OPERATOR'S CAB

J2.2-3.5XN (J45-70XN) [A276];

J1.5-2.0XNT (J30-40XNT) [K160];
E2.2-3.5XN (E45-70XN) [A268];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
[A970];
A1.3XNT, A1.5XNT [D203]

PART NO. 4025482 0100 SRM 1446

 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 authorized Hyster®
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 in-
structions 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 ex-
ceed 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 flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Discharging the Capacitors ................................................................................................................................ 2
Window Replacement ..............................................................................................................................................2
Front Panel ..........................................................................................................................................................2
Remove, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) K160), and J1.6-2.0XN (J30-40XN) (A935)...2
Remove, Lift Truck Models A1.3XNT, A1.5XNT (D203)............................................................................... 4
Clean ................................................................................................................................................................4
Inspect ............................................................................................................................................................. 4
Install, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) K160), and J1.6-2.0XN (J30-40XN) (A935)...5
Install, Lift Truck Models A1.3XNT, A1.5XNT (D203)................................................................................. 5
Rear Panel ........................................................................................................................................................... 5
Remove ............................................................................................................................................................ 5
Clean ................................................................................................................................................................8
Inspect ............................................................................................................................................................. 8
Install .............................................................................................................................................................. 8
Door Window ....................................................................................................................................................... 9
Disassemble Window ......................................................................................................................................9
Clean ..............................................................................................................................................................10
Inspect ........................................................................................................................................................... 10
Assemble Window .........................................................................................................................................10
Window Wipers Replacement ............................................................................................................................... 10
Front Wiper Assembly ...................................................................................................................................... 10
Remove, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) K160), and J1.6-2.0XN (J30-40XN) (A935).10
Remove, Lift Truck Models A1.3XNT, A1.5XNT (D203)............................................................................. 15
Clean ..............................................................................................................................................................16
Inspect ........................................................................................................................................................... 17
Install, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) (K160), and J1.6-2.0XN
(J30-40XN) (A935)......................................................................................................................................... 17
Install, Lift Truck Models A1.3XNT, A1.5XNT (D203)............................................................................... 18
Cab Component Repair ......................................................................................................................................... 19
Roof Liner .......................................................................................................................................................... 19
Remove .......................................................................................................................................................... 19
Clean ..............................................................................................................................................................20
Inspect ........................................................................................................................................................... 20
Install ............................................................................................................................................................ 20
Top Panel ...........................................................................................................................................................21
Remove, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) K160), and J1.6-2.0XN (J30-40XN) (A935).21
Remove, Lift Truck Models A1.3XNT, A1.5XNT (D203)............................................................................. 23
Clean ..............................................................................................................................................................24
Inspect ........................................................................................................................................................... 24
Install, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT (J30-40XNT) K160), and J1.6-2.0XN (J30-40XN) (A935).24
Install, Lift Truck Models A1.3XNT, A1.5XNT (D203)............................................................................... 24
Cab Door Assembly ............................................................................................................................................... 25
Door Assembly ...................................................................................................................................................25

©2014 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Remove .......................................................................................................................................................... 25
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)........................................................................... 25
Lift Truck Models and J1.5-2.0XNT (J30-40XNT) (K160)...................................................................... 25
Disassemble Left Door ..................................................................................................................................28
Disassemble Right Door ............................................................................................................................... 30
Clean ..............................................................................................................................................................30
Inspect ........................................................................................................................................................... 30
Assemble Right Door .................................................................................................................................... 32
Assemble Left Door .......................................................................................................................................32
Install ............................................................................................................................................................ 32
Lift Truck Models and J2.2-3.5XN (J45-70XN) (A276)........................................................................... 32
Lift Truck Models and J1.5-2.0XNT (J30-40XNT) (K160)...................................................................... 33
Cab Heater .............................................................................................................................................................33
Cab Heater ........................................................................................................................................................ 33
Remove .......................................................................................................................................................... 33
Clean ..............................................................................................................................................................38
Inspect ........................................................................................................................................................... 38
Install ............................................................................................................................................................ 38
Troubleshooting ............................................................................................................................................ 40
Weather Panel Replacement ................................................................................................................................ 44
Remove .............................................................................................................................................................. 44
Roof Panels ....................................................................................................................................................44
Front Screen Panel ....................................................................................................................................... 44
Install .................................................................................................................................................................44
Front Screen Panel ....................................................................................................................................... 44
Roof Panels ....................................................................................................................................................44

This section is for the following models:

J2.2-3.5XN (J45-70XN) [A276];

J1.5-2.0XNT (J30-40XNT) [K160];
E2.2-3.5XN (E45-70XN) [A268];
J1.6-2.0XN (J30-40XN) [A935];
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) [A970];
A1.3XNT, A1.5XNT [D203]

ii
0100 SRM 1446 General

General
This Service Manual describes how the cab • Cab doors
operates and includes replacement and repair • Cab heater
instructions for the following cab components (see
Figure 1): • Weather panels

• Front, rear, and cab door window panels Some of the described components are options that
• Windshield wipers may not be present on each cab. The operation of
• Roof liner the various switches and controls can be found in
the Operating Manual.
• Roof top panel

1. FRONT WINDOW PANEL 4. CAB DOOR

2. DOOR WINDOW PANEL 5. ROOF TOP PANEL
3. WINDSHIELD WIPER

Figure 1. Operator's Cab

1
Window Replacement
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 tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
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 adjustments, 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.
Window Replacement
FRONT PANEL
Remove, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) K160), and J1.6-2.0XN
(J30-40XN) (A935)
WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be made
2
0100 SRM 1446
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
controller and prevent the capacitors from
discharging properly. The proper way to
disconnect the battery is by separating the battery
connectors.
Before performing work on the cab, the capacitors
need to be discharged as described below:
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn the key or keyless switch to the OFF
position.
3. Disconnect the battery by separating the
connectors.
4. Block the drive wheels to prevent the lift truck
from moving.
5. Make sure the Emergency-Disconnect switch
HAS NOT been activated. If the Emergency-
Disconnect switch is activated, rotate the
switch to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
the correct thickness. Failure to have the correct
material or thickness may cause the glass to
break easily when struck and may cause personal
injury.
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 the General
section of this manual.
0100 SRM 1446 Window Replacement

NOTE: In Step 1 and Step 2 note placement of 3. Remove and discard seal from front window.
components during removal to aid in installation. See Figure 3.

1. Remove nut, bolt, and six washers from upper
right hand corner of front window. See Fig-
ure 2.
2. Remove nut cover, nut, five washers, and screw
from front window in five places. Remove front
window from overhead guard. See Figure 3.
NOTE: Perform Step 4 for the following lift truck
models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
4. Remove light brackets from overhead guard, if
equipped. See manual Electrical System
2200SRM1369 for procedures.

NOTE: OVERHEAD GUARD NOT SHOWN FOR

CLARITY.

NOTE: OVERHEAD GUARD NOT SHOWN FOR 1. FRONT WINDOW

2. SEAL
CLARITY. WIPER KIT SHOWN NOT THE SAME ON 3. SCREW
ALL LIFT TRUCK MODELS. 4. WASHER
5. BRACKET
1. FRONT WINDOW 6. NUT
2. INSERT 7. NUT COVER
3. WASHER 8. LIGHT BRACKET
4. SCREW
5. NUT COVER Figure 3. Front Panel Assembly
6. WIRE HARNESS
7. WIPER KIT
8. SWITCH
9. CAPSCREW
10. BOLT
11. NUT
12. BRACKET
Figure 2. Front Panel and Wiper

3
Window Replacement 0100 SRM 1446

Remove, Lift Truck Models A1.3XNT, A1.5XNT 1. Using compressed air, blow dirt and debris
(D203) from components as needed.

