service repair workshop manual

1. SERVICE REPAIR
N30FR [A217]

2. 1
LIFT CAPACITIES
N30FR N40EA/ER
N40FR
N45ER
N45FR
N50EA
N50FA
Basic* Capacity at 24 in. load center 3 000 lb 4 000 lb 4 500 lb 5 000 lb
Basic* Capacity at 500 mm load center 1 500 kg 2 000 kg 2 250 kg 2 500 kg
*N30FR with 24 volt battery, 95” (2 388 mm) 2–stage mast, single–reach carriage, Load Backrest Extension, 52”
(1 321 mm) Base Width and 36” (914 mm) forks.
*N40EA/ER with 24 volt battery, 130” (3 300 mm) 2–stage mast, 33.75” (857 mm) carriage (N40EA) or 33” (838
mm) single–reach carriage (N40ER), Load Backrest Extension, 52” (1 321 mm) Base Width and 36” (914 mm) forks.
*N45ER with 36 volt battery, 130” (3 300 mm) 2–stage mast, 33” (838 mm) single–reach carriage, Load Backrest
Extension, 52” (1 321 mm) Base Width and 36” (914 mm) forks.
*N50EA with 36 volt battery, 130” (3 300 mm) 2–stage mast, 33.75” (857 mm) carriage, Load backrest Extension,
52” (1 321 mm) Base Width and 36” (914 mm) forks.
*N40FR with 24 volt battery, 119” (3 023 mm) 2–stage mast, 33” (838 mm) single–reach carriage, Load Backrest
Extension, 52” (1 321 mm) Base Width and 36” (914 mm) forks.
*N45FR with 36 volt battery, 131” (3 300 mm) 2–stage mast, 33” (838 mm) single–reach carriage, Load Backrest
Extension, 52” (1 321 mm) Base Width and 36” (914 mm) forks.
*N50FA with 36 volt battery, 107” (2 718 mm) 2–stage mast, 32.5” (826 mm) carriage, Load backrest Extension,
52” (1 321 mm) Base Width and 36” (914 mm) forks.
5
6
SETTINGS
MASTER DRIVE UNIT
Drive Tire Size
N30FR
All Others 131/2 X 51/2 X 8 (Poly Opt.)
Wheel Nut Torque Cross Pattern to 136 N.m
(100 lbf ft)
Pinion Nut Torque 54 N.m (40 lbf ft)
Bearing Mount
Capscrews
Cross Pattern to 34 N.m
(25 lbf ft) then
68 N.m (50 lbf ft)
Motor Mount
Capscrews
Cross Pattern to
20 N.m (15 lbf ft)
Master Drive Unit
CAPACITIES
3.8 litre (1 gal)
25.4 litre (6.7 gal)Hydraulic Tank (All others)
5485
UNIT VOLTS
24V
36V
7
7
2 (2.3 sec)
1 (1.9 sec)
9 (300A)
9 (288A)
5 (2.6 sec)
4 (1.4 sec)
5 (440A)
3 (640A)
CONTROL SETTINGS
N40–50EA/ER
Control Card Adjustments
CONTROL SETTINGS
N30FR, N40–50FA/FR
FUNCTION DESCRIPTION
Stored Status Code –
Creep Speed 100
Controlled Acceleration 18
Current Limit 255
Plugging Distance (Current) 100
1A Drop Out Current 255
Field Weakening Pick Up 0
Field Weakening Drop Out 0
Regen Braking Current Limit 0
Regen Start 0
Speed Limit (SL1) 0
Speed Limit (SL2) 0
Speed Limit (SL3) 0
Internal Resistance Compensation 0
Battery Voltage for BDI 255
Pedal Position Plug 25
Card Type Selection 0
Steer Pump Time Delay 10
1
2
3
4
7
8
9
10
11
12
13
14
15
16
17
18
18.0 litre (4.75 gal)Hydraulic Tank N30FR
12 x 51/2 x 8 (Rubber)

