Hyster Challenger H40 00xm16ch 52 00xm16ch E117 Parts Manual

Full download:

PARTS
MANUAL
CHALLENGER
H40.00XM-H48.00XM-16CH,
H50.00XM-H52.00XM-16CH
(E117)

CUSTOMER EDITION

1546436 ©2004 Hyster Company

07/2004
This is the cut pages sample. Download all 522 page(s) at: ManualPlace.com
 UNIT CODE E117
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SECTIONS

1 FRAME

2 ENGINES

3 FUEL SYSTEM

4 ELECTRICAL SYSTEM

5 TRANSMISSION

6 DRIVE AXLE

7 STEERING SYSTEM

8 BRAKE SYSTEM

9 HYDRAULIC SYSTEM

10 MAST WITH EMPTY CONTAINER HANDLER

11 CONTAINER HANDLER ATTACHMENT

12 ATTACHMENTS

13 OPTIONS

14 NUMERICAL INDEX

This Parts Manual is divided into 14 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.
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TABLE OF CONTENTS

DESCRIPTION PAGE

A
ACCUMULATOR
PISTON TYPE
AIR CONDITIONING SYSTEM .......................................................................................................................... 1-38
AIR FILTER SYSTEM
AIR INLET CONNECTION
AIR OUTLET CONNECTION
AIR TRANSFER CONNECTION
ALARM
ALTERNATOR AND MOUNTING
ARMREST ASSEMBLY
SEAT............................................................................................................................................................... 1-36
ARMREST SWITCHES...................................................................................................................................... 4-19
AXLE HOUSING
WET BRAKE

B
BRAKE AND INCHING PEDAL LINKAGE
BRAKE ASSEMBLY
DISC
WET BRAKE
WET BRAKE................................................................................................................................................... 8-10
BRAKE SYSTEM
BRAKE VALVE ASSEMBLY................................................................................................................................ 8-12
BREATHER PLUMBING

C
CABATTACHINGPARTS 1-12
CAB FLOORMATS ............................................................................................................................................. 1-20
CAB MOUNT...................................................................................................................................................... 1-10
CABPANELS ..................................................................................................................................................... 1-26
CAB SOUND REDUCTION
CLUTCH
FORWARD
T36000 SERIES.......................................................................................................................................... 5-12
FOURTH SPEED
T36000 SERIES.......................................................................................................................................... 5-18
LOW SPEED
T36000 SERIES
REVERSE AND 2ND SHAFT
T36000 SERIES.......................................................................................................................................... 5-10
THIRD SPEED
T36000 SERIES
CONDENSER..................................................................................................................................................... 1-42
CONTROL PANEL
AIR CONDITIONER
HEATER
CONTROL VALVE
ELECTRONIC INCHING
T36000 SERIES.......................................................................................................................................... 5-26
HYDRAULIC INCHING

©2004 HYSTER COMPANY See Service Manual i

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

C(continued)

T36000 SERIES.......................................................................................................................................... 5-30

CONTROL VALVE ASSEMBLY
AUXILIARY
CAP AND SUPPORT KIT............................................................................................................................... 9-18
LIFT
LIFT AND TILT................................................................................................................................................ 9-16
CONVERTER HOUSING ATTACHMENT
THREE SPEED
T36000 SERIES.......................................................................................................................................... 5-22
COOLANT HEATER STARTING AID
COOLING
CORROSION RESISTOR
COUNTERWEIGHT
FABRICATED.................................................................................................................................................... 1-8
COVERS

D
DC-DC CONVERTER AND ATTACHING PARTS
DEDICATED CARRIAGE
DIFFERENTIAL CARRIER
WET BRAKE
DOOR ATTACHING PARTS 1-14
DRIVE PULLEY
AIR COMPRESSOR
WATER PUMP
DRIVE TIRE AND WHEEL
18.00 X 25..................................................................................................................................................... 13-12
DRIVE TRAIN
FRONT

E
ELECTRICAL ACCESSORIES
ELECTRICAL SYSTEM
SERIES 813 AND 818
SERIES 818.................................................................................................................................................. 11-32
ENGINE ASSEMBLY
ENGINE MOUNT
EXHAUST
EXHAUST MANIFOLD
EXTENSION CYLINDER AND ATTACHING PARTS
SERIES 813 AND 818 .................................................................................................................................. 11-20

F
FAN..................................................................................................................................................................... 2-56
FAN DRIVE
FLOORPLATES, STEPS, AND RAILS
FLOW AMPLIFIER ............................................................................................................................................. 9-26
FLYWHEEL
FRONT ENGINE SUPPORT

ii See Service Manual ©2004 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

F(continued)

FRONT, BRAKE/BACK-UP AND REAR WORK LIGHTS................................................................................... 13-2

FUEL FILTER PLUMBING
FUEL SYSTEM..................................................................................................................................................... 3-2
FUSE BOX
SEALED
FUSES AND RELAYS 4-26