2. Using a lint free cloth, wipe down front window

WARNING and other components as needed.
All windows installed in the cab are made of
safety glass. All replacement windows must be Inspect
made of the correct material and must be made
the correct thickness. Failure to have the correct 1. Inspect front window for damage and cracks,
material or thickness may cause the glass to replace if damaged.
break easily when struck and may cause personal
2. For lift truck models A1.3XNT, A1.5XNT
injury.
(D203), inspect front panel and steel frame for
damage and cracks, replace if damaged.
WARNING
3. Inspect components and hardware for cracks
Disconnect the battery before doing any work on
and defects. Replace as needed.
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 the General

section of this manual.

1. Move wiper blades away from front panel.

2. Remove inserts, wheel nuts, capscrews, and

grab handle from mounting bracket on front
panel frame. See Figure 4.

3. If equipped, remove light brackets from top of

front panel frame. See Electrical System
2200SRM1524 for procedures.

4. Remove top two capscrews used to mount steer-

ing column. See Figure 5.

5. Remove six capscrews, nuts, front panel and

front panel frame from lift truck. See Figure 5.

Clean
1. INSERT
2. WHEEL NUT
WARNING 3. CAPSCREW
Compressed air can move particles so that they 4. GRAB HANDLE
cause injury to the user or to other personnel. 5. MOUNTING BRACKET
Make sure that the path of the compressed air is 6. FRONT PANEL FRAME
away from all personnel. Wear protective goggles Figure 4. Grab Handle, Remove and Install, Lift
or a face shield to prevent injury to the eyes. Truck Models A1.3XNT, A1.5XNT (D203)

4
0100 SRM 1446 Window Replacement

3. Install front window on overhead guard. Install

two washers, screw, two washers, bracket,
washer, nut, and nut cover on front window in
five places. See Figure 3.

4. Install two washers, bolt, four washers, and nut

on upper right hand corner of front window. See
Figure 2.

Install, Lift Truck Models A1.3XNT, A1.5XNT

(D203)
1. Install grab handle to mounting bracket on
front panel frame using inserts, wheel nuts,
and capscrews. See Figure 4.

NOTE: Apply liquid sealant, Hyster P/N

501702902, to capscrews prior to installation.

2. Install front panel and front panel frame to lift

truck with six capscrews and nuts. Tighten cap-
screws to 19 N•m (168 lbf in). See Figure 5.

3. Install top two capscrews for steering column.

See Figure 5.

4. If equipped, install light brackets from top of

1. CAPSCREW (FRONT PANEL AND FRAME)
2. NUT front panel frame. See Electrical System
3. CAPSCREW (STEERING COLUMN) 2200SRM1524 for procedures.
4. LIGHT BRACKET
5. FRONT PANEL 5. Push wiper blades into position on the front
6. FRONT PANEL FRAME panel.
Figure 5. Front Panel and Frame Components, Lift REAR PANEL
Truck Models A1.3XNT, A1.5XNT (D203)
Remove

Install, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) K160), and J1.6-2.0XN
(J30-40XN) (A935)
1. Install seal on front window. See Figure 3.
NOTE: Perform Step 2 for the following lift truck
models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
2. Install light brackets on overhead guard, if
equipped. See section Electrical System
2200SRM1369 for procedures.
1. Remove flange nut, cover, wiper arm, and wiper
blade from wiper motor. See Figure 6.
2. Disconnect wiring harness from wiper motor
and remove wiper motor from rear panel. See
Figure 6.
3. Remove two screws and latch from overhead
guard legs in two places. See Figure 6.
4. Remove five capscrews and bracket from cab
body. See Figure 6.
5. Disconnect gas spring from lower ball stud in
two places. See Figure 7.
6. Remove cap, capscrew and washer from over-
head guard and rear panel in two places. Re-
move rear panel from overhead guard. See Fig-
ure 6.

5
Window Replacement 0100 SRM 1446

7. If damaged, remove ball stud from overhead

guard leg in two places. See Figure 7.

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY.

1. REAR PANEL 8. WIPER MOTOR

2. CAP 9. WIPER BLADE
3. CAPSCREW 10. WIPER ARM
4. WASHER 11. BRACKET
5. SCREW 12. LATCH
6. WIRE HARNESS 13. COVER
7. SWITCH 14. FLANGE NUT

Figure 6. Rear Panel and Wiper Attachment

6
0100 SRM 1446 Window Replacement

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY.

1. REAR PANEL 10. GAS SPRING

2. SEAL 11. KNOB
3. NUT COVER 12. O-RING
4. PLATE 13. PLUG
5. WASHER 14. GRIP
6. HINGE 15. LATCH
7. SCREW 16. CONNECTOR
8. NUT 17. BRACKET
9. BALL STUD 18. CAP

Figure 7. Rear Panel Assembly

7
Window Replacement
8. Remove nut cover, nut, four washers, and hinge
from rear panel in two places. See Figure 7.
9. Remove nut cover, nut, plate, washer, screw,
and cap from hinge. Repeat for second hinge.
See Figure 7.
10. Disconnect gas spring from upper ball stud on
knob in two places. See Figure 7.
11. Remove ball stud from knob in two places. See
Figure 7.
12. Remove screw, three washers, o-ring, and knob
from rear panel in two places. See Figure 7.
13. Remove nut cover, nut, and two washers from
connector on outside of rear panel. Repeat for
opposite side. See Figure 7.
14. Remove plug, grip, nut, two washers, plug, con-
nector, and two washers from inside of rear
panel. Repeat for opposite side. See Figure 7.
15. Remove and discard seal from rear screen. See
Figure 7.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
1. Using compressed air, blow dirt and debris
from components as needed.
2. Using a lint free cloth, wipe down rear screen
and other components as needed.
Inspect
1. Inspect components for cracks and defects. Re-
place as needed.
2. Inspect gas springs for proper travel and exten-
sion. Replace as necessary.
a. Extended length; 735 mm (28.9 in.).
b. Stroke length, 315 mm (12.4 in.).
c. Resistance, 150 N (33.7 lbf).
8
0100 SRM 1446
3. Inspect wiper blade for cracks and tearing. Re-
place as needed.
Install
1. Install seal on rear screen. See Figure 7.
2. Install two washers, connector, plug, two wash-
ers, nut, grip, and plug on inside of rear panel.
Repeat for opposite side. See Figure 7.
3. Install two washers, nut, and nut cover on con-
nector on outside of rear panel. Repeat for oppo-
site side. See Figure 7.
4. Install knob, O-ring, three washers, and screw
on rear screen in two places. See Figure 7.
5. Install ball stud on knob in two places. See Fig-
ure 7.
6. Connect gas spring to upper ball stud on knob
in two places. See Figure 7.
7. Install plate, washer, screw, nut, nut cover, and
cap on hinge. Repeat for second hinge. See Fig-
ure 7.
8. Install washer, hinge, screw, three washers,
nut, and nut cover on rear panel in two places.
See Figure 7.
9. If removed, install ball stud on overhead guard
leg in two places. See Figure 7.
10. Install rear panel on overhead guard. Install
washer, capscrew, and cap on rear panel and
overhead guard in two places. See Figure 6.
11. Connect gas spring to two lower ball stud in
two places. See Figure 7.
12. Install bracket and five capscrews on cab body.
See Figure 6.
13. Install latch and two screws on overhead guard
legs in two places. See Figure 6.
14. Install rear wiper motor on rear panel and con-
nect wiring harness to rear wiper motor. See
Figure 6.
15. If removed, install wiper blade on wiper arm.
See Figure 6.
16. Using a flange nut, install wiper arm and wiper
blade on wiper motor. See Figure 6.
0100 SRM 1446 Window Replacement

DOOR WINDOW 2. Remove two latches from two sliding windows.

