FRAME

E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];

N30XMH, N30XMH 2 [C210];
V30ZMD [D210/E210];
E2.00-3.20XM (E45-65Z) [G108]

PART NO. 897638 100 SRM 558

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or 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 and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Frame Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Main Frame ................................................................................................................................................... 1
Other Frame Weldments............................................................................................................................... 4
Overhead Guard ............................................................................................................................................ 4
Overhead Guard Replacement .......................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement............. 12
Battery Restraint System ............................................................................................................................. 12
Hood................................................................................................................................................................ 13
Hood With E-Hydraulics ............................................................................................................................... 14
Seat Brake...................................................................................................................................................... 15
Operator Restraint System and Seat Assembly .......................................................................................... 15
Automatic Locking Retractor (ALR)......................................................................................................... 15
Emergency Locking Retractor (ELR) ....................................................................................................... 16
Counterweight Replacement ............................................................................................................................. 17
Remove ........................................................................................................................................................... 18
Install ............................................................................................................................................................. 19
Traction Motor Replacement ............................................................................................................................. 20
Remove ........................................................................................................................................................... 20
Install ............................................................................................................................................................. 22
Hydraulic Tank Repair ...................................................................................................................................... 22
Inspect ............................................................................................................................................................ 22
Clean .............................................................................................................................................................. 23
Steam Method............................................................................................................................................ 23
Chemical Solution ..................................................................................................................................... 24
Additional Preparations for Repair .............................................................................................................. 24
Small Leaks, Repair ...................................................................................................................................... 24
Large Leaks, Repair ...................................................................................................................................... 25
Preparations for Usage After Repair............................................................................................................ 25
Painting Instructions......................................................................................................................................... 25
Safety Label Replacement ................................................................................................................................. 26
Battery Specifications........................................................................................................................................ 30

This section is for the following models:

E2.00-3.20XM (E45-65XM, E45-65XM 2) [F108];

N30XMH, N30XMH 2 [C210];
V30ZMD [D210/E210];
E2.00-3.20XM (E45-65Z) [G108]

©2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
100 SRM 558 Description

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
• Seat plate (with optional seat brake)
• 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 levers
The hood is part of the operator and battery restraint
system. The seat is also part of the operator restraint
system. The floor plates are removed for access to the
steering motor. A panel in the bottom of the battery
compartment is removed for access to the traction
motor and the hydraulic pump motor. The electronic
controller and contactors are attached to the frame.
A panel in the counterweight is removed for access
to the controller and contactors. See Figure 16. For
the location of the Master Controller and Electro-Hy-
draulics Valve Driver Module, see the section Elec-
tro-Hydraulic Control Valve 2000 SRM 1224.
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.
The lift trucks are equipped with an adjustable
spacer plate in the battery compartment. See Fig-
ure 2. Adjust the spacer plate to control the move-
ment of the battery in the forward and backward
directions. Tighten the jam nuts on the adjustment
capscrew to prevent the adjustment from changing.

1
Description 100 SRM 558

Figure 1. Lift Truck Frame

2
100 SRM 558 Description

Legend for Figure 1

NOTE: OPTIONAL SIDE PANELS FOR BATTERY COMPARTMENT NOT SHOWN.

A. BATTERY COMPARTMENT
B. BATTERY SPACER PLATE USED ON OLDER LIFT TRUCK MODELS
C. BATTERY SPACER PLATE USED ON NEWER LIFT TRUCK MODELS
1. SPACER PLATE 5. FRAME
2. ACCESS COVERS 6. SIDE STEP
3. COWL 7. FENDER WELDMENT
4. FLOOR PLATE

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. A slot in
the overhead guard permits removal of the battery
without removing the overhead guard.

