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Hyster MAST W25-30ZA2 User Manual

Hyster MAST W25-30ZA2
52 pages
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MAST
REPAIR
N50FA; N40-
45FR [D138]; N30XMH,
N30XMH
2
[C2
10]; N25XMDR3, N30-
40XMR3 [C47
0]; N50XMA3 [C471];
N30XMDR3,
N45XMR3 [G138]; N30XMXDR3,
N45XMXR3 [
B264]; W30-40ZA [B453];
W20-30ZR
[B455]; W25-30-40ZC [B454];
W25-30ZA
2
[B495]; V30ZMD [D210/E210]
P
ART NO. 897447 4000 SRM 482

Table of Contents

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Hyster MAST W25-30ZA2 Specifications

General IconGeneral
Load Capacity2500-3000 kg
Load Capacity (lbs)5500-6600 lbs
Power TypeElectric
ModelW25-30ZA2
Battery Voltage48V
Lift Speed (loaded/unloaded)0.4/0.5 m/s
Lowering Speed (loaded/unloaded)0.5/0.6 m/s

Summary

MAST REPAIR

Mast Repair Model Identification

Lists specific Hyster lift truck models covered by this manual.

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

General Safety Precautions

Outlines essential safety rules for maintenance and repair procedures.

Warning and Caution Symbols

Defines symbols and terms used to indicate hazard levels and precautions.

General Mast Information

Mast Assembly Overview

Describes the scope of the manual, covering two-stage and three-stage masts.

Safety Procedures When Working Near Mast

Mast Safety Procedures

Details critical safety steps and warnings for working near mast components.

Installing Safety Chains

Provides step-by-step instructions for securing mast components with safety chains.

Mast Components and Systems

Load Backrest Extension Removal and Installation

Procedures for removing and installing the load backrest extension.

Carriage Assembly Removal and Installation

Steps for removing and installing the lift truck carriage assembly.

Carriage Load Rollers Removal and Installation

Steps to remove and install load rollers on the carriage.

Side Rollers Disassembly and Assembly

Instructions for disassembling and assembling carriage side rollers.

Fork Replacement

Procedures for replacing forks on the mast carriage.

Two-Stage Mast Assembly Procedures

Two-Stage Mast Assembly Removal

Steps for safely removing a two-stage mast assembly from the lift truck.

Dual-Lift Cylinder Removal and Installation

Steps for removing and installing dual-lift cylinders in the mast.

Single Main-Lift Cylinder Removal and Installation

Procedures for removing and installing single main-lift cylinders.

Inner Mast Assembly Removal and Installation

Steps for removing and installing the inner mast assembly.

Hydraulic Hose Replacement

Instructions for replacing hydraulic hoses in the mast assembly.

Hose and Cable Sheave Replacement

Procedures for replacing hose and cable sheaves.

Two-Stage Lift Chain Removal and Installation

Steps for removing and installing two-stage lift chains.

Load Rollers and Wear Plugs Removal and Installation

Procedures for removing and installing mast load rollers and wear plugs.

Two-Stage Mast Assembly Installation

Steps for installing a fully assembled two-stage mast.

Three-Stage Mast Assembly Procedures

Three-Stage Mast Assembly Removal

Steps for safely removing a three-stage mast assembly from the lift truck.

Specific Model Mast Procedures (N30XMH, etc.)

Procedures specific to certain Hyster mast models.

Free-Lift Cylinder Removal and Installation

Steps for removing and installing the free-lift cylinder.

Standard Main Cylinder Removal and Installation

Procedures for removing and installing standard main lift cylinders.

N30XMH Series Main Cylinder Removal and Installation

Specific instructions for main cylinders on N30XMH series masts.

Inner and Intermediate Mast Assemblies Removal and Installation

Steps for removing and installing inner and intermediate mast weldments.

Hydraulic Hose Replacement (Three-Stage)

Instructions for replacing hydraulic hoses in three-stage masts.

Hose and Cable Sheave Replacement

Procedures for replacing hose and cable sheaves.

Three-Stage Lift Chain Removal and Installation

Steps for removing and installing three-stage lift chains.

Three-Stage Chain Sheave Disassembly and Assembly

Procedures for disassembling and assembling three-stage chain sheaves.

Three-Stage Load Rollers and Wear Plugs Removal and Installation

Steps for removing and installing load rollers and wear plugs on three-stage masts.

Three-Stage Mast Assembly Installation

Procedures for assembling and installing a three-stage mast.

Mast Adjustments and Checks

Mast Operation Check

Steps to check and verify mast assembly operation after service.

Hydraulic System Leaks Check

Procedures for checking the hydraulic system for leaks.

Lift Chains Check

Procedures for inspecting and checking lift chains for wear and damage.

Adjust Mast Wear Plugs

Instructions for adjusting wear plugs on the mast to set clearance.

Adjust Free-Lift Chain (Three-Stage Only)

Procedures for adjusting free-lift chains on three-stage masts.

Adjust Main-Lift Chains

Procedures for adjusting main-lift chains on all masts and three-stage masts.

Adjust Wear Strips

Instructions for checking, replacing, and adjusting mast wear strips.

Carriage Adjustments

Adjust Carriage Wear Plug

Procedures for adjusting wear plugs on the carriage for proper fit.

Adjust Carriage Side Rollers

Steps for adjusting side rollers on the carriage for correct clearance.

Adjust Carriage Thrust Rollers

Procedures for adjusting thrust rollers on the carriage.

Troubleshooting

Common Mast Problems and Solutions

Identifies common mast issues and provides corrective actions.

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