FRAME

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

J2.00-3.20XM (J40-65Z) [A416]

PART NO. 897774 100 SRM 582

Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Main Frame ................................................................................................................................................... 1
Other Frame Weldments............................................................................................................................... 1
Overhead Guard ............................................................................................................................................ 5
Battery and Operator Restraint, Hood, and Seat Assembly ....................................................................... 9
Battery Restraint ..................................................................................................................................... 9
Hood ........................................................................................................................................................... 10
Operator Restraint System and Seat Assembly ...................................................................................... 11
Overhead Guard Replacement .......................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Install ............................................................................................................................................................. 13
Hood, Seat Assembly and Operator Restraint Replacement........................................................................... 15
Hood and Seat Assembly............................................................................................................................... 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 17
Operator Restraint System ........................................................................................................................... 19
Counterweight Replacement ............................................................................................................................. 19
Remove ........................................................................................................................................................... 20
Install, J2.00-3.20XM (J40-60XM) (A216) Lift Trucks ................................................................................ 21
Install, J2.00-3.20XM (J40-60XM 2) (A216) and J2.00-3.20XM (J40-60Z) (A416) Lift Trucks .................. 21
Traction Motor Replacement ............................................................................................................................. 22
Remove ........................................................................................................................................................... 22
Install ............................................................................................................................................................. 24
Hydraulic Tank Repair ...................................................................................................................................... 25
Remove ........................................................................................................................................................... 25
Inspect ............................................................................................................................................................ 25
Clean .............................................................................................................................................................. 26
Steam Method............................................................................................................................................ 26
Chemical Solution Method........................................................................................................................ 26
Additional Preparations for Tank Repair..................................................................................................... 27
Small Leaks, Repair ...................................................................................................................................... 27
Large Leaks, Repair ...................................................................................................................................... 27
Preparations for Usage After Repair............................................................................................................ 27
Install ............................................................................................................................................................. 27
Painting Instructions......................................................................................................................................... 28
Safety Label Replacement ................................................................................................................................. 28
Battery Specifications........................................................................................................................................ 31
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) Model Trucks .................................................................... 31
J2.00-3.20XM (J40-65Z) (A416) Model Trucks............................................................................................. 32

This section is for the following models:

J2.00-3.20XM (J40-60XM, J40-60XM 2) [A216];

J2.00-3.20XM (J40-65Z) [A416]

©2005 HYSTER COMPANY i

100 SRM 582
General
This section has a description and the service procedures for the parts of the frame. These parts include the
frame, counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions.
The procedure for removing the traction motor is also described in this section.
Description
MAIN FRAME
The main frame is a single weldment. See Figure 1.
The main frame has mounts for the following:
• Counterweight
• Overhead guard,
• Battery restraint and hood
• Tilt cylinders
• Steering axle
• Drive axle assembly
• Cowl assembly
• Floor pedals and floor plates
• Side step and fender weldments
• Hydraulic tank
• Pump and motor assemblies (steer, lift, and trac-
tion motors)
• Control valves, and the levers
The hood is part of the operator and battery restraint
system. The seat is part of the operator restraint
system. The floor plates can be removed for access
to the traction motor. The panels on the sides of the
battery compartment can also be easily removed.
The hydraulic tank, lift pump motor assembly, and
the steering pump motor assembly are in a compart-
ment between the battery and the counterweight.
The SCR (silicon controlled rectifier) or transistor
electronic controllers and contactors are in the top
of the counterweight. The top cover of the counter-
weight can be removed for access to the controllers
and contactors for J2.00-3.20XM (J40-60XM) (A216).
See Figure 2. The rear cover of the counterweight
can be removed for access to the controllers and
contactors for J2.00-3.20XM (J40-60XM 2) (A216)
and J2.00-3.20XM (J40-60Z) (A416) See Figure 3.
There are two main frames for lift trucks made for
use in North America and two main frames for lift
trucks made for use in Europe. The frames are dif-
ferent because of the different battery compartment
sizes. There are two battery compartment lengths.
The battery compartment widths are also different
for Europe and North America. See Battery Specifi-
cations, at the back of this manual.
Description
WARNING
The battery must fit the battery compartment
so that the battery restraint will operate cor-
rectly. A loose battery can cause serious in-
jury and property damage if the lift truck over-
turns. Adjust the spacer plate to prevent the
battery from moving more than 13 mm (0.5 in.)
forward or backward.
WARNING
Maximum clearance between the battery and
battery compartment width is 13 mm (0.5 in.).
Maximum clearance between the battery and
the spacer plate is also 13 mm (0.5 in.). The Bat-
tery Specifications chart shows the minimum
size compartment allowed.
The weight of the battery is a large part of the coun-
terweight system on an electric lift truck. Make sure
that the battery is within the weight limits indicated
on the nameplate. Each model of lift truck has a
cast-iron counterweight that provides the additional
weight necessary for the indicated capacity.
OTHER FRAME WELDMENTS
These frame parts are the right-hand and left-hand
side step and fender weldments, and the cowl weld-
ment. See Figure 1. Each part is a weldment
fastened to the main frame to make the frame
assembly. The cowl weldment is a mount for the
front of the overhead guard (see Figure 2 and Fig-
ure 3), the steering column assembly (see Figure 4,
Figure 5, and Figure 6), the release linkage of
the parking brake, and the instrument panel with
light switches. The display panel for J2.00-3.20XM
(J40-60XM) (A216) (see Figure 4) is not part of the
instrument panel. The steering column housing
is the mount for the display panel assembly. The
display panel for J2.00-3.20XM (J40-60XM 2) (A216)
and J2.00-3.20XM (J40-60Z) (A416) are mounted
into the instrument panel. See Figure 5 and Fig-
ure 6.
1
Description 100 SRM 582

