Hyster P2.0 (A290) Parts Manual - PDF DOWNLOAD

P2.0 (A290)

4035872 11/2013

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

SECTIONS 1

FRAME/DRIVE UNIT

2

ELECTRICAL SYSTEM

3

STEER HANDLE/BRAKE SYSTEM

4

HYDRAULIC SYSTEM

5

NUMERICAL INDEX

This Parts Manual is divided into 5 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.

11/2013

UNIT CODE A290 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

B BACKREST ..................................................................................................................................................... 1-16 C CASTER WHEEL ASSEMBLY ........................................................................................................................ 1-14 CONTACTOR ..................................................................................................................................................

2-5 CONTROL PANEL ASSEMBLY ......................................................................................................................

2-4 COVERS ......................................................................................................................................................... 1-18 CYLINDER ASSEMBLY ..................................................................................................................................

4-4 D DECAL AND PLATE LOCATION .................................................................................................................... 1-20 DRIVE TIRES ..................................................................................................................................................

1-6 E EMERGENCY STOP .......................................................................................................................................

2-2

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

1-8

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

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

4-6 4-2

L LIFT LINKAGE ................................................................................................................................................. 1-10 LOAD WHEELS ............................................................................................................................................... 1-12 TANDEM ..................................................................................................................................................... 1-13 M MASTER DRIVE UNIT ATTACHING AND MOUNTING PARTS .....................................................................................................

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

1-2 1-4

T TILLER HANDLE ASSEMBLY ........................................................................................................................

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

3-2 3-4

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

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

2-6 2-8

©2013 HYSTER COMPANY

See Service Manual for service procedures.

i

UNIT CODE A290 NORTH AMERICA

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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

ii

See Service Manual for service procedures.

©2013 HYSTER COMPANY

11/2013

UNIT CODE A290 NORTH AMERICA

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

©2013 HYSTER COMPANY

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.

iii

UNIT CODE A290 NORTH AMERICA

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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 5-1) 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.

iv

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

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.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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.

©2013 HYSTER COMPANY

See Service Manual for service procedures.

v

UNIT CODE A290 NORTH AMERICA

11/2013

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........................................................................................................................ 4035870 Service Manual (Complete)......................................................................................................... 4035857 Parts Manual............................................................................................................................... 4035872

vi

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

1

FRAME/DRIVE UNIT

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UNIT CODE A290 NORTH AMERICA

SECTION 1 FRAME/DRIVE UNIT DESCRIPTION

PAGE

BACKREST .....................................................................................................................................................

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

COVERS .........................................................................................................................................................

DECAL AND PLATE LOCATION ....................................................................................................................

DRIVE TIRES ..................................................................................................................................................

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

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

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

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

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

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

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-16 1-14 1-18 1-20 1-6 1-8 1-10 1-12 1-13 1-2 1-4

1-1

UNIT CODE A290 NORTH AMERICA

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

1-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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

PART NO.

DESCRIPTION

4027715 4035948 .....

4035945 4035944 4035954 ..... .....

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

4035947

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

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

Transmission Housing ....................................................................................

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

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

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

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

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

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

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

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

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

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

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

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

4035949

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

1

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1-3

UNIT CODE A290 NORTH AMERICA

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MASTER DRIVE UNIT (FIGURE 1-2) TRANSMISSION

ITEM 1 2 3 4 5 6 7

1-4

PART NO.

DESCRIPTION

QTY

4027715 .....

4035931 4035933 4035936 4035935 4035934 4035937

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

Housing ..........................................................................................................

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

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

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

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

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

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

1 1 1 1 1 1 1 5

4035949

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

1

See Service Manual for service procedures.

©2013 HYSTER COMPANY

11/2013

UNIT CODE A290 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

1-5

UNIT CODE A290 NORTH AMERICA

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DRIVE TIRES (FIGURE 1-3)

1-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

DRIVE TIRES ITEM 1 1 1 1 1 2 3 4 5 6 7

PART NO.

DESCRIPTION

4028758 4028759 4028760 4028761 4028762 4036731 239906 2063780 1586430 4027715 4033465

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) ............................................................................

Drive Wheel (230 x 84) (Topthane Grip) .............................................................

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

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

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

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

Master Drive Unit (FFigure 1-1).........................................................................