1. BATTERY 4. SPACER PLATE

COMPARTMENT 5. ADJUSTMENT
2. BATTERY CAPSCREW
3. BULKHEAD 6. JAM NUTS

Figure 2. Battery Spacer Plate

3
Description
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 fas-
tened to the main frame to make the frame assembly.
The cowl weldment is a mount for the front of the
overhead guard, the steering column assembly, the
release linkage of the parking brake and the instru-
ment panel with light switches. On newer models of
lift trucks, with SEM (Separately Excited Motor) and
AC (Alternating Current) electronic controllers and
contactors, the display panel is part of the instru-
ment panel. See Figure 3, Figure 4, Figure 6, and
Figure 7. On early model lift trucks, with SCR (Sil-
icon Controlled Rectifier) electronic controllers and
A. STANDARD SEM DISPLAY PANEL
Figure 3. SEM Display Panel
4
100 SRM 558
contactors, the display panel is not part of the in-
strument panel. The steering column housing is the
mount for the display panel assembly. See Figure 5.
OVERHEAD GUARD
WARNING
Do not operate the lift truck without the over-
head guard correctly fastened to the lift truck.
The overhead guard is a weldment that fastens to
the main frame and cowl to help protect the opera-
tor from falling objects. See Figure 5, Figure 6, or
Figure 7.
B. PREMIUM SEM DISPLAY PANEL
100 SRM 558
NOTE: FOR LIFT TRUCK MODELS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS, BOTH THE
STANDARD AND PREMIUM DISPLAY PANELS LOOK IDENTICAL. THE ONLY DIFFERENCE IS IN THE DISPLAY
SOFTWARE AND THE RESULTING FUNCTIONALITY.
Figure 4. AC Display Panel
Overhead Guard Replacement
REMOVE
WARNING
Do not weld, drill, grind, or cut the overhead
guard for mounts, lights, or accessories. The
strength of the overhead guard can be reduced.
1. Remove the battery from the truck. See How
to Change Battery in your vehicle’s Periodic
Maintenance or Operating Manual.
2. Access to the capscrews that hold the rear legs of
the overhead guard to the frame is from the bat-
tery compartment. Remove the capscrews, wash-
ers, and nuts that fasten each leg. See Figure 5,
Figure 6, Figure 7, and Figure 8.
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
Overhead Guard Replacement
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.
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. Tighten capscrews to 55 N•m (41 lbf ft).
Install the capscrews, washers, and nuts that hold
the rear legs to the frame. For lift truck models
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108) and
N30XMH, N30XMH 2 (C210) tighten the capscrews
to 68 N•m (50 lbf ft). For lift truck models V30ZMD
(D210/E210) and E2.00-3.20XM (E45-65Z) (G108)
tighten capscrews to 90 N•m (66 lbf ft). Install
the battery. See How to Change Battery in your
vehicle’s Periodic Maintenance or Operating
Manual.
5
Overhead Guard Replacement 100 SRM 558

Figure 5. Overhead Guard, Steering Column, and Display Panel, Truck Models E2.00-3.20XM
(E45-65XM) (F108) and N30XMH (C210)

6
100 SRM 558 Overhead Guard Replacement

Legend for Figure 5

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SCR ELECTRONIC CONTROLLERS AND
CONTACTORS.
A. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS
B. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS
1. OVERHEAD GUARD 12. ECONOMY DISPLAY PANEL
2. STEERING WHEEL 13. GAUGES
3. ON-DEMAND STEERING COMPONENTS (NOT 14. KEY SWITCH
ALL UNITS) 15. CAPSCREW
4. HORN SWITCH CONNECTOR 16. WASHER
5. COLUMN COVER 17. NUT
6. COLUMN FRAME 18. SCREW
7. STEERING CONTROL UNIT 19. OVERHEAD GUARD HANDLE
8. LATCH MECHANISM 20. HORN BUTTON
9. HOUSING 21. STEERING COLUMN
10. INDICATOR LIGHT ASSEMBLY 22. STEERING COLUMN NUT
11. PREMIUM DISPLAY PANEL

7
Overhead Guard Replacement 100 SRM 558

Figure 6. Overhead Guard, Steering Column, and Display Panel, Truck Models E2.00-3.20XM
(E45-65XM 2) (F108), N30XMH 2 (C210), and V30ZMD (D210)

8
100 SRM 558 Overhead Guard Replacement

Legend for Figure 6

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SEM ELECTRONIC CONTROLLERS AND
CONTACTORS.
1. STEERING WHEEL 10. CAPSCREW
2. SHIFT LEVER MECHANISM 11. WASHER
3. COLUMN COVER 12. NUT
4. LATCH MECHANISM 13. SCREW
5. STEERING CONTROL UNIT 14. OVERHEAD GUARD HANDLE
6. COLUMN FRAME 15. HORN SWITCH CONNECTOR
7. ON-DEMAND STEERING COMPONENTS 16. HORN BUTTON
8. DISPLAY PANEL (PREMIUM DISPLAY PANEL 17. STEERING COLUMN
SHOWN) 18. STEERING COLUMN NUT
9. OVERHEAD GUARD

9
Overhead Guard Replacement 100 SRM 558

Figure 7. Overhead Guard, Steering Column, and Display Panel for Lift Truck Models E2.00-3.20XM
(E40-65Z) (G108) and V30ZMD (E210)

10
100 SRM 558 Overhead Guard Replacement

Legend for Figure 7

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRONIC CONTROLLERS AND CON-
TACTORS.

NOTE: OVERHEAD GUARD FOR LIFT TRUCK MODELS E40-65Z (G108) SHOWN. SEE FIGURE 8 FOR OVER-
HEAD GUARD USED ON E2.00-3.20XM (G108) MODELS.
1. ON-DEMAND STEERING COMPONENTS 12. LATCH MECHANISM
2. SHIFT LEVER MECHANISM 13. CAPSCREW
3. STEERING WHEEL 14. WASHER
4. DISPLAY PANEL 15. NUT
5. COLUMN COVER 16. SCREW
6. COLUMN FRAME 17. OVERHEAD GUARD HANDLE
7. STEERING CONTROL UNIT 18. HORN SWITCH CONNECTOR
8. COWL WELDMENT 19. HORN BUTTON
9. DASH 20. STEERING COLUMN
10. COLUMN MOUNT 21. STEERING COLUMN NUT
11. OVERHEAD GUARD
Legend for Figure 8
1. OVERHEAD 5. CAPSCREW
GUARD 6. WASHER
2. PLUG 7. HANDLE
3. NUT 8. SCREW
4. LOCKWASHER