1. COWL 5. SIDE STEP AND FENDER WELDMENT

2. BATTERY SPACER PLATE 6. ACCESS PANEL
3. BATTERY RETAINER ROD 7. FLOOR PLATES
4. FRAME

Figure 1. Lift Truck Main Frame

Legend for Figure 2

1. OVERHEAD GUARD 4. TOW PIN AND HANDLE 8. HANDLE
2. COVER OF ELECTRONICS 5. CAPSCREW 9. SCREW
COMPARTMENT 6. LOCKWASHER 10. NUT
3. COUNTERWEIGHT 7. WASHER 11. FOAM TAPE

2
100 SRM 582 Description

Figure 2. Overhead Guard and Counterweight J2.00-3.20XM (J40-60XM) (A216) Trucks

3
Description 100 SRM 582

Figure 3. Overhead Guard and Counterweight J2.00-J3.20XM (J40-60XM 2) (A216) and J2.00-3.20XM
(J40-60Z) (A416) Trucks

4
100 SRM 582 Description

Legend for Figure 3

A. OVERHEAD GUARD USED ON J2.00-3.20XM (J40-60XM 2) (A216) TRUCKS
B. OVERHEAD GUARD USED ON J2.00-3.20XM (J40-60Z) (A416) TRUCKS
1. OVERHEAD GUARD 10. COVER
2. HANDLE 11. SOCKET CAPSCREW
3. ROLLING THREAD SCREW 12. LOCKWASHER
4. NUT 13. COUNTERWEIGHT
5. WASHER 14. FOAM TAPE
6. CAPSCREW 15. SPACER
7. COVER 16. BRACKET
8. TOW PIN 17. SELF RETAINING NUT
9. TAPE

OVERHEAD GUARD operator from falling objects. For early model

WARNING
Do not operate the lift truck without the over-
head guard and cowl correctly fastened to the
lift truck.
J2.00-3.20XM (J40-60XM) (A216), see Figure 2. For
later model J2.00-3.20XM (J40-60XM 2) (A216) and
J2.00-3.20XM (J40-60Z) (A416), see Figure 3. A
slot in the overhead guard permits removal of the
battery without removing the overhead guard.

The overhead guard is a weldment that fastens

to the main frame and cowl to help protect the

5
Description 100 SRM 582

A. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS

B. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS
1. STEERING WHEEL 8. ENHANCED DISPLAY PANEL
2. STEERING CONTROL UNIT 9. STANDARD DISPLAY PANEL
3. LATCH MECHANISM 10. HORN BUTTON
4. COLUMN COVER 11. STEERING COLUMN
5. COLUMN FRAME 12. STEERING COLUMN NUT
6. HORN SWITCH CONNECTOR
7. ON-DEMAND STEERING COMPONENTS (NOT
ALL UNITS)

Figure 4. Steering Column and Instrument Panel J2.00-3.20XM (J40-60XM) (A216) Trucks

6
100 SRM 582 Description

1. STEERING WHEEL 8. LATCH MECHANISM

2. SHIFT LEVER MECHANISM 9. HORN SWITCH CONNECTOR
3. COLUMN COVER 10. HORN BUTTON
4. STEERING CONTROL UNIT 11. STEERING COLUMN
5. COLUMN FRAME 12. STEERING COLUMN NUT
6. ON-DEMAND STEERING COMPONENTS
7. DISPLAY PANEL (PREMIUM DISPLAY PANEL
SHOWN)

Figure 5. Steering Column and Display Panel J2.00-3.20XM (J40-60XM 2) (A216) Trucks

7
Description 100 SRM 582

Figure 6. Steering Column and Display Panel J2.00-3.20XM (J40-60Z) (A416) Trucks

Legend for Figure 6

1. ON-DEMAND STEERING COMPONENTS 9. DASH
2. SHIFT LEVER MECHANISM 10. COLUMN MOUNT
3. STEERING WHEEL 11. LATCH MECHANISM
4. DISPLAY PANEL 12. HORN SWITCH CONNECTOR
5. COLUMN COVER 13. HORN BUTTON
6. COLUMN FRAME 14. STEERING COLUMN
7. STEERING CONTROL UNIT 15. STEERING COLUMN NUT
8. COWL WELDMENT

8
100 SRM 582 Description

BATTERY AND OPERATOR RESTRAINT,

HOOD, AND SEAT ASSEMBLY
Battery Restraint

WARNING
The hood and battery restraint, as well as the
latch for the hand lever assembly, must operate
correctly before a lift truck is operated. These
parts are part of the battery restraint system.
The battery restraint system must operate cor-
rectly to help provide reasonable protection to
the operator if the lift truck tips over.

A battery restraint system is installed as a safety de-

vice. See Figure 7. The function on the battery re-
straint system is to hold the battery in the battery
compartment in case of a tip over. Part of the bat-
tery restraint system is a battery restraint rod at the
rear of the battery compartment. See Figure 7. This
A. RETRACTED B. EXTENDED
restraint rod extends over the rear edge of the bat-
tery case to help hold the battery within the battery 1. BATTERY RESTRAINT WARNING LABEL
compartment during a tip over. A handle is used to 2. HOOD
move the restraint rod. The handle of the battery re- 3. BATTERY RESTRAINT HANDLE
straint must be in the DOWN position to close the 4. BATTERY
5. STEEL WELDMENT
hood. The handle can be moved to the DOWN posi-
tion only after the restraint rod is extended over the Figure 7. Battery Restraint Rod
battery. The restraint rod can only be retracted when
the hood is in the UP position.

WARNING
The battery must fit the battery compartment
so that the battery restraint will operate cor-
rectly. A loose battery can cause serious in-
jury and property damage if the lift truck over-
turns. The battery must not be able to move
more than 13 mm (0.5 in.) forward, backward,
or side to side.

An adjustable spacer plate is used at the front of

the battery compartment to prevent forward and
backward movement of the battery. See Figure 8.
The adjustable spacer plate is used inside the bat-
tery compartment. See Figure 8. The spacer plate
must be adjusted for a maximum clearance of 13 mm
(0.5 in.) with the battery against the rear bulkhead.
There must be some clearance to allow battery re-
moval. See the section Periodic Maintenance 1. BATTERY 4. SPACER PLATE
8000 SRM 552 for the J2.00-3.20XM (J40-60XM, COMPARTMENT 5. ADJUSTMENT
J40-60XM 2) (A216) models and Periodic Main- 2. BATTERY CAPSCREW
tenance 8000 SRM 1060 for the J2.00-3.20XM 3. BULKHEAD 6. JAM NUTS
(J40-60Z) (A416) models, to remove the battery and
Figure 8. Battery Spacer Plate
adjust the spacer plate.

