Hyster AP2.0MS (A280) Parts Manual - PDF DOWNLOAD

AP2.0MS (A280)

4054869 09/2013

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

SECTIONS 1

FRAME/DRIVE UNIT

2

ELECTRICAL SYSTEM

3

STEER HANDLE/BRAKE SYSTEM

4

LIFT LINKAGE AND FORKS

5

HYDRAULIC SYSTEM

6

NUMERICAL INDEX

This Parts Manual is divided into 6 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.

09/2013

UNIT CODE A280 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

B BATTERY STOP ............................................................................................................................................. 1-12 C CASTER STANDARD FRAME ...................................................................................................................................

CASTER FRAME WITH SWIVEL WHEEL ...............................................................................................................................

CASTER WHEEL SWIVEL .......................................................................................................................................................

CASTER WHEEL ASSEMBLY ........................................................................................................................

CONTACTOR ..................................................................................................................................................

CONTROLLER ................................................................................................................................................

CYLINDER ASSEMBLY ..................................................................................................................................

1-22 1-18 1-20 1-24 2-4 2-5 5-5

D DASH PANEL ..................................................................................................................................................

2-6

E ELECTRICAL SYSTEM ...................................................................................................................................

2-2

F FORKS AND BATTERY FRAMES 218 MM BATTERY FRAME ........................................................................................................................

290 MM BATTERY FRAME ........................................................................................................................

4-2 4-4

H HOODS AND COVERS ...................................................................................................................................

HYDRAULIC POWER UNIT ASSEMBLY .......................................................................................................

HYDRAULIC PUMP AND CYLINDER MOUNTING ........................................................................................

HYDRAULIC SYSTEM ....................................................................................................................................

1-2 5-6 5-4 5-2

L LABEL AND PLATE LOCATION ..................................................................................................................... 1-14 LIFT LINKAGE .................................................................................................................................................

4-6 LOAD BACKREST .......................................................................................................................................... 1-16 LOAD WHEELS ...............................................................................................................................................

4-7 TANDEM .....................................................................................................................................................

4-8 M MASTER DRIVE UNIT ATTACHING AND MOUNTING PARTS ..................................................................................................... 1-28 TRANSMISSION ......................................................................................................................................... 1-30 MASTER DRIVE UNIT ASSEMBLY ................................................................................................................ 1-26 O OPERATOR PLATFORM ................................................................................................................................

1-4

P PLATFORM STANDARD .................................................................................................................................................

1-5

©2013 HYSTER COMPANY

See Service Manual for service procedures.

i

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

PLATFORM SUPPORT ...................................................................................................................................

1-6

S SIDE GATES ................................................................................................................................................... 1-10 STEERING ARM .............................................................................................................................................

3-8 SUPPORT SPRING ........................................................................................................................................

1-8 T TILLER ............................................................................................................................................................

TILLER ASSEMBLY ........................................................................................................................................

TILLER HEAD ASSEMBLY .............................................................................................................................

3-6 3-2 3-4

W WIRE HARNESS MAIN ...........................................................................................................................................................

2-8 SIDE GATE JUMPER ................................................................................................................................. 2-11

ii

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: spacer 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 Stacking

S/N

Serial Number

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 Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

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 Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

©2013 HYSTER COMPANY

See Service Manual for service procedures.

iii

UNIT CODE A280 NORTH AMERICA

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HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

iv

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: Use the Numerical Index (Page 6-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

Parts Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (FFigure 10)

7.

8.

Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

©2013 HYSTER COMPANY

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows: → S/N D001H2628 Indicates last serial number affected.

S/N D001H2629 → Indicates the first serial number affected.

S/N D001H1553 ↔ S/N D001H3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: → S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 → Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: → D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 → Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

v

UNIT CODE A280 NORTH AMERICA

09/2013

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

vi

See Service Manual for service procedures.

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

PUBLICATIONS Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS

MANUALS with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

PUBLICATION

HYSTER PART NUMBER

Operating Manual........................................................................................................................ 4054720 Service Manual (Complete)......................................................................................................... 4054855 Parts Manual............................................................................................................................... 4054869

©2013 HYSTER COMPANY

See Service Manual for service procedures.

vii

UNIT CODE A280 NORTH AMERICA

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NOTES

viii

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

1

FRAME/DRIVE UNIT

09/2013

UNIT CODE A280 NORTH AMERICA

SECTION 1 FRAME/DRIVE UNIT DESCRIPTION

PAGE

BATTERY STOP .............................................................................................................................................

CASTER STANDARD FRAME ...................................................................................................................................

CASTER FRAME WITH SWIVEL WHEEL ...............................................................................................................................

CASTER WHEEL SWIVEL .......................................................................................................................................................

CASTER WHEEL ASSEMBLY ........................................................................................................................

HOODS AND COVERS ...................................................................................................................................

LABEL AND PLATE LOCATION .....................................................................................................................

LOAD BACKREST ..........................................................................................................................................

MASTER DRIVE UNIT ATTACHING AND MOUNTING PARTS .....................................................................................................

TRANSMISSION .........................................................................................................................................

MASTER DRIVE UNIT ASSEMBLY ................................................................................................................

OPERATOR PLATFORM ................................................................................................................................

PLATFORM STANDARD .................................................................................................................................................

PLATFORM SUPPORT ...................................................................................................................................

SIDE GATES ...................................................................................................................................................

SUPPORT SPRING ........................................................................................................................................

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-12 1-22 1-18 1-20 1-24 1-2 1-14 1-16 1-28 1-30 1-26 1-4 1-5 1-6 1-10 1-8

1-1

UNIT CODE A280 NORTH AMERICA

09/2013

HOODS AND COVERS (FIGURE 1-1)

1-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

HOODS AND COVERS ITEM 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO. ..... a. . . . .

4046102 296013 320157 ..... .....

2041739 4046103 4617681 4617682 293616 4617680 1527879 4617679 .....

18834 .....

DESCRIPTION

QTY

Frame Weldment (Standard) ..............................................................................

Frame Weldment (Caster) ..................................................................................

Cover (Front) ......................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Logo Plate ...........................................................................................................

Hyster Label ........................................................................................................

Clip ......................................................................................................................

Cover (Top) .........................................................................................................

Cover (Tiller Back) ..............................................................................................

Cover (Tiller) .......................................................................................................

Capscrew ............................................................................................................

Cover (Center Top) .............................................................................................

Capscrew ............................................................................................................

Battery Tray ........................................................................................................

Mount (LH) ..........................................................................................................

Cotter Pin ............................................................................................................

Mount (RH) .........................................................................................................

1 1 1 6 8 1 1 4 1 1 1 2 1 5 1 1 2 1

FOOTNOTES: a

Not Illustrated

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-3

UNIT CODE A280 NORTH AMERICA

09/2013

OPERATOR PLATFORM (FIGURE 1-2)

ITEM 1 2 3 4 5 6 7 8

1-4

PART NO.