Figure 8. Overhead Guard, Lift Truck Models

E2.00-3.20XM (G108)

11
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 SRM 558

Battery and Operator Restraint System, Hood and Seat

Brake, and Seat Assembly Replacement
BATTERY RESTRAINT SYSTEM
WARNING
On units with a shorter frame, the gas spring
for the hood can raise the hood at a rapid rate
and cause an injury. Do NOT bend over hood
when raising hood.
A battery restraint system is installed as a safety de-
vice. See Figure 9. The function of the battery re-
straint system, when correctly locked in the down
position, is to hold the battery in the battery com-
partment if an accident causes the lift truck to tip
over. The battery restraint is a steel weldment that
is connected to the frame with a hinge. A sliding
latch mechanism (see Figure 9.) locks the battery re-
straint in the down position for operation. The latch,
at the top center of the counterweight, unlocks the
battery restraint from the frame, so that the battery
restraint can be raised to the up position for access
to the battery. The battery restraint is also the sup-
port for the hood. A gas spring helps lift the hood as-
sembly. A rod is used to hold the hood in the up posi-
tion on units with a longer frame. The operator must
hold the hood assembly with one hand. Use the other
hand to move the rod to the storage position. Lower
the hood and battery restraint assembly to the oper-
ating position. Make sure that the battery restraint
is correctly locked to the frame for operation of the
lift truck.

1. HOOD 7. STOP ROD

2. SEAT 8. RELEASE LABEL FOR STOP ROD
3. LATCH ASSEMBLY 9. COUNTERWEIGHT
4. BATTERY RESTRAINT AND HOOD FRAME 10. LATCH HANDLE
5. GAS SPRING 11. LIFT HANDLE
6. HINGE 12. LATCH WARNING LABEL

Figure 9. Hood, Latch, and Battery Restraint System

12
100 SRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement

WARNING
Correct operation of the battery restraint sys-
tem requires that the battery does not move
more than 13 mm (0.5 in.) horizontally. Make
sure that the battery spacer plate is correctly
adjusted.
Use the lift handle by the seat to raise the hood. See
Figure 10 or Figure 11. A gas spring and stop rod will
hold the assembly in the up position. Make sure that
the battery cannot move more than a total of 13 mm
(0.5 in.) in any one horizontal direction. If necessary,
adjust the battery spacer plate as shown in Figure 2.

WARNING
The battery restraint and its latch mechanisms
must operate correctly before a lift truck is op-
erated.

To operate correctly, the battery restraint must be

locked in the down position. The battery compart-
ment has an adjustable spacer plate, which is used to
prevent forward and backward movement of the bat-
tery. Adjust the spacer plate to prevent movement in
any one horizontal direction of 13 mm (0.5 in.) max-
imum. See Figure 2. Raise the seat. Use the knob
for the latch to release the battery restraint. See Fig-
ure 9. Use the handle on the hood to raise the battery
restraint and hood. Make sure that the battery can-
not move more than a total of 13 mm (0.5 in.) in any
one horizontal direction. Make sure the spacer plate
is correctly adjusted to prevent movement. Push the
hood and the battery restraint down until the latch
locks. Make sure the battery restraint is locked se-
curely. Lift on the handle to make sure it is latched
and will not move.

HOOD
1. HINGE
The hood must be locked in the down position dur- 2. LIFT HANDLE
ing operation. The battery must have the spacer 3. HOOD
plate correctly adjusted to prevent forward or back- 4. LATCH HANDLE
ward movement of 13 mm (0.5 in.) maximum. On 5. SEAT BRAKE PLATE
lift trucks E2.00-3.20XM (E45-65XM, E45-65XM 2)
Figure 10. Hood and Seat Brake Plate Assembly
(F108), N30XMH, and N30XMH 2 (C210), and
With Manual Hydraulics for Lift Truck Models
V30ZMD (D210/E210), if the unit has a seat brake,
E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
raise the seat and seat plate assembly. Use the latch
E2.00-3.20XM (E40-65Z) (G108), N30XMH, and
handle at the rear of the hood (see Figure 10) to
N30XMH 2 (C210), and V30ZMD (D210/E210)
release the hood frame and battery restraint. Raise
the latch handle and slide the handle toward the
right side of the truck. A spring moves the handle
back to the left.

13
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 SRM 558

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 compartment.

Another important part of the battery restraint sys-

tem is the steel weldment that is also the hood frame.
This hood frame is connected to the lift truck frame
with hinges at the rear of the hood. Gas springs help
lift the hood assembly. The seat and other parts of
the operator restraint system fasten to the hood as-
sembly.

NOTE: Before raising the hood, move the steering col-

umn to the forward position and slide the seat all the
way back, and If necessary, move the armrest all the
way back. See Figure 12.

