Hyster J40xnt Parts and Service Frame 1659445 0100SRM1329 (07 2011) US en
December 6, 2022 | Author: Anonymous | Category: N/A
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FRAME J1.5-2.0XNT J1.5-2.0XNT [K160]; J1.6-2.0XN (J30-40XNT) (J30-40XN) [A935] (J30-40XN)
PART NO. 1659445
100 SRM 1329
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR Wh When en lif liftin ting g parts parts or assem assembli blies es,, mak make e sure sure all slings slings,, chain chains, s, or cab cables les are correc correctly tly fas fasten tened ed,, 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. • DISCO DISCONNEC NNECT T THE BAT BATTERY TERY CONN CONNECTOR ECTOR befor before e doing doing any main maintenan tenance ce or repa repair ir on elec electric tric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct correct bloc blocks ks to pr preven eventt the unit from rolli rolling ng or falli falling. ng. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating the Operating Manual or Manual or the the Periodic Maintenance section. 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 use HYSTER APPROVED parts APPROVED parts when making repairs. repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING WARNING and and CAUTION CAUTION notes notes in the instructions. • Gasoline Gasoline,, Liquid Liquid Pe Petrol troleum eum Gas (LPG (LPG), ), Comp Compress ressed ed Natural Gas (CNG) (CNG),, and Diesel fuel are flammable. flamm able. Be sure to follow the necessar necessary y safet safety y prec precautio autions ns when handl handling ing 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 ventilat ventilated. ed.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
Frame
Table of Contents
TABLE OF CONTENTS Introduction........................................................................................................................................................ Introduction........................................................................................................................................................ General........................................................................................................................................................... General ........................................................................................................................................................... Description of Operation ............................................................................................................................... Discharging the Capacitors ........................ .................................... ....................... ....................... ........................ ........................ ........................ ........................ ........................ ................ .... Covers and Floor Plates .....................................................................................................................................
1 1 1 2 4
Overhead Replacement .......................................................................................................................... RemoveGuard ........................................................................................................................................................... Install ............................................................................................................................................................. Hood and Seat Assembly ................................................................................................................................... Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Ground Test Test ................................................................................................................................................... Counterweight Replacement ............ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ................. ..... Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Safety Labels ...................................................................................................................................................... Painting Instructions ............ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ................. ..... Battery Specifications........................................................................................................................................ Specifications ........................................................................................................................................ J1.5-2.0XNT (K160) European Model Trucks .............................................................................................. J30-40XNT J30-40 XNT (K160) US Model Trucks Trucks........................................................................................................... ...........................................................................................................
6 6 9 10 12 13 14 14 16 18 20 23 24 24 25
J1.6-2.0XN (A935) European Model Trucks................................................................................................. Trucks ................................................................................................. J30-40XN J30-40 XN (A935) US Model Trucks.............................................................................................................. Trucks..............................................................................................................
25 26
This section is for the following models: J1.5-2.0XNT (J30-40XNT) J1.5-2.0XNT (J30-40XNT) [K160]; J1.6-2.0XN (J30-40XN) [A935]
©2011 HYSTER COMPANY COMPANY
i
"THE QUALITY KEEPERS"
HYSTER APPROVED PARTS
100 SRM 1329
Introduction
Introduction GENERAL This section contains a description and the service proced pro cedure uress for the parts of the frame frame.. The These se parts include the frame, frame, counte counterweight rweight assembl assembly y, overhead overhead guard, hood and seat assembly, side panels, and labels. Through Throughout out this section, section, forward will refer to travel in the direction of the forks and left and right will be determined by an operator sitting in the seat facing forward. See Figure See Figure 1 for 1 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 2. See Figure 2. for lift truck models • J1.6-2.0XN (J30-40XN) (A935)
DESCRIPTION OF OPERATION The frame is a welded assembly with mounts for the counterweight, overhead guard, mast, steering sys-
A. LEFT SIDE B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation for Lift Truck J1.5-2.0XNT (J30-40XNT) (K160)
tem, hydraulic and See Figur Fiside gure epanels, 3. The The hood ho od op open ensssystem on hi hinge nges s totransaxles. give give acc acces esss to the battery compartment compartment.. The weight of the battery is a major part of the counterweight system on this truck. truck. A slot in the overhe overhead ad guard permits removal of the battery without removing the overhe overhead ad guard. Spacers may be added around the battery as required on some models. Each lift truck has a cast-iron cast-iron counterweight counterweight appropriately weighted for the indicated capacity on the nameplate. The hydraulic pump and motor assembly and hydraulic tank are in the counterweight. counterweight. The countercounterweight cover is removed for access. Th The e AC drive drive mo moto tors rs an and d tr tran ansax saxle less are are loc locat ated ed under the floor plates in the operator compartment. The floor plates are held in position by tabs and are to be removed to give access to components underneath.
A. LEFT SIDE B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 2. Truck Orientation for Lift Truck J1.6-2.0XN (J30-40XN) (A935)
The hydraulic control valve is fastened to the front of the battery compartment and has covers to protect the control valve and control linkages.