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 1 5 1 1 1 1 4

1-7

UNIT CODE A290 NORTH AMERICA

11/2013

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

1-8

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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 (Tandem 923 mm Length) .............................................

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

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

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

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

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

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

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

Fork Frame (Tandem 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

1-9

UNIT CODE A290 NORTH AMERICA

11/2013

LIFT LINKAGE (FIGURE 1-5)

1-10

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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

PART NO.

DESCRIPTION

4028848 4030424 4028402 4028403 4028401 4028906 4028907 4028908 4028909 4028910 4028911 4028840 4028850 4028849 4015768 2305757 302456 .....

4028851 1603253

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

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

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

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

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

Pull Rod (900 MM Standard Fork) ......................................................................

Pull Rod (1000 MM Standard Fork) ....................................................................

Pull Rod (1150 MM Standard Fork) ....................................................................

Pull Rod (900 MM Tandem Fork) .......................................................................

Pull Rod (1000 MM Tandem Fork) .....................................................................

Pull Rod (1150 MM Tandem Fork) .....................................................................

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

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

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

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

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

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

Load Wheels (FFigure 1-6, FFigure 1-7)..........................................................

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

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

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

1-11

UNIT CODE A290 NORTH AMERICA

11/2013

LOAD WHEELS (FIGURE 1-6)

ITEM 1 2 3 4 5 6 7 8

1-12

PART NO.

DESCRIPTION

QTY

2790367 1590873 1590996 2079496 1590992 1590994 1590912 1591000

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

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

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

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

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

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

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

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

See Service Manual for service procedures.

4 2 2 2 1 1 2 2

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

LOAD WHEELS (FIGURE 1-7) TANDEM

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

PART NO.

DESCRIPTION

2790367 1574119 1607371 1590883 2792131 1590886 1590995 1590912 2079496 1590991 1590993

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

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

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

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

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

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

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

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

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

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

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

4 2 4 4 4 4 4 2 2 1 1

1-13

UNIT CODE A290 NORTH AMERICA

11/2013

CASTER WHEEL ASSEMBLY (FIGURE 1-8)

1-14

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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 ..... ..... ..... ..... ..... .....

293658 2099287 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 .............................................................................................................

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

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

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.

1-15

UNIT CODE A290 NORTH AMERICA

11/2013

BACKREST (FIGURE 1-9)

1-16

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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 A290 NORTH AMERICA

11/2013

COVERS (FIGURE 1-10)

1-18

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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

PART NO.

DESCRIPTION

4037291 4037290 4043379 4037289 4037294 4037293 4037292 1527879 18834 2063099 1382472 1502543 1671912 1527880 .....

Cover (Main Pocket Front) ..................................................................................

Cover (Main Pocket Back) ..................................................................................

Plate (Logo) ........................................................................................................

Cover (Main) .......................................................................................................

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

Cover (Center Main) ...........................................................................................

Battery Tray Assembly (Includes 4 Inserts and 1 Magnet) .................................

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

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

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

1 1 1 1 1 1 1 5 2 2

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

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

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

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

5 1 1 3

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1-19

UNIT CODE A290 NORTH AMERICA

11/2013

DECAL AND PLATE LOCATION (FIGURE 1-11)

1-20

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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

PART NO.

DESCRIPTION

1529042 1606674 4035544 4034008 4033898 1529043 2792746 4038222 4038225

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

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

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

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

Label (BDI) ..........................................................................................................

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

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

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

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 1 1 2 2 2 2

1-21

UNIT CODE A290 NORTH AMERICA

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NOTES

1-22

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

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2

ELECTRICAL SYSTEM

11/2013

UNIT CODE A290 NORTH AMERICA

SECTION 2 ELECTRICAL SYSTEM DESCRIPTION

PAGE

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

CONTROL PANEL ASSEMBLY ......................................................................................................................

EMERGENCY STOP .......................................................................................................................................

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

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

2-5 2-4 2-2

©2013 HYSTER COMPANY

2-1

See Service Manual for service procedures.

2-6 2-8

UNIT CODE A290 NORTH AMERICA

11/2013

EMERGENCY STOP (FIGURE 2-1)

2-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

EMERGENCY STOP ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO.

DESCRIPTION

1486162 1594442 320157 239503 1706781 293744 292668 4613983 4614113 4614114 4614096 4613997 4613998 4613999 .....