1. HINGE
2. SEAT BRAKE PLATE
3. HOOD
4. LATCH HANDLE

Figure 11. Hood and Seat Brake Plate Assembly

With E-Hydraulics for Lift Truck Models
E2.00-3.20XM (E40-65Z) (G108) and V30ZMD
(D210/E210)

Release the stop rod by moving it to the right before

lowering hood. See the label in Figure 9. Make sure
the latch handle is fully to the right when closing the
hood so that the latch can engage the latch piece.
Make sure the hood is locked securely. Try to raise
the hood using only the lift handle to make sure the 1. ARMREST ADJUSTMENT HANDLE
hood is latched and will not move.
Figure 12. Armrest Latch Location
HOOD WITH E-HYDRAULICS
The latch that secures the cover for the hood release
handle can be either a locking or non locking latch.
WARNING If the latch is a locking latch, unlock latch with key
The gas spring for the hood can raise the hood first. The cover, latch and hood release handle are
at a rapid rate and cause an injury. DO NOT located on the right side of the hood. See Figure 13.
lean over hood when raising hood.

14
100 SRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement

Pull the latch handle, located on the top of the latch,
to the up position and then pull on latch handle to
move cover away from hood release handle. Pull hood
release handle up to release hood latch mechanism.
See Figure 13. Use handle on the hood to place hood
in the raised position.
Before lowering the hood, make sure the battery
restraint rod is over the battery. Lower the hood
and push hood release handle down to secure hood
to frame. Move cover over hood release handle and
push latch handle down to secure cover to hood. If
latch is a locking latch, lock latch with key.
SEAT BRAKE
On E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108),
N30XMH, and N30XMH 2, and V30ZMD (D210) units
with a seat brake, there is a separate plate with a
hinge fastened to the front of the battery compart-
ment (see Figure 10.) The seat is fastened to this
plate instead of the hood on these units. The linkage
for the seat plate has a spring that holds the plate up
and applies the brake on the rear of the traction mo-
tor. During operation of the lift truck, the seat brake
will be applied to the traction motor if the seat brake
switch, located under the seat, senses that the oper-
ator has left the seat and the parking brake has not
been applied. On these units, push the seat and seat
plate into position over the hood. See Figure 10 and
Figure 14.

OPERATOR RESTRAINT SYSTEM AND

SEAT ASSEMBLY
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of the operator re-
straint system. Each item must be checked to make
sure it is attached securely, functions correctly, and
is in good condition. See Figure 14.

Automatic Locking Retractor (ALR)

NOTE: E2.00-3.20XM (E45-65XM, E45-65XM 2)
(F108), N30XMH, and N30XMH 2, and V30ZMD
(D210) lift trucks produced before November 2005
are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the

1. LATCH 6. PIN seat belt extends and retracts smoothly and is not
2. COVER 7. SCREW frayed or torn. If the seat belt is damaged or does not
3. HOOD RELEASE 8. CAPSCREW operate properly, it must be replaced. See Figure 14.
HANDLE 9. NUT
4. HOOD LATCH 10. LOCKWASHER
MECHANISM 11. WASHER
5. COMPRESSION 12. LATCH HANDLE
SPRING

Figure 13. Latch and Cover With E-Hydraulics

15
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 SRM 558

be activated and hold the operator’s lower torso in

the seat.

A seat belt that is damaged worn or does not operate

properly will not give protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 15.

The following seat belt operation checks must be per-

formed:
• With the hood closed and in the locked position,
pull the seat belt slowly from the retractor assem-
bly. Make sure the seat belt pulls out and retracts
smoothly. If the seat belt does not pull out of the re-
tractor assembly, the internal latch may be locked.
Pull firmly on the seat belt and hold for a moment
to remove slack from the belt in the retractor. Re-
lease the seat belt. Seat belt will retract and the
internal latch will unlock. If the seat belt cannot
be pulled from the retractor assembly or the belt
will not retract, replace the seat belt assembly.
• With the hood closed and in the locked position,
pull the seat belt with a sudden jerk. Make sure the
seat belt will not pull from the retractor assembly.
If the seat belt can be pulled from the retractor,
1. SEAT 4. HOOD when it is pulled with a sudden jerk, replace the
2. HIP RESTRAINT 5. SEAT RAILS seat belt assembly.
3. SEAT BELT AND 6. SEAT PLATE (WITH • With the hood in the open position, make sure the
MOUNT SEAT BRAKE)*
seat belt will not pull from the retractor assembly.
*THE SEAT PLATE IS NOT USED ON E2.00-3.20XM If the seat belt can be pulled from the retractor,
(E40-65Z) (G108) TRUCKS. with the hood in the open position, replace the seat
belt assembly.
Figure 14. Operator Restraint and Seat
Assembly Make sure the seat rails and latch striker are not
loose. The seat rails must lock securely in position
Emergency Locking Retractor (ELR) but move freely when unlocked. The seat rails must
be securely attached to the mounting surface. The
NOTE: Lift trucks produced after November 2005 hood must be fully closed. Lift the hood to make sure
are equipped with the Emergency Locking Retractor it is closed and will not move.
(ELR) style seat belt.
Adjust hood, hood latch, and latch striker when any
When the ELR style seat belt is properly buckled of the parts of the operator restraint system are in-
across the operator, the belt will permit slight op- stalled or replaced. See the section Hood Repair in
erator repositioning without activating the locking this manual for the adjustment procedures for the
mechanism. If the truck tips, travels off a dock, or hood.
comes to a sudden stop, the locking mechanism will

16
100 SRM 558 Counterweight Replacement

Legend for Figure 15

1. OPERATOR WEIGHT ADJUSTMENT
2. FORWARD/BACKWARD ADJUSTMENT
3. SEAT BELT
4. HIP RESTRAINT
5. SEAT
6. SEAT RAIL

Figure 15. Hood and Seat Check

Counterweight Replacement
If the lift truck must be put on blocks for mainte-
nance or repair, see How to Put Lift Truck on
Blocks in the Operating Manual or Periodic
Maintenance section for your vehicle.