DESCRIPTION

QTY

4040615 292566 292600 2791942 1584709 4622253 1324577 292655

Platform (Operator) .............................................................................................

Capscrew .......................................................................................................

Nut ..................................................................................................................

Grease Fitting .................................................................................................

Capscrew .......................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

See Service Manual for service procedures.

1 2 2 2 2 4 8 4

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

PLATFORM (FIGURE 1-3) STANDARD

ITEM 1 2 3 4 5 6 7 8

PART NO.

DESCRIPTION

1585024 1568105 296167 1585574 2792246 1555957 296158 320156

Running Board (Lower ........................................................................................

Running Board (Upper) .......................................................................................

Capscrew ............................................................................................................

Nut , Clip .............................................................................................................

Bushing ...............................................................................................................

Bushing ...............................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 4 4 2 2 2 2

1-5

UNIT CODE A280 NORTH AMERICA

09/2013

PLATFORM SUPPORT (FIGURE 1-4)

1-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

PLATFORM SUPPORT ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

DESCRIPTION

1585029 2794114 2039023 815801 815597 1627335 1627268 1627497 1633957 1627495 1627276 320166 1601871 320162 1584684 302402 1627785 2791942

Running Board ....................................................................................................

Support ...............................................................................................................

Sensor (Sealed) ..................................................................................................

Capscrew ............................................................................................................

Nut ......................................................................................................................

Pin Assy (Assembly) ...........................................................................................

Pin ..................................................................................................................

Pin ..................................................................................................................

Bushing ..........................................................................................................

Roller ..............................................................................................................

Bushing ...............................................................................................................

Washer ...............................................................................................................

Spring .................................................................................................................

Washer ...............................................................................................................

Steel Plate ..........................................................................................................

Locknut ...............................................................................................................

Clip ......................................................................................................................

Grease Fitting .....................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 2 2 4 4 2 1 1 1 1 2 2 2 2 2 2 2 2

1-7

UNIT CODE A280 NORTH AMERICA

09/2013

SUPPORT SPRING (FIGURE 1-5)

ITEM 1 2 3 4 5 6 7 8 9

1-8

PART NO.

DESCRIPTION

QTY

1584746 2770970 292503 2780709 320156 302399 1367822 2795483 1564757

Support ...............................................................................................................

Gas Spring ..........................................................................................................

Capscrew ............................................................................................................

Bushing ...............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Spacer ................................................................................................................

See Service Manual for service procedures.

1 2 1 4 3 2 1 2 3

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-9

UNIT CODE A280 NORTH AMERICA

09/2013

SIDE GATES (FIGURE 1-6)

1-10

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

SIDE GATES ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO. 4038340 1566977 1588375 1637753 1587876 39377 302376 2039023 2794280 1584709 302401 293616 1581556 1596421 296159 320156 136687 1537477 1585341 2033612 a 1588300

DESCRIPTION

QTY

Guard ..................................................................................................................

Guard ..................................................................................................................

Support ...............................................................................................................

Bushing ...............................................................................................................

Gas Spring ..........................................................................................................

O-Ring ................................................................................................................

Dowel ..................................................................................................................

Sensor (Sealed) ..................................................................................................

Plate ....................................................................................................................

Capscrew ............................................................................................................

Locknut ...............................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Plate ....................................................................................................................

Shim ....................................................................................................................

Strap Clamp ........................................................................................................

Support ...............................................................................................................

1 2 1 4 2 2 2 2 1 1 1 6 12 6 4 4 4 2 2 2 1

FOOTNOTES: a

Not Illustrated

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-11

UNIT CODE A280 NORTH AMERICA

09/2013

BATTERY STOP (FIGURE 1-7)

ITEM 1 2

1-12

PART NO.

DESCRIPTION

QTY

1671912 1527880

Stop ....................................................................................................................

Capscrew ............................................................................................................

See Service Manual for service procedures.

1 1

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-13

UNIT CODE A280 NORTH AMERICA

09/2013

LABEL AND PLATE LOCATION (FIGURE 1-8)

1-14

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

LABEL AND PLATE LOCATION ITEM 1 2 3 4 5 6 7 8 9

PART NO. 4034008 1529043 2792746 4038222 4038225 1529042 1606674 a. . . . .

4033847

DESCRIPTION

QTY

Label (E-Stop) .....................................................................................................

Label (Hyster) .....................................................................................................

Label (Lifting Hook) .............................................................................................

Label (Warning) ..................................................................................................

Label (Pinch Warning) ........................................................................................

Label (Hyster) .....................................................................................................

Label (Warranty) .................................................................................................

Nameplate ..........................................................................................................

Label (Hyster Logo) (Hyster) ..............................................................................

1 2 2 2 2 1 1 1 1

FOOTNOTES: a

Contact your Local Hyster Dealer

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-15

UNIT CODE A280 NORTH AMERICA

09/2013

LOAD BACKREST (FIGURE 1-9)

1-16

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

LOAD BACKREST ITEM 1 1 2 3 4 5 6

PART NO.

DESCRIPTION

4036161 4036160 4033999 4034000 4029051 4035851 1528778

Load Backrest (1524 mm) ..................................................................................

Load Backrest (1219 mm) ..................................................................................

Load Backrest Mount (RH) .................................................................................

Load Backrest Mount (LH) ..................................................................................

Capscrew ............................................................................................................

Locknut ...............................................................................................................

Capscrew ............................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 6 6 4

1-17

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER FRAME (FIGURE 1-10) WITH SWIVEL WHEEL

1-18

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER FRAME WITH SWIVEL WHEEL ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

DESCRIPTION

.....

1564280 292539 320161 302402 4038988 292533 1573924 1584709 4038980 2792131 1584709 4038981 302479 4038982 239906 2063780 1586430

Frame Weldment (Caster Frame) .......................................................................

Shock Absorber ..................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Locknut ...............................................................................................................

Support (LH) .......................................................................................................

Capscrew ............................................................................................................

Caster Wheel Assy (FFigure 1-11)....................................................................

Capscrew ............................................................................................................

Support ...............................................................................................................

Bushing ...............................................................................................................

Capscrew ............................................................................................................

Shaft ...................................................................................................................

Roll Pin ...............................................................................................................

Support (RH) .......................................................................................................

Static Strap .........................................................................................................

Stud ....................................................................................................................

Nut ......................................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 2 2 4 4 1 2 2 8 2 2 4 1 2 1 1 1 1

1-19

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER WHEEL (FIGURE 1-11) SWIVEL

1-20

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER WHEEL SWIVEL ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13

PART NO.

DESCRIPTION

1573924 2053147 2053146 2053143 1599501 1599566 292600 1599510 1599507 1599508 1599509 194723 1599511

Caster Wheel Assy .............................................................................................

Capscrew .......................................................................................................

Spacer ............................................................................................................

Bearing ...........................................................................................................

Plate ...............................................................................................................

Support ...........................................................................................................

Nut ..................................................................................................................

