INTRODUCTION
GENERAL
This section contains a description and service proce-
dures for the parts of the frame for the E30FR-24,
E30FR, E35FR, E40FR, E45FR and E50FR series of
electric lift trucks. These parts include the overhead
guard, access panels, battery compartment tray and la-
bel positions.
DESCRIPTION
The frame is a single weldment. The frame provides
mounting for the overhead guard, mast, steer fork as-
sembly, traction motor drive assembly and the hydraulic
tank. The battery compartment is equipped with a slid-
ing roller tray for battery removal. An access door is lo-
cated on the rear of the lift truck to allow for inspection
and maintenance of the hydraulic lift pump and the pow-
er steering mechanism. An access panel in front of the
operator’s compartment allows for maintenance inspec-
tion of the motor controller, electrical components and
the hydraulic control valve. The hydraulic tank is lo-
cated on the front of the electric lift truck.
9
2 1. OVERHEAD GUARD
3 6. DRIVE WHEEL
8 4
5
FIGURE 1 – COMPONENTS MOUNTED ON THE FRAME
1
There are three standard frame sizes used for these lift
trucks. Frame size is determined by the size of the bat-
tery compartment. The E30FR-24 has the smallest bat-
tery compartment. The battery compartment on the
standard E30FR and E35FR frames is 5 mm (0.2 inch)
shorter but 16 mm (0.63 inch) wider than the E30FR-24.
The battery compartment on the standard E40FR,
E45FR and E50FR frames is slightly wider than the
E30-35FR but slightly narrower than the E30FR-24 and
133.4 mm (5.25 inches) higher than the E30FR-24 and
117.4 mm (4.62 inches) higher than the E30-35FR se-
ries frames.
For extra stability, all lift trucks with a three stage full
free lift mast capable of lifting a load above 6248 mm
(246 inches) and all lift trucks with a four stage full free
lift (FFL) mast, have a wide track frame that is 116.8 mm
(4.6 inches) wider than standard.
All models use solid tires. The E30FR-24, E30FR and
E35FR lift trucks come equipped with rubber tires as
standard equipment. The E40FR, E45FR and E50FR lift
trucks come equipped with poly tires as standard
equipment.
2. MAST
3. LOAD BACKREST EXTENSION
4. CARRIAGE
5. FORKS
7. BATTERY
8. STEER WHEEL
(NOT SHOWN IN THIS VIEW)
9. OPERATOR’S COMPARTMENT
 DISASSEMBLY AND ASSEMBLY
OVERHEAD GUARD
Removal
(See FIGURE 2)
1. Lower the forks completely.
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.


To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery and separate the battery con-
nector.
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Remove the front cover and the top cover (refer to
FRONT COVER–REMOVAL and TOP COVER–RE-
MOVAL procedures in this section).
8. Attach a lifting device to the top of the overhead
guard and take up any slack.
NOTE: If the truck is equipped with a flashing light
or work lights attached to the overhead guard, discon-
nect the two-pin connector (at the rear post for a flashing
light; at the front for work lights) and remove any wire
ties attaching the wires to the truck.


The overhead guard assembly is heavy. Be sure that
all lifting devices (hoists, cables, chains, slings, etc.)
are suitable and of adequate capacity to lift the over-
head guard assembly.
9. Remove the two bolts securing the overhead guard
to the front of the truck.
10. Remove the four bolts securing the rear post of the
overhead guard to the rear frame of the truck.
CAUTION
When removing the overhead guard, do not allow
the posts to swing and damage any components on
the lift truck.
11. Using the lifting device, carefully lift the overhead
guard straight up and away from the truck. It may be
necessary to tap the front crossbar of the overhead guard
with a rubber mallet to free the overhead guard from the
frame.
Installation
NOTE: If the truck is equipped with work lights or a
flashing light attached to the overhead guard, special
care should be used when installing the overhead guard
to avoid damaging the wiring.
1. Lower the overhead guard assembly into position
on the truck.
NOTE: The front crossbar of the overhead guard rests
on supports on the inner surface of the frame, and is
clamped between the front of the frame and angles
welded within the frame. See FIGURE 2.
2. Attach the front of the overhead guard to the front
frame of the truck. Do not completely tighten the front
attachment bolts at this time.
3. Lower the overhead guard until the bolt holes of the
rear post align with the holes in the rear frame. Attach
the rear post to the truck frame.
4. Tighten the front and rear bolts to 108 N
m (80 lbf
ft) torque.
5. Connect any light harness disconnected during the
removal portion of this procedure.
NOTE: Ensure the top cover front clip is in place on
the front crossbar of the overhead guard.
6. Replace the top cover and front cover (refer to TOP
COVER–INSTALLATION and FRONT COVER–
INSTALLATION procedures in this section).
2
7. Connect the battery. BATTERY RETAINERS