9
Description 100 SRM 582

Hood Another important part of the battery restraint sys-

WARNING
The gas springs for the hood can raise the hood
at a rapid rate and cause an injury. DO NOT get
over hood when raising hood.
WARNING
The batteries for these lift trucks must fit the
battery compartment width with a maximum
of 13 mm (0.5 in.) clearance. The Battery Spec-
ifications at the back of this manual, shows the
minimum sizes of the battery compartments.
tem is the steel weldment that is also the hood frame.
See Figure 7. This hood frame is connected to the
lift truck frame with hinges at the rear of the hood
(see Figure 13). The front of the hood and frame is
locked in the closed position by the assembly for the
hydraulic hand levers. A latch releases the assembly
to tilt forward and allow the hood to raise. See Fig-
ure 9. Gas springs help lift the hood assembly. The
seat and other parts of the operator restraint system
fasten to the hood assembly.

A. CLOSED OVER HOOD B. OPEN

1. HAND LEVER ASSEMBLY 4. LATCH HANDLE
2. HOOD 5. LATCH
3. SEAT

Figure 9. Hood and Hand Lever Assembly with Latch

10
100 SRM 582
Operator Restraint System and Seat
Assembly
Figure 10. Seat Assembly and Operator
Restraint
Overhead Guard Replacement
REMOVE
WARNING
Do not weld, drill, grind, or cut the overhead
guard for mounts of lights or accessories. The
strength of the overhead guard can be reduced.
1. Remove the battery as described in the section
Periodic Maintenance 8000 SRM 552 for
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216)
models and Periodic Maintenance 8000 SRM
1060 for J2.00-3.20XM (J40-60Z) (A416) models.
2. Access to the capscrews that hold the rear legs of
the overhead guard to the frame is from the bat-
tery compartment. See Figure 11 and Figure 12.
Overhead Guard Replacement
Legend for Figure 10
1. SEAT
2. HIP RESTRAINT
3. SEAT BELT AND MOUNT
4. SEAT RAILS
5. CAPSCREW
The operator restraint system has the seat, hip re-
straints, and the seat belt. The system helps the op-
erator stay within the lift truck in case of a tip over.
See Figure 10.
Make sure that the seat is not loose on the rails.
Make sure the seat rails are not loose. The seat rails
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached
to the mounting surface.
Remove the capscrews, washers, and nuts that
fasten each leg.
3. Remove the capscrews, washers, and nuts that
hold each front leg of the overhead guard to the
cowl. Disconnect any electric wires from under
the cowl that go through the front legs of the over-
head guard. When the overhead guard is lifted
from the frame, make sure these electric wires
move through the holes in the frame at the front
and rear so that they are not damaged.
4. Use a lifting device or another person to help lift
the overhead guard from the lift truck.
11
Overhead Guard Replacement 100 SRM 582

Figure 11. Overhead Guard and Counterweight J2.00-3.20XM (J40-60XM) (A216) Trucks

12
100 SRM 582 Overhead Guard Replacement

Legend for Figure 11

1. OVERHEAD GUARD 7. WASHER
2. COVER OF ELECTRONICS COMPARTMENT 8. HANDLE
3. COUNTERWEIGHT 9. SCREW
4. TOW PIN AND HANDLE 10. NUT
5. CAPSCREW 11. NUT
6. LOCKWASHER 12. FOAM TAPE

INSTALL
Put the overhead guard on the lift truck. Install
any electric wires from the overhead guard legs
through the holes in the frame. Install the cap-
screws, washers, and nuts that hold each front leg
to the frame. See Figure 11 and Figure 12. Tighten
the capscrews to 102 N•m (75 lbf ft). Install the
capscrews, washers, and nuts that hold the rear legs
to the frame. Tighten the capscrews to 102 N•m
(75 lbf ft). Install the battery as described in the
section Periodic Maintenance 8000 SRM 552 for
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) mod-
els and Periodic Maintenance 8000 SRM 1060 for
J2.00-3.20XM (J40-60Z) (A416) models.

13
Overhead Guard Replacement 100 SRM 582

Figure 12. Overhead Guard and Counterweight J2.00-J3.20XM (J40-60XM 2) (A216) and
J2.00-3.20XM (J40-60Z) (A416) Trucks

14
100 SRM 582 Hood, Seat Assembly and Operator Restraint Replacement

Legend for Figure 12

A. OVERHEAD GUARD USED ON J2.00-3.20XM (J40-60XM 2) (A216) TRUCKS
B. OVERHEAD GUARD USED ON J2.00-3.20XM (J40-60Z) (A416) TRUCKS
1. OVERHEAD GUARD 10. COVER
2. HANDLE 11. SOCKET CAPSCREW
3. ROLLING THREAD SCREW 12. LOCKWASHER
4. NUT 13. COUNTERWEIGHT
5. WASHER 14. FOAM TAPE
6. CAPSCREW 15. SPACER
7. COVER 16. BRACKET
8. TOW PIN 17. SELF RETAINING NUT
9. TAPE