See Figure 8.
Disassemble Window
3. Remove two sliding windows from window
NOTE: If repair to non-sliding window is neces- frame. See Figure 8.
sary, contact local glass repair shop.
4. Remove and discard four guides from two slid-
NOTE: The following procedure applies to right ing windows. See Figure 8.
and left doors with sliding windows.
5. Remove and discard seal from rear of sliding
1. Remove window frame and window assembly window. See Figure 8.
from door assembly. See Figure 8.

NOTE: RIGHT-HAND SIDE SHOWN.

1. SLIDING WINDOW 5. CLIP

2. SEAL 6. WINDOW FRAME
3. LATCH 7. EDGE PROTECTOR
4. STRIP SEAL 8. GUIDE
Figure 8. Window Components

9
Window Wipers Replacement
6. Remove and discard five seals from window
frame. See Figure 8.
7. Remove and discard strip seal from window
frame. See Figure 8.
8. Remove and discard six clips from window
frame. See Figure 8.
9. Remove and discard edge protector from win-
dow frame. See Figure 8.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
1. Using compressed air, blow dirt and debris
from components as needed.
2. Using a lint free cloth, wipe down windows on
both doors and other components as needed.
Inspect
1. Inspect all components and hardware for cracks
and defects. Replace as needed.
Window Wipers Replacement
FRONT WIPER ASSEMBLY
NOTE: Lift truck models E2.2-3.5XN (E45-70XN)
(A268) are not equipped with windshield wiper and
motor.
Remove, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) K160), and J1.6-2.0XN
(J30-40XN) (A935)
1. Disconnect wire harness from wiper motor con-
nector.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
10
0100 SRM 1446
2. Inspect latch assembly and hardware. Ensure
proper operation.
3. Inspect windows for chips and cracks. Replace
as necessary.
Assemble Window
NOTE: The following procedure applies to right
and left doors.
1. Install edge protector and six clips on window
frame. See Figure 8.
2. Install strip seal and five seals on window
frame. See Figure 8.
3. Install seal on rear of sliding window. See Fig-
ure 8.
4. Install four guides on two sliding windows. See
Figure 8.
5. Install two sliding windows on window frame.
See Figure 8.
6. Install two latches to sliding windows. See Fig-
ure 8.
7. Install window frame and window assembly to
door assembly. See Figure 8.
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
2. Disconnect wire harness from washer pump
connector.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
0100 SRM 1446 Window Wipers Replacement

NOTE: Perform Step 3 and Step 4 for lift truck 5. Disconnect hose (15) from connector (11). See
models J2.2-3.5XN (J45-70XN) (A276). Figure 10.

3. Disconnect hose (6) from connector (7). See Fig-
ure 9.
4. Remove two clamps (5), hose (6), and nozzle (4)
from wiper arm. Set aside for installation. See
Figure 9.
NOTE: Perform Step 6 and Step 7 for lift truck
models J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970).
6. Disconnect hose (17) from connector (7). See
Figure 11.

NOTE: Perform Step 5 for the following lift truck 7. Disconnect hose from nozzle clip. Remove noz-
models zle clip and nozzle from wiper arm. See Fig-
• J1.5-2.0XNT (J30-40XNT) (K160) ure 11.

• J1.6-2.0XN (J30-40XN) (A935) 8. Remove two flange nuts, wiper arms, and wiper
blade from wiper motor. See Figure 12.

1. WIPER MOTOR 9. CHECK VALVE

2. WIPER ARM 10. BRACKET
3. WIPER BLADE 11. RESERVOIR
4. NOZZLE (CLIP) 12. WASHER
5. CLAMP 13. CAPSCREW
6. HOSE 14. WASHER PUMP CONNECTOR
7. CONNECTOR (SPRAY NOZZLE) 15. WIPER MOTOR CONNECTOR
8. HOSE
Figure 9. Front Wiper Assembly for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)

11
Window Wipers Replacement 0100 SRM 1446

1. WIPER MOTOR 9. NUT

2. WIPER ARM 10. CHECK VALVE
3. WIPER BLADE 11. CONNECTOR
4. RESERVOIR 12. CHECK VALVE CONNECTOR
5. CAP 13. HOSE
6. CAPSCREW 14. HOSE
7. WASHER 15. HOSE
8. BRACKET 16. WIRING CONNECTOR
Figure 10. Front Wiper Assembly for Lift Truck Models J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN
(J30-40XN) (A935)

12
0100 SRM 1446 Window Wipers Replacement

Figure 11. Front Wiper Assembly for Lift Truck Models J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970)

13
Window Wipers Replacement 0100 SRM 1446

Legend for Figure 11

1. CAPSCREW 11. CHECK VALVE

2. WASHER 12. INSERT
3. NUT 13. SWITCH
4. WIPER ARM 14. FUSES
5. WIPER BLADE 15. FUSES MOUNTING BRACKET
6. WIPER MOTOR 16. WIRE HARNESS
7. CONNECTOR (SPRAY NOZZLE) 17. HOSE
8. CAP 18. NOZZLE CLIP
9. RESERVOIR BRACKET 19. HOSE
10. WASHER RESERVOIR 20. WASHER PUMP CONNECTOR

1. WIPER MOTOR 5. WIPER ARM

2. WASHER 6. FLANGE NUTS
3. NUT 7. WIPER BLADE
4. NUT COVER

Figure 12. Wiper Attachment

14
0100 SRM 1446
9. Remove wiper blade from wiper arm.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
10. Remove two nut covers, two nuts, two washers,
and wiper motor from lift truck. See Figure 12.
11. Disconnect hose from reservoir.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
NOTE: Perform Step 12 and Step 13 for lift truck
models J2.2-3.5XN (J45-70XN) (A276).
12. Remove two capscrews, two washers, and reser-
voir from cowl.
13. Remove four capscrews, washers, and reservoir
from bracket. See Figure 9.
NOTE: Perform Step 14 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
14. Remove three caps, three nuts, six washers,
three capscrews, reservoir, and bracket from
overhead guard leg. See Figure 10.
NOTE: Perform Step 15 and Step 16 for lift truck
models J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970).
15. Remove two capscrews, washers, nuts, and res-
ervoir from cowl. See Figure 11.
Window Wipers Replacement
16. Remove caps, capscrews, washers, nuts, and
reservoir from bracket. See Figure 11.
17. Disconnect and remove check valve. Set aside
for installation.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
NOTE: Perform Step 18 for lift truck models
J2.2-3.5XN (J45-70XN) (A276).
18. Disconnect and remove connector from hose (8).
Set hose aside for installation. See Figure 9.
NOTE: Perform Step 19 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
19. Disconnect and remove connector (11) from
hose (13). Set aside for installation. See Fig-
ure 10.
NOTE: Perform Step 20 for lift truck models
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970).
20. Disconnect and remove connector (7) from hose
(19). See Figure 11.
Remove, Lift Truck Models A1.3XNT, A1.5XNT
(D203)
1. Disconnect wire harness from wiper motor con-
nector. See Figure 13.
2. Disconnect washer pump connector from
washer reservoir. See Figure 13.
3. Disconnect hose (19) from connector (14). See
Figure 13.
4. Disconnect hose from nozzle clip. Remove noz-
zle clip and nozzle from wiper arm. See Fig-
ure 13.
15
Window Wipers Replacement 0100 SRM 1446

5. Remove two flange nuts, wiper arms, and wiper 11. Disconnect and remove check valve. Set aside
blade from wiper motor. See Figure 12. for installation.

6. Remove screw, nut, washer, and wiper blade 12. Disconnect and remove connector (14) from
from wiper arm. See Figure 13. hose (16). See Figure 13.

7. Remove two nut covers, two nuts, two washers, Clean

and wiper motor from lift truck. See Figure 12.