WARNING
The counterweight is very heavy. Make sure
that the crane and lifting devices have enough
lifting capacity to safely lift the counterweight.
The weights of the counterweights are shown
in Table 1.

The counterweight normally is not removed for most

repairs. Replacement of the SCR Electronic Con-
trollers is easier with the counterweight removed.
Replacement of the SEM, and AC Controllers is ac-
complished by removing the cover from the counter-
weight. See Figure 16. The counterweight is fas-
tened to the frame with four capscrews. The weights 1. COUNTERWEIGHT AND SEAL
for the counterweights are shown in Table 1. 2. UPPER CAPSCREW AND WASHERS
3. ACCESS COVER AND SEAL
4. COVER CAPSCREW AND WASHERS
5. LOWER CAPSCREW AND WASHER

Figure 16. Counterweight Assembly

17
Counterweight Replacement 100 SRM 558

Table 1. Counterweights Table 1. Counterweights (Continued)

Model (mm*) Weight + 50 kg

Model (mm*) Weight + 50 kg
(110 lb)
(110 lb)
0 kg
0 kg
(0 lb)
(0 lb)
E2.00XM 700
E50XM, XM 2 700
(F108) and
(F108) and
E2.25XM
E2.50XM
(F108)
(F108) and
E2.00XM
E50Z (G108)
(G108)
and E2.50XM
E2.50XM 847 (G108)
(F108) and
E60XM, XM 2 847
E50XM, XM 2 544 kg (1200 lb)
F108) and
(F108)
E3.00XM 976 kg (2150 lb)
2.50XM (G108)
(F108) and
and E50Z
E60Z (G108)
(G108)
and E3.00XM
E3.00XM 1015 (G108)
(F108) and
N30XMH, and 1015
E3.00XM
N30XMH 2
(G108)
(C210) and
E45XM, XM 2 700 V30ZMD
(F108) and (D210/E210)
E40-45Z
*Approximate battery compartment lengths.
(G108)
E55XM, XM 2 847
(F108) and REMOVE
E2.50XM
(F108) and 1. Remove the battery from the truck. See How
E55Z (G108) to Change Battery in your vehicle’s Periodic
770 kg (1700 lb)
and E2.50XM Maintenance or Operating Manual for the
(G108) procedures.
E65XM, XM 2 1015 2. Install the counterweight lifting tool to the coun-
(F108) and terweight with a 1 UNC × 2 in. (50 mm) bolt.
E3.00-3.20XM See Figure 17 and Figure 18. Connect a clevis
(F108) and to the counterweight lifting tool. The clevis must
E65Z (G108) have a pin diameter of 16.0 to 19.0 mm (0.625 to
and E3.00- 0.750 in.). Fasten a chain or sling to the clevis.
3.20XM (G108) Make sure the chain or sling and crane has the
*Approximate battery compartment lengths. capacity to lift the counterweight. See Table 1.
Use the crane to hold the weight of the counter-
weight.

3. From inside the battery compartment near the

bottom, remove the two top capscrews that hold
the counterweight to the frame. Remove the cap-
screws, nuts, and washers from the tow pin area
of the counterweight. Use the crane to lift the

18
100 SRM 558
counterweight away from the frame. Make sure
that you do not damage the electronic controller.
1. LIFT CHAIN 3. CLEVIS
2. LIFTING TOOL 4. COUNTERWEIGHT
Figure 17. Lift the Counterweight
INSTALL
NOTE: The access panel to the electronic controller
can be removed from the counterweight to make
checks and adjustments on the controller. Before
installing access panel, check the seal to make sure
it fully seals the controls compartment and that
there are no gaps between the seal, seal blocks, wire
harness, battery bulkhead covers, or counterweight.
Make sure the lugs are correctly engaged when the
access panel is installed again, or the panel will fall
from the counterweight during operation.
Counterweight Replacement
1. Use a crane and the lifting tool, during removal,
to lift the counterweight into position. See Fig-
ure 16. Make sure that you do not damage the
electronic controller during installation. Install
the two upper capscrews near the bottom of
the battery compartment that hold the counter-
weight to the frame. Install the lower capscrews,
washers, and nuts in the tow pin area of the
counterweight. Tighten the upper capscrews to
380 N•m (280 lbf ft). Tighten the lower (tow
pin) capscrews and nuts to 66 N•m (49 lbf ft). If
removed, tighten the access cover capscrews to
52 N•m (38 lbf ft).
2. Disconnect the sling or chain. Remove the lifting
tool from the counterweight.
3. See How to Change Battery in your vehicle’s
Periodic Maintenance or Operating Man-
ual. Install the battery into the truck.
NOTE: THE MATERIAL IS ASTM A36 STEEL, 12.7 mm
(0.50 in.) THICK.
Figure 18. Counterweight Lifting Tool
19
Traction Motor Replacement 100 SRM 558