Bushing ..........................................................................................................

Caster Wheel ..................................................................................................

Wheel .........................................................................................................

Bushing ......................................................................................................

Ball Bearing ................................................................................................

Capscrew .......................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 1 1 1 2 1 1 1 2 1

1-21

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER (FIGURE 1-12) STANDARD FRAME

ITEM 1 2 3 4 5 6 7

1-22

PART NO.

DESCRIPTION

QTY

.....

4006485 296028 4035851 239906 2063780 1586430

Frame Weldment (Standard) ..............................................................................

Caster Wheel Assembly (FFigure 1-13)............................................................

Capscrew ............................................................................................................

Locknut ...............................................................................................................

Static Strap .........................................................................................................

Stud ....................................................................................................................

Nut ......................................................................................................................

See Service Manual for service procedures.

1 2 8 8 1 1 1

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-23

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER WHEEL ASSEMBLY (FIGURE 1-13)

1-24

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

CASTER WHEEL ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 19 20 21

PART NO. 4006485 4024053 ..... ..... ..... ..... ..... .....

2099287 293658 4024052 .....

4010117 4010120 4010123 4010119 4010126 4024051 4010127 .....

2047199 2047200 2047201 2047202 a 296027 a 1460477

DESCRIPTION

QTY

Caster Wheel Assembly .....................................................................................

Support ...........................................................................................................

Fork ............................................................................................................

Snap Ring ..................................................................................................

Bearing .......................................................................................................

Plate ...........................................................................................................

Snap Ring ..................................................................................................

Cap .............................................................................................................

Locknut ...........................................................................................................

Capscrew .......................................................................................................

Bumper Assy (Includes Spring) ......................................................................

Spring .........................................................................................................

Fork ................................................................................................................

Pin ..................................................................................................................

Axle Shaft .......................................................................................................

Adjuster ..........................................................................................................

Screw .............................................................................................................

Wheel Assy ....................................................................................................

Guard .........................................................................................................

Axle ............................................................................................................

Wheel Assy ................................................................................................

Wheel .....................................................................................................

Tube .......................................................................................................

Bearing ..................................................................................................

Capscrew ............................................................................................................

Nut ......................................................................................................................

2 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 2 1 2 2 1 1 1 2 8 8

FOOTNOTES: a

Not Illustrated, Caster Mounting

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-25

UNIT CODE A280 NORTH AMERICA

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MASTER DRIVE UNIT ASSEMBLY (FIGURE 1-14)

1-26

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

MASTER DRIVE UNIT ASSEMBLY ITEM 1 1 2 3 4 5 6 7 8 9 10 11 11 11 11 12

PART NO. ..... a. . . . .

4616136 4057159 4035948 4057155 4057156 4033465 4613997 4613998 4613999 4028758 a 4028759 a 4028760 a 4028761 4036731

DESCRIPTION

QTY

Frame Weldment (Standard) ..............................................................................

Frame Weldment (Caster) ..................................................................................

Master Drive Unit ................................................................................................

Transmission Assy (FFigure 1-16)................................................................

Frame .............................................................................................................

Motor (FFigure 1-15).....................................................................................

Brake Assy (FFigure 1-15)............................................................................

Capscrew ............................................................................................................

Power Cable (U) .................................................................................................

Power Cable (V) .................................................................................................

Power Cable (W) ................................................................................................

Drive Wheel (230 x 84) (Rubber) ........................................................................

Drive Wheel (230 X 75) (Vulkollan) ....................................................................

Drive Wheel (230 x 84) (Non Marking) ...............................................................

Drive Wheel (230 X 75) (Poly) ............................................................................

Wheel Nut ...........................................................................................................

1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 5

FOOTNOTES: a

Not Illustrated

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-27

UNIT CODE A280 NORTH AMERICA

09/2013

MASTER DRIVE UNIT (FIGURE 1-15) ATTACHING AND MOUNTING PARTS

1-28

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

MASTER DRIVE UNIT ATTACHING AND MOUNTING PARTS ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13

PART NO.

DESCRIPTION

4616136 4035948 4057159 4035945 4035944 4057155 ..... .....

4035946 ..... ..... ..... .....

4057156

Master Drive Unit ................................................................................................

Frame .............................................................................................................

Transmission Assy .........................................................................................

Screw .............................................................................................................

Bearing ...........................................................................................................

Motor ..............................................................................................................

O-Ring ............................................................................................................

Woodruf Key ...................................................................................................

Nut (Grooved Nut) ..........................................................................................

Speed Sensor .................................................................................................

Screw .............................................................................................................

Retaining Ring ................................................................................................

Fitted Key .......................................................................................................

Brake Assy .....................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 16 1 1 1 1 1 1 4 2 1 1

1-29

UNIT CODE A280 NORTH AMERICA

09/2013

MASTER DRIVE UNIT (FIGURE 1-16) TRANSMISSION

ITEM 1 2 3 4 5 6 7

1-30

PART NO.

DESCRIPTION

QTY

4616136 4057159 4035931 4035933 4057153 4035935 4035934 4035937

Master Drive Unit ................................................................................................

Transmission Assy .........................................................................................

Cover ..............................................................................................................

Snap Ring .......................................................................................................

Pinion .............................................................................................................

Breather ..........................................................................................................

O-Ring ............................................................................................................

Bolt .................................................................................................................

See Service Manual for service procedures.

1 1 1 1 1 1 1 5

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

2

ELECTRICAL SYSTEM

09/2013

UNIT CODE A280 NORTH AMERICA

SECTION 2 ELECTRICAL SYSTEM DESCRIPTION

PAGE

CONTACTOR ..................................................................................................................................................

2-4 CONTROLLER ................................................................................................................................................

2-5 DASH PANEL ..................................................................................................................................................

2-6 ELECTRICAL SYSTEM ...................................................................................................................................

2-2 WIRE HARNESS MAIN ...........................................................................................................................................................

2-8 SIDE GATE JUMPER ................................................................................................................................. 2-11

©2013 HYSTER COMPANY

See Service Manual for service procedures.

2-1

UNIT CODE A280 NORTH AMERICA

09/2013

ELECTRICAL SYSTEM (FIGURE 2-1)

2-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

ELECTRICAL SYSTEM ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

DESCRIPTION

..... .....

4039150 4619266 4613999 4613998 4613997 4614114 .....

1502543 320157 239503 1706781 1596421 1581556 293616 1670032 4034532

Dash Panel (FFigure 2-4)..................................................................................

Controller (FFigure 2-3).....................................................................................

Wire Harness (Main) (FFigure 2-5)....................................................................

Wire Harness (Side Gate Jumper) (FFigure 2-6)..............................................

Power Cable (W) ................................................................................................

Power Cable (V) .................................................................................................

Power Cable (U) .................................................................................................

Power Cable (Jumper Contactor to B+) ..............................................................

Self Clinching Stud .............................................................................................

Nut (Flange) ........................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Fuse ....................................................................................................................