8. Disconnect hose from reservoir. WARNING

Compressed air can move particles so that they
9. Remove two capscrews, washers, nuts, caps,
cause injury to the user or to other personnel.
and reservoir from mounting bracket on right
Make sure that the path of the compressed air is
front overhead guard leg.
away from all personnel. Wear protective goggles
10. Remove two capscrews, washers, nuts, caps, or a face shield to prevent injury to the yes.
and reservoir from reservoir mounting bracket.
1. Using compressed air, clean outside of wiper
See Figure 13.
motor, reservoir and wiper arms.

1. CAP 11. WIPER BLADE

2. NUT 12. WIPER ARM
3. WASHER 13. WIPER MOTOR
4. CAPSCREW 14. CONNECTOR (SPRAY NOZZLE)
5. WASHER RESERVOIR 15. CHECK VALVE
6. WASHER RESERVOIR MOUNTING BRACKET 16. HOSE
7. SCREW 17. WIRE HARNESS
8. WASHER PUMP CONNECTOR 18. WIPER MOTOR CONNECTOR
9. SWITCH 19. HOSE
10. NOZZLE CLIP

Figure 13. Front Wiper Assembly, Lift Truck Models A1.3XNT, A1.5XNT (D203)

16
0100 SRM 1446
Inspect
1. Inspect hoses for cracks and wear. Replace if
damaged.
2. Check washer reservoir for leaks by filling with
water and checking seams. Replace if leaking.
3. Inspect wiper blades for cracks and tearing. Re-
place as needed.
Install, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) (K160), and J1.6-2.0XN
(J30-40XN) (A935)
NOTE: Perform Step 1 through Step 4 for lift truck
model J2.2-3.5XN (J45-70XN) (A276).
1. Connect hose (8) to connector. See Figure 9.
2. Connect check valve into hose (8). Connect hose
(8) to other end of check valve. See Figure 9.
3. Install reservoir, washers, and four capscrews
on bracket. See Figure 9.
4. Using two washers and two capscrews, install
reservoir on cowl.
NOTE: Perform Step 5 through Step 7 for lift truck
models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
5. Connect hose (13) to connector (11). See Fig-
ure 10.
6. Connect check valve to hose (13). Connect hose
(14) to other end of check valve. See Figure 10.
7. Install bracket, pump, six washers, three cap-
screws, three nuts, and three caps on overhead
guard leg. See Figure 10.
NOTE: Perform Step 8 through Step 11 for lift
truck models J4.0-5.0XN (J80-100XN) (A970).
8. Connect hose (19) to connector (7). See Fig-
ure 11.
9. Connect check valve to hose.
10. Install reservoir to bracket using, four nuts,
washers, capscrews, and caps. See Figure 11.
Window Wipers Replacement
11. Using two nuts, washers, and capscrews, install
reservoir to cowl.
12. Connect hose to reservoir.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
13. Using two washers, two nuts, and two caps, in-
stall wiper motor to lift truck. See Figure 12.
14. Install wiper blade on wiper arm.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
15. Using two flange nuts, install wiper arm and
wiper blade on wiper motor.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
NOTE: Perform Step 16 and Step 17 for lift truck
models J2.2-3.5XN (J45-70XN) (A276).
16. Install nozzle (4), hose (6), and two clamps (5)
on wiper arm. See Figure 9.
17. Connect hose (6) to connector (7). See Figure 9.
17
Window Wipers Replacement
NOTE: Perform Step 18 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
18. Connect hose (15) to connector (11). See Fig-
ure 10.
NOTE: Perform Step 19 for lift truck models
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970).
19. Install nozzle clip and nozzle into wiper arm.
Connect hose (17) to nozzle. See Figure 11.
20. Connect wire harness to wiper motor connector.
See Figure 9 for lift truck models
• J2.2-3.5XN (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
21. Connect wire harness to washer pump connec-
tor.
See Figure 9 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 10 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
18
0100 SRM 1446
See Figure 11 for lift truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
Install, Lift Truck Models A1.3XNT, A1.5XNT
(D203)
1. Connect hose (16) to connector (14). See Fig-
ure 13.
2. Connect check valve to hose.
3. Install reservoir to mounting bracket using two
capscrews, nuts, washers, and caps. See Fig-
ure 13.
4. Using two capscrews, nuts, washers, and caps,
install reservoir and mounting bracket to right
overhead guard leg.
5. Connect hose to reservoir. See Figure 13.
6. Using two washers, two nuts, and two caps, in-
stall wiper motor to lift truck. See Figure 12.
7. Install wiper blade on wiper arm using screw,
washer, and nut. See Figure 13.
8. Using two flange nuts, install wiper arm and
wiper blade on wiper motor. See Figure 12.
9. Install nozzle clip and nozzle into wiper arm.
Connect hose (19) to nozzle. See Figure 13.
10. Connect hose (19) to connector (14). See Fig-
ure 13.
11. Connect washer pump to washer reservoir.
12. Connect wire harness to wiper motor. See Fig-
ure 13.
0100 SRM 1446 Cab Component Repair

Cab Component Repair

ROOF LINER Legend for Figure 14

Remove 1. TOP PANEL

2. CAP
NOTE: Perform Step 1 for lift truck model 3. CAPSCREW
4. WASHER
J2.2-3.5XN (J45-70XN) (A276). 5. ROOF LINER
6. DOME LIGHT
1. Remove seven caps, seven capscrews, and seven 7. SCREW
washers from roof liner. See Figure 14.

NOTE: Perform Step 2 for lift truck models

• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)

2. Remove seven capscrews and seven washers

from roof liner. See Figure 15.

NOTE: Perform Step 3 for lift truck models

J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970).

3. Remove eight capscrews and eight washers

from roof liner. See Figure 16.

1. TOP PANEL
2. CAPSCREW
3. WASHER
4. ROOF LINER
5. DOME LIGHT
6. SCREW

Figure 15. Roof Liner for Lift Truck Model

J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN
(J30-40XN) (A935)

Figure 14. Roof Liner for Lift Truck Model

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

19
Cab Component Repair 0100 SRM 1446

6. Remove rear wiper switch from roof liner (if

equipped).

7. Remove roof liner from overhead guard.

Clean

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

1. Using compressed air, blow dirt and debris off

of roof liner.

2. Using a lint free cloth, wipe down overhead

guard.

Inspect
1. TOP PANEL 1. Inspect roof liner for cracks and defects. Re-
2. CAPSCREW
3. WASHER place as needed.
4. ROOF LINER
5. DOME LIGHT 2. Inspect hardware for defects, replace as needed.
6. SCREW
Install
Figure 16. Roof Liner for Lift Truck Models
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) 1. Install roof liner on overhead guard.
(A970)
2. Route wire harness and washer hose through
notched cut out in rear of roof liner as noted
NOTE: Note position of wire harness and washer during removal.
hose through notched cutout in rear of roof liner.
3. Install rear wiper switch to preformed cutout of
4. Disconnect dome light harness and rear wiper roof liner (if equipped).
switch harness (if equipped).
4. Using two screws, install dome light on roof
5. Remove two screws and dome light from roof liner.
liner.
See Figure 14 for truck models
See Figure 14 for truck models • J2.2-3.5XN (J45-70XN) (A276)
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 15 for truck models
See Figure 15 for truck models • J1.5-2.0XNT (J30-40XNT) (K160)
• J1.5-2.0XNT (J30-40XNT) (K160) • J1.6-2.0XN (J30-40XN) (A935)
• J1.6-2.0XN (J30-40XN) (A935)
See Figure 16 for lift truck models
See Figure 16 for lift truck models • J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
J100XNL) (A970)
5. Connect dome light harness and rear wiper
switch harness, if equipped.

