service repair manual

1. SERVICE REPAIR
E70XL E80XL E100XL E120XL [C098]

2. 1
LIFT TRUCK WEIGHTS*
E3.50XL (E70XL) 7,190
KILOGRAMS POUNDS
E4.00XL (E80XL) 8,260
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
*Weights are for lift trucks without Batteries or
Mast assemblies. See the Tables for BATTERY
SPECIFICATIONS and MAST WEIGHTS to calcu-
late the total weight of a lift truck.
9,915
9,540
10,090
2,660
3,750
4,500
4,330
4,580
MODEL
E3.50–4.00XL
(E70–80XL)
18 x 6 x 12 1/8
22 x 9 x 16
E4.50–5.50XL
(E100–120XL)
18 x 7 x 12 1/8 22 x 10 x 16
MODEL STEERING DRIVE
TIRE SIZES
22 x 10 x 16
22 x 12 x 16
HYDRAULIC SYSTEM
MAIN CONTROL VALVE
Lift Circuit
Tilt and Auxiliary Circuit
STEERING CIRCUIT
20.6 MPa (3000 psi)
15.5 MPa (2250 psi)
10.3 MPa (1500 psi)
* Oil temperature 50 to100°C (120–210°F).
ITEM SPECIFICATION
RELIEF PRESSURES*
PUMP VOLUME
SINGLE HYDRAULIC PUMP – Larger
DUAL HYDRAULIC PUMPS – Smaller 11.9 cc/rev (0.72 cu in/rev), or
36 litres/min (9.5 gpm) @ 2000 rpm
19.2 cc/rev (1.17 cu in/rev), or
23 litres/min (6.1 gpm) @ 2000 rpm
HYDRAULIC SYSTEM CAPACITY
HYDRAULIC TANK CAPACITY
25.8 litre (6.8 gal)
ITEM SPECIFICATION
(To FULL mark) 33.3 litre (8.8 gal)
49.2 litre (13.0 gal)
9.9 litre (10.5 gal)
E3.50XL (E70XL)
E4.00XL (E80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
CAPACITIES
DIFFERENTIAL / SPEED REDUCER
BRAKE FLUID 0.25 litre (0.5 pt)
5.2 litre (5.5 qt)
This section is for the following models:
E3.50–5.50XL (E70–120XL)

3. 2
E3.50–4.00XL
(E70–80XL)
E4.50–5.50XL
(E100–120XL)
MODEL TYPE OF MAST
MAXIMUM
FORK HEIGHT
APPROXIMATE
WEIGHT
millimeters kilograms poundsinches
2–Stage VISTA
Full Free–Lift VISTA
3–Stage VISTA
2–Stage VISTA
Full Free–Lift VISTA
3–Stage VISTA
3073
3696
4305
3073
3696
4369
4928
5550
2819
3454
4051
2819
4125
4674
5309
121
145.5
169.5
121
145.5
172
194
218.5
111
136
159.5
111
162.5
184
209
645
713
781
1420
1570
1720
661
726
1455
1600
888
972
1955
2140
2250
636
706
776
1400
1555
1710
679 1495
888
987
1955
2175
2250
1022
1022
MAST WEIGHTS
TWO–STAGE MAST
LIFTING LOWERING
RATED LOADNO LOAD NO LOAD RATED LOAD
m/sec ft/min m/sec ft/min m/sec ft/min
E3.50XL (E70XL)
m/sec ft/min
FULL FREE–LIFT MAST
THREE–STAGE MAST
0.20
0.29
0.19
0.28
0.53
0.53
0.53
0.53
(36 V)
(48 V)
(36 V)
(48 V)
39
54
37
53
104
104
104
104
0.35
0.44
0.35
0.44
0.48
0.48
0.48
0.48
68
86
68
86
95
95
95
95
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
0.17
0.25
0.17
0.25
0.46
0.46
0.46
0.46
34
48
33
47
90
90
90
90
0.30
0.38
0.30
0.38
0.38
0.38
0.38
0.38
59
75
59
75
74
74
74
74
E4.00XL (E80XL)
E3.50XL (E70XL)
E4.00XL (E80XL)
E3.50XL (E70XL)
E4.00XL (E80XL)
0.33
0.41
0.33
0.41
0.39
0.39
0.39
0.39
64
81
64
81
77
77
77
77
0.19
0.27
0.18
0.27
0.50
0.50
0.50
0.50
37
51
35
50
98
98
98
98
PERFORMANCE WITH SINGLE HYDRAULIC PUMP MOTOR
MAST SPEEDS
MODEL