Nut ......................................................................................................................

Washer ...............................................................................................................

Capscrew ............................................................................................................

Capscrew ............................................................................................................

Strap Clamp ........................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 1 1 1 1 3 3 6 4 1 4 8 4 5 2

2-3

UNIT CODE A280 NORTH AMERICA

09/2013

CONTACTOR (FIGURE 2-2)

ITEM 1 2 3 4 5 6 7

2-4

PART NO.

DESCRIPTION

QTY

383931 378547 379522 384398 383985 383984 1374238 379524

Contactor ............................................................................................................

Contact (Fixed) ...............................................................................................

Screw .............................................................................................................

Cover (Top) ....................................................................................................

Spring .............................................................................................................

Contact (Moving) ............................................................................................

Coil and Frame ...............................................................................................

Insulator ..........................................................................................................

See Service Manual for service procedures.

1 1 2 1 1 1 1 1

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

CONTROLLER (FIGURE 2-3)

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO.

DESCRIPTION

4038853 4617360 383931 2042675 1594442 293744 292668 .....

2303104 1502543 1514429 1670032 292669 4034532

Control Panel ......................................................................................................

Controller (Curtis 1232) ......................................................................................

Contactor (SW 80) (FFigure 2-2).......................................................................

Horn ....................................................................................................................

Isolator ................................................................................................................

Screw ..................................................................................................................

Nut ......................................................................................................................

Self Clinching Stud .............................................................................................

Stud ....................................................................................................................

Nut (Flange) ........................................................................................................

Nut ......................................................................................................................

Capscrew ............................................................................................................

Capscrew ............................................................................................................

Strap Clamp ........................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 1 2 2 3 7 3 6 5 2 2

2-5

UNIT CODE A280 NORTH AMERICA

09/2013

DASH PANEL (FIGURE 2-4)

ITEM 1 2 3 4 4 5 6 7 8

2-6

PART NO.

DESCRIPTION

QTY

4039090 1486162 4038296 1707683 4032917 293616 1581556 1596421 4038796

Dash Panel .........................................................................................................

Emergency Disconnect Switch ...........................................................................

Ignition Switch .....................................................................................................

Gauge .................................................................................................................

Plug (Alternate Part) ...........................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Buss Bar .............................................................................................................

See Service Manual for service procedures.

1 1 1 1 1 4 8 4 1

©2013 HYSTER COMPANY

09/2013

UNIT CODE A280 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

2-7

UNIT CODE A280 NORTH AMERICA

09/2013

WIRE HARNESS (FIGURE 2-5) MAIN

2-8

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

WIRE HARNESS MAIN ITEM 1 2 2 2 2 3 4 4 4 4 5 5 5 6 6 6 6 7 7 7 8 8 8 8 9 10 10 10 10 11 11 11 11 12 12 12 12 13 13 13 13 14 14 15 16 17 18 18 18

PART NO.

DESCRIPTION

4039150 2033694 .....

2056243 2035276 2068741 252293 .....

1530960 1463140 1530961 .....

2059812 2302852 .....

1547629 1508232 2060555 .....

1369409 2309579 .....

1531973 1531974 1463141 1306270 .....

1561559 1561755 1463140 .....

1508206 1508232 2060555 .....

1508211 1508232 2060555 .....

1463189 1463196 1463141 .....

1532219 1500901 89220 1566117 .....

1484397 1532664

Wire Harness (Main) ...........................................................................................

Fuse Holder (FU2) ..........................................................................................

Connector Assembly (CPS01 AC Controller) .................................................

Connector (35 Way) ...................................................................................

Connector (Socket Female) .......................................................................

Plug ............................................................................................................

E-Ring (T21 B (-)) ...........................................................................................

Connector Assembly (CRP11 Side Gate Sensors Jumper) ...........................

Connector ...................................................................................................

Terminal (Pin) .............................................................................................

Connector (Secondary Lock) .....................................................................

Connector Assembly (CRP08 Handset) .........................................................

Connector (4 Way) .....................................................................................

Pin ..............................................................................................................

Connector Assembly (CPS16 Tiller Head Prox Sensor) ................................

Connector (3 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Connector Assembly (CPS07 Batt Discharge Indicator) ................................

Connector (8 Way) .....................................................................................

Socket ........................................................................................................

Connector Assembly (CPS06 Tiller Handle) ..................................................

Connector ...................................................................................................

Connector (Secondary Lock) .....................................................................

Terminal (Socket) .......................................................................................

Terminal (T04 Main Contactor Coil) ...............................................................

Connector Assembly (CRP04 Brake Coil) ......................................................

Connector (2 Pin) .......................................................................................

Connector (Secondary Lock) .....................................................................

Terminal (Pin) .............................................................................................

Connector Assembly (CPS02 Temp Sen) ......................................................

Connector (2 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Connector Assembly (CPS03 Encoder) .........................................................

Connector (4 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Connector Assembly (CPS10 Back Up Alarm) ..............................................

Connector ...................................................................................................

Connector (Secondary Lock) .....................................................................

Terminal (Socket) .......................................................................................

Connector Assembly (CPS05 Lowering Valve Coil) .......................................

Connector ...................................................................................................

Clip .................................................................................................................

Clamp .............................................................................................................

Dust Cap ........................................................................................................

Connector Assembly (CPS09 PC Service Tool) ............................................

Connector (3-Way) .....................................................................................

Connector (Secondary Lock) .....................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 28 7 1 1 1 6 1 1 1 4 1 1 3 1 1 1 3 1 1 1 6 1 1 1 1 2 1 1 2 1 1 1 4 1 1 1 1 4 1 1 1 3 1 1 1 1 2-9

UNIT CODE A280 NORTH AMERICA

09/2013

WIRE HARNESS MAIN ITEM 18 19 20 21 21 21 21 22 22 22 22 23 24 25 26 27 28 29 30

2-10

PART NO. 1597773 206028 1310142 .....

1547629 1508232 2060555 .....

1547629 1508232 2060555 1306270 1306270 1306270 1306270 1306270 1310142 1306270 1306270

DESCRIPTION

QTY

Terminal .....................................................................................................

E-Ring (T12 Battery Disconnect) ....................................................................

Terminal (T10 Key SW) ..................................................................................

Connector Assembly (CPS12 Man On Platform Sensor) ...............................

Connector (3 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Connector Assembly (CPS13 Platform Up Sensor) .......................................

Connector (3 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Terminal (T01 Battery Disconnect) .................................................................

Terminal (T07 Horn) .......................................................................................

Terminal (T09 Pump Coil) ..............................................................................

Terminal (T08 Pump Coil) ..............................................................................

Terminal (T03 Key SW) ..................................................................................

Terminal (T02 Emergency Stop) ....................................................................

Terminal (T05 Main Contactor Coil) ...............................................................

Terminal (T06 Horn) .......................................................................................

See Service Manual for service procedures.