20
0100 SRM 1446
NOTE: Perform Step 6 for lift truck model
J2.2-3.5XN (J45-70XN) (A276).
6. Install seven washers, seven capscrews, and
seven caps on roof liner. See Figure 14.
NOTE: Perform Step 7 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
7. Install seven washers and seven capscrews on
roof liner. See Figure 15.
NOTE: Perform Step 8 for lift truck models
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970).
8. Install eight washers and eight capscrews on
roof liner. See Figure 16.
TOP PANEL
Remove, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) K160), and J1.6-2.0XN
(J30-40XN) (A935)
NOTE: Perform Step 1 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
1. Disconnect front light wiring. See section Elec-
trical System 2200SRM1369, Lights, for
proper procedures.
Cab Component Repair
WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be the cor-
rect thickness. Failure to use the correct material
or thickness may cause the glass to break easily
when struck and may cause personal injury.
NOTE: Due to use of glue and RTV sealer, replace-
ment of top screen is to be done only if damaged.
2. Remove and discard grommets from top panel
assembly. See Figure 17.
3. Remove four nuts, four washers, four cap-
screws, and roof panel from top panel assembly.
See Figure 17.
4. Remove and discard seal from screen. See Fig-
ure 17.
5. Remove two nuts, four washers, two hinges,
and pin from screen. See Figure 17.
6. Remove two nut covers, two nuts, two washers,
and plate from screen. See Figure 17.
7. Remove screw, spring, and grip from screen.
See Figure 17.
8. Remove two nut covers, two nuts, two washers,
and grip mounting plate from screen. See Fig-
ure 17.
21
Cab Component Repair 0100 SRM 1446

Figure 17. Top Panel

22
0100 SRM 1446 Cab Component Repair

Legend for Figure 17

1. ROOF PANEL 9. PLATE

2. TOP PANEL ASSEMBLY 10. GRIP MOUNTING PLATE
3. GROMMET 11. NUT COVER
4. SCREEN 12. GRIP
5. PIN 13. SPRING
6. HINGE 14. SCREW
7. WASHER 15. SEAL
8. NUT

Remove, Lift Truck Models A1.3XNT, A1.5XNT

(D203)

The top panel is attached to top of overhead guard

using adhesive tape and pressing it on. See Fig-
ure 18.

WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be the cor-
rect thickness. Failure to use the correct material
or thickness may cause the glass to break easily
when struck and may cause personal injury.

NOTE: Due to use of glue and adhesive tape, re-

placement of top screen is to be done only if dam-
aged.

1. Remove damaged top panel from lift truck. Pull

top panel from overhead guard, using a cutting
tool to remove glue and adhesive tape from
overhead guard as top panel is pulled from
overhead guard. See Figure 18.

1. TOP PANEL ASSEMBLY

2. ADHESIVE TAPE
3. OVERHEAD GUARD

Figure 18. Top Panel, Lift Truck Models A1.3XNT,

A1.5XNT (D203)

23
Cab Door Assembly
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the yes.
1. Using compressed air, blow dirt and debris
from all components as needed.
2. Using warm soapy water, clean plastic, rubber,
and vinyl components. Wipe dry with a lint free
cloth.
3. For lift truck models A1.3XNT, A1.5XNT
(D203), clean top of overhead guard to remove
any glue residual from use of adhesive tape.
Inspect
1. Inspect hinges, rod, spring and grip for damage
or cracks. Replace as needed.
Install, Lift Truck Models J2.2-3.5XN
(J45-70XN) (A276), J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970), J1.5-2.0XNT
(J30-40XNT) K160), and J1.6-2.0XN
(J30-40XN) (A935)
1. Install grip mounting plate, two washers, two
nuts, and two nut covers on screen. See Fig-
ure 17.
2. Install grip, spring, and screw on screen. See
Figure 17.
3. Install plate, two washers, two nuts, and two
nut covers on screen. See Figure 17.
24
0100 SRM 1446
4. Install pin, two hinges, four washers, and two
nuts on screen. See Figure 17.
5. Install seal on screen. See Figure 17.
6. Install roof panel, four washers, four capscrews,
and four nuts on top panel assembly. See Fig-
ure 17.
7. Install two grommets to top panel assembly.
See Figure 17.
NOTE: Perform Step 8 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
8. Install front light wiring. See section Electri-
cal System 2200SRM1369, Lights, for proper
procedures.
Install, Lift Truck Models A1.3XNT, A1.5XNT
(D203)
1. Ensure overhead guard is clean and free of old
adhesive tape and glue.
2. Peel off backing from adhesive tape and attach
adhesive tape to all four sides of overhead
guard. See Figure 18.
3. Position top panel above top of overhead guard.
See Figure 18.
4. Press top panel onto top perimeter of overhead
guard and adhesive tape, making sure all edges
are aligned correctly.
0100 SRM 1446
Cab Door Assembly
DOOR ASSEMBLY
Remove
Lift Truck Models J2.2-3.5XN (J45-70XN)
(A276) and J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970)
WARNING
The door assemblies are heavy, verify the lifting
device being used during repairs can lift the
weight of the parts and assembly.
1. Disconnect gas spring from top of door assem-
bly. See Figure 19.
2. Remove three capscrews from upper hinge. Re-
move three capscrews from lower hinge. See
Figure 19.
3. Using a lifting device, remove door assembly
from lift truck and set aside.
4. Remove three caps, three bolts, four washers,
bolt, guard, striker, and block from front over-
head guard leg. See Figure 19.
5. Remove gas spring from overhead guard.
6. Remove two caps, two capscrews, two washers,
and bracket from overhead guard. See Fig-
ure 19.
7. Repeat Step 1 through Step 6 for opposite side.
Cab Door Assembly
Lift Truck Models J1.5-2.0XNT (J30-40XNT)
(K160) and J1.6-2.0XN (J30-40XN) (A935)
WARNING
The door assemblies are heavy, verify the lifting
device being used during repairs can lift the
weight of the parts and assembly.
1. Disconnect gas spring from top of door assem-
bly. See Figure 20.
2. Remove two screws from mounting plate and
hinge in two places. Remove three bolts from
mounting plate and overhead guard leg in two
places. See Figure 20.
3. Using a lifting device, remove door assembly
from lift truck and set aside.
4. Remove two caps, two capscrews, two washers,
bolt, guard, bracket and block from front over-
head guard leg. See Figure 20.
5. Remove gas spring from overhead guard.
6. Remove two caps, two capscrews, two washers,
and bracket from overhead guard. See Fig-
ure 20.
7. Repeat Step 1 through Step 6 for opposite side.
25
Cab Door Assembly 0100 SRM 1446

1. DOOR ASSEMBLY (RH) 9. BRACKET

2. DOOR ASSEMBLY (LH) 10. GAS SPRING
3. HINGE (UPPER) 11. NUT
4. HINGE (LOWER) 12. BALL STUD
5. BOLT 13. CAPSCREW
6. GUARD 14. WASHER
7. BLOCK 15. CAP
8. STRIKER
Figure 19. Door Assembly for Lift Truck Model J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970)

26
0100 SRM 1446 Cab Door Assembly

Figure 20. Door Assembly for Lift Truck Model J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN (J30-40XN)
(A935)

27
Cab Door Assembly 0100 SRM 1446

Legend for Figure 20

1. DOOR ASSEMBLY 8. GUARD

2. DOOR ASSEMBLY 9. BOLT
3. MOUNTING PLATE 10. SCREW
4. HINGE 11. CAPSCREW
5. GAS SPRING 12. WASHER
6. BRACKET 13. CAP
7. BLOCK 14. CAP

Disassemble Left Door 3. Remove screw, washer, lock plate cover, and
plate from door assembly. See Figure 21.
NOTE: Perform Step 1 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276) 4. Disconnect rod from latch. See Figure 21.

• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, 5. Remove screw, washer, door handle, tube, rod,
J100XNL) (A970) and lock from door assembly. See Figure 21.

1. Remove and discard two seals from door assem- 6. Remove seven fasteners and door cover from
bly. See Figure 21. door assembly. See Figure 21.

NOTE: Perform Step 2 for lift truck models 7. Remove two screws and latch from door assem-
• J1.5-2.0XNT (J30-40XNT) (K160) bly. See Figure 21.
• J1.6-2.0XN (J30-40XN) (A935) 8. Remove screw and plate from grip. See Fig-
ure 21.
NOTE: Lift truck models J1.5-2.0XNT
(J30-40XNT) (K160) and J1.6-2.0XN (J30-40XN) 9. Remove two screws, two washers, seal, and grip
(A935) have a one piece seal around door assembly. from door assembly. See Figure 21.
2. Remove and discard seal from door assembly.
See Figure 21.

28
0100 SRM 1446 Cab Door Assembly

1. SEAL 9. FASTENER
2. SCREW 10. COVER (DOOR)
3. WASHER 11. LOCK
4. LOCK PLATE COVER 12. LATCH
5. PLATE 13. DOOR ASSEMBLY
6. ROD 14. GRIP
7. TUBE 15. WINDOW
8. DOOR HANDLE 16. DOOR WINDOW

Figure 21. Left Door Components

29
Cab Door Assembly
Disassemble Right Door
NOTE: Perform Step 1 and Step 2 if lift truck is
equipped with cab heater.
1. Remove eight screws and four washers from
cab heater and heater control (if equipped). See
Figure 23.
2. Disconnect wiring harness from cab heater and
heater control. Remove cab heater and heater
control from door assembly. See Figure 24.
3. Remove and discard two seals from door assem-
bly. See Figure 22.
4. Remove four screws, four washers, and plate
from door assembly. See Figure 22.
5. Remove four screws and cover from door assem-
bly. See Figure 22.
6. Remove four screws, and handle from inside
door assembly. See Figure 22.
7. Remove two screws and clamp from inside door
assembly. See Figure 22.
8. Remove two screws, two washers, and plate
from door assembly. See Figure 22.
9. Remove seven fasteners and cover from door as-
sembly. See Figure 22.
10. Disconnect rod from latch. See Figure 22.
11. Remove two screws and latch from door assem-
bly. See Figure 22.
12. Remove two screws, two washers, two nuts,
rod, and lever from door assembly. See Fig-
ure 22.
13. Remove screw and plate from grip. See Fig-
ure 22.
NOTE: Perform Step 14 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
30
0100 SRM 1446
14. Remove four screws, four washers, seal, and
grip from door assembly. See Figure 22.
NOTE: Perform Step 15 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
15. Remove three screws, three washers, seal, and
grip from door assembly. See Figure 22.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
1. Using compressed air, blow dirt and debris
from components as needed.
2. Using a lint free cloth, wipe down components
as needed.
Inspect
1. Inspect all components and hardware for cracks
and defects. Replace as needed.
2. Inspect latch assembly and hardware. Ensure
proper operation.
3. Inspect hinges and lubricate as necessary.
4. Inspect gas springs for proper travel and exten-
sion.
a. Left door extended length 406 mm (16 in.).
Right door extended length
880 mm (34.6 in.).
b. Left door stroke 160 mm (6.3 in.). Right door
stroke 393 mm (15.5 in.).
c. Left door resistance 200 N (50 lbf). Right side
resistance 200 N (50 lbf).
0100 SRM 1446 Cab Door Assembly

1. WINDOW 9. NUT
2. SEAL 10. LEVER
3. GRIP 11. WASHER
4. DOOR 12. ROD
5. SCREW 13. FASTENER
6. HANDLE 14. LATCH
7. PLATE 15. CLAMP
8. COVER

Figure 22. Right Door Components

31
Cab Door Assembly
Assemble Right Door
NOTE: Perform Step 1 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
1. Install seal, grip, four washers, and four screws
on door assembly. See Figure 22.
NOTE: Perform Step 2 for lift trucks
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
2. Install seal, grip, three washers, and three
screws on door assembly. See Figure 22.
3. Install plate and screw on grip. See Figure 22.
4. Install lever, rod, two nuts, two washers, and
two screws on door assembly. See Figure 22.
5. Install latch and two screws on door assembly.
See Figure 22.
6. Attach rod to latch. See Figure 22.
7. Install cover and seven fasteners on door as-
sembly. See Figure 22.
8. Install plate, two washers, and two screws on
door assembly. See Figure 22.
9. Install clamp and two screws on door assembly.
See Figure 22.
10. Install handle and four screws on door assem-
bly. See Figure 22.
11. Install plate, four washers, and four screws on
door assembly. See Figure 22.
12. Install cover and four screws on door assembly.
See Figure 22.
13. Install two seals on door assembly. See Fig-
ure 22.
NOTE: Perform Step 14 and Step 15 if lift truck is
equipped with cab heater.
14. Connect wiring to heater control and cab
heater. See Figure 24.
15. Install heater control, cab heater, four washers
and eight screws on door assembly. See Fig-
ure 23.
32
0100 SRM 1446
Assemble Left Door
1. Install seal, grip, two washers, and two screws
on door assembly. See Figure 21.
2. Install plate and screw on grip. See Figure 21.
3. Install latch and two screws on door assembly.
See Figure 21.
4. Install door cover and seven fasteners on door
assembly. See Figure 21.
5. Install lock, rod, door handle, tube, washer, and
screw onto door assembly. See Figure 21.
6. Connect rod onto door latch. See Figure 21.
7. Install plate, cover, washer, and screw on door
assembly. See Figure 21.
NOTE: Perform Step 8 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
8. Install two seals to door assembly. See Fig-
ure 21.
NOTE: Perform Step 9 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
9. Install seal to door assembly. See Figure 21.
Install
Lift Truck Models J2.2-3.5XN (J45-70XN)
(A276) and J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970)
NOTE: Use sealant, Hyster P/N 2064554 or equiva-
lent, during installation of capscrews and bolts.
1. Install ball stud and screw onto door assembly.
See Figure 19.
2. Install bracket, two washers, two capscrews,
and two caps on overhead guard. See Figure 19.
3. Install gas spring on overhead guard. See Fig-
ure 19.
4. Install striker, block, guard, bolt, four washers,
three bolts, and three caps on front overhead
guard legs. See Figure 19.
0100 SRM 1446
5. Using a lifting device, lift door assembly in
place and install six capscrews on overhead
guard at rear of door. See Figure 19.
6. Repeat Step 1 through Step 5 for opposite side
door installation.
Lift Truck Models J1.5-2.0XNT (J30-40XNT)
(K160) and J1.6-2.0XN (J30-40XN) (A935)
1. Install bracket, two washers, two capscrews,
and two caps on overhead guard. See Figure 20.
2. Install gas spring on overhead guard. See Fig-
ure 20.
Cab Heater
CAB HEATER
Remove
1. Remove two screws and connector cover from
cab heater. See Figure 23.
2. Disconnect wiring harness from cab heater. See
Figure 23.
3. Remove four screws, four washers, and cab
heater from door assembly. See Figure 23.
4. Remove two air filters from cab heater. See Fig-
ure 23.
5. Remove four screws and heater control from
door assembly. See Figure 23.
6. Disconnect wire harness from heater control.
See Figure 23.
NOTE: Step 7 does not apply to lift truck models
J1.5-2.0XNT (K160) manufactured after November,
2014. For these models, go to Step 8.
7. Remove two nuts, two washers, and two cap-
screws from wire harness and plate located on
hydraulic tank. See Figure 24.
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
Cab Heater
3. Install striker, block, guard, bolt, two washers,
two bolts, and two caps to front overhead guard
legs. See Figure 20.
4. Using a lifting device, lift door assembly in
place and install six bolts and four screws to
hinge mounting plate on overhead guard legs at
rear of door. See Figure 20.
5. Repeat Step 1 through Step 4 for opposite side
door installation.
8. For lift truck models J1.5-2.0XNT (K160) man-
ufactured after November, 2014, remove two
nuts, two washers, and two screws from contac-
tor mounting plate. Remove contactor mounting
plate and contactor from plate weldment on
counterweight. See Figure 25.
NOTE: Step 9 does not apply to lift truck models
J1.5-2.0XNT (K160) manufactured after November,
2014. For these models, go to Step 10.
9. Remove two nuts, two washers, and two screws
from contactor and plate located on hydraulic
tank. See Figure 24.
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
10. For lift truck models J1.5-2.0XNT (K160) man-
ufactured after November, 2014, remove two
nuts, two washers, and two capscrews from con-
tactor and contactor mounting plate located in
counterweight cavity. See Figure 25.
11. Disconnect contactor from wire harness and re-
move from plate weldment.
12. Remove wiring harness from lift truck.
NOTE: Perform Step 13 only if heater fan motor is
inoperative prior to removing from lift truck.
33
Cab Heater 0100 SRM 1446

