MAST

DESCRIPTION
N30-40XMR2, N25XMDR2 [C470]; N50XMA2 [C471];
N30XMDR2, N45XMR2 [G138]; N30XMXDR3,
N45XMXR3 [B264]; W30-40ZA [B454]; W20-30ZR [B455];
W25-30-40ZC [B453]; W20-30-40XTA [A453]; W20-30-
40XTC [A454]; W2030XTR [A455]; N30XMH, N30XMH 2 [C210];
V30ZMD [D210/E210]; W25-30ZA 2 [B495]

PART NO. 897445 4000 SRM 480

 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 Maintenance section.

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use 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 hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mast Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Mast Weldments ................................................................................................................................................ 3
Carriages ............................................................................................................................................................ 4
Two-Stage Mast.................................................................................................................................................. 7
Description ..................................................................................................................................................... 7
Operation ....................................................................................................................................................... 12
Three-Stage Mast............................................................................................................................................... 12
Description ..................................................................................................................................................... 12
Operation ....................................................................................................................................................... 15

This section is for the following models:

N30-40XMR2, N25XMDR2 [C470];

N50XMA2 [C471];
N30XMDR2, N45XMR2 [G138];
N30XMXDR3, N45XMXR3 [B264];
W30-40ZA [B454];
W20-30ZR [B455];
W25-30-40ZC [B453];
W20-30-40XTA [A453];
W20-30-40XTC [A454];
W2030XTR [A455];
N30XMH, N30XMH 2 [C210];
V30ZMD [D210/E210];
W25-30ZA 2 [B495]

©2008 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
4000 SRM 480 General

General
This section has the description and the operation for
the two-stage and the three-stage mast assemblies.

The mast unit code and serial number are stamped

on the outside of the right-hand outer weldment of
the mast. See Figure 1.

The repair procedures for the mast assemblies are

located in the section Mast, Repair 4000 SRM 482.
The information for the lift cylinders is located in the
section Lift Cylinders 4000 SRM 481. The informa-
tion for the reach carriages is in the section Reach
Carriages 4500 SRM 971.

A mast is used to raise a load vertically. Hydraulic

cylinders are installed vertically on the masts.
The cylinders raise and lower the vertical frames
or weldments and the reach or straddle carriage.
These mast assemblies can be either two-stage or
three-stage masts. See Figure 2. Each type of mast
is described separately in this section.

The mast assemblies include the following parts:

• Outer mast weldment
• Inner mast weldment
• Intermediate mast weldment (three-stage only)
• Main cylinder(s)
• Free-lift cylinder (three-stage only)
• Load rollers
• Lift chains and sheaves 1. OUTER WELDMENT (RIGHT SIDE)
• Sheave support (three-stage only) 2. INFORMATION LOCATION
3. FORKS AND CARRIAGE
• Hydraulic tubing, hoses, and sheaves
• Electrical cable for the reach carriage Figure 1. Mast Information

1
General 4000 SRM 480

NOTE: DEPENDING ON MODEL, MASTS MAY DIFFER.

Figure 2. Two-Stage Mast

2
4000 SRM 480
Mast Weldments
The main vertical frames of a mast assembly are
called weldments. These weldments are assembled
so they telescope. The inner mast weldment moves
inside the outer mast weldment. The carriage moves
inside the inner mast weldment. On a three-stage
mast, there is an intermediate mast weldment lo-
cated between the inner mast and outer mast weld-
ments. The outer mast weldment is attached to the
lift truck frame. The outer mast weldment can also
be a support for the overhead guard on certain lift
trucks.
When the telescopic weldments and the carriage lift
a load, forces are put on the mast assembly. To de-
crease friction caused by these forces, load rollers,
wear plugs, side rollers, and thrust rollers are in-
stalled between the moving parts. Wear strips are
also used on certain models. The side rollers and load
rollers, with the wear plugs, travel along the chan-
nels within the weldments. The thrust rollers and
wear strips travel on the outside edges of the weld-
ments.
Mast Weldments
The two-stage LFL (Limited Free Lift) masts gener-
ally have two main-lift cylinders installed vertically
on the outer weldment that raise the inner mast
weldment and chains attached to the weldments
that simultaneously raise the carriage. Two-stage
FFL (Full Free Lift) masts also have a free-lift
cylinder centered in the inner weldment which
activates first to pull the chains that raise the car-
riage. However, models W25/30ZA 2, W30/40ZA, and
W25/30/40ZC lift trucks with two-stage LFL have
only one main lift cylinder centered in the inner
weldment which pulls chain that raise both the
inner weldment and the carriage.
The three-stage FFL models have two main lift
cylinders installed vertically on the outer weldment
that raise the intermediate mast weldment and lift
chains attached to the weldments which raise the
inner mast weldment simultaneously. Three-stage
FFL masts also have a free-lift cylinder centered in
the inner weldment which activates first to pull the
chains that raise the carriage.
3
Carriages 4000 SRM 480