3 1 1 1 1 3 1 1 1 3 1 1 1 1 1 1 1 1 1

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

WIRE HARNESS (FIGURE 2-6) SIDE GATE JUMPER

ITEM 1 1 1 1 2 2 2 2 3 4 4 4 4

PART NO.

DESCRIPTION

4619266 .....

1531973 1531974 1463141 .....

1547629 1508232 2060555 124297 .....

1547629 1508232 2060555

Wire Harness ......................................................................................................

Connector Assembly (CPS11 Side Gate Sensor Jumper Harness) ...............

Connector ...................................................................................................

Connector (Secondary Lock) .....................................................................

Terminal (Socket) .......................................................................................

Connector Assembly (CPS14 Side Gate RGT) ..............................................

Connector (3 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

Clamp .............................................................................................................

Connector Assembly (CPS15 Side Gate Left) ...............................................

Connector (3 Way) .....................................................................................

Terminal (Pin) .............................................................................................

Wire Seal ....................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 6 1 1 3 1 1 1 1 3 1

2-11

UNIT CODE A280 NORTH AMERICA

09/2013

NOTES

2-12

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

3

STEER HANDLE/BRAKE SYSTEM

09/2013

UNIT CODE A280 NORTH AMERICA

SECTION 3 STEER HANDLE/BRAKE SYSTEM DESCRIPTION

PAGE

STEERING ARM .............................................................................................................................................

TILLER ............................................................................................................................................................

TILLER ASSEMBLY ........................................................................................................................................

TILLER HEAD ASSEMBLY .............................................................................................................................

3-8 3-6 3-2 3-4

©2013 HYSTER COMPANY

3-1

See Service Manual for service procedures.

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER ASSEMBLY (FIGURE 3-1)

3-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 10 11

PART NO.

DESCRIPTION

4033899 4038337 .....

4038336 293616 1581556 1596421 1556313 58924 2039023 4613950

Tiller Head (FFigure 3-2)...................................................................................

Tiller (FFigure 3-3).............................................................................................

Steering Arm Assembly (FFigure 3-4)...............................................................

Hub .....................................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Nut ......................................................................................................................

Ball Bearing ........................................................................................................

Snap Ring ...........................................................................................................

Sensor (Sealed) ..................................................................................................

Wire Harness (Tiller) ...........................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 4 8 4 2 1 1 1

3-3

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER HEAD ASSEMBLY (FIGURE 3-2)

3-4

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER HEAD ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 21 21 22

PART NO. 4033899 1499660 320152 4013194 1466595 1467779 1466607 1531075 4011997 2111838 293761 1466606 4013196 2097314 1652960 4016755 1466935 4013193 1594131 4036438 1466605 4011993 4036439 4036440 1498102 1466604 a 1466602

DESCRIPTION

QTY

Tiller Head ..........................................................................................................

Capscrew .......................................................................................................

Washer ...........................................................................................................

Accelerator Control (RH Butterfly) ..................................................................

Bushing (Butterfly Control) .............................................................................

Cover (Belly Switch) .......................................................................................

Spring (Return Control) ..................................................................................

Spring .............................................................................................................

Horn Button ....................................................................................................

Tiller Head (Lower Half) (Lower Half) .............................................................

Capscrew .......................................................................................................

Spring (Horn) ..................................................................................................

Cover (Rear Cover) ........................................................................................

Screw .............................................................................................................

Support ...........................................................................................................

Printed Circuit Board ......................................................................................

Camshaft ........................................................................................................

Accelerator Control (LH Butterfly) ..................................................................

Spring (Control Return) ..................................................................................

Handle (Upper Half) .......................................................................................

Label (LH Switch Functions) ..........................................................................

Push Button Switch Assembly (On-Off) .........................................................

Push Button Switch ....................................................................................

Cover (Top for Push Button) ..................................................................

Microswitch (On-Off) ..................................................................................

Label (RH Switch Functions) ..........................................................................

Label (Tiller Handle) HYSTER .......................................................................

1 2 2 1 2 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1

FOOTNOTES: a

Not Illustrated

©2013 HYSTER COMPANY

See Service Manual for service procedures.

3-5

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER (FIGURE 3-3)

3-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

TILLER ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO.

DESCRIPTION

1632574 1474013 2770970 2780709 1359482 2794748 302044 2770989 2794114 293727 2041665 1551430 296150 2792053 2791931 2791987 1551431 293795 293762 136687

Knob ...................................................................................................................

Steering (Tiller Handle) .......................................................................................

Gas Spring ..........................................................................................................

Bushing ...............................................................................................................

E-Ring .................................................................................................................

Spring .................................................................................................................

Screw ..................................................................................................................

Guard ..................................................................................................................

Support ...............................................................................................................

Capscrew ............................................................................................................

Wire Harness (Tiller Sensor Wire Harness) ........................................................

Plate ....................................................................................................................

Capscrew ............................................................................................................

Pin .......................................................................................................................

Washer ...............................................................................................................

Bushing ...............................................................................................................

Bumper ...............................................................................................................

Capscrew ............................................................................................................

Capscrew ............................................................................................................

Nut ......................................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 2 2 1 2 1 1 2 1 1 2 2 2 2 1 1 1 1

3-7

UNIT CODE A280 NORTH AMERICA

09/2013

STEERING ARM (FIGURE 3-4)

ITEM 1 2 3 4 5 6 7 8 9

3-8

PART NO.

DESCRIPTION

QTY

4038461 4039971 4039967 293797 320156 1627244 1584709 293613 1581556

Steering Tiller ......................................................................................................

Arm .....................................................................................................................

Bracket ................................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

Steel Tube ..........................................................................................................

Capscrew ............................................................................................................

Capscrew ............................................................................................................

Washer ...............................................................................................................

See Service Manual for service procedures.

1 1 1 4 4 3 3 4 4

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

4

LIFT LINKAGE AND FORKS

09/2013

UNIT CODE A280 NORTH AMERICA

SECTION 4 LIFT LINKAGE AND FORKS DESCRIPTION

PAGE

FORKS AND BATTERY FRAMES 218 MM BATTERY FRAME ........................................................................................................................

290 MM BATTERY FRAME ........................................................................................................................

LIFT LINKAGE .................................................................................................................................................

LOAD WHEELS ...............................................................................................................................................

TANDEM .....................................................................................................................................................

4-2 4-4 4-6 4-7 4-8

©2013 HYSTER COMPANY

4-1

See Service Manual for service procedures.

UNIT CODE A280 NORTH AMERICA

09/2013

FORKS AND BATTERY FRAMES (FIGURE 4-1) 218 MM BATTERY FRAME

4-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

FORKS AND BATTERY FRAMES 218 MM BATTERY FRAME KEY: A: 520 mm Wide x 218 mm Battery Frame B: 560 mm Wide x 218 mm Battery Frame C: 670 mm Wide x 218 mm Battery Frame ITEM 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NO.