1. CAB HEATER 6. CONTROL (HEATER)

2. WIRE HARNESS 7. CONNECTOR COVER
3. SCREW 8. AIR FILTER
4. CAPSCREW 9. SECONDARY AIR FILTER
5. WASHER
Figure 23. Cab Heater

34
0100 SRM 1446 Cab Heater

1. CAB HEATER 7. NUT

2. WIRE HARNESS 8. CAPSCREW
3. CONTACTOR 9. PLATE WELDMENT
4. BOOT 10. HEATER CONTROL
5. SCREW 11. FUSE HOLDER AND FUSE
6. WASHER
Figure 24. Cab Heater Electrical, Lift Truck Models J1.5-2.0XNT (K160) Manufactured Before November,
2014, J2.2-3.5XN (J45-70XN) (A276) Without Outdoor Protection/Wash-Down Package, and J30-40XNT
(K160), J1.6-2.0XN (J30-40XN) (A935), E2.2-3.5XN (E45-70XN ) (A268), J5.0-5.5XN6 (J80-120XN, J100XNL)
(A970), and A1.3XNT, A1.5XNT (D203)

35
Cab Heater 0100 SRM 1446

Figure 25. Cab Heater Electrical, Lift Truck Models J1.5-2.0XNT (K160) Manufactured After November,
2014

36
0100 SRM 1446 Cab Heater

Legend for Figure 25

1. CAB HEATER 8. SCREW

2. HEATER CONTROL 9. WIRE HARNESS
3. FUSE HOLDER AND FUSE 10. NUT
4. CONTACTOR 11. WASHER
5. COUNTERWEIGHT 12. PLATE WELDMENT
6. CONNECTOR 13. CAPSCREW
7. BOOT 14. CONTACTOR MOUNTING PLATE

1. CAB HEATER 7. FUSE HOLDER AND FUSE

2. CAPSCREWS 8. CONTACTOR
3. WASHER 9. BOOT
4. HEATER CONTROL 10. NUT
5. SCREW 11. PLATE WELDMENT
6. WIRE HARNESS
Figure 26. Cab Heater Electrical Components For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) With
Outdoor Protection/Wash-down Package

37
Cab Heater
13. Remove 25 Amp fuse from fuse holder and in-
spect for broken element. Replace as necessary.
See Figure 24.
See Figure 24 for lift truck models
• J1.5-2.0XNT (K160) manufactured before
November, 2014
• J30-40XNT (K160)
• J1.6-2.0XN (J30-40XN) (A935)
• E2.2-3.5XN (E45-70XN ) (A268)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
• A1.3XNT, A1.5XNT (D203)
• J2.2-3.5XN (J45-70XN) (A276) without
Outdoor Protection/Wash-down package
See Figure 25 for lift truck models
• J1.5-2.0XNT (K160) manufactured after
November, 2014
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
1. Using compressed air, blow dirt and debris
from cab heater, heater control, air filters and
all other components as necessary.
2. Using a lint free cloth, wipe down components
as needed.
Inspect
1. Inspect components for damage and cracks. Re-
place as needed.
2. Inspect air filters after cleaning, replace as nec-
essary.
3. Inspect wiring harness for damage and exposed
wires. Replace as necessary.
38
0100 SRM 1446
Install
NOTE: Perform Step 1 only if Step 13 in Remove
section was performed.
1. Install new 25 Amp fuse into fuse holder.
See Figure 24 for lift truck models
• J1.5-2.0XNT (K160) manufactured before
November, 2014
• J30-40XNT (K160)
• J1.6-2.0XN (J30-40XN) (A935)
• E2.2-3.5XN (E45-70XN ) (A268)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
• A1.3XNT, A1.5XNT (D203)
• J2.2-3.5XN (J45-70XN) (A276) without
Outdoor Protection/Wash-down package
See Figure 25 for lift truck models
• J1.5-2.0XNT (K160) manufactured after
November, 2014
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
2. Install heater wiring harness on lift truck.
3. Connect wiring harness to contactor.
See Figure 24 for lift truck models
• J1.5-2.0XNT (K160) manufactured before
November, 2014
• J30-40XNT (K160)
• J1.6-2.0XN (J30-40XN) (A935)
• E2.2-3.5XN (E45-70XN ) (A268)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
• A1.3XNT, A1.5XNT (D203)
• J2.2-3.5XN (J45-70XN) (A276) without
Outdoor Protection/Wash-down package
See Figure 25 for lift truck models
• J1.5-2.0XNT (K160) manufactured after
November, 2014
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
0100 SRM 1446
NOTE: Step 4 does not apply to lift truck models
J1.5-2.0XNT (K160) manufactured after November,
2014. For these models, go to Step 5.
4. Install two capscrews, two washers and two
nuts to contactor and plate located on hydraulic
tank.
See Figure 24 for lift truck models
• J1.5-2.0XNT (K160) manufactured before
November, 2014
• J30-40XNT (K160)
• J1.6-2.0XN (J30-40XN) (A935)
• E2.2-3.5XN (E45-70XN ) (A268)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
• A1.3XNT, A1.5XNT (D203)
• J2.2-3.5XN (J45-70XN) (A276) without
Outdoor Protection/Wash-down package
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
5. For lift truck models J1.5-2.0XNT (K160) man-
ufactured after November, 2014, install contac-
tor to contactor mounting plate in counter-
weight cavity using two capscrews, two wash-
ers, and two nuts. See Figure 25.
NOTE: Step 6 does not apply to lift truck models
J1.5-2.0XNT (K160) manufactured after November,
2014. For these models, go to Step 7.
Cab Heater
6. Install two capscrews, two washers and two
nuts to wire harness and plate located on hy-
draulic tank. See Figure 24.
See Figure 26 for lift truck models J2.2-3.5XN
(J45-70XN) (A276), equipped with Outdoor Pro-
tection/Wash-down package.
7. For lift truck models J1.5-2.0XNT (K160) man-
ufactured after November, 2014, install contac-
tor and contactor mounting plate to plate weld-
ment located on counterweight using remove
two screws, two washers, and two nuts. See
Figure 25.
8. Connect wiring harness on heater control. See
Figure 23.
9. Using four screws, install heater control on
door assembly. See Figure 23.
10. Install two air filters on cab heater. See Fig-
ure 23.
11. Using four screws and four washers, install cab
heater on door assembly. See Figure 23.
12. Connect wiring harness on cab heater. See Fig-
ure 23.
13. Using two screws, install connector cover on
cab heater. See Figure 23.
39
Cab Heater 0100 SRM 1446

Troubleshooting NOTE: For repair procedures, as directed by Error

Code E0 through E9, refer to Figure 27 and Table 1
NOTE: If a malfunction disappears, heater will re- through Table 7.
turn to normal operation.