1382472 1502543 1670032

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

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

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

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

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

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

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

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

Power Cable (E-Stop) .........................................................................................

Power Cable (Jumper) ........................................................................................

Battery Cable ......................................................................................................

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

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

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

Control Panel (FFigure 2-2)...............................................................................

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

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

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

3 5

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

2-3

UNIT CODE A290 NORTH AMERICA

11/2013

CONTROL PANEL ASSEMBLY (FIGURE 2-2)

ITEM 1 2 2 3 4 5 6 7 8 9

2-4

PART NO.

DESCRIPTION

QTY

4033489 4038296 4041497 1707683 4612315 2042675 383931 2303104 1307884 1514429 292669

Control Panel Bracket .........................................................................................

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

Key .................................................................................................................

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

Controller (Traction AC 200) ...............................................................................

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

Contactor (FFigure 2-3).....................................................................................

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

1 1 1 1 1 1 1 6

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

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

6 2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

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CONTACTOR (FIGURE 2-3)

ITEM 1 2 3 4 5 6 7

PART NO.

DESCRIPTION

383931 378547 379522 384398 383985 383984 1374238 379524

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

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

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

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

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

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

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

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 2 1 1 1 1 1

2-5

UNIT CODE A290 NORTH AMERICA

11/2013

WIRE HARNESS (FIGURE 2-4) MAIN

2-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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

PART NO.

DESCRIPTION

4614576 .....

2056243 2035276 252293 1306270 .....

2059812 2302852 .....

1369409 2309579 .....

1484397 1330434 1532664 1566117 1306270 1306270 1306270 .....

1532219 .....

1531973 1531974 1463139 .....

1463189 1463139 1463196 .....

1508206 1508232 .....

1508211 1508232 .....

1561559 1561755 1463138 1566117 2033694

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

Connector Assembly (CPS01 Main Controller) ..............................................

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

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

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

Terminal (Key Switch) ....................................................................................

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

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

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

Connector Assembly (CPS07 BDI) ................................................................

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

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

Connector Assembly (CPS09 PC Connector) ................................................

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

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

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

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

Terminal (Main Contactor) ..............................................................................

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

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

Connector Assembly (CPS05 Lower Valve) ...................................................

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

Connector Assembly (Handle) .......................................................................

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

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

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

Connector Assembly (CPS10 Backup Alarm) ................................................

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

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

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

Connector Assembly (CPS02 Temperature Sensor) .....................................

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

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

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

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

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

Connector Assembly (CPS04 Brake) .............................................................

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

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

Terminal Pin ...............................................................................................

Dust Cap (Fuse 2) ..........................................................................................

Fuse Holder (Main Contactor) ........................................................................

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

1 1 1 23 1 2 1 1 4 1 1 3 1 1 3 1 1 4 2 2 1 1 1 1 1 6 1 1 4 1 1 1 2 1 1 4 1 1 1 2 1 1

2-7

UNIT CODE A290 NORTH AMERICA

11/2013

WIRE HARNESS (FIGURE 2-5) TILLER

ITEM 1 1 1 2 2 2 3 3 3 3

2-8

PART NO.

DESCRIPTION

QTY

4613950 .....

1369409 2309579 .....

2048593 2309579 .....

1530960 1530961 1463138

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

Connector Assembly ......................................................................................

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

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

Connector Assembly ......................................................................................

Connector (6 Way) .....................................................................................

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

Connector Assembly ......................................................................................

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

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

Terminal Pin ...............................................................................................

See Service Manual for service procedures.

1 1 1 2 1 1 4 1 1 1 6

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

3

STEER HANDLE/BRAKE SYSTEM

11/2013

UNIT CODE A290 NORTH AMERICA

SECTION 3 STEER HANDLE/BRAKE SYSTEM DESCRIPTION

PAGE

TILLER HANDLE ASSEMBLY ........................................................................................................................

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

3-2 3-4

©2013 HYSTER COMPANY

3-1

See Service Manual for service procedures.

UNIT CODE A290 NORTH AMERICA

11/2013

TILLER HANDLE ASSEMBLY (FIGURE 3-1)

3-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

TILLER HANDLE ASSEMBLY ITEM 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO.