3. 2
HYDRAULIC SYSTEM SPECIFICATIONS*
LIFT PUMP N30FR
Maximum Output 11.9 cm3/revolution (0.73 in3/rev)
Maximum Pressure 21 MPa (3046 psi)
Speed 500 to 3500 RPM
LIFT PUMP (All Others)
Maximum Output 19.2 cm3/revolution (1.217 in3/rev)
Maximum Pressure 21 MPa (3046 psi)
Speed 650 to 3500 RPM
RELIEF VALVE PRESSURES
Lift system 17.2 MPa (2500 psi)
Range 16.9 to 17.6 MPa (2450 to 2550 psi)
Auxiliary functions system 13.8 MPa (2000 psi)
Range 13.4 to 14.1 MPa (1950 to 2050 psi)
HYDRAULIC SYSTEMS CAPACITY
N30FR
Center of sight gauge 18.0 litre (4.75 gal)
Oil available for use 16.1 litre (4.38 gal)
All Others
Center of sight gauge 22.3 litre (5.9 gal)
Oil available for use 19.7 litre (5.2 gal)
*All measurements made when the hydraulic oil temperature is 54–66°C (130–150°F)
279/362
11.00/14.25
279/311
11.00/12.25
BATTERY SPECIFICATIONS
MODEL VOLTS
MINIMUM
COMPARTMENT SIZE
LENGTH x WIDTH
BATTERY SIZE*
MIN/MAX
LENGTH WIDTH
WEIGHT
MIN MAX
Compartment width is across width of lift truck. Battery length installed across lift truck, battery width installed
front to back.
*Maximum height for all batteries is 787 mm (31.0 in).
536 x 983
21.12 x 38.69
438/527
17.25/20.75
999 kg
2200 lb
1271 kg
2800 lb
N30FR
24V
355 x 983
14.5 x 38.69
24V 318 x 983
12.5 x 38.69
889/983
35.0/38.69
590 kg
1300 lb
681 kg
1500 lb
748 kg
1650 lb
N40EA/ER
279/298
11.0/11.75
24V
368 x 975
14.50 x 38.38
24V
308 x 975
12.12 x 38.38
590 kg
1300 lb
681 kg
1500 lb
748 kg
1650 lb
817 kg
1800 lb
817 kg
1800 lb
889/972
35.0/38.2536V
36V
36V
419 x 975
16.50 x 38.38
279/362
11.00/14.25
330/362
13.00/14.25
817 kg
1800 lb
1090 kg
2400 lb
908 kg
2000 lb
391/413
15.38/16.25
726 kg
1600 lb
908 kg
2000 lb
N45–50EA
726 kg
1600 lb
24V
36V
419 x 983
16.50 x 38.69
N40FR
N50FA
24V
36V
N45FR 36V
476 x 983
18.75 x 38.69
817 kg
1800 lb
1090 kg
2400 lb
330/413
13.00/16.25
908 kg
2000 lb
1180 kg
2600 lb
391/467
15.38/18.38

4. 3
REACH CARRIAGE SPECIFICATIONS
N40–45ER N30FR, N40–45FR
Scissor Arm Center Bearing
Nut Torque
Initially tighten to 108 N.m (lb ft),
loosen and tighten to 40 N.m (25 lb ft)
––––
Reach Cylinder Torques
Rod Nut 47 to 54 N.m (35 to 40 lbf ft) 95 N.m (70 lbf ft)
Retainer 237 to 271 N.m (175 to 200 lbf ft) 129 to 142 N.m (95 to 105 lbf ft)
Rod End Capscrews –––– 48 to 54 N.m (35 to 40lbf ft)
Tilt Cylinder Torques
Rod Nut 221 to 258 N.m (163 to 190 lbf ft) 150 N.m (110 lbf ft)
Retainer 229 to 321 N.m (169 to 237 lbf ft) 122 to 156 N.m (90 to 115 lbf ft)
Reach Mechanism Strokes 603.6 to 616.4 mm (2.75 to 24.25 in) 603.6 to 616.4 mm (23.75 to 24.25 in)
907.6 to 920.4 mm (35.75 to 36.25 in) 907.6 to 920.4 mm (35.25 to 36.25 in)
1060.6 to 174.4 mm (41.75 42.25 in) 1060.6 to 1073.4 mm (41.75 to 42.25 in)
Reach Cylinder Strokes
24 in. Reach 142.7 mm (5.62 in) 99 mm (3.9 in)
36 in. Reach 102.9 mm (4.05 in) 71 mm (2.8 in)
42 in. Reach 121.7 mm (4.79 in) 89 mm (3.5 in)
Reach Cyl. Adjustment
Carriage And Mast Dimension “A” ––––
Single–Reach 2–Stage 28.7 to 34.8 mm (1.13 to 1.37 in) ––––
Single–Reach 3–Stage 16.0 to 22.1 mm (0.63 to 0.87 in) ––––
Double–Reach 2–Stage 148.1 to 154.2 mm (5.83 to 6.07 in) ––––
Double–Reach 3–Stage 148.1 to 154.2 mm (5.83 to 6.07 in) ––––
Tilt Cylinder Stroke 69.5 to 72.5 mm (2.74 to 2.86 in) 75.5 mm (2.97 in)
Side–Shift Cyl. Strokes
Narrow Carriage 101.6 mm (4.0 in) 101.6 mm (4.0 in)
Wide Carriage 203.2 mm (8.0 in) ––––
Fork Tilt Angle
Down 2° 3°
Up 4° 4°