Hood, Seat Assembly and Operator Restraint Replacement

HOOD AND SEAT ASSEMBLY
Remove
WARNING
The gas spring for the hood can raise the hood
at a rapid rate and cause an injury. DO NOT
get over hood when raising hood.
NOTE: The hood and seat assembly can be removed
as a unit or the seat assembly can be removed with
the hood assembly installed on the truck frame. Do
only the steps necessary. If the hood and seat as-
sembly will be removed as a unit, do Step 1 through
Step 4. To remove the seat assembly from the hood
assembly, do Step 1 through Step 3 and Step 5
through Step 7.
Remove the hood and seat assembly as follows (see
Figure 13):
1. Turn the key to the OFF position and remove the
key.
the top of the battery to prevent accidental short
circuits.
3. Disconnect the connector for the seat switch
wires near the rear of the hood frame. If the
hood will be removed, remove the Emergency
Stop knob and the power disconnect assembly
from the hood.
4. Fasten the hood assembly so that it cannot lower
and carefully remove the gas springs from the
hood. Have an assistant help hold the hood as-
sembly. Remove the screws that fasten the hood
assembly to the lift truck frame. See Figure 13
and Figure 14. Carefully remove the hood assem-
bly.
5. Push the connector of the seat switch wire
through the grommet in the hood. It can be
necessary to remove the grommet from the hole
in the hood for enough clearance to get the con-
nector through the grommet. Inspect seat switch
and replace if worn or damaged. See Figure 13

6. Remove the screws that fasten the seat to the

WARNING hood and hood frame. Close and latch the hood
Never put tools or other metal on the battery. and put the seat on its side for access to the seat
Metal on the battery can cause a short circuit switch.
and possible damage or injury.
7. Use a flat blade screwdriver or other tool with
2. Open the hood and disconnect the battery con- a flat blade to carefully lift the switch free of the
nector. Install a cardboard or plywood cover on seat pan. Slide the switch out of the seat cushion.

15
Hood, Seat Assembly and Operator Restraint Replacement 100 SRM 582

Figure 13. Hood Remove

16
100 SRM 582 Hood, Seat Assembly and Operator Restraint Replacement

Legend for Figure 13

A. TOP VIEW C. HOOD IN OPEN POSITION
B. SIDE VIEW
1. HOOD HANDLE 7. SEAT RAILS
2. EMERGENCY STOP BUTTON 8. HOOD BRACKET SPRING
3. HOOD 9. CAPSCREW, WASHER, AND NUT
4. SEAT SWITCH 10. WASHER, NUT, AND BOLT
5. GAS SPRING 11. BATTERY COVER
6. SEAT 12. OVERHEAD GUARD

Install in the hole of the hood, connect the wire connec-

NOTE: If just the seat assembly was removed, in-
stall seat assembly onto hood by performing Step 1,
Step 2, Step 4, and Step 5. If the hood and seat as-
sembly were removed, install hood and seat assembly
by performing Step 3 through Step 5.
1. Carefully slide the seat switch into the cavity of
the seat cushion until the end of the switch with
the wires is aligned over the hole in the pan.
Push on the switch until the clips of the switch
are fastened to the seat. See Figure 13.
tor, and push the connector back inside the hood
frame.
3. If the hood assembly was removed, have an assis-
tant help align the hood assembly in the correct
position. Install the screws that fasten the hood
assembly to the lift truck frame. See Figure 13.
Hold the hood assembly in the open position and
carefully install the gas springs.
4. Install the power disconnect assembly on the
hood. Install the Emergency Stop knob.

2. Carefully install the grommet over the wire con- 5. Remove cardboard or plywood from top of bat-
nector (see Figure 14.) Install the seat on the tery.
hood and tighten the nuts. Install the grommet

17
Hood, Seat Assembly and Operator Restraint Replacement 100 SRM 582

1. HOOD 7. GAS SPRING 13. COVER

2. STEEL WELDMENT 8. FOAM TAPE 14. SCREW
3. PLATE 9. SPACER 15. HANDLE
4. WASHER 10. BRACKET 16. STRAP CLAMP
5. LOCKWASHER 11. CAPSCREW 17. BOLT
6. NUT 12. TRIM 18. GROMMET

Figure 14. Hood Assembly

18
100 SRM 582 Counterweight Replacement

OPERATOR RESTRAINT SYSTEM

The parts of the operator restraint system are as
follows: the seat belt, hip restraint brackets, seat
and mounting, battery restraint (restraint rod and
hood plate), and the assembly for the hydraulic hand
levers and latch. See Figure 13 and Figure 15. Each
item must be checked to make sure it is attached se-
curely, functions correctly, and is in good condition.

The seat belt must latch securely. Make sure the seat
belt extends and retracts smoothly and is not dam-
aged or torn. If the seat belt cannot be pulled from
the retractor assembly, the seat belt assembly must
be replaced.

1. SEAT
2. HIP RESTRAINT
3. SEAT BELT AND MOUNT
4. SEAT RAILS
5. CAPSCREW

Figure 15. Operator Restraint and Seat

Assembly

Counterweight Replacement
If the lift truck must be put on blocks for mainte- lifting capacity to safely lift the counterweight.
nance and repair, see the section Periodic Mainte- The weights of the counterweights are shown
nance 8000 SRM 552 for J2.00-3.20XM (J40-60XM, in Table 1.
J40-60XM 2) (A216) models and Periodic Mainte-
nance 8000 SRM 1060 for J2.00-3.20XM (J40-60Z) The counterweight normally is not removed for most
(A416) models, for the procedures of putting the lift repairs. The counterweight is fastened to the frame
truck on blocks. with four capscrews. The weights for the counter-
weights are shown in Table 1.
WARNING
The counterweight is very heavy. Make sure
that the crane and lifting devices have enough