Carriages
The standard straddle carriage is a separate assem- sits on forks attached to the carriage. The forks are
bly that only moves vertically within the channels held in place by lock pins. See Figure 5.
of the inner mast weldment. See Figure 3. Side
rollers and load rollers with wear plugs, attached to NOTE: Some lift trucks have reach carriages that ex-
the straddle carriage, travel in the channels of the tend and retract. These carriages have a separate
inner mast weldment. Thrust rollers travel on the fork carriage as part of the carriage assembly.
outer edges of the mast weldment. These rollers de-
See the section Reach Carriages 4500 SRM 971 for
crease friction and keep the carriage aligned between
information on the reach carriages.
the inner channels. The load backrest extension is
attached to this fork carriage. See Figure 4. The load

1. CARRIAGE FRAME 11. WEAR PLUG

2. SCREW 12. SHIM
3. NUT 13. SIDE ROLLER
4. STUD 14. LOCKWASHER
5. THRUST ROLLER 15. SCREW
6. WASHER 16. GREASE FITTING
7. SNAP RING 17. SNAP RING
8. GREASE FITTING 18. CHAIN ANCHOR
9. LOAD ROLLER 19. COTTER PIN
10. SNAP RING 20. FORK REMOVAL NOTCH

Figure 3. Carriage

4
4000 SRM 480 Carriages

1. FORKS
2. CARRIAGE FRAME
3. LOAD BACKREST
4. LATCH ASSEMBLY (KNOB TYPE SHOWN)

Figure 4. Forks and Load Backrest

5
Carriages 4000 SRM 480

A. LEVER TYPE LOCK PIN ASSEMBLY (OLD B. KNOB TYPE LOCK PIN ASSEMBLY (NEW
STYLE) STYLE)
1. FORK 6. WEDGE
2. LOCK PIN 7. KNOB
3. SPRING 8. LEVER
4. WASHER 9. COTTER PIN
5. WASHER 10. LOCK PIN ASSEMBLY