5. 1
INTRODUCTION
GENERAL
This section has the description for the parts of the
frame. These parts include the frame weldment, door,
floor plate and covers. The outer channel of the mast is
part of the lift truck frame. The overhead guard fastens
to the mast. The base arms are part of the weldment for
the outer channel of the mast.
DESCRIPTION (See FIGURE 2.)
The frame has mounts for the following parts:
• the mast assembly
• the steering system parts
• the electrical system parts
• the hydraulic system parts
• the door, floor plate, access panels and covers
The overhead guard fastens to the mast. The posts for
the overhead guard fasten between the overhead guard
and the frame. Repair procedures for parts that fasten to
the frame are in separate sections. See the section for
the system that has the part to be repaired.
REPAIR
REMOVAL AND DISASSEMBLY
(See FIGURE 2.)
There is very little repair required on the frame. Most
repairs can be done by removing the necessary system
parts. See the section for the system that has the part
that must be removed. To separate the frame weldment
from the mast weldment, see one of the following sec-
tions: N40–50EA, N40–45ER 4000 SRM 348, VISTA
UPRIGHT – REPAIR. N50FA, N30FR, N40–45FR
4000 SRM 482, VISTA MAST – REPAIR. To replace
the load wheels in the load arms, see one of the follow-
ing sections: N40–50EA, N40–45ER 8000 SRM 373,
PERIODIC MAINTENANCE. N50FA, N30FR,
N40–45FR see this section Replace The Load
Wheels. The caster is part of the steering axle assem-
bly. See the section 1600 SRM 378, STEERING SYS-
TEM to replace the caster or caster wheels.
Replace The Load Wheels
(See FIGURE 1.)
NOTE: The load wheels are in the base arms. The base
arms are part of the outer mast weldment on
N40–50EA, N40–45ER units. The base arms are part
of the frame weldment on N50FA, N30FR, N40–45FR
units.
NOTE: This procedure applies to both the two–stage
and three–stage masts.
Put the base arms up on blocks as described in the OP-
ERATING MANUAL or the PERIODIC MAIN-
TAINCE section for your lift truck. For easier installa-
tion, remove and install one load wheel before remov-
ing the next load wheel. The load wheel brackets are
held in the load arms by the load wheels. Make sure the
base arms and load wheels do not support any weight. If
1. BASE ARM
2. LOAD WHEEL
BRACKET
3. LOAD WHEEL
4. AXLE
5. AXLE SLEEVE
FIGURE 1. REPLACE THE LOAD WHEELS
6. BEARING
7. AXLE NUT
8. GREASE FITTING
(FREEZER/COR-
ROSION ONLY)
12058
6
8
31
5
7
2
8
4
3
4
6
2
7
1
necessary, install blocks under the base arms. Remove
the axle nut, axle with washer and the load wheel. Re-
move the axle sleeve from the load wheel. Completely
fill new bearings with the grease shown in the Mainte-
nance Schedule of the section PERIODIC MAINTE-