1
Introduction
100 SRM 1329
NOTE: FRAM NOTE: FRAME E SHOWN FROM RIGHT SIDE AND REAR. rame Figure 3. F rame
DISCHARGING DISCHARG ING THE CAPACITORS WARNING DO NOT make repairs or adjustments unless you you have have been been pr prope operly rly traine trained d and and autho authoriz rized ed to do so so.. Impro Improper per rep repair airs s and and adjus adjustm tment ents s can crea create te dangero dangerous us operati operating ng cond conditio itions. ns. DO NO NOT T oper operat ate e a lift lift tr truc uck k th that at need needs s re re-pair pairs. s. Re Repo port rt the need need for for re repa pair irs s to your your supervisor immediately. If repair is necessary, at atta tach ch a DO NOT NOT OPER OPERA ATE tag tag on th the e stee steeri ring ng wheel and discon disconnect nect the battery battery.. Disconnect the battery and allow the capacitors before opening any ment me ntto cover codischarge vers s or in insp spect ecting ing or rep repai airin ring gcompartthe el elecectrical system. DO NOT place tools on top of the batt battery ery.. If a tool tool ca caus uses es a sh short ort cir circu cuit, it, the high high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are performed with the battery battery connected connected.. DO NOT connect connect the battery until the procedure instructs you to do so. Never Never wear wear any met metal allic lic items items on
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your fing ers, e rs, arms, arms, or neck. neck. Met Metal al ite items ms can ally ly make make an electr electrica icall conne connecti ction on accidental accident and cause injury. cause injury. rming g any tests tests or adjust adjustment ments, s, Before perfo Before performin lift tr truck uck to pr preve event nt une unexp xpect ected ed block blo ck the lift t. movement. movemen itor r in the tran transis sistor tor control controller ler(s) (s) The cap capac acito an electr ele ctric ical al charge cha rge fo for r ab abou out t 10 can hold hold after the ba batte ttery ry is disco disconne nnect cted ed.. seconds after nt an electri electrical cal shock and personal personal To preve prevent discharge e the cap capaci acitor( tor(s) s) before before ininjury, discharg ng or repai repairin ring g any any comp compone onent nt in th the e specting specti compartm rtment ent.. Mak Make e certa certain in that drive dri ve unit compa the battery battery has been disconnected. DO NOT short short across the motor controller ter with a screwdriver or jumper wire. minals with minals rtain in the the Emer Emergen gency cy-Di -Disc sconn onnec ectt Make certa has not been activ activate ated. d. This wi will ll isoswitch has late the the controller and prevent the capacitors harging ing properly properly.. The proper proper way from disc discharg to disconnect disconnect the battery is by separating the ry connecto connectors. rs. battery batte
100 SRM 1329
1. En Ensur sure e the capacit capacitors ors are disc dischar harged ged by per perfor formming Step Step 2 2 through through Step Step 6 below. 6 below. 2. Turn the key key or keyless switch switch to the OFF the OFF position. 3. Disconnect the battery by separating the connecconnectors.
Introduction
5. Make Make sure sure the Emergen Emergencycy-Disc Disconn onnect ect switch switch HAS HA S NOT NOT be bee en activa vatted. If the the Eme Emergencygen cy-Disc Disconn onnect ect switch switch is activa activated ted,, rotate rotate the switch to the right until it pops up. 6. Push Push horn butto button. n. Wait 30 second secondss to be sure capacitors are fully discharged.
4. Block the drive drive wheels to prevent prevent the lift truck from moving.
3
Covers and Floor Plates
100 SRM 1329
Covers and Floor Plates Various Various covers and floor plates provide access to components compon ents during service and securely cover areas during normal normal operation. operation. Covers in the floor of the operator opera tor compartment allow acce access ss to the traction contro con troller llers, s, AC dri drive ve mot motors ors,, servic service e and par parking king
brakes. brake s. A cove coverr on the top of the the coun counte terw rwei eight ght provide pro videss access access to the hydrau hydraulic lic tank, tank, hydrau hydraulic lic pump and motor assembly, and the hoist controller. See Figure See Figure 4. 4.
Legend for Figure 4 NOTE: CO COUN UNTER TERWEI WEIGH GHT T FOR J1.5-2 J1.5-2.0X .0XNT NT (J30-4 (J30-40XN 0XNT) T) (K160 (K160)) LIF LIFT T TR TRUC UCK K SHOW SHOWN N AS AN EXAMPL EXAMPLE E ONLY. 1. 2. 3. 4.
4
FLOOR FLOOR PLATE MANUAL TE MANUAL HYDRAULIC FLOOR PLATE PLATE BRAKE BRAKE PEDAL PEDAL FLOOR FLOOR PL PLA ATE E-HYD E-HYDRA RAULIC ULIC FLOOR FLOOR MA MAT TM MAN ANUAL UAL HYDRAULIC
5. 6. 7. 8.
FLO FLOOR OR MA MAT T E-HYDRAULIC E-HYDRAULIC MANUAL MANUAL HY HYDRA DRAULIC ULIC CO COVER VERS S HO HOSE SE CO COVER VER COU COUNTE NTERW RWEI EIG GHT COVER
100 SRM 1329
Covers and Floor Plates
Figure 4. Covers and Floor Plates
5
Overhead Guard Replacement
100 SRM 1329
Overhead Guard Replacement or opposite front leg. 5. Repeat Step Repeat Step 4 f 4 f or
WARNING The over The overhe head ad gu guar ard d is part part of th the e op oper erat ator or proprotection system. system. DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck. The overhead overhead guard is designed to provide pr protecti otection on to the operator from falling objects and in the event of a tip over. over. A high visibilit visibility y design allows allows for an unobstructed view while maintaining structural integrity tegrit y. Removal of the battery battery is simplified by the slot in the overhead overhead guard. This provide providess access to the battery with an overhead lifting device without removing the overhead guard.
shers, front capscrew, and vibra6. Remove nut, wa washers, tion mount top from top from front leg and frame. See Figure 5 fo See Figure 5 forr lift truck models • J1.5-2.0XNT (J30-40XNT) (J30-40XNT) (K160) or lift truck models See Figure 6. See Figure 6 . f or • J1.6-2.0XN (J30-40XN) (J30-40XN) (A935) or opposite front leg. 7. Repeat Step Repeat Step 6 f 6 f or 8. Use a lifting device to lift overhead guard until it is just higher than higher than the counterweight.
NOTE: Tag electrical electrical wiring and note routing during removal to aid aid in installation.
REMOVE WARNING
nnect electrical wiring for display. 9. Tag and disco disconnect Remove display display from display cover.
guard is heav heavy y. Ma Make ke sure the The overhead overhead guard in, ey eyeb ebol olts ts,, an and d cran crane e or lift liftin ing g sl sling ing,, cha chain, device have have the capacity to lift the overhead guard.
routing of electrical wires into, out of, NOTE: Note routing or on the overhead overhead guard during removal to aid in installation. installatio n.
seat.. See See Hood and Seat As1. Remove hood hood and seat sembly section section in this manual.
NOTE: Tag electrical electrical connectors during removal to aid in installation. installation.
capscrew,, washe washers, rs, and vibration vibration 2. Remove rrea earr capscrew rom rear leg and count counterweigh erweight. t. mount top f rom
nnectt el elec ectr tric ical al wire wiress th that at go 10. Tag and and di disc sco onnec overhead guard. guard. Careful Carefully ly through the legs legs of overhead remove the wiring wiring if necessary.
5 for lift truck models See Figure 5 See Figure NT (J30-4 (J30-40XNT) 0XNT) (K160) • J1.5-2.0X NT
remove e ov over erhe head ad gu guar ard d from from lif liftt 11. Completely remov truck.