Traction Motor Replacement

REMOVE
This procedure will show the removal of the traction
motor through the battery compartment. Some lift
trucks have a seat brake that actuates a brake on
the armature shaft of the traction motor. See Fig-
ure 19 and Figure 20. On lift trucks E2.00-3.20XM
(E45-65XM, E45-65XM 2) (F108), N30XMH, and
N30XMH 2 (C210), and V30ZMD (D210) the seat
brake linkage under the floor plate must be dis-
connected at the front of the traction motor be-
fore the motor is removed. On lift truck models
E2.00-3.20XM (E40-65Z) (G108) V30ZMD (E210)and
the guide pipe and electrical connections for the seat
brake must be disconnected from the traction motor
before motor is removed. See Figure 20.

1. GUIDE PIPE CONNECTION

2. ELECTRICAL CONNECTION
3. SEAT BRAKE

Figure 20. Traction Motor With Seat Brake

1. TRACTION MOTOR
2. LEVER OF SEAT BRAKE LINKAGE
3. NUT, CAPSCREW, WASHERS, AND BUSHING
4. SPRING
Figure 19. Traction Motor With Seat Brake for
Lift Trucks ModelsE2.00-3.20XM (E45-65XM,
E45-65XM 2) (F108), N30XMH, and N30XMH 2
(C210), and V30ZMD (D210)
NOTE: The traction motor can be removed separately
or as a unit with the drive train. These removal
methods require removal from under the lift truck
with the use of a floor jack. These methods are 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.
for Lift Trucks ModelsE2.00-3.20XM (E40-65Z)
(G108) and V30ZMD (E210)
1. See How to Change Battery in your vehicle’s
Periodic Maintenance or Operating Man-
ual. Remove the battery from the truck. Then
remove the floor plates and the access panel in
the bottom of the battery compartment.
NOTE: Replace the hydraulic tank breather with a
plug to help prevent oil flow when disconnecting the
tank-to-pump hydraulic line.
2. On lift trucks E2.00-3.20XM (E45-65XM, E45-
65XM 2) (F108), N30XMH, and N30XMH 2 (C210)
and V30ZMD (D210), disconnect the ball of the
ball joint from the lever of the seat brake linkage
under the floor plate.
3. Disconnect the power cables from the traction
motor. If installed, disconnect the wires for the

20
100 SRM 558
brush wear indicators and the temperature sen-
sor at the motor. Make an identification of which
cable and wire is connected to each terminal.
4. Put the lift truck on blocks for easier access to
the bottom bolts between the traction motor and
the speed reducer. Remove the bolts that fasten
the speed reducer and the motor.
5. Install a sling to hold the traction motor. See Fig-
ure 21. Use a wood block and a board under the
sling as shown in the illustration to control the
traction motor during removal and installation.
Use the crane to hold the weight of the traction
motor. See Figure 22.
NOTE: USE A WOOD BLOCK AND BOARD UNDER
SLING FOR A LEVER. TRACTION MOTOR FOR
MODELS E2.00-3.20XM (E45-65XM, E45-65XM 2)
(F108), N30XMH AND N30XMH 2 (C210), AND
V30ZMD (D210) SHOWN. TRACTION MOTOR FOR
E2.00-3.20XM (E40-65Z) (G108) AND V30ZMD (E210)
IS SIMILAR.
1. SLING
2. BOARD AND BLOCK
3. TRACTION MOTOR
Figure 21. Install Sling to Lift Traction Motor
Traction Motor Replacement
NOTE: The traction motors are in different config-
urations for different applications of the lift trucks.
Traction motors weigh approximately 90 to 140 kg
(200 to 310 lb). Make sure that the sling cannot slide
and permit the traction motor to fall.
6. Remove the motor mount that holds the traction
motor to the frame. Pull the traction motor from
the speed reducer. See Figure 22.
NOTE: TRACTION MOTOR FOR MODELS E2.00-
3.20XM (E45-65XM, E45-65XM 2) (F108), N30XMH
AND N30XMH 2 (C210), AND V30ZMD (D210/E210)
SHOWN. TRACTION MOTOR FOR E2.00-3.20XM
(E40-65Z) (G108) IS SIMILAR.
Figure 22. Use Crane to Lift Traction Motor
7. Use the crane to move the traction motor to a
space to make repairs. If installed on lift truck
models E2.00-3.20XM (E45-65XM, E45-65XM 2)
(F108), N30XMH and N30XMH 2 (C210), and
V30ZMD (D210/E210), remove the bracket,
lever, and spring for the seat brake. Remove
the brake assembly from the traction motor as
described in the section Brake System 1800
SRM 574.
21
Hydraulic Tank Repair 100 SRM 558

INSTALL
1. If the truck has a seat brake, install the brake
assembly on the traction motor as described in
the section Brake System 1800 SRM 574. For
lift truck models E2.00-3.20XM (E45-65XM, E45-
65XM 2) (F108), N30XMH and N30XMH 2 (C210),
and V30ZMD (D210/E210), install the bracket,
lever, and spring for the brake. Install a sling
to lift the traction motor. Use a wood block and
a board under the sling to control the traction
motor during installation. See Figure 22.