DESCRIPTION

4613950 4028840 4009088 4047416 1528482 1581739 2039858 1450356 4601335 4031237 96730 4031901 4030424 4009809 1527880 4035851 1567539 4033899

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

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

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

Gas Spring (Alternate Part) ................................................................................

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

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

Ball Stud .............................................................................................................

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

Sensor ................................................................................................................

Mounting Weldment ............................................................................................

Grommet .............................................................................................................

Shaft Assembly (Tiller Handle Pivot) ..................................................................

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

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

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

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

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

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

©2013 HYSTER COMPANY

QTY

See Service Manual for service procedures.

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

3-3

UNIT CODE A290 NORTH AMERICA

11/2013

TILLER HEAD ASSEMBLY (FIGURE 3-2)

3-4

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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 4023861 1466935 4013193 1594131 4036438 1466605 4011993 4036439 4036440 1498102 1466604 a 1466602

DESCRIPTION

QTY

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

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

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

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

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

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

Spring , Directional Control Return (Return Control) ......................................

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

Horn Button Cover ..........................................................................................

Tiller Head Assembly (Lower Half) (Composite) (Lower Half) ........................

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

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

Cover , Rear (For Push Button) (Rear Cover) ................................................

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

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

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

1 2 2 1 2 1 1 1 1 1 3 1 1 1 1 1

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

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

Spring , Directional Control Return (Control Return) ......................................

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

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

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

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

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

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

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

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

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 A290 NORTH AMERICA

11/2013

NOTES

3-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

4

HYDRAULIC SYSTEM

11/2013

UNIT CODE A290 NORTH AMERICA

SECTION 4 HYDRAULIC SYSTEM DESCRIPTION

PAGE

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

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

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

4-4 4-6 4-2

©2013 HYSTER COMPANY

4-1

See Service Manual for service procedures.

UNIT CODE A290 NORTH AMERICA

11/2013

HYDRAULIC SYSTEM (FIGURE 4-1)

4-2

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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 4-2)...............................................................................

Hydraulic Power Unit (FFigure 4-3)...................................................................

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

4-3

UNIT CODE A290 NORTH AMERICA

11/2013

CYLINDER ASSEMBLY (FIGURE 4-2)

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 ......................................................................................................

Cylinder Liner .................................................................................................

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

Cylinder Head .................................................................................................

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

4-4

QTY

See Service Manual for service procedures.

©2013 HYSTER COMPANY

11/2013

UNIT CODE A290 NORTH AMERICA

NOTES

©2013 HYSTER COMPANY

See Service Manual for service procedures.

4-5

UNIT CODE A290 NORTH AMERICA

11/2013

HYDRAULIC POWER UNIT ASSEMBLY (FIGURE 4-3)

4-6

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

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.

4-7

UNIT CODE A290 NORTH AMERICA

11/2013

NOTES

4-8

See Service Manual for service procedures.

©2013 HYSTER COMPANY

UNIT CODE A290 NORTH AMERICA

11/2013

5

NUMERICAL INDEX

UNIT CODE A290 NORTH AMERICA

11/2013

SECTION 5 NUMERICAL INDEX PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

16482 18834 39373 96730 222399 239503 239906 252293 292668 292669 293658 293744 293761 296027 302456 320152 320157 378547 379522 379524 383931

4-3 1-19 4-4 3-3 4-3 2-3 1-7 2-7 2-3 2-4 1-15 2-3 3-5 1-15 1-11 3-5 2-3 2-5 2-5 2-5 2-4 2-5 2-5 2-5 2-5 2-7 2-7 2-7 2-7 2-7 2-7 2-8 2-5 3-3 1-15 2-7 2-8 2-7 2-7 2-7 2-7 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-5

4 9 11 10 4 4 3 2 7 9 8 6 10

1484397 1486162 1498102 1499660 1502543

10 2 3 1 2 7 6

1527880

2-7 2-3 3-5 3-5 1-19 2-3 4-7 2-7 2-7 2-7 2-7 2-4 1-19 4-3 1-19 3-3 3-3 1-17 1-21 1-21 2-8 2-8 3-5 2-7 2-7 2-7 2-7 2-7 2-7 2-7 2-7 3-3 4-3 1-13 3-3 1-7 1-12 1-13 1-13 1-12 1-13 1-13 1-12 1-13 1-12 1-13 1-12 1-12 3-5