DESCRIPTION

4028566 4028567 4028568 4028569 4028570 4028571 4028572 4028573 4028574 4028575 4028576 4028577 4028578 4028579 4028580 4028581 4028582 4028583 4052293 4052294 4052295 4052296 4052297 4052298

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

©2013 HYSTER COMPANY

A

See Service Manual for service procedures.

1 1 1 .. .. .. .. .. ..

1 1 1 .. .. .. .. .. ..

1 1 .. .. .. ..

QTY B .. .. ..

1 1 1 .. .. .. .. .. ..

1 1 1 .. .. .. .. ..

1 1 .. ..

C .. .. .. .. .. ..

1 1 1 .. .. .. .. .. ..

1 1 1 .. .. .. ..

1 1

4-3

UNIT CODE A280 NORTH AMERICA

09/2013

FORKS AND BATTERY FRAMES (FIGURE 4-2) 290 MM BATTERY FRAME

4-4

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

FORKS AND BATTERY FRAMES 290 MM BATTERY FRAME KEY: A: 520 mm Wide x 290 mm Battery Frame B: 560 mm Wide x 290 mm Battery Frame C: 670 mm Wide x 290 mm Battery Fame ITEM 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PART NO.

DESCRIPTION

4040840 4040841 4040842 4040849 4040850 4040851 4040843 4040844 4040845 4040852 4040853 4040854 4040846 4040847 4040848 4040855 4040856 4040857 4052299 4052300 4052301 4052302 4052303 4052304

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Standard 923 mm Length) ............................................

Fork Frame (Standard 1023 mm Length) ..........................................

Fork Frame (Standard 1173 mm Length) ..........................................

Fork Frame (Tandom 923 mm Length) .............................................

Fork Frame (Tandom 1019 mm Length) ...........................................

Fork Frame (Tandom 1171 mm Length) ...........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

Fork Frame (Standard 973 mm Length) ............................................

Fork Frame (Standard 1125 mm Length) ..........................................

©2013 HYSTER COMPANY

A

See Service Manual for service procedures.

1 1 1 1 1 1 .. .. .. .. .. .. .. .. .. .. .. ..

1 1 .. .. .. ..

QTY B .. .. .. .. .. ..

1 1 1 1 1 1 .. .. .. .. .. .. .. ..

1 1 .. ..

C .. .. .. .. .. .. .. .. .. .. .. ..

1 1 1 1 1 1 .. .. .. ..

1 1

4-5

UNIT CODE A280 NORTH AMERICA

09/2013

LIFT LINKAGE (FIGURE 4-3)

ITEM 1 1 1 2 3 4 5 6 7 8 8 8 8 9 10 11 12

4-6

PART NO.

DESCRIPTION

QTY

4028401 4028402 4028403 4028850 4028849 4028848 4028840 4015768 2305757 4035047 4035046 1590996 1590880 1603253 302456 4028851 4030424

Rocker Arm Assembly (520 mm) ........................................................................

Rocker Arm Assembly (560 mm) ........................................................................

Rocker Arm Assembly (670 mm) ........................................................................

Shaft (Front Fork Frame Pivot) ...........................................................................

Shaft (Pull Rod Pivot) .........................................................................................

Shaft (Drive Frame Pivot) ...................................................................................

Bushing ...............................................................................................................

Capscrew ............................................................................................................

Grease Fitting .....................................................................................................

Load Wheel (Poly) ..............................................................................................

Load Wheel (Poly) ..............................................................................................

Load Wheel (Std) ................................................................................................

Load Wheel (Tandom) ........................................................................................

Axle (Pin) ............................................................................................................

Roll Pin ...............................................................................................................

Shaft (Rear Fork Pivot) .......................................................................................

Capscrew ............................................................................................................

See Service Manual for service procedures.

1 1 1 2 2 2 6 6 6 2 2 2 2 2 2 2 2

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

LOAD WHEELS (FIGURE 4-4)

KEY: A: Standard B: PU ITEM 1 1 2 3 3 4 5 6 7 8

QTY A B

PART NO.

DESCRIPTION

2790367 4036268 1590873 4036271 1590996 2079496 1590992 1590994 1590912 1591000

Bushing ......................................................................................................

Bushing ......................................................................................................

Lever ..........................................................................................................

Roller ..........................................................................................................

Load Wheel ................................................................................................

Bearing Ball ...........................................................................................

Load Wheel ............................................................................................

Spacer ...................................................................................................

Bushing ..................................................................................................

Capscrew ...................................................................................................

©2013 HYSTER COMPANY

See Service Manual for service procedures.

4 ..

2 ..

2 2 1 1 2 2

..

4 2 2 .. .. .. .. ..

2

4-7

UNIT CODE A280 NORTH AMERICA

09/2013

LOAD WHEELS (FIGURE 4-5) TANDEM

KEY: A: Standard B: PU ITEM 1 1 2 3 4 5 5 6 7 7 8 9 10 11

4-8

QTY A B

PART NO.

DESCRIPTION

2790367 4036268 1574119 1607371 1590883 2792131 4036269 1590886 4036270 1590995 1590912 2079496 1590991 1590993

Bushing ......................................................................................................

Bushing ......................................................................................................

Lever ..........................................................................................................

Washer .......................................................................................................

Rocker Plate ...............................................................................................

Bushing ......................................................................................................

Bushing ......................................................................................................

Capscrew ...................................................................................................

Roller ..........................................................................................................

Load Wheel ................................................................................................

Bushing ..................................................................................................

Bearing Ball ...........................................................................................

Roller .....................................................................................................

Spacer ...................................................................................................

See Service Manual for service procedures.

4 ..

2 4 4 4 ..

4 ..

4 2 2 1 1

..

4 2 4 4 ..

4 ..

4 .. .. .. .. ..

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

5

HYDRAULIC SYSTEM

09/2013

UNIT CODE A280 NORTH AMERICA

SECTION 5 HYDRAULIC SYSTEM DESCRIPTION

PAGE

CYLINDER ASSEMBLY ..................................................................................................................................

HYDRAULIC POWER UNIT ASSEMBLY .......................................................................................................

HYDRAULIC PUMP AND CYLINDER MOUNTING ........................................................................................

HYDRAULIC SYSTEM ....................................................................................................................................

5-5 5-6 5-4 5-2

©2013 HYSTER COMPANY

5-1

See Service Manual for service procedures.

UNIT CODE A280 NORTH AMERICA

09/2013

HYDRAULIC SYSTEM (FIGURE 5-1)

5-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

HYDRAULIC SYSTEM ITEM 1 2 3 4 4 5 6 7 8

PART NO.

DESCRIPTION

2074624 4612314 2094732 222399 16482 4613260 1527879 1569917 4006514

Cylinder Assy (FFigure 5-3)...............................................................................

Hydraulic Power Unit (FFigure 5-4)...................................................................

Screw ..................................................................................................................

Fitting ..................................................................................................................

O-Ring ............................................................................................................

Hose Assy ...........................................................................................................