19
Counterweight Replacement
Table 1. Counterweights
Model (mm*)
J2.00XM and J2.50XM, J40XM, J40XM 2, 717 mm
(A216) J40Z (A416) and J50XM, J50XM 2,
(A216) and J50Z (A416)
J2.50XM and J3.00XM, J50XM, J50XM 2, 861 mm
(A216) J50Z (A416) and J60XM, J60XM 2,
(A216) and J60Z (A416)
J3.20XM and J60XM, J60XM 2, (A216) 861 mm
and J60Z (A416)
*Approximate battery compartment lengths.
REMOVE
NOTE: For early model J2.00-3.20XM (J40-60XM)
(A216) lift trucks, do Step 1 through Step 4 and
Step 6 and Step 7. For later model J2.00-3.20XM
(J40-60XM 2) (A216) lift trucks and for J2.00-3.20XM
(J40-60Z) (A416) lift trucks, do Step 1 and Step 5
through Step 7.
1. Remove the battery. See the section Periodic
Maintenance 8000 SRM 552 for J2.00-3.20XM
(J40-60XM, J40-60XM 2) (A216) models and Pe-
riodic Maintenance 8000 SRM 1060 for J2.00-
3.20XM (J40-60Z) (A416) models, for the proce-
dures to remove the battery.
2. Remove the top cover of the counterweight (cover
over electronics compartment). See Figure 11.
WARNING
Do not touch the terminals of capacitor C1 of
the traction or lift motor SCR controllers. The
charge on the capacitors can cause electrical
shock and personal injury. Disconnect the
battery and use an insulated screwdriver or
jumper wire to make a short circuit across the
capacitor terminals. The short circuit will dis-
charge each capacitor and prevent electrical
shocks.
3. Remove the three capscrews that fasten the mo-
tor controllers to the counterweight. See Fig-
ure 16. Carefully lift the controller assembly up
20
100 SRM 582
+50 kg (110 lb)
Weight
0 kg (0 lb)
685 kg (1510 lb)
750 kg (1653 lb)
to a nearly vertical position. Use cord or wire fas-
tened to the overhead guard to hold the controller
assembly in this vertical position.
4. Install a lifting eye in the hole at the top rear of
the counterweight. Use a lifting eye [shaft length
approximately 200 mm (8 in.)] with a washer and
nut. Fasten a sling or chain to the lifting eye.
Make sure the chain or sling and crane has the
capacity to lift the counterweight. See Table 1.
Raise the crane to make sure the crane is the
support for the weight of the counterweight.
5. Remove the top cover on the counterweight and
the cover in the front part of the counterweight
that covers the electronic control compartment.
See Figure 12. Fasten a sling or chain around the
counterweight. Make sure the chain or sling and
crane has the capacity to lift the counterweight.
See Table 1.
6. From inside the battery compartment near the
bottom, remove the two top capscrews that hold
the counterweight to the frame. Remove the
capscrews, nuts, and washers that fasten the
counterweight between the wheels under the
tow pin. Use the crane to lift the counterweight
away from the lift truck frame. On J2.00-3.20XM
(J40-60XM 2) (A216) and J2.00-3.20XM (J40-60Z)
(A416) Lift Trucks, make sure that you do not
damage the motor controller assembly.
7. Put the counterweight in a position so that it can-
not fall and cause damage or in injury.
100 SRM 582
1. COUNTERWEIGHT
Figure 16. Remove Motor Controllers, J2.00-3.20XM (J40-60XM) (A216) Models Only
INSTALL, J2.00-3.20XM (J40-60XM) (A216)
LIFT TRUCKS
1. Use a crane and a lifting eye to lift the coun-
terweight into position at the rear of the truck.
Make sure that you do not damage the motor
controller assembly during installation. See Fig-
ure 11. Install the two upper capscrews near the
bottom of the battery compartment that hold the
counterweight to the frame. Install the lower
capscrews, washers, and nuts in the tow pin area
of the counterweight. Tighten the upper cap-
screws to 320 N•m (236 lbf ft). Tighten the lower
(between wheels) capscrews and nuts to 66 N•m
(49 lbf ft). If removed, tighten the cover cap-
screws to 52 N•m (38 lbf ft).
NOTE: The top cover of the counterweight can be re-
moved from the counterweight to make checks and
adjustments on the controller.
2. Disconnect the sling or chain. Remove the lifting
eye from the counterweight and install the motor
controller assembly (see Figure 16). Install the
top cover on the counterweight.
Counterweight Replacement
2. CAPSCREWS
3. Install the battery. See the section How to
Change Battery in Periodic Maintenance
8000 SRM 552.
INSTALL, J2.00-3.20XM (J40-60XM 2)
(A216) AND J2.00-3.20XM (J40-60Z) (A416)
LIFT TRUCKS
1. Use a crane and either a sling or chain to lift
the counterweight into position at the rear of
the truck. See Figure 12. Install the two up-
per capscrews near the bottom of the battery
compartment that hold the counterweight to the
frame. Install the lower capscrews, washers,
and nuts in the tow pin area of the counter-
weight. Tighten the upper capscrews to 320 N•m
(236 lbf ft). Tighten the lower (between wheels)
capscrews and nuts to 66 N•m (49 lbf ft). If
removed, tighten the cover capscrews to 52 N•m
(38 lbf ft).
2. Disconnect the sling or chain. Install the top
cover and the electronic control compartment
cover, on the front of the counterweight.
21
Traction Motor Replacement
3. Install the battery. See the section Periodic
Maintenance 8000 SRM 552 for J2.00-3.20XM
(J40-60XM 2) (A216) models and Periodic Main-
tenance 8000 SRM 1060 for J2.00-3.20XM (J40-
Traction Motor Replacement
REMOVE
This procedure will show the removal of the traction
motor from the speed reducer with the drive train
installed in the lift truck. See Figure 17, Figure 18,
and Figure 19.
For repair procedures to the traction motor, see the
section DC Motor Maintenance 620 SRM 294 for
all lift truck models or the section AC Motor Repair
620 SRM 1053 for lift truck models J2.00-3.20XM
(J40-60Z) (A416).
NOTE: The traction motor can be removed separately
or as a unit with the drive train. Removal with the
drive train requires the use of a floor jack and is more
difficult. The lift truck must be on blocks with clear-
ance for the jack and traction motor to be removed as
a unit. The hydraulic lines from the hydraulic tank
must also be disconnected if this method is used.
Remove the traction motor from the speed reducer
and lift truck as follows (see Figure 17):
1. Put the lift truck on blocks for easier access to
the bottom bolts between the traction motor and
the speed reducer.
2. Disconnect the battery connector and remove the
key from the key switch. Remove the floor plates.
NOTE: It is not necessary to disconnect the hydraulic
line from the master cylinder to remove the traction
motor. If the hydraulic line is not disconnected, it
will not be necessary to remove air from the brake
system after installation. The master cylinder has a
cap that does not leak, so it is not necessary to remove
the reservoir.
22
100 SRM 582
60Z) (A416) models, for the procedures to install
the battery.
3. During the removal of the following items, make
sure to install plugs in hydraulic lines that are
disconnected. Install a tag on all wires or cables
for correct connection during installation. Do not
disassemble the pedal assemblies any more than
necessary for clearance to remove the traction
motor. This will prevent having to make adjust-
ments after installation. Remove the following
components or fasten them in a position for clear-
ance to remove the traction motor:
• Horn
• MONOTROL™ or Accelerator Pedal Assembly
• Brake Pedal Assembly with Master Cylinder
and Hydraulic Line
• Parking Brake Pedal Assembly
• Two Hydraulic Lines for Steering System that
are Over Traction Motor
• Power Cables and Sensor Wires of Traction Mo-
tor
4. Remove the bottom bolts that fasten the speed
reducer and the motor. Make an alignment mark
on the traction motor and the speed reducer case
for correct installation.
5. Install a lifting eye in the hole in the top of the
motor. The hole has M10 × 1.5 mm threads and
is near the center of the motor on top. Connect a
special lifting device or chain (for a crane) to the
lifting eye to hold the traction motor. See Fig-
ure 18 or Figure 19. Use a special lifting device
fastened to the overhead guard or use a crane to
hold the weight of the traction motor.
100 SRM 582 Traction Motor Replacement