OVERHEAD GUARD REAR POST
Removal
1. Remove the overhead guard from the truck (see
Overhead Guard Removal procedure in this section).
Removal
NOTE: The battery retainers for the lift truck are not
interchangeable from side to side.
1. Lower the forks completely.
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.

2. Remove the rear post for the overhead guard. 


Installation
1. Install the rear post between the two tabs of the
overhead guard. See FIGURE 2. Tighten the lock nut to
remove any excess movement.
2. Install the overhead guard (see OVERHEAD
GUARD–INSTALLATION procedure in this section).
1
2 Installation
To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery by separating the battery
connector.
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Lift the battery retainer straight up until the tabs on
the front of the battery retainer align with the cutouts in
the truck frame.
8. Rotate the front edge of the battery retainer out until
the tabs of the retainer clear the frame of the truck.
9. Move the battery retainer toward the front of the
truck until the rear flange of the battery retainer is free
from the frame of the truck.
1. Insert the rear tabs of the battery retainer into the
slot at the rear of the battery compartment opening.
2. Rotate the front of the battery retainer toward the
truck until the tabs on the front of the battery retainer en-
ter the slots.
3. Lower the battery retainer to its normal position.
NOTE: There should be no more than a 12.5 mm (0.5
inch) gap around the battery in any horizontal direction.
If necessary, install shims to meet this specification.
4. Connect the battery.

1. OVERHEAD GUARD BATTERY ROLLERS

2. REAR POST
Removal
FIGURE 2 – OVERHEAD GUARD ASSEMBLY 1. Lower the forks completely.
3
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.


To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery by separating the battery
connector.
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Remove the battery retainer and the battery..
8. Lift upward on the battery roller to remove the bat-
tery roller assembly from the holder.
9. Slide the washers and plastic roller off the battery
roller shaft.
Installation
1. Slide the plastic battery roller onto the battery roller
shaft and install one flat washer at each end.
2. Align the flats on the end of the shaft vertically
above the slots in the floor of the battery compartment
and lower the assembly into the slots.
3. Install the battery. Install the battery retainer. Con-
nect the battery connector.
FRONT COVER
Removal
(See FIGURE 3)
1. Lower the forks completely.
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.


To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery by separating the battery
connector.
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Locate the two cover latch handles on the front
cover. See FIGURE 3.
8. Gently lift up on the latch handles and pull forward,
away from the front of the truck.
9. Once the top of the cover is released, lift upward on
the cover and remove from the truck.
Installation
1. Place the lower edge of the front cover into the sup-
port channels.
2. Gently press the upper portion of the front cover
into place until the latches click into position.
3. Connect the battery connector.
TOP COVER
Removal
NOTE: The top cover is held in place with six frame-
mounted spring-type retaining clips and one front clip
on the overhead guard crossbar. See FIGURE 3. Nor-
mally this cover does not require any tools to remove.
Care must be used when removing this cover to avoid
possible breakage.
1. Lower the forks completely.
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.


