PARTS

MANUAL
ELECTRIC
N30XMDR3, N45XMR3
(G138)

CUSTOMER EDITION

1487039 ©2002 Hyster Company

08/2002
 UNIT CODE G138
08/2002 NORTH AMERICA

SECTIONS

1 FRAME

2 ELECTRICAL SYSTEM

3 DRIVE UNIT

4 STEERING SYSTEM

5 BRAKE/ACCELERATOR SYSTEM

6 HYDRAULIC SYSTEM

7 MAST-THREE STAGE FULL FREE-LIFT

8 CARRIAGE

9 OPTIONS

10 NUMERICAL INDEX

This Parts Manual is divided into 10 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the
pages to the corresponding tab.
 UNIT CODE G138
08/2002 NORTH AMERICA

TABLE OF CONTENTS

DESCRIPTION PAGE

B
BACKREST .......................................................................................................................................................... 9-8
BATTERY CONNECTOR ................................................................................................................................... 2-20
BATTERY TRAY ................................................................................................................................................. 9-16
BRAKE ASSEMBLY ............................................................................................................................................. 5-5
BRAKE PEDAL AND OPERATOR SENSING SWITCH ....................................................................................... 5-8
BRAKE SYSTEM
S/N G138N-1631Z⇒......................................................................................................................................... 5-2

C
CARRIAGE
INNER FRAME ................................................................................................................................................. 8-6
SCISSOR
24 IN. REACH ............................................................................................................................................... 8-2
42 IN. REACH ............................................................................................................................................... 8-4
CASTER ASSEMBLY ........................................................................................................................................... 3-4
CHAINS, PINS, AND ANCHORS
THREE STAGE FULL FREE-LIFT
N45XMR3 - N30XMDR3 STANDARD ......................................................................................................... 7-10
CONTACTOR PANEL
"E" CONSTRUCTION ....................................................................................................................................... 2-6
"EE" CONSTRUCTION..................................................................................................................................... 2-8

D
DECAL AND PLATE LOCATION .......................................................................................................................... 1-8
DOUBLE REACH HYDRAULICS ....................................................................................................................... 6-20
DRIVE UNIT
S/N G138N-1631Z⇒......................................................................................................................................... 3-8
⇒S/N G138N-1631Z......................................................................................................................................... 3-6

E
ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-2
ELECTRICAL COMPONENTS........................................................................................................................... 2-18

F
FORKS
HOOK TYPE
D/B 10/2001⇒............................................................................................................................................... 9-6
⇒D/B 10/2001............................................................................................................................................... 9-4
FREE LIFT CYLINDER
D/B 06/2002⇒ ................................................................................................................................................ 7-18
THREE STAGE FULL FREE-LIFT
N45XMR3 - N30XMDR3 STANDARD
⇒D/B 06/2002 ......................................................................................................................................... 7-16

G
GEAR PUMP ...................................................................................................................................................... 6-14

©2002 HYSTER COMPANY See Service Manual i

for service procedures.
 UNIT CODE G138
NORTH AMERICA 08/2002

TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

H
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-6
HOOD AND COVERS .......................................................................................................................................... 1-2
HYDRAULIC CONTROL VALVE
D/B 05/2002⇒ .................................................................................................................................................. 6-8
⇒D/B 05/2002 .................................................................................................................................................. 6-6
HYDRAULIC MOTOR......................................................................................................................................... 6-16
HYDRAULIC PUMP AND MOTOR..................................................................................................................... 6-12
HYDRAULIC STEER MOTOR
S/N G138N-1631Z⇒....................................................................................................................................... 4-10
⇒S/N G138N-1631Z....................................................................................................................................... 4-12
HYDRAULIC SYSTEM ......................................................................................................................................... 6-2
HYDRAULIC TANK ASSEMBLY......................................................................................................................... 6-10

I
INTEGRAL SIDE-SHIFT ASSEMBLY................................................................................................................. 8-16
INTEGRAL SIDE-SHIFTER CYLINDER ............................................................................................................ 8-12
INTEGRAL TILT ASSEMBLY.............................................................................................................................. 8-14

L
LIFT LIMIT SWITCH
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-21
LIFT PUMP CONTACTOR.................................................................................................................................. 2-16
LIGHT AND FAN ASSEMBLY............................................................................................................................. 9-12

M
MAIN CYLINDER ARRANGEMENT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-12
MAIN FREE-LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-8
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
N45XMR3 - N30XMDR3 STANDARD ......................................................................................................... 7-14
MAST MOUNTED HEADLIGHTS ........................................................................................................................ 9-9
MASTER CYLINDER ......................................................................................................................................... 5-10
MASTER DRIVE UNIT ......................................................................................................................................... 3-2
MULTI-FUNCTION CONTROL HANDLE ........................................................................................................... 2-10

O
OPERATOR GUARD ............................................................................................................................................ 1-6
OUTER, INTERMEDIATE, AND INNER
THREE STAGE FULL FREE-LIFT
N45XMR3 - N30XMDR3 STANDARD ........................................................................................................... 7-2

P
POWER STEER ARRANGEMENT
⇒S/N G138N-1631Z......................................................................................................................................... 4-2
POWER STEER CONTACTOR .......................................................................................................................... 2-12
POWER STEERING ARRANGEMENT
S/N G138N-1631Z⇒......................................................................................................................................... 4-4

ii See Service Manual ©2002 HYSTER COMPANY

for service procedures.
 UNIT CODE G138
08/2002 NORTH AMERICA

TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

R
REACH CYLINDER
24 IN. AND 42 IN. REACH.............................................................................................................................. 8-10
REAR WORKING LIGHT ................................................................................................................................... 9-10

S
SHELF HEIGHT SELECTOR ............................................................................................................................... 9-2
SINGLE REACH HYDRAULICS......................................................................................................................... 6-18
SLAVE CYLINDER ............................................................................................................................................... 5-6
STEER AND AUXILIARY MOTOR
"EE" CONSTRUCTION................................................................................................................................... 4-18
STANDARD
"E" CONSTRUCTION.................................................................................................................................. 4-16
STEER AND AUXILIARY PUMP ........................................................................................................................ 4-20
STEER AND AUXILIARY PUMP AND MOTOR ................................................................................................. 4-14
STEER CONTROL UNIT
S/N G138N-1631Z⇒......................................................................................................................................... 4-8
⇒S/N G138N-1631Z......................................................................................................................................... 4-6

T
TANDEM LOAD WHEEL .................................................................................................................................... 9-14
TRACTION CONTACTOR .................................................................................................................................. 2-14
TRACTION MOTOR
S/N G138N-1631Z⇒....................................................................................................................................... 3-12
⇒S/N G138N-1631Z....................................................................................................................................... 3-10

©2002 HYSTER COMPANY See Service Manual iii

for service procedures.
 UNIT CODE G138
NORTH AMERICA 08/2002

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

TERM DEFINITION TERM DEFINITION

Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment
MSTS Microprocessor Spark Timing System
D/B Date Break
NPT National Pipe Threads
dbA Decibel "A" Scale
O/S Oversize
DE Drive End
PTO Power Take Off
ECH Empty Container Handler
RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High
S/N Serial Number
Stacking
TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High
Stacking UL Type D Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High UL Type DS Diesel-Powered Safety Rating
Stacking UL Type E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating
Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking
UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module
UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice
UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable
U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPROM Electrically Programmable Read Only
Memory V Volts

iv See Service Manual ©2002 HYSTER COMPANY

for service procedures.