MAST

DESCRIPTION
N35ZDR, N45ZR [C264]; N35ZDR2, N45ZR2 [D264];
N30ZDR, N35-40ZR [D470]; N35-40ZR2, N30ZDR2 [E470];
N30ZDRS, N35-40ZRS [A265];
N35-40ZRS2, N30ZDRS2 [B265]

PART NO. 1590945 4000 SRM 1194

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.

• 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
Safety Procedures When Working Near Mast.................................................................................................. 3
Mast Weldments ................................................................................................................................................ 4
Reach Carriage Assembly.................................................................................................................................. 4
Three-Stage Mast............................................................................................................................................... 6
Description ..................................................................................................................................................... 6
Operation ....................................................................................................................................................... 7

This section is for the following models:

N35ZDR, N45ZR [C264];

N35ZDR2, N45ZR2 [D264];
N30ZDR, N35-40ZR [D470];
N35-40ZR2, N30ZDR2 [E470];
N30ZDRS, N35-40ZRS [A265];
N35-40ZRS2, N30ZDRS2 [B265]

©2013 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
4000 SRM 1194 General

General
This section contains the description and operation The mast assemblies include the following parts:
for three-stage mast assemblies. • Outer Mast Weldment
• Intermediate Mast Weldment
Masts can be identified by unit codes and serial num- • Inner Mast Weldment
bers which are stamped on the outside of the right- • Main Lift Cylinders
side, outer weldment of the mast. • Free-Lift Cylinder
• Load Rollers
The repair procedures for the mast assemblies and
• Lift Chains and Sheaves
their components are outlined in the sections Mast,
• Sheave Support
Repair 4000 SRM 1195, Lift Cylinders 4000 SRM
• Hydraulic Tubing, Hoses, and Sheaves
481, and Reach Carriages 4500 SRM 1196.
• Wiring Harness for the Reach Carriage
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 weld-
ments and the reach carriage assembly. Mast assem-
blies used on these model lift trucks are three-stage
masts. See Figure 1.

1
General 4000 SRM 1194

Figure 1. Mast

2
4000 SRM 1194 Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast

WARNING
All chains, ropes, and lifting equipment MUST
be fully examined by qualified personnel at
least once a year or more at frequent intervals
according to the local conditions of use.
WARNING
Perform the following steps from the side of the
mast using a ladder. Never stand under the car-
riage until safety chains are installed.
1. Remove forks from carriage if possible.

WARNING 2. Raise mast to align the crossmembers of the in-

Mast parts are heavy and may shift. Distances
between parts are small. Serious injury can re-
sult if part of the body is hit by parts of the mast
or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure the power is off and the key
is removed. Attach a DO NOT OPERATE tag
to the control handle.
• DO NOT make repairs or adjustments unless
you have been properly trained and autho-
rized to do so. Repairs and adjustments must
be performed by trained service technicians.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• Move the truck to a safe location with room to
raise the mast if necessary. Block the wheels
of the truck to prevent movement.
termediate mast weldment with a crossmember
on outer weldment.
3. Wrap a safety chain, 9.5 mm (3/8 in.) minimum
size, around crossmembers of inner and outer
weldment. Secure it in place. See Figure 2.
4. Lower mast until safety chain stops mast. Lower
the mast until all components of the mast that
can move are completely lowered. Make sure
there is no movement of mast.
5. Turn key switch to the OFF position, disconnect
the battery, and attach a DO NOT OPERATE
tag to the control handle.
6. Wrap a second safety chain, 9.5 mm (3/8 in.) min-
imum size, around crossmembers of intermedi-
ate and outer weldments. Secure it in place as
an additional precaution.

The forks may be difficult to see when the mast is

raised. Be careful not to hit your head when working
around raised forks. Also, be careful not to trip over
forks on or near the floor. If possible, remove forks
from carriage before safety chaining the mast.

WHEN WORKING NEAR THE MAST, ALWAYS:

• Lower the mast and carriage completely. Make
sure there is no movement in the mast. Make sure
all parts of the mast that can move are fully low-
ered.

OR

• If the mast must be in a raised position for re-

pairs, install a safety chain around the top or mid-
dle crossmember of the outer weldment and the
crossmember of the inner weldment to secure the 1. OUTER MAST WELDMENT
mast. 2. INNER MAST LOWER CROSSMEMBER
3. SAFETY CHAIN
4. CARRIAGE CROSSMEMEBER