To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery by separating the battery
connector.
4
 1. TOP COVER
2. RIGHT PAD
3. FRONT PAD
4. CONTROL COVER
5. FLOOR MAT
6. FRONT COVER
7. FRONT COVER LATCH

3
2

FIGURE 3 – PADS, COVERS AND FLOOR MAT

5
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Using the finger hole in the tool depression of the
top cover, gently pull up until the first spring clips re-
lease the top cover.
8. As each spring clip on the left side releases the top
cover, move the handhold as close as possible to the next
spring clip. Gently pull up until the cover is released
from all of the spring clips on the left side.
9. To release the right side of the cover, move the bat-
tery disconnect forward, grasp the rear edge of the open-
ing, and gently pull upward.
10. Once the top cover is released from the spring clips,
lift the rear edge of the cover up until it is clear of the rear
leg of the overhead guard. Move the entire cover toward
the rear of the truck until the top cover is free from the
front clip and the overhead guard.
11. Remove the cover from the truck.
Installation
1. Tilt the top cover so that the front edge of the cover
is lower than the rear edge and slide into place on the
truck.
2. Align the cutouts on the front edge of the top cover
with the front posts of the overhead guard. Move the
front edge of the top cover into place, making sure the
front clip is properly in place. Lower the rear of the top
cover into place.
3. Align the cutouts in the lip of the cover with the
spring clips on the truck frame.
4. Press downward at each spring clip until the cover is
secured.
5. Connect the battery.
CONTROL COVER
Removal
1. Lower the forks completely.
2. Move the mast to the full forward position.
3. Turn the key switch to the off “O” position.


To prevent electrical shock and injury, disconnect
the battery, separate the connector and discharge
the capacitor bank before inspecting or repairing
any component.
4. Disconnect the battery and separate the battery con-
nector.
5. Turn the key switch to the “I” position. The operator
display will light and go off. After the display is com-
pletely dark, the capacitor bank is fully discharged.
6. Turn the key switch to the off “O” position.
7. Remove the top cover (see TOP COVER–RE-
MOVAL procedure in this section).
8. Remove the steering tiller.
9. Remove the seven screws securing the control
cover.
10. Lift the control cover over the control handle and re-
move it from the truck.
Installation
1. Place the control cover into position over the con-
trol handle and secure in place.
2. Install the steering tiller.
3. Replace the top cover (see TOP COVER–INSTAL-
LATION procedure in this section).
4. Connect the battery.
OPERATOR COMPARTMENT PADS
Removal
NOTE: The pads in the operator compartment are se-
cured in place with Velcro. When removing the pads,
use care to avoid detaching the Velcro from either the
pad or the frame of the truck. If the Velcro does come
loose use a silicone adhesive to secure the Velcro to ei-
ther the pad or the frame.
1. Grasp the outside edge of the pad and carefully sep-
arate the pad from the mating portion of the Velcro at-
tached to the frame of the truck.
2. Rotate the pad outward until the remainder of the
Velcro release.
3. Remove the pad.
6
Installation
(See FIGURE 3)
1. Align the pad so the Velcro meet.
2. Firmly press the pad into place.
3. Gently pull on the outside edges of the pad to verify
the attachment.
FLOOR MAT/BRAKE PEDAL PAD
NOTE: Normal servicing of the truck does not re-
quire the removal of the floor mat.
Removal
NOTE: The floor mat in the operator compartment
and the brake pedal pad are secured in place with a sili-
cone adhesive. The pads will be damaged when re-
moved. It is recommended that replacement pads be
available prior to removal of the old pads. use a silicone
adhesive to secure the floor mat to the frame or brake
pedal pad to the brake pedal.
1 Using an appropriate scraper, pry up the outside
edge of the pad.
2 Carefully peel the pad away from the floor or brake
pedal.
3 Scrape the floor surface or brake pedal to remove as
much of the old pad material as possible.
4 Clean any remaining residue from the floor of the
operator compartment.
Installation
1 On a properly prepared surface, apply a thin film of
adhesive on either the brake pedal or the floor of the
truck. (Follow the manufacturer’s instructions on the la-
bel of the adhesive.)
2. Align the proper pad with the compartment.
3. Firmly press the pad into position.
4. Allow the adhesive to cure per the manufacturer’s
recommendations.
LABEL REPLACEMENT
(See FIGURE 4)
If the labels or information plates are missing or are
damaged, they must be replaced.
7


Labels that have WARNING or CAUTIONS must be
replaced if they are damaged.
If an mast of a different size or an accessory carriage is
installed, the capacity rating can change. Changes in the
size or number of drive tires will change the capacity rat-
ing. See a HYSTER lift truck dealer for a replacement
nameplate. The nameplate information must be correct
for safety.
NOTE: The nameplate is installed using rivets. The
old rivets must be removed before installing the new
nameplate.


Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow 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 or 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 cor-
ners and edges are tight.
4. Install protective cover with rivets.
PAINTING INSTRUCTIONS


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.
NOTE: Protect all electronic controls and wiring
from heat and moisture produced by steam cleaning or
chemical solvents.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted. Use a solvent for painted
surfaces. Do not use solvent on new paint. Make sure all NOTE: Protect electrical components, wiring and
oil and grease is removed. battery connector contacts from overspray.
2. Use sandpaper to remove the top surface of the paint
and rust from the metal. All metal surfaces where the 3. Protect all surfaces that will not be painted.
paint is removed must be painted. Use a primer. Apply
the primer before applying the final coat of paint.
4. Paint the surfaces. Use the correct paint for Hyster
lift trucks. Follow the directions on the container. See
CAUTION FIGURE 4 for painting instructions.
Do not paint the pads, plastic covers or knobs, cables,
electrical components, safety labels, mast chains and
hoses or controls. 5. Install new safety labels.

8
 TOP VIEW WITH OVERHEAD GUARD REMOVED

1 1.5

8.5
6 9 7
2.31 0.75 0.75

6.5
2.0
19, 20, 21 15
4
2 10
17 12 13
2.0
1.5 0.5 5
1.25 25

6.5
11.25 1.5
4.0
0.75
16 1.5
2.5 5.5
0.25
2.5 10.81

18
SEE VIEW A
REAR VIEW RIGHT SIDE VIEW
1. LABEL, MULTI-FUNCTION HANDLE 14. LABEL, OPERATOR MANUAL BASE
2. LABEL, BATTERY CONNECTOR 15. LABEL, HYSTER YELLOW
3. LABEL, MAST WARNING 16. LABEL, HYSTER BLACK
4. LABEL, BATTERY DISCONNECT 17. LABEL, HYSTER
5. LABEL, PINCH POINT 18. LABEL, MODEL
6. LABEL, MAST WARNING 19. SERIAL PLATE
7. LABEL, OPERATOR WARNING 20. SERIAL PLATE COVER
8. LABEL, COVER, OPERATOR MANUAL 21. RIVETS
9. LABEL, OVERHEAD GUARD 22. OPERATOR MANUAL BASE
10. LABEL, BATTERY SIZE 23. RIVETS
11. LABEL, HYDRAULIC OIL ONLY 24. OPERATOR MANUAL COVER
12. LABEL, NOTICE TO USER 25. LABEL, EE
13. LABEL, LOAD CAPACITY 26. PATENT LABEL

FIGURE 4 – LABELS AND PAINTING SHEET 1 OF 2

9
 2.12 11.0

0.63
14, 22, 23, 24
INSTALL SO THAT THE
COVER OPENS TO 3
THE LEFT 2.37 3

3.5 11
26
1.0
8 0.5
VIEW A 0.5
5

1.0
5

FRONT VIEW WITH MAST REMOVED

THE LIFT TRUCK IS TO BE PAINTED WITH HYSTER YELLOW WITH THE

FOLLOWING EXCEPTIONS.

AREAS NOT TO BE PAINTED: HYSTER RED (HCE-53)

FLOOR MAT FORKS
BRAKE PAD HYSTER BLACK (HCE-51
FRONT AND RIGHT PADS
OPERATOR COMPARTMENT
COVERS
OVERHEAD GUARD
PLASTIC KNOBS
MULTI-FUNCTION HANDLE OVERHEAD GUARD POST
TIRES UPRIGHT AND CARRIAGE
LIFT CHAINS BRAKE PEDAL
SWITCHES STEERING TILLER
NAME AND PATENT PLATES BATTERY DISCONNECT LEVER
GAUGES
HOSES
SAFETY LABELS

FIGURE 4– LABELS AND PAINTING SHEET 2 OF 2

10
 NOTES

11