1594442 1603253 1603821 1603825 1603826 1606674 1607371 1652960 1670032 1671912 1706781 1707683 2033694 2035276 2039858 2042675 2047199 2047200 2047201 2047202 2048593 2056243 2059812 2063099 2063780 2074624

2-3 1-11 4-7 4-7 4-7 1-21 1-13 3-5 2-3 1-19 2-3 2-4 2-7 2-7 3-3 2-4 1-15 1-15 1-15 1-15 2-8 2-7 2-7 1-19 1-7 4-3 4-4 4-4 4-4 4-4 4-4 1-12 1-13 4-3 3-5 1-15 3-5 2-7 2-4 1-11 2-7 2-8 2-8 1-12 1-13 1-13 4-4 1-21 4-4

4006485 4006514 4009088 4009809 4010117 4010119 4010120 4010123 4010126 4010127 4011993 4011997 4013193 4013194 4013196 4015768 4016755 4024051 4024052 4024053 4027715

1-15 4-3 3-3 3-3 1-15 1-15 1-15 1-15 1-15 1-15 3-5 3-5 3-5 3-5 3-5 1-11 3-5 1-15 1-15 1-15 1-3 1-4 1-7 1-11 1-11 1-11 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-7 1-7 1-7 1-7 1-7

383984 383985 384398 1306270

1330434 1369409 1374238 1450356 1460477 1463138 1463139 1463189 1463196 1466595 1466602 1466604 1466605 1466606 1466607 1466935 1467779

5 4 3 3 7 8 9 6 5 1 6 7 15 3 11 12 12 12 4 22 20 11 6 16 5

©2013 HYSTER COMPANY

1506131 1508206 1508211 1508232 1514429 1527879

1528482 1528778 1529042 1529043 1530960 1530961 1531075 1531973 1531974 1532219 1532664 1561559 1561755 1566117 1567539 1569917 1574119 1581739 1586430 1590873 1590883 1590886 1590912 1590991 1590992 1590993 1590994 1590995 1590996 1591000 1594131

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

2076498 2076499 2076501 2076502 2079496 2094732 2097314 2099287 2111838 2302852 2303104 2305757 2309579 2790367 2792131 2792464 2792746 2798721

See Service Manual for service procedures.

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

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 4028762

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

UNIT CODE A290 NORTH AMERICA

11/2013

NUMERICAL INDEX (continued) PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

PART NO.

PAGE ITEM

4028840

1-11 3-3 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-17 1-11 3-3 3-3 3-3 1-7 2-4 1-21 3-3 3-5 1-17 1-17

4034008 4035544 4035751 4035752 4035754 4035755 4035756 4035757 4035758 4035775 4035776 4035777 4035783 4035784 4035785 4035787 4035851

1-21 1-21 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 1-17 3-3 1-4 1-4 1-4 1-4 1-4 1-4

4035944 4035945 4035946 4035947 4035948 4035949

1-3 1-3 1-3 1-3 1-3 1-3 1-4 1-3 1-17 1-17 3-5 3-5 3-5 1-7 1-19 1-19 1-19 1-19 1-19 1-19 1-21 1-21 2-4 2-4

4043379 4047416 4052293 4052294 4052295 4052296 4052297 4052298 4601335 4603400 4612314

1-19 3-3 1-9 1-9 1-9 1-9 1-9 1-9 3-3 4-4 4-3 4-7 2-4 4-3 2-8 3-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-7

4028848 4028849 4028850 4028851 4028906 4028907 4028908 4028909 4028910 4028911 4029051 4030424 4031237 4031901 4033465 4033489 4033898 4033899 4033999 4034000

5-2

5 2 1 7 6 12 4 4 4 4 4 4 4 2 12 9 11 7 1 5 17 2 3

4035931 4035933 4035934 4035935 4035936 4035937

4 3 2 4 10 11 12 6 7 7 8 8 9 5 5 15 2 3 6 5 4 7

4035954 4036160 4036161 4036438 4036439 4036440 4036731 4037289 4037290 4037291 4037292 4037293 4037294 4038222 4038225 4038296 4041497

See Service Manual for service procedures.

4 3 8 13 1 5 1 1 19 21 21 2 4 2 1 7 6 5 8 9 2 2

4612315 4613260 4613950 4613983 4613997 4613998 4613999 4614096 4614113 4614114 4614576

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

©2013 HYSTER COMPANY