6.. for lift truck models See Figure 6 See Figure • J1.6-2.0X N (J30-40XN) (A935)
12. Remove two vibration v ibration mount bottoms from counterweight; remove terweight; remove two vibration mount bottoms
3. Repeat Ste Repeat Step p 2 for opposite rear leg. 4. Remove three three capscrews from cowl and front leg. 5 for lift truck models See Figure 5 See Figure NT (J30-4 (J30-40XNT) 0XNT) (K160) • J1.5-2.0X NT 6.. for lift truck models See Figure 6 See Figure • J1.6-2.0X N (J30-40XN) (A935)
and two retaining retaining washers from frame. See Figure See Figure 5 for 5 for lift truck models T (J30-40XNT) (J30-40XNT) (K160) • J1.5-2.0XN J1.5-2.0XNT See Figure 6. See Figure 6 . for lift truck models • J1.6-2.0XN J1.6-2.0XN (J30-40XN) (A935)
Legend for for Figure 5 1. 2. 3. 4. 5.
REAR REAR CAPSCR CAPSCREW EW WAS ASHE HER R REAR REAR LE LEG G VIBRA VIBRATION MOUN MOUNT T TOP TOP VIBRA VIBRATION TION MOUNT BOTTOM BOTTOM
6. COUNT COUNTER ERWEI WEIGHT GHT
6
7. 8. 9. 10. 11.
NUT FR FRON ONT T CA CAPSC PSCREW REW FR FRON ONT T LEG LEG FRAME CAPSCREW
12. OVERHEAD GUARD GUARD
13. GRAB HANDLE 14. COWL 15. DISPLAY COVER COVER 16. RETAINING WASHER 17. CLIP NUT
100 SRM 1329
Overhead Guard Replacement
Figure 5. 5 . Overhead Guard for Lift Truck J1.5-2.0XNT J 1.5-2.0XNT (J30-40XNT) (K160)
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Overhead Guard Replacement
Figure 6. Overhead Guard for Lift Truck J1.6-2.0XN (J30-40XN) (A935)
8
100 SRM 1329
100 SRM 1329
Overhead Guard Replacement
Legend for Figure 6 1. 2. 3. 4. 5. 6. 7.
RE REAR AR CAPSC CAPSCRE REW W WAS ASHE HER R REAR REAR LEG LEG T TOP VIBRA VIBRATION TION MOUN MOUNT COUNTER COUNTERWEIG WEIGHT HT NUT FR FRONT ONT CAPSC CAPSCRE REW W
8. FRON ONT T LEG 9. FR FRAM AME E LEG 13. R Remo emove ve two capscr capscrews ews and gra grab b han handle dle from from front leg. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935)
NOTE: Perf Perfor orm m foll followi owing ng st step ep if gr grab ab handl handle e is mounted onto rear leg. 14. R Remo emove ve two capscr capscrews ews and gra grab b han handle dle from from rear leg. See Figure See Figure 5 for 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 15. Remove Remove two capscr capscrews, ews, display cover, cover, and two clip nuts from overhead guard. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935)
INSTALL 1. Install grab handle and capscrews onto front leg. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935)
NOTE: Perform the following step if grab handle is mounted onto rear leg. 2. Install Install grab handle and two capsc capscrews rews onto onto rear leg. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160)
10. CAPSCREW 11. GRAB HANDLE 12. OVERHEAD GUARD 13. COWL 14. DISPLAY COVER 15. VIBRATION MOUNT BOTTOM 16. RETAINING WASHER WASHER 17. CLIP NUT See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 3. Install Install two retaining retaining washers and two vibration vibration mount bottoms onto frame; install two vibration mount bottoms onto counterweight. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 4. just Using a lifting device, device , position overhead guar guard d above mounting holes on counterweight and frame. 5. Route electrical electrical wires through overhead overhead guard legs as noted during removal.
NOTE: Make sure electrical wires do not get pinched when overhead guard is lowered onto mounts. 6. Carefully Carefully lower overhead guard onto vibration mount bottoms on counterweight and frame. 7. Instal Installl front front capscr capscrew ew,, vibratio vibration n mount mount top, top, wash wa sher ers, s, an and d nut nut in into to fron frontt le leg g and and fram frame. e. Tighten capscrews to 66 Nm (49 lbf ft). See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 8. Repeat Step Repeat Step 7 for 7 for opposite front leg. 9. Instal Installl vibrat vibration ion mount top, washer washerss and rear capscrew into rear leg and counterweight. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure See Figure 6. 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 10. Repeat Step Repeat Step 9 for 9 for opposite rear leg.
9
Hood and Seat Assembly
100 SRM 1329
11. Install 11. Install three capscrews into cowl and front leg. See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure See Figure 6. 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 12. Repeat Step 12. Repeat Step 11 for 11 for opposite front leg. 13. Install 13. Install two clip nuts, display cover and two capscrews onto overhead overhead guard.
See Figure 5 for See Figure 5 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 6. See Figure 6. for lift truck models • J1.6-2.0XN (J30-40XN) (A935) 14. Install display display into display cover. cover. Conne Connect ct electrical wiring to display as noted during removal. 15. Install Install hood and se seat. at. See See Hood and Seat Assembly Repair section Repair section in this manual.
