050-43-7. Service Tools
Table 9050-43-8. Test Specifications
Table 9050-43-9. Service Tools
Table 9050-43-10. Test Specifications
Table 9050-43-11. Test Specifications
Table 9050-43-13. Test Specifications
Table 9050-43-14. Test Specifications
Table 9050-43-16. Test Specifications
Table 9050-43-18. Test Specifications
Table 9050-43-20. Test Specifications
Table 9050-43-22. Test Specifications
Table 9060-10-1. Display Panel
Table 9060-10-2. Activity Logs
Table 9060-10-3. Calibration
Table 9060-10-4. Diagnostics
Table 9060-10-6. Truck Status
Table 9060-10-7. Display Adjustments
Table 9080-50-1. Abbreviations and Acronyms
AC Motor Repair2 topics
  • Discharging the Capacitors for Lift Truck Models E30-40HSD 2 (B2
  • Discharging the Capacitors (All Other Models)
Traction Motor Repair
Hydraulic Motor Repair8 topics
  • Traction Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) an
  • Traction Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) a
  • Hydraulic Motor for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
  • Hydraulic Motor for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
  • Hydraulic Motor for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
  • Hydraulic Motor for Lift Truck E30-40HSD 2 (B219)
  • Hydraulic Motor for Lift Truck J4.0-5.0XN (J80-100XN) (A970) and
Table 1. Speed Sensor Connector
Table 2. Thermal Sensor Connector
Diagrams
Operator's Cab
Window Replacement3 topics
  • Front Panel
  • Rear Panel
  • Door Window
Window Wipers Replacement1 topic
  • Front Wiper Assembly
Cab Component Repair2 topics
  • Roof Liner
  • Top Panel
Cab Door Assembly1 topic
  • Door Assembly
Cab Heater
Weather Panel Replacement for Lift Truck Model E2.2-3.5XN (E45-7
Table 1. Connector C1
Table 2. Connector C2
Table 3. Connector C3
Table 4. Connector C4
Table 5. Connector C5
Table 6. Connector C6
Table 7. Connector C7

Inside this manual

Real pages from this service manual (2,806 pages). Open the sample pages (PDF, 361 KB)

Sample pages from the Hyster E2.2-3.5XN (E45-70XN) (A268) Forklift Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page
  • Specifications, page 1,448: Lift Height
  • Troubleshooting, page 2,179: Drive Axle/Unit
  • Diagram, page 2,523: Diagrams, Schematics, or Arrangements
  • Color page, page 1,738: Diagnostic Trouble Codes
  • Color page, page 2,402: Observed Symptoms

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 2,806 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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