Capscrew ............................................................................................................

Pin .......................................................................................................................

Spacer ................................................................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 2 1 1 1 2 1 2

5-3

UNIT CODE A280 NORTH AMERICA

09/2013

HYDRAULIC PUMP AND CYLINDER MOUNTING (FIGURE 5-2)

ITEM 1 2 3

5-4

PART NO.

DESCRIPTION

QTY

.....

2094732 1527879

Self Clinching Stud .............................................................................................

Screw ..................................................................................................................

Capscrew ............................................................................................................

See Service Manual for service procedures.

2 2 2

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

CYLINDER ASSEMBLY (FIGURE 5-3)

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11

2074624 ..... .....

2792464 ..... .....

2076501 2798721 2076502 2076499 2076498 39373

Cylinder Assy ......................................................................................................

Shell ...............................................................................................................

Head ...............................................................................................................

Cylinder Head (Gland) ....................................................................................

Piston .............................................................................................................

Rod .................................................................................................................

O-Ring ............................................................................................................

Wiper ..............................................................................................................

Seal ................................................................................................................

O-Ring ............................................................................................................

O-Ring ............................................................................................................

O-Ring ............................................................................................................

1 1 1 1 1 1 2 1 1 1 2 1

12

4603400

Kit-Seal ...............................................................................................................

1

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

5-5

UNIT CODE A280 NORTH AMERICA

09/2013

HYDRAULIC POWER UNIT ASSEMBLY (FIGURE 5-4)

5-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

HYDRAULIC POWER UNIT ASSEMBLY ITEM 1 2 3 3 4 5 6 7 7 8 8 9 10 11 12 13

PART NO. 4612314 1603821 4035751 1603825 1603826 4035752 4035787 4035758 4035775 4035776 4035777 4035784 4035785 4035755 4035756 4035757 1506131 a 4035754 a 4035783

DESCRIPTION

QTY

Hydraulic Power Unit ..........................................................................................

Motor ..............................................................................................................

Nut ..................................................................................................................

Hydraulic Motor Sub Unit ...............................................................................

Kit-Seal .......................................................................................................

Check Valve ...................................................................................................

Fitting ..............................................................................................................

Relief Valve ....................................................................................................

Pipe ................................................................................................................

Strainer .......................................................................................................

Valve ..............................................................................................................

Kit-Seal Valve .............................................................................................

Restrictor ........................................................................................................

Tank ...............................................................................................................

O-Ring ........................................................................................................

Plug (Filter) .................................................................................................

Clamp Assembly ........................................................................................

Tool (Check Valve) .........................................................................................

Solenoid .........................................................................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FOOTNOTES: a

Not Illustrated

©2013 HYSTER COMPANY

See Service Manual for service procedures.

5-7

UNIT CODE A280 NORTH AMERICA

09/2013

NOTES

5-8

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

6

NUMERICAL INDEX

UNIT CODE A280 NORTH AMERICA

09/2013

SECTION 6 NUMERICAL INDEX PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

16482 18834 39373 39377 58924 89220 124297 136687

5-3 1-3 5-5 1-11 3-3 2-9 2-11 1-11 3-7 1-21 2-10 5-3 2-3 1-19 1-22 2-9 1-8 1-19 1-19 1-4 1-4 1-21 1-4 2-5 2-5 3-8 1-3 1-11 2-3 2-6 3-3 1-25 3-7 2-5 3-5 3-7 3-7 3-8 1-3 1-25 1-22 3-7 1-5 1-11 1-5 3-7 1-11 1-8 1-11

302402

1-7 1-19 4-6 1-19 3-5 1-5 1-8 1-11 3-8 1-3 2-3 1-19 1-7 1-7 2-4 2-4 2-4 2-4 2-5 2-4 2-4 2-4 1-7 1-7 2-9 2-10 2-10 2-10 2-10 2-10 2-10 2-10 2-10 2-10 1-4 3-7 1-8 2-9 2-4 1-25 2-9 2-9 2-9 2-9 2-11 2-9 2-9 3-5 3-5

1466604 1466605 1466606 1466607 1466935 1467779 1474013 1484397 1486162 1498102 1499660 1500901 1502543

3-5 3-5 3-5 3-5 3-5 3-5 3-7 2-9 2-6 3-5 3-5 2-9 2-3 2-5 5-7 2-9 2-9 2-9 2-9 2-9 2-10 2-10 2-11 2-11 2-5 1-3 5-3 5-4 1-12 1-17 1-15 1-15 2-9 2-9 3-5 2-9 2-11 2-9 2-11 2-9 2-9 1-11 2-9 2-10 2-10 2-11 2-11 3-7 3-7

1555957 1556313 1561559 1561755 1564280 1564757 1566117 1566977 1568105 1569917 1573924

1-5 3-3 2-9 2-9 1-19 1-8 2-9 1-11 1-5 5-3 1-19 1-21 4-8 1-11 2-3 2-6 3-3 3-8 1-7 1-4 1-11 1-19 1-19 3-8 1-8 1-5 1-7 1-11 1-5 1-19 1-22 1-11 1-11 1-11 4-7 4-6 4-8 4-8 4-7 4-8 4-8 4-7 4-8 4-7 4-8 4-6 4-7 4-7 3-5

194723 206028 222399 239503 239906 252293 292503 292533 292539 292566 292600 292655 292668 292669 293613 293616

293658 293727 293744 293761 293762 293795 293797 296013 296027 296028 296150 296158 296159 296167 302044 302376 302399 302401

4 16 11 6 9 16 3 17 20 12 19 4 12 16 5 3 3 7 3 2 3 7 8 7 13 8 11 12 16 5 5 9 10 6 10 19 18 4 3 3 13 7 15 3 7 7 6 11

©2013 HYSTER COMPANY

302456 302479 320152 320156

320157 320161 320162 320166 378547 379522 379524 383931 383984 383985 384398 815597 815801 1306270

1310142 1324577 1359482 1367822 1369409 1374238 1460477 1463140 1463141 1463189 1463196 1466595 1466602

16 5 10 14 2 8 5 16 5 4 11 4 14 12 1 2 7 3 5 4 3 5 4 9 23 24 25 26 27 29 30 20 28 7 5 7 7 6 4 10 8 13 1 13 13 4

1506131 1508206 1508211 1508232

1514429 1527879 1527880 1528778 1529042 1529043 1530960 1530961 1531075 1531973 1531974 1532219 1532664 1537477 1547629

1551430 1551431

See Service Manual for service procedures.