Hood and Seat Assembly The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restra res traint int tha thatt complet completely ely covers covers the batter battery y compart compart-ment me nt.. See See Figure 7. 7. When When corre correctl ctly y locked locked to the frame, it will hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is a stamped steel cover. Two hinges at the back attach attach to the overh overhead ead guard. guard. A rotor lock latch assembly on the front of the hood locks the hood closed during operation. A gas-controll gas-controlled ed strut holds the hood in the open position. Opening the latch assembly unlocks the hood from the frame so the hood can be raised to access the battery.. See tery See Figure 8. 8. The latch latch assembl assembly y must be in good condition and properly secured before the lift truck tru ck can be operated operated.. To raise th the e hood on a lift truck with manual hydraulics, the manual hydraulic lever lev er and link linkage age ass assemb embly ly must be moved moved.. Pul Pulll latch handle under manual hydraulic cover toward the seat, allowing the lever and linkage assembly to drop forward forward out of the way way.. If the sliding latch assembly does lock the hood inwill thenot closed the lever andnot linkage assembly lockposition, into position and the lift truck will not operate. A large, red push-button switch is mounted on the lever and linkage assembly for manual hydraulics and in the armrest console for the electro-hydraulics. This switch is an emergency battery disconne disconnect ct that allows the operator to quickly disconnect the battery while whil e seate seated d on the lift truck truck in case case of an eme emerge rgency ncy.. The seat assembly slides on seat rails that are fastened to the hood hood by four capscrews capscrews.. A lever at the left front side of the base controls the adjustment of
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the seat to the forward and backward positions. Optional seats are available in cloth or vinyl with features such as non-suspension, full suspension, and limited swivel. All seats have a seat switch installed in the bottom cushion that senses operator presence. When the operator is not on the seat, the seat switch opens and interru inte rrupts pts the contro controlle llerr stoppin stopping g operat operation ion of the lift truck as follows: • After 1.5 seconds, hydraulic functions will cease to operate. • The lift truck, through regenerative braking, will slowly come to a complete stop. The hood, seat belt, hip restraint brackets, seat, and seat mount mount are all parts parts of the operat operator or restra restraint int system. Che Checks cks and adjustme adjustments nts for the operator operator restraint str aint syst system em are descri described bed in the Oper Operatin ating g Manual or ual See Periodic Maintenance 8000 See Periodic Maintenance 8000 SRM 1339 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Periodic Maintenance 8000 See Periodic Maintenance 8000 SRM 1373 for lift truck models • J1.6-2.0XN (J30-40XN) (A935) To raise the hood hood and seat assembly, assembly, move the seat to the rear rear of the hood. hood. Move the steerin steering g column to the most forward forward position. If lift truck is equipped with manual hydraulics, release and move the hydraulic lever and linkage assembly forward. Open the latch mechanism and raise the hood.
100 SRM 1329
1.
SEAT
Hood and Seat Assembly
2.
HOOD
3.
SEAT SWITCH CONNECTOR
Figure 7. Hood and Seat Assembly
11
Hood and Seat Assembly
100 SRM 1329
REMOVE 1. Disconnect battery connector. connector.
NOTE: Tag electrical connectors during removal to aid in installation. 2. Tag and disconnec disconnectt the electrical electrical connectors connectors to the emergency battery disconnect and the seat switch. 3. Disconn Disconnect ect seat harness harness and remove remove from hood.
NOTE: The seat assembly does not have to be removed from the hood hood for for the hood to to be removed removed from the lift lift truck. truck. Perform Perform St Step ep 4 if remo removin ving g se seat at asse assemmbly. 4. To remove seat assembly assembly,, disconn disconnect ect electric electrical al conn connec ecto tors rs if no nott alrea already dy do done ne,, remo remove ve fo four ur screws scr ews,, washer washers, s, spacer spacerss if requir required, ed, and seat seat assembly from hood. 5. Raise hood. 6. Remove gas spring spring.. See Figure See Figure 9. 9. 7. Lower hood. 8. Remove two cap captive tive screws, screws, tow pin, and counterweight cover from counterweight. 9. Remove two nuts sec securing uring hood moun mounting ting bolts. bolts. See Figure See Figure 9. 9.
PLACEMENT ENT A. MOUNTING MOUNTING PLACEM B. MOUNTING HARDW HARDWARE ARE 1. 2. 3. 4. 5. 6. 7.
HOOD HOOD LA LATCH TCH HOOD FRON FRONT T BU BULKH LKHEAD EAD CAPS CAPSCR CREW EW NUT OPEN OPEN POSITI POSITION ON CLOSE CLOSED D PO POSIT SITION ION Figure 8. 8 . Latch Mechanism
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10. Remove washers and hood mounting bolts from hood hoo d hinges hinges and hood mounti mounting ng brackets brackets.. See Figure 9. 9. 11. Release latch and lift hood out of lift truck. 12. If necessary, hood mounting brackets can be removed from overhead guard rear legs by removing the nuts and capscrews. See Figure 9. 9.
100 SRM 1329
1. 2. 3. 4. 5.
HOOD GA GAS S SP SPRI RING NG NUT WAS ASHE HER R HOOD MOUNTING MOUNTING BOLT BOLT
Hood and Seat Assembly
6. HO HOOD OD HI HING NGE E 7. OVERHEAD VERHEAD GU GUARD ARD REAR REAR LEG 8. HOOD HOOD M MOUNT OUNTING ING BRA BRACKE CKET T 9. CAPS CAPSCRE CREW W Figure 9. Hood Mounting
INSTALL 1. Install Install hood mounting bracke brackets, ts, capscre capscrews, ws, and nuts onto overhead guard rear legs, if removed. Do not fully tighten capscrews capscrews at this time. time. See Figure 9. 9.
3. Instal Installl hood hood mountin mounting g bolts bolts and washers washers onto onto hood hoo d hinges hinges and hood hood mounti mounting ng brackets brackets.. See Figure 9. 9. 4. Install Install nuts onto onto hood mounting mounting bolts. bolts. See FigSee Figure 9. ure
2. Lower hood hood into position position..
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Counterweight Replacement
100 SRM 1329
5. Allo Allow w hood hood to en engag gage e la latc tch h and adjust adjust ho hood od for adeq adequat uate e latch latch enga engageme gement nt with the hood hood striker. Adequate engagement is when the latch completely clears the 90 degree bend of the hood striker. 6. Tighten capscrews on hood mounting brackets. brackets. 7. Raise hood.
2. Usi Using ng an ohm ohm mete meterr, place place a test test le lead ad at th the e armrest mounting bolt and another at the truck frame. The resistance resistance needs needs to read 5 Ohms or less.. See Figure less See Figure 10. 10 . 3. If the resist resistance ance is greater greater than 5 Ohms, double double check installation installation of seat assembly, assembly, both ends of seat wiring harness, and wiring harness ground strap.
8. Insta Install ll gas spring. spring. See See Figure Figure 9. 9. 9. Rei Reinsta nstall ll seat, if removed, removed, and rout route e sea seatt harharness through hood and connect to seat. 10. Connect 10. Connect the electrical wiring harness to the seat switch. 11. Close 11. Close the hood. Make Make certa certain in that the latch latch is properly engaged. 12. Install counterweight cover, captive screws, and 12. tow pin onto counterweight. 13. Move 13. Mov e man manual hydraul hydraulic ic lev lever erand andlock lin linkag kage e asse assemmbly back toual upright position in place. 14. Connect 14. Connect the battery connector.
GROUND TEST NOTE: If the static discharge ground connection is not secured properly it could lead to the possible failure of the traction and/or pump motor controllers controllers..