Figure 5. Lock Pin Assembly

6
4000 SRM 480
Two-Stage Mast
DESCRIPTION
The two-stage mast assembly has two weldments.
See Figure 6 or Figure 7. They are the inner mast
weldment and the outer mast weldment. The in-
ner mast weldment has a load roller on each bottom
channel section. The load rollers travel along the
channels within the outer mast weldment. The outer
mast weldment has one load roller located at the top
of the inside of each channel. The outside channels of
the inner mast weldment travel on these load rollers
during channel movement. The load rollers permit
them to control the forces during movement of the
mast. These forces are from the front, back, and
sides. Wear strips are also used on some models to
control side forces. The wear strips are installed at
the bottom of the inner mast weldment. The wear
strips are on the outer edge of the channels of the in-
ner mast weldment. Shims are used under the wear
strips to keep the correct clearance between the weld-
ments.
For masts with dual lift cylinders, the two-stage mast
assembly has two single-stage main cylinders. Both
cylinders are installed vertically behind each chan-
nel of the outer mast weldment. See Figure 8. The
base of the main cylinders fit into pins that are lo-
cated in the bottom crossmember of the outer mast
weldment. Lock plates are used to position the main
cylinders. These lock plates are bolted to the lower
end of each outer mast channel. Removable supports
for the main cylinders are bolted to the chain anchor
weldments. The rods of each main cylinder are fas-
tened to the top crossmember of the inner mast weld-
ment with a snap ring. The inner mast weldment ex-
tends from the outer mast weldment as the cylinder
rods extend.
Two-Stage Mast
For masts with a single lift cylinder, the two-stage
mast assembly has one single-stage main cylinder.
This main cylinder is installed vertically in the cen-
ter of the mast weldments. The base of the main
cylinder is bolted to the center of the bottom cross-
member of the outer mast weldment. The cylinder
rod is bolted to the center of the top crossmember of
the inner mast weldment. The main cylinder has the
chain anchors welded to it. See Figure 9. The inner
mast weldment extends from the outer mast weld-
ment as the cylinder rods extend.
For masts with dual lift cylinders, two lift chains con-
trol the movement of the carriage. See Figure 10.
The chains fasten to the chain anchor supports that
are welded on each channel of the outer mast weld-
ment. The chains go up and over the chain sheaves
and then connect to the carriage. The chain sheaves
are installed at the inside of the channels near the
top of the inner mast weldment. The chains transfer
the force from the main cylinders to the carriage.
For masts with a single lift cylinder, two lift chains
control the movement of the carriage. See Figure 11.
The chains fasten to the chain anchor supports that
are welded on the single cylinder. The chains go
up and over the chain sheaves and then connect to
the carriage. The chain sheaves are installed to the
bracket above the single cylinder. The chains trans-
fer the force from the main cylinder to the carriage.
7
Two-Stage Mast 4000 SRM 480

1. INNER WELDMENT 7. LIFT TRUCK FRAME 13. SHIM

2. CHAIN SHEAVE 8. HYDRAULIC HOSE (LIFT) 14. MOUNT CAPSCREWS FOR
3. RETAINER 9. FLOW REGULATOR HOUSING MAST ASSEMBLY
4. LOAD ROLLER 10. HYDRAULIC TUBE (LIFT) 15. REGULATOR MOUNT PLATE
5. LIFT CYLINDER 11. LOCK PLATE 16. LOCATING DOWEL PIN
6. OUTER WELDMENT 12. NUTPLATE 17. WEAR STRIP

Figure 6. Two-Stage Dual Lift Cylinders-Mast Assembly Components

8
4000 SRM 480 Two-Stage Mast

Figure 7. Two-Stage Single Lift Cylinder-Mast Assembly Components

9
Two-Stage Mast 4000 SRM 480

Legend for Figure 7

1. INNER WELDMENT 6. LOAD ROLLER
2. OUTER WELDMENT 7. SNAP RING
3. BUSHING 8. PLUG
4. SCREW 9. PIN
5. NUT

1. CAPSCREW
2. WASHER
3. LIFT CYLINDER
4. FITTING
A. BACK VIEW 5. TUBE
6. FITTING
1. LIFT CYLINDER 7. FLOW REGULATOR
2. OUTER WELDMENT 8. HOUSING
3. HYDRAULIC TUBE (LIFT) 9. FITTING
4. REGULATOR MOUNT PLATE 10. CAPSCREW
5. FLOW REGULATOR HOUSING
6. HYDRAULIC HOSE (LIFT) Figure 9. Two-Stage Single Lift Cylinder-
7. ELECTRIC CABLE FOR REACH CARRIAGE Hydraulic Connections
8. HOSES FOR REACH OR SIDESHIFT CARRIAGE