4. 3
TWO–STAGE MAST
LIFTING LOWERING
RATED LOADNO LOAD NO LOAD RATED LOAD
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
FULL FREE–LIFT MAST
THREE–STAGE MAST
MAST SPEEDS
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
E3.50XL (E70XL)
E4.00XL (E80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
E3.50XL (E70XL)
E4.00XL (E80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
(36 V)
(48 V)
E3.50XL (E70XL)
E4.00XL (E80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
PERFORMANCE WITH TWO HYDRAULIC PUMP MOTORS
91
118
91
118
69
89
69
89
54
76
52
73
40
57
38
53
0.48
0.48
0.37
0.37
95
95
73
73
104
104
89
89
90
90
––
––
––
––
––
––
0.52
0.52
0.44
0.44
0.45
0.45
74
74
0.37
0.37
––
––
51
71
49
88
39
54
36
50
51
72
49
69
39
54
36
50
0.39
0.39
0.32
0.32
77
77
63
63
0.49
0.49
0.43
0.43
98
98
86
86
84
109
84
109
64
82
64
82
86
106
86
106
64
80
64
80
0.46
0.59
0.46
0.59
0.35
0.45
0.35
0.45
0.27
0.38
0.26
0.37
0.20
0.29
0.19
0.27
0.42
0.55
0.42
0.55
0.32
0.41
0.32
0.41
0.43
0.54
0.43
0.54
0.33
0.40
0.33
0.40
0.26
0.36
0.25
0.44
0.21
0.27
0.18
0.25
0.26
0.36
0.25
0.35
0.21
0.27
0.18
0.25
MODEL

5. 4
MODEL
MINIMUM COM-
PARTMENT SIZE
LENGTH WIDTH
WEIGHT
MIN MAX
E3.50–4.00XL
(E70–80XL)
E4.50XLS
(E100XLS)
E4.50XL
(E100XL)
E5.50XL
(E120XL)
998 x 1146 mm
(39.3 x 45.1 in)
950 / 1115 mm
(37.4 / 43.9 in)
950 / 990 mm
(37.4 / 38.9 in)
1542 kg
(3400 lb)
2300 kg
(5070 lb)
2300 kg
(5070 lb)
1633 kg
(3600 lb)
1166 x 1146 mm
(45.9 x 45.1 in)
1166 x 1146 mm
(45.9 x 45.1 in)
1115 / 1150 mm
(43.9 / 45.3 in)
1115 / 1150 mm
(43.9 / 45.3 in)
1814 kg
(4000 lb)
2750 kg
(6063 lb)
1919 kg
(4230 lb)
2750 kg
(6063 lb)
617 mm (24.3 in) = maximum height for batteries with a cover used in lift trucks without a hood.
585 mm (23.0 in) = maximum height for batteries without a cover used in lift trucks with a hood.
NOTE: Maximum tolerances are +0 and –13 mm (+0 and –0.5 in) for the size of the battery compartment.
The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a
battery compartment.
The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use
the spacers designed by Hyster Company to prevent the battery from moving more than 13 mm (0.5 in) in
any horizontal direction.
WARNING
BATTERY SIZE
MIN/MAX
LENGTH x WIDTH
BATTERY SPECIFICATIONS
950 / 1115 mm
(37.4 / 43.9 in)
950 / 1115 mm
(37.4 / 43.9 in)
950 / 1115 mm
(37.4 / 43.9 in)
998 x 1146 mm
(39.3 x 45.1 in)
950 / 990 mm
(37.4 / 38.9 in)

6. 5
VOLTS
NO LOAD NO LOAD RATED LOAD RATED LOAD
mph amperes mph amperes
TRACTION MOTOR, 280 mm (11 in) DIAMETER
Across the Battery
TRACTION MOTOR, 330 mm (13 in) DIAMETER
Across the Battery
TRACTION MOTOR, 330 mm (13 in) DIAMETER
Field Weakening
SPEED + 15% acceptable. CURRENT + 20% acceptable.
Speeds measured with a fully charged battery. Lift truck operated for 1/2 hour to warm up.
Speeds are an average of forward and reverse speeds.
Steering current is subtracted from currents listed in this chart.
TRACTION SPEED and TRACTION MOTOR CURRENT
E3.50XL (E70XL)
E4.00XL (E–80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
E3.50XL (E70XL)
E4.00XL (E–80XL)
E3.50XL (E70XL)
E4.00XL (E–80XL)
E4.50XLS (E100XLS)
E4.50XL (E100XL)
E5.50XL (E120XL)
36
48
36
48
36
48
36
48
36
48
36
48
36
48
36
48
36
48
36
48
6.5
8.3
95
102
96
104
5.9
7.6
5.7
7.4
107
116
113
120
6.7
8.7
6.5
8.5
6.2
8.3
6.0
8.0
122
126
126
130
134
135
139
140
6.0
7.8
5.8
7.6
5.4
7.1
5.1
6.7
139
145
145
150
157
163
168
175
190
202
198
213
212
226
224
239
8.8
10.8
8.6
10.8
8.4
10.6
8.2
10.4
169
189
172
189
177
195
183
200
8.0
10.3
7.7
9.9
7.3
9.4
7.0
9.0
MODEL
km/h km/h
10.6
13.4
10.5
13.4
10.8
14.0
10.5
13.7
10.0
13.4
12.9
14.2
17.4
13.9
17.4
13.5
17.1
13.2
16.7
6.6
8.3
9.5
12.2
9.2
11.9
9.7
12.6
9.3
12.2
8.7
11.4
8.2
10.8
12.9
16.6
12.4
15.9
11.7
15.1
11.3
14.5
9.7

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