1. ARM ARMRE REST ST BOLT BOLT 2. FR FRAM AME E Figure 10. 10 . Ground Test
1. To ensur ensure e proper installation installation of seat assembly and associated associated bracketin bracketing, g, perform perform conti continuity nuity test.
Counterweight Replacement WARNING DO NOT operate the lift truck if the capscrews for the counterw counterweig eight ht are not installed. installed. The counter cou nterweig weight ht is a structu structural ral mem member ber of the truck truc k chassi chassis. s. The counter counterweig weight ht can cannot not be removed mov ed without without first first supportin supporting g the frame. frame. If the capscr capscrews ews are not properly properly installed installed the counterweight will not support the lift truck.
14
ce, cast iron counterweight counterweight is used to offset A one-pie one-piece, the weight weight of the load and support the rear suspension of the the lift truck, see figures indicated below. The weight of the counterweight is shown in the tables below. re 11 and 11 and Table 1 for 1 for lift truck models See Figure See Figu • J1.5-2.0 XNT (J30-40XNT) (K160) e 12 12 and and Table 2 for 2 for lift truck models See Figure See Figur • J1.6-2.0 XN (J30-40XN) (A935)
100 SRM 1329
Counterweight Replacement
Table 1. Counterweig Table Counterweights hts for Lift Tr Truck uck J1.5-2.0XNT (J30-40XNT) (K160) Model
eight mm (in)* Weight
+ 13.8 13.8 kg (30 lb) 13.8 kg (30 lb)
J1.5-2.0XNT (J30-40XNT)
546 mm (21.5 in.)
690 kg (1521 lb)
J1.5-2.0XNT (J30-40XNT)
642 mm (25.3 in.)
690 kg (1521 lb)
J1.5-2.0XNT (J30-40XNT)
750 mm (29.5 in.)
690 kg (1521 lb)
*Approximate battery compartment lengths.
Table Tabl e 2. Counterweig Counterweights hts for Lift Tr Truck uck J1.6-2.0XN (J30-40XN) (A935) Figure 11. Counterweight for Lift Truck J1.5-2.0XNT (J30-40XNT) (K160)
Model
mm (in)*
Weight
+ 20 kg (44 lb) 0 kg (0 lb)
J1.6-2.0XN (J30-40XN)
546 mm (21.5 in. (21.5 in.))
670 kg (1477 lb)
J1.6-2.0XN (J30-40XN)
642 mm (25.3 in. (25.3 in.))
670 kg (1477 lb)
J1.6-2.0XN (J30-40XN)
750 mm (29.5 (29. 5 in. in.))
670 kg (1477 lb)
*Approximate battery compartment lengths. A compartment space, accessed by removal of the counterweight cover, has been designed to house the hydraul hydr aulic ic tank, tank, hydraul hydraulic ic pump and mot motor or,, hoist hoist concontroller, and electrical connections.
Figure 12. Counterweight for Lift Truck J1.6-2.0XN (J30-40XN) (A935)
A battery platform is used to support the battery on the lift truck frame. frame. The battery battery platform also serves as part of the counterweight system and requires the use of an overhead lifting device for removal or installation. stallat ion. Be sure to replace replace the same battery battery platform, or one of equal weight, if the platform must be removed.
15
Counterweight Replacement
100 SRM 1329
REMOVE
7. Inse Insert rt eye bo bolts lts into into counte counterwei rweight ght.. See Figure 14 ure 14.. Attach Attach lifting device to eye bolts to hold counterweight.
1. Remove battery. See Periodic Maintenance 8000 See Periodic Maintenance 8000 SRM 1339 for lift truck • J1.5-2.0XNT (J30-40XNT) (K160)
NOTE: Ensure Ensure frame frame is support supported, ed, as specifi specified ed in Steering System 1600 System 1600 SRM 1331 prior to removal. 8. Re Remov move e uppe upperr capsc capscre rews ws an and d wash washer erss from from
See Periodic Maintenance 8000 See Periodic Maintenance 8000 SRM 1373 for lift truck • J1.6-2.0XN (J30-40XN) (A935) . 2. Remove overhead overhead guard. guard. See Overhead See Overhead Guard Replacement section Replacement section in this manual. 3. Remo Remove ve hyd hydra raul ulic ic pump pump an and d mo moto torr and hydrau drauli licc tank tank fro from m coun counte terwe rweigh ight. t. See See Hydraulic System 1900 System 1900 SRM 1333. 4. Remo Remove ve cont contro rolle llerr from from coun counte terwe rweigh ight. t. Electrical System 2200 System 2200 SRM 1337.
Se See e
5. Remove steer a axle, xle, including wheels and tires. See Steering System 1600 SRM 1331 for lift truck • J1.5-2.0XNT (J30-40XNT) (K160)
frame and counterweight. See Figure See Figure 13 13.. 9. Re Remov move e lower lower capsc capscre rews ws and and wash washer erss from from frame and counterweight. See Figure See Figure 13 13.. 10. Usin Using g lifting lifting devi device, ce, lift counte counterwei rweight ght away away from lift truck frame.
NOTE: Perform Perform Step Step 11 through 11 through Step Step 15 15 for for lift truck J1.6-2.0XN (J30-40 J1.6-2.0XN (J30-40XN) XN) (A935). NOTE: Ensure Ensure frame frame is support supported, ed, as specifi specified ed in Steering System 1600 System 1600 SRM 1363 prior to removal. 11. Remove two capscrews from top of rear bulkhead and counterweight counterweight.. See Figure See Figure 15. 15. 12. Remove two capscrews from rear bulkhead and spacer plates. plates. Remove rear rear bulkhead. bulkhead. See FigSee Figure 15 ure 15..
WARNING See Steering System 1600 SRM 1363 for lift truck • J1.6-2.0XN (J30-40XN) (A935).
The counterwei counterweight ght is very heav heavy y. Make sure the slings and overhead lifting device have the capacity to lift the counterweight.
NOTE: Perform Perform Step Step 6 through 6 through Step Step 10 for 10 for lift truck J1.5-2.0XNT (J30-40XNT) (K160).
13. Wrap two slings through slots in top of counterweight. Attach Attach slings to lifting lifting device device.. See FigSee Figure 16 ure 16..
6. Remo Remove ve nut nuts, s, caps capscre crews ws,, was washer hers, s, and steer plate from counterweight. See Figure See Figure 13. 13.