22 20 11 6 16 5 2 18 2 21 1 15 10 10 13 11 12 6 11 12 21 22 2 4 11 13 6 3 2 6 6 2 4 4 7 8 1 8 1 14 18 18 6 21 22 2 4 12 17

1574119 1581556

1584684 1584709

1584746 1585024 1585029 1585341 1585574 1586430 1587876 1588300 1588375 1590873 1590880 1590883 1590886 1590912 1590991 1590992 1590993 1590994 1590995 1590996 1591000 1594131

6 8 10 10 2 9 17 2 2 7 8 1 2 13 15 6 6 9 15 5 10 9 12 7 1 1 1 19 4 18 7 5 3 2 8 4 6 7 8 10 5 11 6 7 8 3 8 18 6-1

UNIT CODE A280 NORTH AMERICA

09/2013

NUMERICAL INDEX (continued) PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

1594442 1596421

2-5 1-11 2-3 2-6 3-3 2-10 1-21 1-21 1-21 1-21 1-21 1-21 1-21 1-7 4-6 5-7 5-7 5-7 1-15 4-8 3-8 1-7 1-7 1-7 1-7 1-7 1-7 3-7 1-7 1-11 3-5 2-3 2-5 1-12 2-3 2-6 1-11 2-9 2-9 1-7 1-11 3-3 3-7 1-3 2-5 1-25 1-25 1-25 1-25 1-21 1-21 1-21

2056243 2059812 2060555

2-9 2-9 2-9 2-9 2-9 2-10 2-10 2-11 2-11 1-19 1-22 2-9 5-3 5-5 5-5 5-5 5-5 5-5 4-7 4-8 5-3 5-4 3-5 1-25 3-5 2-9 2-5 4-6 2-9 1-8 3-7 3-7 1-8 3-7 4-7 4-8 3-7 1-4 1-7 3-7 3-7 1-19 4-8 1-5 5-5 1-15 1-7 3-7 1-11 3-7 1-8 5-5

4006485

1-22 1-25 5-3 1-25 1-25 1-25 1-25 1-25 1-25 3-5 3-5 3-5 3-5 3-5 4-6 3-5 1-25 1-25 1-25 4-6 4-6 4-6 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 1-27 1-27 1-27 1-27 4-6 4-6 4-6 4-6 4-6 1-17 4-6 2-6

4033465 4033847 4033899

1-27 1-15 3-3 3-5 1-17 1-17 1-15 2-3 2-5 4-6 4-6 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 1-17 1-22 1-30 1-30 1-30 1-30 1-30 1-29 1-29 1-29 1-27 1-29 1-17 1-17 4-7 4-8 4-8 4-8 4-7 3-5 3-5 3-5 1-27 1-15 1-15 2-6 3-3

1597773 1599501 1599507 1599508 1599509 1599510 1599511 1599566 1601871 1603253 1603821 1603825 1603826 1606674 1607371 1627244 1627268 1627276 1627335 1627495 1627497 1627785 1632574 1633957 1637753 1652960 1670032 1671912 1706781 1707683 2033612 2033694 2035276 2039023 2041665 2041739 2042675 2047199 2047200 2047201 2047202 2053143 2053146 2053147 6-2

5 14 14 7 7 18 5 9 10 11 8 13 6 13 9 1 3 3 7 3 6 7 11 6 10 8 17 1 9 4 14 17 12 1 13 4 20 1 2 3 8 10 11 7 4 19 19 20 21 4 3 2

2063780 2068741 2074624 2076498 2076499 2076501 2076502 2079496 2094732 2097314 2099287 2111838 2302852 2303104 2305757 2309579 2770970 2770989 2780709 2790367 2791931 2791942 2791987 2792053 2792131 2792246 2792464 2792746 2794114 2794280 2794748 2795483 2798721

2 5 6 11 12 21 22 2 4 17 6 2 1 10 9 6 8 4 9 3 2 13 8 9 5 9 7 7 2 3 8 4 4 1 1 15 4 18 16 14 11 5 5 3 3 2 9 9 6 8 7

4006514 4010117 4010119 4010120 4010123 4010126 4010127 4011993 4011997 4013193 4013194 4013196 4015768 4016755 4024051 4024052 4024053 4028401 4028402 4028403 4028566 4028567 4028568 4028569 4028570 4028571 4028572 4028573 4028574 4028575 4028576 4028577 4028578 4028579 4028580 4028581 4028582 4028583 4028758 4028759 4028760 4028761 4028840 4028848 4028849 4028850 4028851 4029051 4030424 4032917

See Service Manual for service procedures.

2 8 11 14 12 13 15 17 21 8 17 3 12 6 15 16 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 11 11 11 5 4 3 2 11 4 12 4

4033999 4034000 4034008 4034532 4035046 4035047 4035751 4035752 4035754 4035755 4035756 4035757 4035758 4035775 4035776 4035777 4035783 4035784 4035785 4035787 4035851 4035931 4035933 4035934 4035935 4035937 4035944 4035945 4035946 4035948 4036160 4036161 4036268 4036269 4036270 4036271 4036438 4036439 4036440 4036731 4038222 4038225 4038296 4038336

7 9 1 2 3 1 18 14 8 8 2 4 10 11 12 6 7 7 8 8 9 5 5 4 2 3 6 5 7 4 3 8 4 1 1 1 1 1 5 7 3 19 21 21 12 4 5 3 4

©2013 HYSTER COMPANY

UNIT CODE A280 NORTH AMERICA

09/2013

NUMERICAL INDEX (continued) PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

4038337 4038340 4038461 4038796 4038853 4038980 4038981 4038982 4038988 4039090 4039150

3-3 1-11 3-8 2-6 2-5 1-19 1-19 1-19 1-19 2-6 2-3 2-9 3-8 3-8 1-4 4-5 4-5 4-5 4-5 4-5

4040845 4040846 4040847 4040848 4040849 4040850 4040851 4040852 4040853 4040854 4040855 4040856 4040857 4046102 4046103 4052293 4052294 4052295 4052296 4052297

4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 1-3 1-3 4-3 4-3 4-3 4-3 4-3

4052298 4052299 4052300 4052301 4052302 4052303 4052304 4057153 4057155

4-3 4-5 4-5 4-5 4-5 4-5 4-5 1-30 1-27 1-29 1-27 1-29 1-27 1-29 1-30 5-5 5-3 5-7 5-3

1 1 1 1 1 1 1 4 5 5 6 13 3 2 1 12 2

4613950 4613997

5

4622253

3-3 1-27 2-3 1-27 2-3 1-27 2-3 2-3 1-27 1-29 1-30 2-5 1-3 1-3 1-3 1-3 2-3 2-11 1-4

4039967 4039971 4040615 4040840 4040841 4040842 4040843 4040844

2 1 1 8 1 10 13 15 6 1 3

©2013 HYSTER COMPANY

3 2 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 2 8 1 1 1 1 1

4057156 4057159 4603400 4612314 4613260

See Service Manual for service procedures.

4613998 4613999 4614114 4616136 4617360 4617679 4617680 4617681 4617682 4619266

11 8 7 9 6 10 5 8 2 2 14 12 9 10 4 6

6-3

UNIT CODE A280 NORTH AMERICA

09/2013

NUMERICAL INDEX (continued) NOTES

6-4

See Service Manual for service procedures.

©2013 HYSTER COMPANY