A. TOP VIEW, J2.00-3.20XM (J40-60XM, J40-60XM 2) C. SIDE VIEW, J2.00-3.20XM (J40-60XM,

(A216) MODELS J40-60XM 2) (A216) MODELS
B. TOP VIEW, J2.00-3.20XM (J40-60Z) (A416) D. SIDE VIEW, J2.00-3.20XM (J40-60Z) (A416)
MODELS MODELS
1. TRANSMISSION AND DIFFERENTIAL 6. CAPSCREW, NUT, AND WASHER
2. TRACTION MOTOR 7. PIN
3. CAPSCREW, NUT, AND WASHER 8. CAPSCREW, WASHER, AND LOCK NUT
4. TRACTION MOTOR MOUNTING PLATE (TO 9. DRIVE AXLE
TRANSMISSION AND DIFFERENTIAL) 10. SPEED REDUCER
5. TRUCK FRAME

Figure 17. Remove and Install Traction Motor

23
Traction Motor Replacement 100 SRM 582

INSTALL
1. Install a lifting eye in the hole in the top of the
motor. Use a special lifting device fastened to the
overhead guard or a chain and crane to lift the
motor. See Figure 18 or Figure 19.

2. Lower the traction motor into position in the lift

truck. Align the traction motor with the speed re-
ducer. See Figure 17. Align the alignment marks
made during removal.
1. TRACTION MOTOR 3. SLING NOTE: If a different traction motor is being installed,
2. LIFTING EYE
it can be necessary to adjust the capscrew that is be-
Figure 18. Lift Traction Motor From Truck, tween the housing for the speed reducer/differential
J2.00-3.20XM (J40-60XM, J40-60XM 2) (A216) and the bottom of the traction motor.

3. Use a board or pry bar if necessary to push the

traction motor into the speed reducer.

4. Align the bolt holes in the speed reducer and the

motor housing. Install the bolts that hold the
traction motor to the speed reducer. Tighten the
bolts to 38 N•m (28 lbf ft). See Figure 17.

5. Remove the lifting device and, if necessary,

adjust the support capscrew. Loosen the jam
nut and adjust the capscrew until the head just
touches the traction motor. Turn the capscrew
1. TRACTION MOTOR 3. SLING an additional 1/2 turn counterclockwise to push
2. LIFTING EYE on the traction motor. Tighten the jam nut to
Figure 19. Lift Traction Motor From Truck, 33 N•m (24 lbf ft) without moving the capscrew.
J2.00-3.20XM (J40-60Z) (A416) Remove the lifting eye.

NOTE: The traction motors are in different configura-
tions for different applications of the lift trucks. Trac-
tion motors weigh approximately 90 to 140 kg (200 to
310 lb).
6. Remove all the other bolts that fasten the speed
reducer and the motor. Pull the traction motor
from the speed reducer. See Figure 18 or Fig-
ure 19.
7. Use the crane to move the traction motor to a
space to make repairs.
6. Install all power cables, wires, hydraulic lines,
and pedal assemblies as removed. Fill the cav-
ity of pivot for the parking and service brake
pedals with multipurpose grease during instal-
lation. Remove the air from the brake system as
described in the section the Brake System 1800
SRM 566.
7. Operate the steering system and check for leaks.
Repair any leaks. Install all panels, covers, and
floor plates.

24
100 SRM 582 Hydraulic Tank Repair

Hydraulic Tank Repair

REMOVE
1. Turn the key to the OFF position and remove the
key.
WARNING
Never put tools or other metal on the battery.
Metal on the battery can cause a short circuit
and possible damage or injury.
2. Open the hood and install a cardboard or plywood
cover on the top of the battery to prevent acciden-
tal short circuits.
3. Turn the steering wheel for a full left turn for
access to the drain plug near the front of the right
rear wheel. See Figure 20. Install a container
under the drain plug of the hydraulic tank with
a capacity of 27.4 liter (7.25 gal).
4. Remove the drain plug and let the oil drain from
the hydraulic tank. Install and tighten the drain
plug.
5. Remove and install plugs in all the hoses
fastened to the hydraulic tank. Remove the
breather/dipstick/fill cap and install a plug in
the opening of the fill tube.
6. Remove the screws from the bracket that fas-
tens the bracket holding the hydraulic tank in
the truck frame. See mount bracket assembly of
Figure 20. Remove the bracket assembly.
7. Carefully lift the hydraulic tank up out of the
frame.
INSPECT
WARNING
Special procedures must be followed when
large leaks or other repairs need welding or
cutting. All work must be done by authorized
personnel. If the tank is cleaned inside of a
building, make sure there is enough ventila-
tion. See the following manuals for additional
information:
• Safe Practices for Welding and Cutting Con-
tainers That Have Held Combustibles by the
American Welding Society, F4.1 - 1999.
• Safety In Welding and Cutting, American Na-
tional Standard, AWS Z 49.1 - 1999.

WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.

CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
1. HYDRAULIC TANK
2. FILTER ter dealer.
3. MOUNT BRACKET ASSEMBLY
4. FILL CAP/BREATHER/DIPSTICK Make a visual inspection of all sides of the tank. In-
5. RETURN TO TANK spect the welds for cracks and leakage. Check for
6. RETURN FROM SYSTEM wet areas, accumulation of dirt, and loose or miss-
7. DRAIN PLUG ing paint caused by leakage. Areas of the tank that
8. LIFT PUMP SUPPLY PORT are not easily seen can be checked with an inspection
9. STEERING PUMP SUPPLY PORT
mirror and a light that is approved for locations with
Figure 20. Hydraulic Tank Assembly flammable vapors.

25
Hydraulic Tank Repair
The hydraulic tank is a separate sheet metal tank
and can be removed from the lift truck if necessary to
check for leaks or for replacement. Repairs for leaks
in the hydraulic tank can require special procedures
described in the next paragraphs. The most common
cause of leaks is from rust caused by the moisture of
condensation or a plugged hydraulic tank breather.
Drain any water out of the tank by removing the
drain plug and letting the tank drain until there is
no water in the oil.
CLEAN
WARNING
When cleaning the tank, do not use solutions
that make dangerous gases at normal temper-
atures or when heated. Wear eye and face pro-
tection. Protect the body from burns.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear eye and face protection. Protect
the body from burns.
Steam Method
When cleaning with steam, use a hose with a mini-
mum diameter of 19 mm (0.75 in.). Control the pres-
sure of the steam by a valve installed at the nozzle of
the hose. If a metal nozzle is used, it must be made of
a material that does not make sparks. Make an elec-
trical connection between the nozzle and the tank.
Connect a ground wire to the tank to prevent static
electricity.
Use the following procedure to clean the tank with
steam:
1. Remove all the parts from the tank. Install the
drain plug.
2. Fill the tank 1/4 full with a solution of water and
sodium bicarbonate (baking soda) or sodium car-
bonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of wa-
ter.
26
100 SRM 582
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.
3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the
tank are flushed with the solution. Drain the
tank.
4. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors
must come from all the openings.
5. Flush the inside of the tank with boiling water.
Make sure all the loose material is removed from
the inside of the tank.
6. Make an inspection of the inside of the tank. If it
is not clean, repeat Step 4 and Step 5 and make
another inspection. When making inspections,
use a light that is approved for locations with
flammable vapors.
7. Put plugs in all the openings in the tank. Wait 15
minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indi-
cator for gas vapors. If the amount of flammable
vapors is above the lower flammable limit, repeat
the cleaning procedures.
Chemical Solution Method
If the tank cannot be cleaned with steam, use the
following procedure:
1. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low the instructions given by the manufacturer.
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.
2. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
100 SRM 582
3. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning
compound is removed.
4. Make an inspection of the inside of the tank.
If the tank is not clean, repeat Step 1 through
Step 3. Make another inspection of the tank.
When making inspections, use a light that is ap-
proved for locations with flammable vapors.
5. Check the tank for flammable vapors as de-
scribed in the previous section Step 7. If the
amount of flammable vapors is not below the
lower flammable limit, repeat the cleaning pro-
cedures.
ADDITIONAL PREPARATIONS FOR TANK
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
tainers That Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
used as follows:
1. Fill the tank with water to just below the point
where the work will be done. Make sure the
space above the level of the water has a vent.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
"Safety in Welding and Cutting," AWS Z 49.1 -
1999.
SMALL LEAKS, REPAIR
Use the following procedure to seal small leaks:
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
2. Apply Loctite®290 to the leak. Follow the in-
structions of the manufacturer.
Hydraulic Tank Repair
LARGE LEAKS, REPAIR
1. Use one of the procedures described under Clean,
Steam Method of cleaning tank or Chemical So-
lution Method of cleaning tank to clean and pre-
pare the tank for repairs.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety In Welding and Cutting AWS Z 49.1 -
1999.
PREPARATIONS FOR USAGE AFTER
REPAIR
1. Add more water to the tank so that the water
goes above the point of where the work was done.
Check to see if there are any leaks coming from
tank.
2. If there are no leaks coming from the tank, re-
move all the water from the tank.
INSTALL
1. Turn the key to the OFF position and remove the
key.
WARNING
Never put tools or other metal on the battery.
Metal on the battery can cause a short circuit
and possible damage or injury.
2. Open the hood and install a cardboard or plywood
cover on the top of the battery to prevent acciden-
tal short circuits. See Figure 20.
3. Carefully position the hydraulic tank over the
correct position in the frame and install the hoses
on the bottom of the tank. Lower the tank into
the correct position in the frame.
4. Install the other hoses and if removed, the filter
on the tank. Install the bracket that fastens the
hydraulic tank in the truck frame. See mount
bracket assembly of Figure 20.
5. Fill the tank to the FULL mark on the dipstick
and install the breather/dipstick/fill cap.
6. Operate the lift and steering systems and check
for leaks.
27
Safety Label Replacement
Painting Instructions
WARNING
Always use solvents and paints in an area
with ventilation. Do not use solvents or paints
near heat, fire, or electrical equipment that
can make sparks. Follow the manufacturer’s
instructions and Cautions.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted. Use a solvent for
painted surfaces to remove grease and oil before
sanding. Do not use solvent on new paint. Make
sure all oil and grease is removed.
2. Use sandpaper to remove the top surface of the
paint and rust from the metal. All metal surfaces
where the paint is completely removed, must be
painted. Use a primer. Apply the primer before
applying the final coat of paint.
3. Protect all surfaces that will not be painted. See
the list of items in Figure 21.
Safety Label Replacement
WARNING
Labels that have WARNINGS or CAUTIONS
must be replaced if they are damaged. If a mast
of a different size or an accessory carriage is
installed, the capacity rating can change.
Changes in the kind of drive tires can change
the capacity rating. See a dealer for HYSTER
lift trucks for a replacement nameplate. The
nameplate information is a safety item and
must be correct for the equipment and config-
uration of the lift truck.
NOTE: If the labels or information plates are missing
or have damage, they must be replaced.
NOTE: The nameplate is installed using rivets. The
old rivets must be removed before installing a new
nameplate.
28
100 SRM 582
CAUTION
Do not paint the pads, plastic covers or knobs,
cables, labels, and information plates or con-
trols. Paint can make some assemblies not op-
erate correctly.
4. Paint the surfaces. Use the correct paint from
your dealer for Hyster lift trucks. Follow the di-
rections on the container. The correct arrange-
ment of colors is shown in Figure 21.
WARNING
Make sure all labels are installed after paint-
ing is complete. Safety labels are installed on
the lift truck to give information about possi-
ble hazards. It is important that all safety la-
bels are installed on the lift truck and can be
read.
5. Check that all labels are installed in the correct
locations on the lift truck. See Figure 22. New
labels are available from your dealer for Hyster
lift trucks.
1. Before installing a new label, make sure the sur-
face is dry and has no oil or grease. Do not use
solvent on new paint. Clean the surface of old
paint using a cleaning solvent. See Figure 22.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position
above the surface. The label cannot be moved
after it touches the surface. Put the label on the
surface. Make sure all air is removed from under
the label and the corners and edges are tight.
100 SRM 582 Safety Label Replacement