14. Remo Remove ve lower lower capscr capscrews ews,, nuts, nuts, and was washer herss from from frame and counterweight. See Figure See Figure 15 15..
WARNING ht is very heavy heavy. Mak Make e sure The counterweig counterweight yebolt lts, s, and ov overh erhead ead lifti lifting ng the the chai chains ns,, eyebo device have the capacity capacity to lift lift the countercounterweight.
16
15. Re Remov move e uppe upperr capsc capscre rews ws an and d wash washer erss from from frame fra me and count counterw erweigh eight. t. See See Figure 15. 15. Using lifting device, lift counterweight away from frame.
100 SRM 1329
1. 2. 3. 4.
STEER STEER PLATE COUNTER COUNTERWEIG WEIGHT HT CA CAPSC PSCRE REW W NUT
Counterweight Replacement
5. 6. 7. 8.
WAS ASHE HER R UP UPPE PER R CA CAPSC PSCRE REW W LO LOWER WER CAPSCR CAPSCREW EW FR FRAM AME E
Figure 13. Frame and a nd Counterweight for Lift Truck J1.5-2.0XNT J1. 5-2.0XNT (J30-40XNT) (K160)
17
Counterweight Replacement
100 SRM 1329
Legend for Figure 14 1. COUNTER COUNTERWEI WEIGHT GHT 2. EY EYE E BOL BOLT
INSTALL WARNING The counterweight counterweight is very hea heavy vy.. Mak Make e sure the the chai chains ns,, ey eyeb ebol olts ts,, and ov overh erhea ead d li lift fting ing e capac capacity ity to li lift ft th the e co count untererdevice devi ce have th the weight. Step 1 1 through Step through Step 5 5 for for lift truck NOTE: Perform Perform Step J30-40XNT) (K160). J1.5-2.0XNT J1.5-2.0 XNT ( g device, lower counterweight into 1. Using a liftin lifting position on lift lift truck.
Figure 14. 14 . Counterweight Lift for Lift Truck J1.5-2.0XNT (J30-40XNT) (K160)
2. Install washers washers and lower capscrews into frame eight. See Figure See Figure 13. 13. Tighten capand counterw counterweight. screws to 250 N•m 250 N•m (184 lbf ft).
Figure 15. 15 . Frame and Counterweight for Lift Truck J1.6-2.0XN J1. 6-2.0XN (J30-40XN) (A935)
18
100 SRM 1329
Counterweight Replacement
Legend for Figure 15 NOTE: MAJOR NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. 1. RE REAR AR BULKH BULKHEA EAD D 2. CA CAPSC PSCRE REW W 3. SP SPACER ACER PLATE PLATE
4. FRAM FRAME E 5. COUNTE COUNTERWE RWEIGHT IGHT 6. LOWER LOWER CAPSCREW CAPSCREW
7. NUT 8. WAS ASHE HER R 9. UPP UPPER ER CAPSC CAPSCRE REW W
rs,, lo lowe werr ca caps pscr crew ews, s, an and d nu nuts ts 8. Install Install washe washers into frame and ccoun ounter terweig weight. ht. See See Figure 15. 15. Tighten capscrews capscrews to 250 N•m (184 lbf ft). remove ve from from counte counterr9. Detach Detach both both sling slingss and remo gure 16 16. . weight.. See Fi weight See Figure 10. Place rear bulkhead bulkhead in position and install two capscrews capscr ews into into rear bulkhead and spacer plates. See Figure See Figure 15. 15. 11. Install two capscrews capscrews into top of rear bulkhead See Figure 15. 15. and counterweight. counterweight. See Figure axle, with wheels wheels and tires, tires, onto onto 12. Install Install steer steer axle, ght. counterweight. counterwei See Steering Steering System 1600 SRM 1331 for lift truck T (J30-40XNT) (K160) • J1.5-2.0XN J1.5-2.0XNT
1. COUNTER COUNTERWEIG WEIGHT HT 2. SLIN SLING G Figure 16. 16 . Counterweight Lift for Lift Truck J1.6-2.0XN (J30-40XN) (A935) 3. Install Install washers and upper cap capscrews screws int into o frame and counterweight. See Figure See Figure 13 13.. Tighten capscrews to 755 N•m (557 lbf ft). 4. weight. Remove Remove lifting lift devi device ce bolts from from counte counterrSeeing See Figure Figure 14. 14and . eye bolts 5. Inst Instal alll stee steerr plate plate,, wa wash sher ers, s, caps capscr crew ews, s, an and d nuts onto counterweight counterweight.. Tighten capscrews capscrews to 300 N•m (221 lbf ft). See Figure See Figure 13 13..
NOTE: Perform Perform Step Step 6 through 6 through Step Step 11 for 11 for lift truck J1.6-2.0XN J1.6-2. 0XN (J30-40 (J30-40XN) XN) (A935). 6. Using a lifting device, device, lower counterwe counterweight ight into position on lift truck frame. 7. Install Install washers and upper cap capscrews screws int into o frame and counterweight. See Figure See Figure 15 15.. Tighten capscrews to 755 N•m (557 lbf ft).
See Steering Steering System 1600 SRM 1363 for lift truck • J1.6-2.0XN (J30-40XN) (J30-40XN) (A935). 13. Install controller controller into into counterweight. counterweight. See ElecSee Elec 2200 SRM 1337. trical System System 2200 14. Install hydraulic hydraulic tank and hydraulic pump and rweight.. See Hydraulic See Hydraulic Sysmotor into counte counterweight tem 1900 tem 1900 SRM 1333. SRM 1333. See Overhead Guard 15. Install overhead overhead guard. See Overhead Replacementt section in this manual. Replacemen 16. Install battery. battery. c Maintenance 8000 Maintenance 8000 SRM 1339 for See Periodic See Periodi lift truck T (J30-40XNT) (K160) • J1.5-2.0XN J1.5-2.0XNT c Maintenance 8000 Maintenance 8000 SRM 1373 for See Periodic See Periodi lift truck • J1.6-2.0XN J1.6-2.0XN (J30-40XN) (A935) .