Figure 2. Safety Chain the Mast

3
Reach Carriage Assembly
NOTE: The mast operator guard MUST be removed
to install safety chain. Remove safety chain and in-
stall guard AFTER repairs are complete.
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 intermediate mast weldment. The car-
riage moves inside the inner mast weldment. The
outer mast weldment is attached to the lift truck
frame. The outer mast weldment is a support for the
overhead guard.
When the telescopic weldments and the carriage
lift a load, forces are put on the mast assembly.
To decrease friction caused by these forces, load
rollers, wear plugs, side rollers, and thrust rollers
Reach Carriage Assembly
Reach carriages are used to extend the forks of the
carriage beyond the ends of the base arms. There are
two types of reach carriages. There is a single-reach
carriage with one set of scissor arms. The other car-
riage has two sets of scissor arms for double reach.
See Figure 3. The rear and front frame assemblies
are connected by a scissor linkage. The top of the scis-
sor arm weldment is fastened to the top of the rear
frame by pins located within the rear frame assem-
bly. The top of each scissor arm at the front frame is
fastened by pins located at the top of the front frame
4
4000 SRM 1194
are installed between the moving parts. Wear strips
are used on these models. The side rollers and
load rollers, with the wear plugs, travel along the
channels within the weldments. The thrust rollers
and wear strips travel on the outside edges of the
weldments.
The three-stage masts have two main cylinders that
raise the intermediate weldment, with lift chains
raising the inner mast weldment, free-lift cylinder,
and carriage. The free-lift cylinder raises lift chains
that lift the carriage.
assembly. On double reach units, the ends of each
set of scissor arms and scissor arm weldments are
fastened together by studs with bushings. The bush-
ings protect the studs from wear as the arms pivot.
Large bearings at the center pivot of each scissor
arm assembly allow the linkage to extend and retract
smoothly. The forks and load backrest are mounted
to the fork carriage which attaches to the top of the
front frame assembly by pins. The forks hang on the
fork carriage and are held in position with lock pins.
See Figure 4.
4000 SRM 1194 Reach Carriage Assembly

A. SINGLE-REACH CARRIAGE B. DOUBLE-REACH CARRIAGE

1. FORK CARRIAGE 6. FRONT FRAME ASSEMBLY
2. TILT CYLINDER 7. FRONT SELECTOR VALVE
3. REAR FRAME ASSEMBLY 8. VALVE COVER PLATE
4. REAR SELECTOR VALVE 9. HOSE AND WIRING GUIDE
5. SCISSOR ARMS 10. REACH CYLINDER

Figure 3. Reach Carriage Assembly (Major Components)

5
Three-Stage Mast
1. FORK 4. SPRING
2. KNOB 5. PIN
3. LOCK PIN
Figure 4. Forks and Lock Pin Assembly
Three-Stage Mast
DESCRIPTION
The three-stage mast assembly consists of three pri-
mary mast weldments. There is an outer, an interme-
diate, and an inner mast weldment. The weldments
are telescopic and have load rollers and wear strips
or wear plug arrangements. The three-stage masts
have three hydraulic cylinders: the free-lift cylinder
and two main cylinders. See Figure 5. They are all
single-stage lift cylinders. The free-lift cylinder fas-
tens to the inner mast weldment and controls the
movement of the carriage. The free-lift chains trans-
fer force from the free-lift cylinder to the carriage.
The two main cylinders fasten to the intermediate
mast weldment and control the movement of the in-
termediate mast. The two outer lift chains transfer
the force from the main cylinders to the inner mast
weldment.
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 positioned vertically between
the channels of the inner mast weldment. A free-lift
sheave support is positioned on the rod of the free-lift
cylinder and the lower end is locked in position on
the bottom crossmember of the frame. The free-lift
6
4000 SRM 1194
A tilt cylinder tilts the forks by pushing the bottom of
the front frame out. Each carriage is also available
with the optional sideshift function.
NOTE: The reach assembly can be removed from the
mast assembly with the load backrest and forks at-
tached. The three-stage mast assemblies can also be
removed with the reach assembly installed. Perform
only those procedures necessary for repair. See the
section Reach Carriages 4500 SRM 1196.
sheave support also has sheaves for the hoist chain,
hydraulic hose, and electrical cable.
The free-lift chain fastens to a chain anchor on the
inner mast crossmember or to a bracket welded to
the rear of the free-lift cylinder (depending on mast
model). The chain then goes through the sheave sup-
port and fastens to the rear frame of the reach assem-
bly. When the free-lift cylinder rod extends, the reach
assembly rises 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 outer
mast weldments. The cylinders fasten to the outer
mast weldment 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 cylin-
der are bolted to the chain anchor weldments or the
crossmember of the outer mast weldments (depend-
ing on mast model. The rods of each main cylinder
are fastened to the top crossmember of the interme-
diate mast weldment with snap rings.
The lift 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 in-
termediate mast weldment, the chains raise the
4000 SRM 1194 Three-Stage Mast

inner mast weldment, the free-lift cylinder, and the

carriage.

OPERATION
The three-stage mast operates in two phases. See
Figure 6. 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. 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.

1. MAIN LIFT CYLINDERS

2. FREE-LIFT CYLINDER
3. TO TRUCK CONTROL VALVE
4. FLOW REGULATOR HOUSING
5. FREE-LIFT HOSE SHEAVE
6. HYDRAULIC TUBE (MAIN LIFT)
7. HYDRAULIC HOSE (MAIN LIFT)

Figure 5. Mast Hydraulic Connections

7
Three-Stage Mast 4000 SRM 1194

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 6. Three-Stage Mast Assembly Operation

8
 TECHNICAL PUBLICATIONS

4000 SRM 1194 7/13 (11/06)(10/06) Printed in U.S.A.