6. 2
NANCE, 8000 SRM 373 or PERIODIC MAINTE-
NANCE, 8000 SRM 410. Install the bearings in the re-
placement load wheel. Make sure the seal of each bear-
ing is toward the outside of the load wheel. Fill the area
between the bearings with the same grease and install
the axle sleeve. Install the washer on the axle. Install the
load wheel, axle and axle nut.
NOTE: On units that have the freezer and corrosion op-
tion, add additional grease through each grease fitting.
Covers, Panels and Plates
(See FIGURE 2. or FIGURE 3.)
The special plastic covers that protect the parts can be
removed by removing the screws that fasten them. The
small plate under the Direction/Speed control is under
the large cover for the electrical compartment. The door
must be open to remove the large cover for the electrical
compartment. Remove the capscrew at the top of the
left–hand post for the overhead guard to permit the post
to move with the door. Then remove the screw that fas-
tens the door and open the door. The cover over the hy-
draulic tank can be removed without removing any oth-
er covers or panels. The panels at each end of the bat-
tery compartment can be removed by lifting the latch
that fastens the panel. The floor plate is removed by lift-
ing the corner of the floor plate to raise it above the lip
of the frame.
FIGURE 2. N40–50EA, N40–45ER FRAME
12059
1. MAST ASSEMBLY
2. FRAME WELDMENT
3. DOOR
4. OVERHEAD GUARD
5. POST FOR OVERHEAD GUARD
6. COVERS AND PLATES
7. FLOOR PLATE
8. LATCH
9. PADS

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8. 3
6. OVERHEAD GUARD
7. POST FOR OVERHEAD GUARD
8. TANK COVER
9. PAD
10. FLOOR PLATE
11. REAR DOOR
FIGURE 3. N30FR, N40–45FR, N50FA FRAME
1. FRAME WELDMENT
2. BATTERY DOOR (EE
RATING ONLY)
3. BATTERY PLATE
4. COVER
5. BATTERY SPACER
1
2
2
4
3
4
4
5
5 3
89
9
6
7
7
10
11

9. 4
CHANGES TO THE OVERHEAD GUARD
WARNING
Do not weld mounts for lights or accessories to the
overhead guard. The strength of the overhead
guard can be reduced by welding or heating.
Install lights and accessories or their mounts with
clamps. The strength of the overhead guard can be
reduced if holes are drilled in the wrong location or
are too large. Contact your dealer for Hyster lift
trucks before welding or drilling holes in any part of
the overhead guard.
PAINTING INSTRUCTIONS
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. Wear protection for eyes
and skin. 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. When using cleaning solvents, always follow
the recommendations of the manufacturer.
1. Remove all dirt from the surface to be painted. Clean
the area to be painted. Use a solvent for painted sur-
faces. 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 removed must be painted. Use a primer. Apply
the primer before applying the final coat of paint.
CAUTION
Do not paint the pads, plastic covers or knobs,
cables, electrical components, safety labels, mast
chains and hoses or controls.
3. Protect all surfaces that will not be painted.
4. Paint the surfaces. Use the correct paint for Hyster
lift trucks. Follow the directions on the container. See
FIGURE 4.or FIGURE 5. for red, black and yellow ar-
eas.
SAFETY LABELS
(See FIGURE 4. or FIGURE 5.)
WARNING
Safety labels are installed on the lift truck to give in-
formation about operation and possible hazards. It
is important that all safety labels are installed on the
lift truck and can be read.
Do NOT add to or modify the lift truck. Any change
to the lift truck, the tires or its equipment can
change the lifting capacity. The lift truck must be
rated as equipped and the nameplate must show the
correct capacity rating. Contact your dealer for
Hyster lift trucks for a replacement nameplate.
If a label must be replaced, use the following procedure
to install a new label:
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. Wear protection for eyes
and skin. When using cleaning solvents, always fol-
low the recommendations of the manufacturer.
1. Make sure the surface is dry and has no oil or grease.
Do not use solvent on new paint. Clean the surface of
old paint with 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 that
all air is removed from under the label and the corners
and edges are tight.