19
Safety Labels
100 SRM 1329
Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazard haz ards. s. It is impo importa rtant nt tha thatt all safe safety ty labels are installed on the lift truck and can be read. DO NOT add to or modif modify y the lift lift truc truck. k. An Any y change to the lift truck, the tires, or its equipmentt can chang men change e the lifting lifting cap capaci acity ty.. The lift truck tru ck mus mustt be rated rated as eq equip uippe ped d and and the nam nameeplate must show the new capacity rating. Contact your Hyster lift truck dealer for a replacement nameplate. nameplate. If a label must be replaced, use the following procedure to install a new label. See Figure 17 See Figure 17 for for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160) See Figure 18 See Figure 18 for for lift truck models • J1.6-2.0XN (J30-40XN) (A935)
WARNING Always use solvents and paints in an area with n. DO NOT use solvents o or r adequate ventilatio ventilation.
paints near heat, heat, fire, or electrical equipment sparks. Follo ollow w the manufacmanufacthat can create create sparks. cautions. turer’s instructions instructions and cautions. household clean1. Clean the painted painted surface. Use household ing products to clean new paint and clean old paint with cleaning cleaning solvent. DO NOT use solint. Make sure the surface is dry vent on new pa paint. and is clean of o f dirt, oil, and grease. 2. Remove the paper paper from the back of the label and the e edges. edges. Do not touc touch h the hold the label label by th adhesive surface. surface.
CAUTION The label cannot be moved after it touches the surface. 3. Car Carefu efully lly hold the label in the correct correct positio position n above the surface and carefully apply to the correct location. location. Make sure that all air is removed removed from under the label by smoothing any wrinkles or bubbles with your fingers working from the center out. Check that the corners and edges are tight against the surface. surface.
i gure 17 Legend for F igure NOTE: NOT ALL NOTE: NOT ALL LABELS USED ON J1.5-2.0XNT (J30-40XNT) (K160) LIFT TRUCK MODELS ARE SHOWN IN SEE PARTS MANUAL FOR MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON J1.5-2.0XNT (J30FIGURE 17. 17. SEE PARTS 40XNT) (K160) (K160) LIFT TRUCKS. 1.
OV OVERHEAD ERHEAD GUARD GUARD IMP IMPACT ACT WARNING WARNING (INNER LEFT SIDE) 2. BATTE BATTER RY SPACER SPACER
10. HYSTER 11. CAPACITY PLATE 12. AC LABEL
3. 4. 5. 6. 7. 8. 9.
13. COUNTERWEIGHT LABEL 14. PATENTS AND TRADEMARKS 15. "EE" UL LABEL LABEL (OPTIONAL) 16. FREEZER (OPTIONAL) 17. CAPACITY LABEL 18. UL LABEL 19. NO RIDER LABEL
20
MAST MA WLUMN ARNING ARNN ING TILT TILTST CO COLUM T PI PINC NCH H POIN POINT OPERA OPERATOR TOR WARN WARNING ING PINCH PINCH POINT POINT STRAINT OPERA OPERATO TOR R RE RESTRAINT MAST MAST WARNING ARNING
100 SRM 1329
Safety Labels
Figure 17. 17 . Label Locations for Lift Truck J1.5-2.0XNT (J30-40XNT) (K160)
21
Safety Labels
100 SRM 1329
Figure 18. 18 . Label Locations for Lift Truck J1.6-2.0XN J 1.6-2.0XN (J30-40XN) (A935)
22
100 SRM 1329
Painting Instructions
Legend for Figure 18 NOTE: NOT ALL LABELS USED ON J1.6-2.0XN (J30-40XN) (A935) LIFT TRUCK MODELS ARE SHOWN IN FIGNOTE: NOT IN FIGURE 18 URE 18.. SEE SEE PARTS PARTS MANUAL FOR MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON J1.6-2.0XN (J30-40XN) (A935) LIFT TRUCKS. 1. BATTER BATTERY Y DISCO DISCONNECT 2. BA BATTERY TTERY SPACER SPACER 3. PATENT AND TRADEMARK TRADEMARKS S 4. HY HYSTE STER R LOG LOGO O 5. PIN PINCH CH POINT POINT 6. OPERA OPERATO TOR RW WARNI ARNING NG 7. WARRAN WARRANTY TY LABEL LABEL 8. LI LIFT FTIN ING G EY EYE E 9. MO MODE DEL L LABE LABEL L 10. UL LABEL 11. UL LABEL 12. "EE" UL LABEL (OPTIONAL) 13. LOCK/UNLOCK LABEL LABEL
14. FREEZER 15. HYSTER LOGO 16. NO RIDER 17. CAP CAPACITY ACITY PLAT PLATE E 18. OPERA OPERATOR TOR RESTRAINT 19. BRAND LABEL 20. MAST WARNING 21. WARNING LABEL 22. PINCH POINT 23. NAMEPLA NAMEPLATE TE 24. TILT COLUMN 25. COUNTERWEIGHT LABEL
uctions Painting Instr Instructions WARNING Always use solvents and paints in an area with venti ven tila latio tion. n. DO NOT use use so solv lvent ents s or pain paints ts near heat, fir fire, e, or ele electri ctrical cal equipment equipment that can make sparks sparks.. Foll ollow ow the man manufac ufacture turer’s r’s instructions instruct ions and cautions cautions.. 1. Remove all dirt dirt from the surface surface to be painted. Clean Cle an the area to be painte painted. d. Use a sol solvent vent for painted surfaces to remove grease and oil before sanding. DO NOT use solvent solvent on new paint. paint. Make sure all oil and grease is removed. 2. Use Use sand sandpap paper er to remov remove e the top su surfa rface ce of paint pai nt and rust from from the meta metal. l. All met metal al sursurfaces fac es whe where re the paint paint is complet completely ely removed removed,, must be primed. primed. Apply Apply primer primer befo before re applyi applying ng the paint.
CAUTION DO NOT put tape on cylinder rods to protect from fro m pai paint. nt. Use a thick thick layer of mul multipu tipurpos rpose e grease to protect cylinder cylinder rods. Cylinders can be damaged if operated with tape on the cylinder rod. 3. Protect Protect all surfaces surfaces that will not be painte painted. d. DO NOT paint: NOT paint: Pedal Pads Lever Knobs Instrument Panel Steering Wheel
Labels and Information Information Plates Seat Assembly and Rails Information Case Tires Mast Chains and Hoses Battery Connector Key Switch Cylinderr Rods Cylinde All Plastic Covers
CAUTION DO NO NOT T pa pain intt th the e pads pads,, plas plasti tic c co cove vers rs or knobs, knob s, cables, cables, labels labels,, inform informatio ation n plates plates,, or controls. control s. Paint Paint can make some assemblies not operate correctly. 4. Pa Paint int the surface surfaces. s. Use the correc correctt paint from from yourr dealer you dealer for Hyster® Hyster® lift truck trucks. s. Foll ollow ow the directions on the container.