Figure 8. Two-Stage Dual Lift Cylinders-

Hydraulic Connections

10
4000 SRM 480 Two-Stage Mast

1. SNAP RING
2. CAPSCREW AND LOCKWASHER
3. SUPPORT
4. SHAFT
5. SPACER
6. SHEAVE
7. BALL BEARING
8. RETAINING RING
NOTE: REACH CARRIAGE SHOWN. CHAIN AN- 9. WASHER
10. CHAIN
CHOR ON STRADDLE CARRIAGE SIMILAR. 11. COTTER PIN
12. PIN
1. INNER WELDMENT 13. CHAIN ANCHOR
2. CHAIN SHEAVE 14. NUT
3. BEARING 15. LOCKWASHER
4. SNAP RING 16. PIN
5. LIFT CHAIN 17. CHAIN ANCHOR
6. COTTER PIN 18. SNAP RING
7. PIN 19. LUBE FITTING
8. CHAIN ANCHOR 20. COTTER PIN
9. ADJUSTMENT NUTS
10. OUTER WELDMENT
Figure 11. Lift Chains and Sheaves Single Lift
Figure 10. Lift Chains and Sheaves Dual Lift Cylinder
Cylinders

11
Three-Stage Mast
OPERATION
As the rods in the main cylinders extend, they move
the inner mast weldment out of the outer mast weld-
ment. See Figure 12. Since the chain sheaves are
fastened to the inner mast weldment, the force from
the cylinder rods transfer the lifting motion to the
carriage.
A. POSITION 1
1. OUTER WELDMENT
2. LIFT CYLINDERS (1 OR 2)
3. LIFT CHAINS (2)
Figure 12. Two-Stage Assembly Operation
Three-Stage Mast
DESCRIPTION
The three-stage mast assembly has three weldments.
See Figure 13. There is an outer mast weldment,
an intermediate mast weldment, and an inner mast
weldment. The weldments are telescopic and have a
load roller and wear strip (similar to the two-stage
mast) or wear plug arrangement. The three-stage
masts have three hydraulic cylinders: the free-lift
cylinder and two main cylinders. See Figure 14 and
12
4000 SRM 480
The weight of the load, carriage, and inner mast
weldment makes the rods retract to push the oil
from the cylinders. The oil flows from the cylinders
through the flow control valves, located at the base
of the cylinders and in the manifold. It then flows
to the hydraulic tank. Each main cylinder has a
lowering control valve installed in its base. These
lowering control valves control the lowering speed of
a load if a hydraulic line breaks.
B. POSITION 2
4. INNER WELDMENT
5. CHAIN SHEAVE (2)
6. CARRIAGE
Figure 15. They are all single-stage lift cylinders.
The free-lift cylinder fastens to the inner mast weld-
ment and controls the movement of the carriage. The
free-lift chains transfer force from the free-lift cylin-
der to the carriage. The two main cylinders fasten
to the intermediate mast weldment and control the
movement of the intermediate mast. The two outer
lift chains transfer the force from the main cylinders
to the inner mast weldment.
4000 SRM 480 Three-Stage Mast

Figure 13. Three-Stage Mast Assembly Components

13
Three-Stage Mast 4000 SRM 480

Legend for Figure 13

1. INNER WELDMENT 7. FREE-LIFT CHAIN
2. INTERMEDIATE WELDMENT 8. CHAIN ANCHOR
3. OUTER WELDMENT 9. CLAMP
4. FREE-LIFT CYLINDER 10. CHAIN SHEAVE ASSEMBLY (RH)
5. MAIN LIFT CYLINDER A. CHAIN SHEAVE
A. LOCK PLATE B. BALL BEARING
B. RETAINER C. SNAP RING
6. SHEAVE SUPPORT ASSEMBLY 11. MAIN LIFT CHAIN
A. SPACER 12. LOAD ROLLER
B. SNAP RING
C. BALL BEARING
D. CHAIN SHEAVE
E. SPACER
F. SHAFT

A. REAR VIEW HOSE ROUTING - LIFT

1. FREE-LIFT HOSE SHEAVE
2. FREE-LIFT CYLINDER
3. FLOW REGULATOR HOUSING
4. HYDRAULIC TUBE (MAIN LIFT) A. REAR VIEW HOSE ROUTING - LIFT
5. HYDRAULIC HOSE (MAIN LIFT)
6. TO TRUCK CONTROL VALVE 1. FREE-LIFT HOSE SHEAVE
2. FREE-LIFT CYLINDER
Figure 14. Three-Stage Mast Hydraulic 3. FLOW REGULATOR HOUSING
4. TO TRUCK CONTROL VALVE
Connections, Straddle Carriage 5. HYDRAULIC TUBE (MAIN LIFT)
6. HYDRAULIC HOSE (MAIN LIFT)