2. Lower the traction motor into position in the lift

truck. Align the traction motor with the speed
reducer. See Figure 23.

3. Use a board or pry bar as 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).
5. Remove the sling and install the traction motor
mount. If equipped, install the ball of the ball
joint on the lever for the seat brake.
6. Install the power cables and the access and floor
plates. Tighten the power cable connectors to 21
to 25 N•m (15 to 18 lbf ft).
7. See How to Change Battery in your vehicle’s
Periodic Maintenance or Operating Man-
ual. Install the battery into the truck.
NOTE: TRACTION MOTOR FOR MODELS E2.00-
3.20XM (E45-65XM, E45-65XM 2) (F108), N30XMH
AND N30XMH 2 (C210), AND V30ZMD (D210/E210)
SHOWN. TRACTION MOTOR FOR E2.00-3.20XM
(E40-65Z) (G108) IS SIMILAR.
1. SLING
2. BOARD AND WOOD BLOCK
3. TRACTION MOTOR
Figure 23. Align Traction Motor With Speed
Reducer

Hydraulic Tank Repair

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-
ter dealer.
Make a visual inspection of all sides of the tank. See
Figure 24. Inspect the welds for cracks and leakage.
Check for wet areas, accumulation of dirt, and loose
or missing paint caused by leakage. Areas of the tank

22
100 SRM 558 Hydraulic Tank Repair

that are not easily seen can be checked with an in-
spection mirror and a light that is approved for loca-
tions with flammable vapors.
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 pro-
cedures 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 the water out of the tank by remov-
ing 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 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.

Steam Method
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.

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
A. HYDRAULIC BREATHER AND ADAPTER USED is away from all personnel. Wear protective
ON OLDER MODEL E2.00-3.20XM (E45-65Z) goggles or a face shield to prevent injury to the
(G108) AND V30ZMD (D210) LIFT TRUCKS.
B. HYDRAULIC BREATHER AND ADAPTER USED eyes.
ON NEWER MODEL E2.00-3.20XM (E45-65Z)
(G108) AND V30ZMD (D210/E210) LIFT TRUCKS. 3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the
1. BREATHER tank are flushed with the solution. Drain the
2. FILL/DIPSTICK tank.
3. MOUNT BRACKET ASSEMBLY
4. HYDRAULIC TANK
5. MAIN PUMP SUPPLY 4. Put steam into the tank until the tank does not
6. STEERING PUMP SUPPLY PORT have odors and the metal is hot. Steam vapors
7. DRAIN PLUG must come from all the openings.
8. BREATHER ADAPTER

Figure 24. Hydraulic Tank

23
Hydraulic Tank Repair
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
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.
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
24
100 SRM 558
amount of flammable vapors is not below the
lower flammable limit, repeat the cleaning pro-
cedures.
ADDITIONAL PREPARATIONS FOR
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.
NOTE: Make sure to install the tank so that the fill
neck is centered in the opening in the step of the
frame. Make sure to install all plugs, hoses, and
clamps to prevent leaks when oil is added to the tank.
SMALL LEAKS, REPAIR
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can
cause an explosion.
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.
100 SRM 558
LARGE LEAKS, REPAIR
1. To clean and prepare the tank for repair, use one
of the two cleaning procedures in the Clean sec-
tion of this SRM.
2. Use acceptable welding practices to repair the
tank. See the American National Standard
Safety In Welding and Cutting, AWS Z49.1 -
1999.
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 25.
CAUTION
Do not paint the pads, plastic covers or knobs,
cables, labels, information plates, or controls.
Painting Instructions
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.
Paint can make some assemblies not operate
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 25.
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 safety labels are installed in the
correct locations on the lift truck. See Figure 26.
New labels are available from your dealer for
Hyster lift trucks.
25
Safety Label Replacement 100 SRM 558

NOTE: DO NOT PAINT THE FOLLOWING ITEMS: PEDAL PADS, LEVER KNOBS, INSTRUMENTS, STEERING
WHEEL, SEAT ASSEMBLY, SEAT RAILS, INFORMATION CASE AND COVER, TIRES, MAST CHAINS AND
HOSES, ALL LABELS AND INFORMATION PLATES, BATTERY CONNECTOR, PARKING BRAKE HANDLE, KEY
SWITCH, CYLINDER RODS, ALL PLASTIC COVERS, AND STEERING COLUMN COVER.

NOTE: LIGHT AREAS - YELLOW, DARK AREAS - BLACK, FORKS - RED. USE COLORS APPROVED BY HYS-
TER. DO NOT PAINT ITEMS IN PREVIOUS NOTE.

Figure 25. Color Arrangement

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.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
NOTE: If the labels or information plates are miss-
ing or have damage, they must be replaced. See Fig-
ure 26 or Figure 27.
1. Before installing a new label, make sure the sur-
face is dry and has no oil or grease. Do not use

26
100 SRM 558 Safety Label Replacement

solvent on new paint. Clean the surface of old
paint using a cleaning solvent.
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.