NOTE: USE COLORS APPROVED BY HYSTER COMPANY. DO NOT PAINT THE FOLLOWING ITEMS: PEDAL
PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY AND SEAT RAILS, INFORMA-
TION CASE AND COVER, TIRES, MAST CHAINS AND HOSES, ALL LABELS AND INFORMATION PLATES, BAT-
TERY CONNECTOR, PARKING BRAKE HANDLE, KEY SWITCH, CYLINDER RODS, ALL PLASTIC COVERS,
AND STEERING COLUMN COVER.

NOTE: LIGHT AREAS = YELLOW; DARK AREAS = BLACK; AND FORKS = RED.

Figure 21. Color Arrangement

29
Safety Label Replacement 100 SRM 582

Figure 22. Label Positions

30
100 SRM 582 Battery Specifications

Legend for Figure 22

NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 22. SEE THE
PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON THESE LIFT TRUCKS.
A. LABEL IS UNDER HOOD, NEAR CENTER
1. MAST WARNING LABEL 12. MODEL LABEL
2. TIP OVER (OPERATOR RESTRAINT) 13. HYSTER LOGO
3. OVERHEAD GUARD TEST PLATE (LEFT SIDE)* 14. FIRE SAFETY LABEL*
4. OPERATOR WARNING LABEL (RIGHT SIDE) 15. NO RIDERS
5. PARK BRAKE WARNING 16. PINCH POINT
6. PATENT PLATE 17. NO ONE ON OR UNDER FORKS
7. U.L. INSPECTION PLATE* 18. NAMEPLATE
8. BATTERY SPACER 19. WARNING LABEL FOR RESTRAINT ROD
9. EMERGENCY BATTERY DISCONNECT (UNDERSIDE OF HOOD)
10. LIFT AND TILT LABEL 20. YELLOW LETTERS
11. AUXILIARY FUNCTIONS LABEL

*NORTH AMERICA ONLY

**EUROPE ONLY

Battery Specifications
J2.00-3.20XM (J40-60XM, J40-60XM 2)
(A216) MODEL TRUCKS
Minimum Battery Size Min/Max
Model Compartment Size Weight
Length × Width Length Width

J2.00-2.50XM* 712 × 1032 mm 1025/1028 mm 708/711 mm

1558 kg (3435 lb)
72/80V (28.0 × 40.6 in.) (40.4/40.5 in.) (27.9/28.0 in.)
J40-50XM,* 690 mm (27.2 in.) 1776 kg (3916 lb)
J40-50XM 2 36V 712 × 986 mm
982 mm (38.7 in.)
J40-50XM,* (28.0 × 38.8 in.) 686 mm (27.0 in.) 1790 kg (3947 lb)
J40-50XM 2 48V
J2.50-3.20XM 856 × 1032 mm 1025/1028 mm 852/855 mm
1863 kg (4108 lb)
72/80V (33.7 × 40.6 in.) (40.4/40.5 in.) (33.5/33.7 in.)
*Short Wheelbase 784 mm (30.9 in.) = maximum height for all batteries.
NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
NOTE: Battery compartment length is front-to-back. Width is side to side. The length dimension of the battery
must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.)
maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

31
Battery Specifications 100 SRM 582

Minimum Battery Size Min/Max

Model Compartment Size Weight
Length × Width Length Width

J50-60XM, J50-60XM 2 805 mm (31.7 in.) 2127 kg (4690 lb)

36V 856 × 986 mm
982 mm (38.7 in.)
J50-60XM, J50-60XM 2 (33.7 × 38.8 in.) 835 mm (32.9 in.) 2209 kg (4871 lb)
48V
*Short Wheelbase 784 mm (30.9 in.) = maximum height for all batteries.
NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
NOTE: Battery compartment length is front-to-back. Width is side to side. The length dimension of the battery
must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.)
maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

J2.00-3.20XM (J40-65Z) (A416) MODEL

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

J2.00-2.50XM 712 × 1032 mm 1025/1028 mm 708/711 mm 1470 kg 1879 kg

(J40-50Z) (28.0 × 40.6 in.) (40.4/40.5 in.) (27.9/28.0 in.) (3241 lb) (4143 lb)
J2.50-3.20XM 856 × 1032 mm 1025/1028 mm 852/855 mm 1770 kg 2233 kg
(J50-65Z) (33.7 × 40.6 in.) (40.4/40.5 in.) (33.5/33.7 in.) (3902 lb) (4923 lb)
NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
NOTE: Battery compartment length is front-to-back. Width is side to side. The "length" dimension of the
battery must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to
0.5 in.) maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING
The battery must fit the battery compartment so that the battery restraint system will operate
correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate
to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

32