NOTE: For Error Codes 3 to 9; After five repeated

errors of same kind, heater will turn off automati-
cally and return to Standby Mode.

Error Code Error Measure

E0 External keyswitch off 1. Check that the keyswitch is switched
on.
2. Check that there is voltage to the key-
switch.
E1 Thermostat Sensor Error 1. Check the Printed Circuit Board
(PCB) connector.
2. Inspect the sensor and sensor wiring
for damage.
3. Replace the sensor.
E2 Overheat Protection Sensor Error See Error Code E1.
E3 Overheat Protection Activated 1. Inspect heater outlets for debris or ob-
struction of air flow.
2. Clean the inlet air filter.
3. Inspect heater inlet for debris or ob-
struction of air flow.
E4 Max Temperature in the Cabin Achieved Normal operating cabin temperature is
35°C (95°F). The heater will automatically
turn off and back on again at a lower tem-
perature. Inspect all air outlet louver's for
proper directionality. Ensure all louver's are
directing warm air away from heater inlet.

40
0100 SRM 1446 Cab Heater

Error Code Error Measure

E5, E6 Fan Error; Current Consumption too high The fan does not rotate smoothly or has stop-
ped. Replace the fan.
E7 Fan Error; Current Consumption too low Does the fan rotate? If no:
1. Check the fan in-line fuse.
2. Check the fan connections.
3. Check that there is voltage between
the PCB and fan.
4. Check that the feed through capaci-
tors are conducting.
5. Replace the fan.
If yes:
1. Clean the inlet filter.
2. Check that there are no obstacles in
the air inlet and air outlet.
E8 Voltage Too Low 1. Disconnect the power to the Heater
for a minimum of seven seconds; con-
nect again and test.
2. Battery voltage too low; charge lift
truck battery.
E9 Voltage too High Disconnect the power to the heater for a
minimum of seven seconds; connect again
and test.

41
Cab Heater 0100 SRM 1446

1. HEATER ELEMENT 11. IN LINE FUSE

2. FAN 12. FUSE HOLDER
3. EMC FILTER 13. CONTROL PANEL CONTACT
4. CONTROL BOARD 14. C1 CONNECTOR
5. THERMOSTAT SENSOR 15. C2 CONNECTOR
6. OVERHEAT SENSOR 16. C3 CONNECTOR
7. CONTROL PANEL 17. C4 CONNECTOR
8. WIRE 18. C5 CONNECTOR
9. EMC FILTER 19. C6 CONNECTOR
10. EMC FILTER 20. C7 CONNECTOR

Figure 27. Cab Heater Wiring Schematic

42
0100 SRM 1446 Cab Heater

Table 1. Connector C1 Table 4. Connector C4

Pin # Connector Function Pin # Connector Function

1 Driver Low Power 1 Thermostat Sensor (+5V)
2 Driver Full Power 2 Thermostat Sensor (Sense)
3 Incoming Ground (-) 3 Ground (-) Not Connected
4 Incoming Ground (-)
Table 5. Connector C5
5 Incoming Power (+)
Pin # Connector Function
Table 2. Connector C2 1 +12V
Pin # Connector Function 2 RS485B
1 + 12 V 3 RS485A
2 + From Start Key 4 Ground (-)
3 Control Output for Defroster
Table 6. Connector C6
4 Ground (-)
Pin # Connector Function
Table 3. Connector C3 1 Fan -
Pin # Connector Function 2 Fan +
1 Overheat Sensor (+5V)
Table 7. Connector C7
2 Overheat Sensor (Sense)
Pin # Connector Function
1-6 Programming Connector

43
Weather Panel Replacement
Weather Panel Replacement for Lift Truck Model E2.2-3.5XN
(E45-70XN) (A268)
REMOVE
WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be made
the correct thickness. Failure to have the correct
material or thickness may cause the glass to
break easily when struck and may cause personal
injury.
NOTE: Before replacing roof or front screen panel,
remove all broken glass bits. Verify replacement
glass is dry, clean, and free of grease.
Roof Panels
1. Remove nuts, washers, and "S" brackets from
din bolts. See Figure 28.
2. Remove nuts, capscrews, washers, and roof
mounting brackets from overhead guard canopy
and roof panel. See Figure 28.
3. Remove nuts, capscrews, washers, and "U"
brackets from panel plates and overhead guard.
See Figure 28.
NOTE: The rear roof panel contains an access
panel for the opening in the overhead guard, the ac-
cess panel may be removed if necessary. Perform
Step 4 through Step 6 to remove access panel.
4. Remove nuts, capscrews, and washers from
hinges and plates. See Figure 29.
5. Remove access panel from rear roof panel. See
Figure 29.
6. Remove nuts, washers, capscrews, and hinges
from rear roof panel. See Figure 29.
Front Screen Panel
1. Remove nuts capscrews, washers, and front
screen upper bracket from overhead guard can-
opy and front screen panel. See Figure 30.
44
0100 SRM 1446
2. Remove front screen panel from front screen
lower brackets. See Figure 30.
3. Remove front screen upper seals from overhead
guard. See Figure 30.
INSTALL
Front Screen Panel
1. Install front screen upper seals on overhead
guard. See Figure 30.
2. Install front screen upper brackets. See Fig-
ure 30.
3. Install front screen panel into front screen
lower brackets. See Figure 30.
4. Install front screen upper brackets, washers,
capscrews, and nuts onto front screen panel
and overhead guard canopy. See Figure 30.
Roof Panels
NOTE: Perform Step 1 and Step 2 if access panel
was removed.
1. Install hinges, washers, capscrews, and nuts
onto rear roof panel. See Figure 29.
2. Install access panel, washers, capscrews, and
nuts onto hinges and plates. See Figure 29.
3. Install "U" brackets, washers, capscrews, and
nuts on overhead guard and panel plates. See
Figure 28.
4. Install roof mounting brackets, washers, cap-
screws, and nuts on roof panel and overhead
guard canopy. See Figure 28.
5. Install "S" brackets, washers, and nuts onto din
bolts. See Figure 28.
0100 SRM 1446 Weather Panel Replacement

Figure 28. Roof Panels for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

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Weather Panel Replacement 0100 SRM 1446

Legend for Figure 28

A. BOTTOM VIEW B. FRONT VIEW

1. ROOF PANEL 7. "S" BRACKET
2. OVERHEAD GUARD CANOPY 8. "U" BRACKET
3. NUT 9. OVERHEAD GUARD
4. WASHER 10. PANEL PLATES
5. ROOF MOUNTING BRACKET 11. DIN BOLTS
6. CAPSCREW

1. REAR ROOF PANEL 5. CAPSCREW

2. ACCESS PANEL 6. WASHER
3. PLATE 7. NUT
4. HINGE

Figure 29. Rear Roof Panels for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

46
0100 SRM 1446 Weather Panel Replacement

1. FRONT SCREEN UPPER BRACKET 6. FRONT SCREEN PANEL

2. OVERHEAD GUARD CANOPY 7. FRONT SCREEN LOWER BRACKET
3. NUT 8. FRONT SCREEN UPPER SEAL
4. CAPSCREW 9. OVERHEAD GUARD
5. WASHER

Figure 30. Front Screen Panel for Lift Truck E2.2-3.5XN (E45-70XN) (A268)

47
 NOTES

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 TECHNICAL PUBLICATIONS

0100 SRM 1446 9/14 (8/13)(11/12)(3/12)(8/11)(5/11)