NOTE: INSTALL NEW LABEL IN THE SAME LOCATION AS ORIGINAL.

NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 26. SEE THE
PARTS MANUAL FOR ALL LABELS USED AND THEIR POSITIONS.
1. MAST WARNING LABEL 12. U.L. INSPECTION PLATE
2. TIPOVER (OPERATOR RESTRAINT) 13. FIRE SAFETY LABEL (U.S. AND CANADA)
3. OVERHEAD GUARD TEST PLATE (LEFT SIDE) 14. CORROSION OR FREEZER PROTECTION
4. OPERATOR WARNING LABEL (RIGHT SIDE) 15. PINCH POINT
5. NAMEPLATE 16. BATTERY DISCONNECT
6. LATCH WARNING LABEL 17. NO RIDERS
7. PATENT PLATE 18. NO ONE ON OR UNDER FORKS
8. BATTERY SPACER 19. LABEL FOR RELEASE OF STOP ROD (ON
9. MODEL LABEL BATTERY RESTRAINT NEAR GAS SPRING)
10. HYSTER LOGO 20. YELLOW LETTERS
11. PARK BRAKE WARNING

Figure 26. Label Positions

27
Safety Label Replacement 100 SRM 558

Figure 27. Label Positions E-Hydraulics

28
100 SRM 558 Safety Label Replacement

Legend for Figure 27

NOTE: INSTALL NEW LABEL IN THE SAME LOCATION AS ORIGINAL.

NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 27. SEE THE
PARTS MANUAL FOR ALL LABELS USED AND THEIR POSITIONS.
1. JOYSTICK AUXILIARY 15. MODEL
2. MINILEVER AUXILIARY 16. HYSTER LOGO
3. MANUAL AUXILIARY 17. PINCH POINT
4. UL LABEL 18. HYSTER
5. NAMEPLATE 19. PROP ROD
6. NO RIDERS 20. HOOD E-HYDRAULICS
7. CAUTION E-HYDRAULICS 21. HOOD LATCH
8. NO ONE ON OR UNDER FORKS 22. PARKING BRAKE
9. UL INSPECTION PLATE 23. BATTERY DISCONNECT
10. PATENT PLATE 24. OPERATOR RESTRAINT
11. UL SAFETY/NONSAFETY 25. OVERHEAD GUARD
12. CORROSION OR FREEZER INSPECTION 26. OPERATOR WARNING
13. BATTERY SPACER 27. MAST WARNING
14. AC LOGO 28. HYSTER

29
Battery Specifications 100 SRM 558

Battery Specifications
Table 2. Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2) (F108), N30XMH,
and N30XMH 2 (C210) and V30ZMD (D210/E210)

Min. Com- Battery Size Min/Max Weight

Model partment Size
Length × Width Length Width Min Max

E2.00-
695 × 987 mm 681/691 mm 1043 kg 1497 kg
2.50XM* (E40-
(27.4 × 38.8 in.) (26.8/27.2 in.) (2300 lb) (3300 lb)
E50XM, XM 2*
E2.50XM-
E3.00XM* 842 × 987 mm 800/838 mm 1317 kg 1771 kg
(E55-E60XM, (33.1 × 38.8 in.) (31.5/32.9 in.) (2903 lb) (3904 lb)
XM 2* 978/983 mm
(38.5/38.7 in.)
E3.00-3.20XM
(E65XM, XM 2)
and
1010 × 987 mm 1001/1006 mm 1553 kg 1998 kg
N30XMH,
(39.7 × 38.8 in.) (39.4/39.6 in.) (3424 lb) (4405 lb)
XMH 2, and
V30ZMD
(D210/E210)
* Short wheelbase trucks. 612 mm (24.1 in.) = maximum height for all batteries. This dimension is 31.5 mm
(1.24 in.) less with optional battery rollers.
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
and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or back-
ward.

30
100 SRM 558 Battery Specifications

Table 3. Lift Truck Models E2.00-3.20XM (E40-65Z) (G108)

Min. Com- Battery Size Min/Max Weight

Model partment Size
Length × Width Length Width Min Max

E2.00-2.50XM 695 × 987 mm 681/691 mm 1043 kg 1497 kg

(E40- E50Z) (27.4 × 38.8 in.) (26.8/27.2 in.) (2300 lb) (3300 lb)
E2.50-
842 × 987 mm 978/983 mm 800/838 mm 1317 kg 1771 kg
E3.00XM
(33.1 × 38.8 in.) (38.5/38.7 in.) (31.5/32.9 in.) (2903 lb) (3904 lb)
(E55-E60Z)
E3.00-3.20XM 1010 × 987 mm 1001/1006 mm 1553 kg 1998 kg
(E65Z) (39.7 × 38.8 in.) (39.4/39.6 in.) (3424 lb) (4405 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
and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or back-
ward.

31
 NOTES

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32
 TECHNICAL PUBLICATIONS

100 SRM 558 11/07 (11/06)(1/06)(7/05)(6/04)(5/04)(11/03)(7/03)(10/94) Printed in U.S.A.