WARNING Make sure all labels are installed after painting is complete. Safety labels labels are installed on the lift truck to give information about possible hazards. hazards. It is importan importantt that all safety safety labels are installed on the lift truck and can be read. 5. Check that that all labels are installed installed in the correct correct locations on the lift truck. See Safety See Safety Labels. Labels.
NOTE: Use colors approved by Hyster Company.
23
Battery Specifications
100 SRM 1329
Battery Specifications J1.5-2.0XNT J1.5-2.0X NT (K160) EUROPEAN MODEL TRUCKS TRUCKS Minimum Compartment Size Length × Width
Model
J1.5-1.6XNT
Battery Size Min/Max
Weight
Length
Width
Minimum
Maximum
546 x 991 mm (21.5 x 39 in.)
50 508 8 mm (20 in.)
970 mm (38.2 in.)
800 kg (1764 lb)
1100 kg 1100 (2425 lb)
J1.8XNT
640 x 9914 mm (25.2 x 39 in.)
597/635 mm (23.5/25 (23.5/2 5 in.)
975/986 mm (38.4/38.8 (38.4/3 8.8 in.)
1225 kg 1225 (2700 lb)
1300 kg 1300 (2865 lb)
J2.0XNT
750 x 991 mm (29.5 x 39 in.)
700/737 mm (25.5/29 (25.5/2 9 in.)
830 mm (36.7 in.)
1000 100 0 kg (2200 lb)
1300 130 0 kg (2865 lb)
olerances es of the batter battery y com compar partme tment nt are +3 and 0 m mm m (+0.12 (+0.12 and 0 in.). in.). The batt battery ery size col column umn NOTE: Toleranc shows the size range that will permit the battery to still fit into a battery compartment. NOTE: Battery Battery compar compartment tment lengt length h is front to back. Width is side to side. The "length" "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side 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.
24
100 SRM 1329
Battery Specifications
J30-40XNT J30-40X NT (K160) US MODEL TRUCKS Minimum Compartment Size Length Leng th × Width
Model
Battery Size Min/Max
Weight
Length
Width
Minimum
Maximum
J30XNT
546 (21.5x x991 39 mm in.)
50 508 8 in.) mm (20
970 mm (38.2 in.)
80 800 0 kg (1765 lb)
1100 110 0 kg (2425 lb)
J35XNT
640 x 991 mm (25.2 x 39 in.)
597/635 mm (23.5/25 in.)
975/986 mm (38.4/38.8 (38.4/3 8.8 in.)
1225 kg 1225 (2700 lb)
1300 kg 1300 (2865 lb)
J40XNT
750 x 991 mm (29.5 x 39 in.)
700/737 mm (25.5/29 in.)
830 mm (36.7 in.)
1000 kg 1000 (2200 lb)
1300 kg 1300 (2865 lb)
NOTE: Toleran olerances ces of the batter battery y com compar partme tment nt are +3 and 0 m mm m (+0. (+0.12 12 and 0 in.). in.). The batter battery y size col column umn shows the size range that will permit the battery to still fit into a battery compartment. NOTE: Battery Battery compartment compartment length length is front to back. Width is side to side. The "length" "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side dimension.
WARNING The battery must fit the battery compartment so that the battery system operate correctly. Use only batteries with the correct length shown in this restraint table. Adjust the will spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.
J1.6-2.0XN (A935) EUROPEAN MODEL TRUCKS Minimum Compartment Size Length × Width
Model
Battery Size Min/Max
Weight
Length
Width
Minimum
Maximum
J1.6XN
546 x 991 mm (21.5 x 39 in.)
50 508 8 mm (20 in.)
970 mm (38.2 in.)
80 800 0 kg (1765 lb)
1100 110 0 kg (2425 lb)
J1.8XN
640 x 991 mm (25.2 x 39 in.)
597/635 mm (23.5/25 in.)
975/986 mm (35.4/38.8 in.) (35.4/38.8
1225 kg (2700 lb)
1300 130 0 kg (2865 lb)
J2.0XN
750 x 991 mm (29.5 x 39 in.)
700/737 mm (25.5/29 in.)
830 mm (36.7 in.)
1000 kg (2200 lb)
1300 kg 1300 (2865 lb)
olerances ces of the batter battery y com compar partme tment nt are +3 and 0 mm (+0.12 (+0.12 and 0 in.). in.). The batt battery ery size col column umn NOTE: Toleran shows the size range that will permit the battery to still fit into a battery compartment. NOTE: Battery Battery compartment compartment length length is front to back. Width is side to side. The "length" "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side 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.
25
Battery Specifications
100 SRM 1329
J30-40XN J30-40X N (A935) US MODEL TRUCKS Minimum Compartment Size Length × Width
Model
Battery Size Min/Max
Weight
Length
Width
Minimum
Maximum
J30XN
546 (21.5x x991 39 mm in.)
50 508 8 in.) mm (20
970 mm (38.2 in.)
80 800 0 kg (1765 lb)
1100 110 0 kg (2425 lb)
J35XN
640 x 991 mm (25.2 x 39 in.)
597/635 mm (23.5/25 in.)
975/986 mm (35.4/38.8 (35.4/38 .8 in.)
1225 kg 1225 (2700 lb)
1300 kg 1300 (2865 lb)
J40XN
750 x 991 mm (29.5 x 39 in.)
700/737 mm (25.5/29 in.)
830 mm (36.7 in.)
1000 kg 1000 (2200 lb)
1300 kg 1300 (2865 lb)
NOTE: Toleranc olerances es of the batter battery y com compar partme tment nt are +3 and 0 m mm m (+0.12 (+0.12 and 0 in.). in.). The batt battery ery size col column umn shows the size range that will permit the battery to still fit into a battery compartment. NOTE: Battery Battery compar compartment tment lengt length h is front to back. Width is side to side. The "length" "length" dimension of the battery must fit within the battery compartment front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side dimension.
WARNING The battery must fit the battery compartment so that the battery system operate correctly. Use only batteries with the correct length shown in this restraint table. Adjust the will spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.
26
TECHNICAL PUBLICATIONS 100 SRM 1329
7/11 (7/10)(2/10)(1/09)(7/08) Printed in U.S.A.
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