G
GANTRY CARRIAGE
WITH MECHANICAL PILE SLOPE
WITH POWER PILE SLOPE

H
HANDLEVER INSTALLATION
HANGER ASSEMBLY
SERIES 818.................................................................................................................................................... 11-2
HEADER HOSE
HEATER AND AIR CONDITIONER ASSEMBLY 1-46
HEATER AND AIR CONDITIONER MOUNT
HEATER ASSEMBLY
HEATER HOSE ARRANGEMENT
HORN AND ATTACHING PARTS ....................................................................................................................... 4-22
HUB AND SHAFT
WET BRAKE..................................................................................................................................................... 6-8
HYDRAULIC PUMP
MAIN............................................................................................................................................................... 9-28
STEERING
DUAL........................................................................................................................................................... 9-30
HYDRAULIC STOP ASSEMBLY
SERIES 813 AND 818 .................................................................................................................................... 11-6
HYDRAULIC SUPPLY AND RETURN
SHEET 1 OF 2
SHEET 2 OF 2
HYDRAULIC SYSTEM
SERIES 813.................................................................................................................................................. 11-34
SERIES 818.................................................................................................................................................. 11-36
HYDRAULIC TANK AND ATTACHING PARTS................................................................................................... 9-20
HYDRAULIC VALVE AND ATTACHING PARTS 9-8

I
INDICATOR DISPLAY ASSEMBLY
INTAKE MANIFOLD ........................................................................................................................................... 2-58

J
JOYSTICK INSTALLATION ................................................................................................................................ 9-38

©2004 HYSTER COMPANY See Service Manual iii

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

L
LABELS.............................................................................................................................................................. 1-56
LIFT ACCUMULATOR AND ATTACHING PARTS .............................................................................................. 9-22
LIFT CYLINDER
12650 MM (498.0 IN.) LIFT HEIGHT
LIFTING BRACKET
LIGHT BAR AND MOUNT
CAB

M
MAIN FRAME
SERIES 813 AND 818
MANIFOLD
CAB................................................................................................................................................................. 9-32
LIFT AND TILT
MAIN
MAST ASSEMBLY.............................................................................................................................................. 10-2
MAST INSTALLATION

N
NOISEPANEL...................................................................................................................................................... 2-3

O
OIL COOLER WATER PLUMBING
OIL FILLER ARRANGEMENT
HAND COVER
OIL FILTER
OIL FILTER AND COOLER HEAD
OILPAN.............................................................................................................................................................. 2-12

P
PENDULAR TWIST LOCK
SERIES 813 AND 818 .................................................................................................................................. 11-12
PILOT VALVE ASSEMBLY
JOYSTICK....................................................................................................................................................... 9-40
PIVOT ARM ASSEMBLY.................................................................................................................................... 1-34
PUMP DRIVE AND SHAFT
T36000 SERIES

R
RADIATOR PLUMBING
RADIO CONSOLE.............................................................................................................................................. 4-18
REGULATING PRESSURE VALVE AND CHARGE PUMP
T36000 SERIES
ROTATING BEACON 13-6

S
SEATASSEMBLY
AIR.................................................................................................................................................................. 1-32
MECHANICAL ................................................................................................................................................ 1-30
SIDE-SHIFT CYLINDER

iv See Service Manual ©2004 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

S(continued)

SERIES 813 AND 818 .................................................................................................................................. 11-15

SLEWING CYLINDER
SERIES 813 AND 818 .................................................................................................................................. 11-17
STAIR LIGHT
STARTER MOTOR
STEEL DOOR
LEFT HAND
RIGHT HAND.................................................................................................................................................. 1-16
STEER TIRE AND WHEEL
STEERING AXLE AND ATTACHING PARTS
STEERING AXLE ASSEMBLY
STEERING COLUMN AND ATTACHING PARTS
STEERING COLUMN ASSEMBLY
STEERING CONTROL VALVE
STEERING CYLINDER...................................................................................................................................... 7-10
STOP KIT ASSEMBLY....................................................................................................................................... 11-4

T
THERMOSTAT
THERMOSTATHOUSING
THROTTLE PEDAL LINKAGE
TILTCYLINDER ................................................................................................................................................. 9-46
TILTCYLINDER AND ATTACHING PARTS
TIRES AND WHEELS
DRIVE AND STEER
18.00 X 33 X 36 PLY................................................................................................................................. 13-14
TRAINING SEAT................................................................................................................................................ 1-28
TRANSMISSION
T40000 SERIES
CASE AND REAR COVER
ELECTRIC CONTROL VALVE
FIRST SPEED CLUTCH
FIRST SPEED GEARS ............................................................................................................................... 5-44
FORWARD CLUTCH SHAFT
FORWARD, REVERSE, SECOND AND FOURTH CLUTCH SHAFT......................................................... 5-43
FOURTH SPEED CLUTCH SHAFT............................................................................................................ 5-56
INPUT DRIVE GEARS
MODULATOR VALVE.................................................................................................................................. 5-66
OUTPUT FLANGE AND SHAFT................................................................................................................. 5-60
OUTPUT SHAFT GEARS ........................................................................................................................... 5-58
PUMP DRIVE
REGULATING VALVE AND CHARGE PUMP ............................................................................................. 5-62
SECOND AND REVERSE CLUTCH SHAFT
THIRD SPEED CLUTCH SHAFT................................................................................................................ 5-48
THIRD SPEED GEARS
TORQUE CONVERTER AND DRIVE PLATE ............................................................................................. 5-34
TORQUE CONVERTER HOUSING
TURBINE SHAFT, STATOR SUPPORT AND OIL BAFFLE 5-36
TRANSMISSION CASE AND REAR COVER