Figure 15. Three-Stage Mast Hydraulic

Connections, Reach Carriage

14
4000 SRM 480
Movement of the carriage that does not cause an in-
crease in the height of the mast assembly is free-lift.
The three-stage mast has free-lift. The free-lift cylin-
der raises the carriage to the top of the mast as-
sembly before the intermediate and inner mast weld-
ments move.
The free-lift cylinder is designed so that the cylinder
is positioned vertically in a locating hole in the lower
crossmember of the inner mast weldment. A free-lift
sheave support is positioned on the rod of the free-lift
cylinder. The free-lift sheave support has sheaves for
the hoist chain, hydraulic hose, and electrical cable
(reach carriage only).
The free-lift chain fastens to a bracket welded to the
rear of the free-lift cylinder. The chain then goes
through the sheave support and fastens to the car-
riage. When the free-lift cylinder rod extends, the
carriage travels at two times the speed of the rod.
The two main cylinders control the movement of the
intermediate mast weldment. The cylinders are in-
stalled vertically behind the channels of the weld-
ments. The cylinders fasten to the outer mast weld-
ment at the back of each channel. The base of each
cylinder is located by a pin installed in the lower
crossmember bracket of the outer mast weldment.
Removable supports for the main cylinder are bolted
to the chain anchor weldments. The rods of each
main cylinder are fastened to the top crossmember
of the intermediate mast weldment with snap rings.
The hoist chains fasten to the anchors near the
top rear of the outer mast weldment. The chains
go over the sheaves at the top of the intermediate
mast weldment. The other end of the chains fasten
to the chain anchors at the bottom of the inner
mast weldment. When the main cylinders raise the
intermediate mast weldment, the chains raise the
inner mast weldment, the free-lift cylinder, and the
carriage.
Three-Stage Mast
OPERATION
The three-stage mast operates in two phases. See
Figure 16. First, the free-lift cylinder extends and
lifts the carriage to the top of the mast assembly
at two times the speed of the free-lift cylinder rod
speed. When the free-lift cylinder reaches the end of
its stroke, the main cylinders begin to extend. The
main cylinders raise the intermediate mast weld-
ment. Since the hoist chains go over the sheaves
of the intermediate mast weldment, the inner mast
weldment also raises. The inner mast weldment
rises at two times the speed of the intermediate
mast weldment.
The three main cylinders are connected hydraulically
in parallel. When the LIFT function begins, the pres-
sure of the oil is increased in all the main cylinders.
The free-lift cylinder raises the weight of the car-
riage and the load on the forks. The main cylinders
must raise the carriage, the load on the forks, plus
the weight of the intermediate and inner mast weld-
ments. It takes less force to extend the rod of the
free-lift cylinder, so this rod and the carriage will
move first.
When the LOWER function begins, the oil from the
main cylinders returns to the hydraulic tank. The
main cylinders lower first since they have a greater
load. When the main cylinder rods have fully re-
tracted, the free-lift rod retracts. All the oil from
the cylinders returns to the hydraulic tank through
the flow control valves, located in the manifold at-
tached to the bottom of the outer mast weldment.
Each cylinder has a lowering control valve installed
in its base. These lowering control valves control the
lowering speed of a load if a hydraulic line breaks.
15
Three-Stage Mast 4000 SRM 480

A. LOWERED POSITION B. RAISED POSITION

1. OUTER WELDMENT 6. FREE-LIFT CYLINDER
2. MAIN LIFT CYLINDERS (2) 7. INNER WELDMENT
3. MAIN LIFT CHAINS (2) 8. FREE-LIFT CHAIN (2)
4. INTERMEDIATE WELDMENT 9. CARRIAGE
5. CHAIN SHEAVE (2)

Figure 16. Three-Stage Mast Assembly Operation

16
 TECHNICAL PUBLICATIONS

4000 SRM 480 4/08 (11/06)(5/04)(4/03)(5/98)(4/97)(1/96)(7/95)(6/92) Printed in U.S.A.