10. 5
FIGURE 4. N40–50EA, N40–45ER LABEL POSITIONS AND PAINT
12060
* NAMEPLATE INFORMATION MUST BE COMPLETE
** FASTEN USING WASHERS AND POP–RIVETS
# HYSTER YELLOW IF NOT BLACK OR RED
1. NAMEPLATE
2. UL INSPECTION PLATE (E or EE)
3. TILT, EXTEND/RETRACT
4. LIFT/LOWER
5. WARNING FOR SAFETY
6. 6 mm (0.25 in)
7. EV–100 DECAL
8. PATENT LABEL
9. 584 mm (23.00 in)
10. 420 mm (16.50 in)
11. 25 mm (1.00 in)
12. 51 mm (2.00 in)
13. 64 mm (2.50 in)
14. 95 mm (3.75 in)
15. 28 mm (1.10 in)
16. 13 mm (0.50 in)
17. POWER (BATTERY) DISCONNECT
18. CASE, OPERATING MANUAL**
19. 267 mm (10.50 in)
*
**
20. IMPACT TEST PLATE, OVERHEAD GUARD
21. 43 mm (1.70 in)
22. DEALER DECAL (2)
23. 103 mm (40.50 in)
24. MAST SAFETY (2)
25. 3 mm (0.12 in)
26. REACH CARRIAGE SAFETY (2)
27. HYSTER BLACK#
28. HYSTER RED#
29. NOTICE TO USER
30. 279 mm (11.00 in)
31. FORWARD/REVERSE
32. MODEL LABEL (2)
33. FIRE SAFETY, UL (2)
34. SIDE–SHIFT
18**
28
2
10
29
1*
2
34
15
6
16
6
16 12
17
21
25
12
14
1
4
31
3330
27
18**
22
27
27
5
20
27
27
27
27
27
30
13 7
9 11
19
27
27
16
24
23
3
17
8

11. 6
FIGURE 5. N30FR, N50FA, N40–45FR LABEL POSITIONS AND PAINT
12060
* NAMEPLATE INFORMATION MUST BE COMPLETE
** FASTEN USING WASHERS AND POP–RIVETS
# HYSTER YELLOW IF NOT BLACK OR RED
1. NAMEPLATE
2. NOTICE TO USER
3. UL INSPECTION PLATE (E or EE)
4. CASTER ARTICULATION WARNING
5. KNOB, PUSH BUTTON AND LABEL WITHOUT S–S
6. KNOB, ROCKER SWITCH AND LABEL WITH S–S
7. LIFT/LOWER LABEL
8. FORWARD/REVERSE LABEL
9. 28 mm (1.10 in)
10. 33 mm (1.30 in)
11. 2.3 mm (0.09 in)
12. 13 mm (0.50 in)
13. WARNING FOR SAFETY
14. PATENT LABEL
15. DRIVE WHEEL ARTICULATION WARNING
16. 279 mm (11.00 in)
17. 6 mm (0.25 in)
18. 102 mm (4.00 in)
19. 420 mm (16.50 in)
20. 216 mm (8.50 in)
*
**
21. 330 mm (13.00 in)
22. 64 mm (2.50 in)
23. 51 mm (2.00 in)
24. CASE, OPERATING MANUAL**
25. IMPACT TEST PLATE, OVERHEAD GUARD
26. MAST SAFETY LABEL (2)
27. PINCH POINT WARNING LABEL (2)
28. LOAD BACKREST WARNING LABEL
29. FIRE SAFETY, UL (2)
30. MODEL LABEL (2)
31. DEALER LABEL (2)
32. 267 mm (10.50 in)
33. 1474 mm (58.00 in)
34. 76 mm (3.00 in)
35. HYSTER BLACK#
36. HYSTER RED#
24**
36
3
15
2
1*
3
5
5
9 10
3
1211
32
17
23
12
17
16
18
20
23
22
1
6 7 8
2930
4
24**
31
35
35
13
25
27
26
2814
19
21
33
34
35
35 35
35