©2004 HYSTER COMPANY See Service Manual v

for service procedures.
 UNIT CODE E117
EUROPE 07/2004

TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

T(continued)

T36000 SERIES................................................................................................................................................ 5-8

TRANSMISSION CONTROLLER AND SHIFT LEVER
TRANSMISSION LINES AND ATTACHING PARTS
TURBOCHARGER
TURBOCHARGER PLUMBING

U
UNDERFLOOR COVER MOUNT
UNIVERSAL SHAFT

V
VALVE
EXTENSION CYLINDER
SERIES 813 AND 818
VALVE ASSEMBLY
SERIES 813.................................................................................................................................................. 11-26
SERIES 813 AND 818 .................................................................................................................................. 11-28
VALVE COVER................................................................................................................................................... 2-66
VIBRATION DAMPER

W
WATER PUMP
WATER SEPARATOR
WEARPADS
SERIES 813 AND 818
WHEEL AND DRIVE PLATE
T36000 SERIES
WINDOW INSTALLATION
WINDOW WIPER SYSTEM
SHEET 1 OF 2
SHEET 2 OF 2................................................................................................................................................. 1-54
WIRE HARNESS
ARMREST
CAB LIGHT
CHASSIS ........................................................................................................................................................ 4-30
CLOSED CAB
FRONT LIGHTS.............................................................................................................................................. 4-64
JOYSTICK............................................... 4-62
JUMPER
LIGHT SWITCH
SHEET 1 ..................................................................................................................................................... 4-45
SHEET 2 ..................................................................................................................................................... 4-46
LUBRICATION PUMP
POWER PILE SLOPE
MAST .......................................................................................................................................................... 4-38
SOLENOID VALVE...................................................................................................................................... 4-39
REAR.............................................................................................................................................................. 4-35
REAR WIPER
ROTATING BEACON

vi See Service Manual (C) 2004 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

W(continued)

SIDE CONSOLE
SHEET 1 OF 2
SHEET 2 OF 2
STAIR LIGHT
STEERING COLUMN................................................................. 4-55
SWITCHES
TRANSMISSION
T36000 SERIES
T40000 SERIES
UNDER FLOOR
WASH PUMPS ............................................................................................................................................... 4-36
WIRING ACCESSORIES
ELECTRONIC CONTROL MODULE

©2004 HYSTER COMPANY See Service Manual vii

for service procedures.
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ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

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 PowerTake Off
ECH Empty Container Handler
RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High
S/N Serial Number
Stacking
TMM TruckManagementModule
ECH-4 Empty Container Handler - 4 High
Stacking ULType D Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High ULType DS Diesel-Powered Safety Rating
Stacking ULType E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High ULType EE Battery-Powered Safety Rating
Stacking ULType ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High ULType G Gasoline-Powered Safety Rating
Stacking
ULType GS Gasoline-Powered Safety Rating
ECM Electronic Control Module
ULType LP Gas-Powered Safety Rating
ECN Engineering Change Notice
ULType LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable
U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPROM Electrically Programmable Read Only
Memory V Volts

viii See Service Manual ©2004 HYSTER COMPANY

for service procedures.
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HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.

©2004 HYSTER COMPANY See Service Manual ix

for service procedures.
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HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT previous page, BEARING CAP(Item 2) is a
HIGHER ASSEMBLY IS NOT KNOWN: subpart of the major assembly CASE.

1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASEassembly.

2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
TableofContentstodeterminetheassemblywhich parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.

3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on.Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.

5. Use the Numerical Index on Page 14-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (.....) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with an ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERINGPARTS
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
columns are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.

x See Service Manual ©2004 HYSTER COMPANY

for service procedures.
 UNIT CODE E117
07/2004 EUROPE

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 and 1980.
The letters "I", "O", and "Q" shall nat 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.

©2004 HYSTER COMPANY See Service Manual xi

for service procedures.
 UNIT CODE E117
EUROPE 07/2004

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast 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 mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code

letter, and date of manufacture are stamped
approximately six inches below the top of most
forks.

2. The carriage group number is stamped on the

right hand side of the top crossmember (pin type)
or on the back of the right hand end of the bottom
crossmember (hook type). A date code has two
letters in line with or below the carriage group
number.

3. The mast identification number has a unit code,

a letter indicating the plant of manufacture, and
a serial number. Underneath the production
sequence number is a four digit number that
indicates the carriage travel in millimeters.

4. The tilt and lift cylinder group numbers are stamped

on the cylinder shell.

Always refer to the group, serial, or part number

when ordering service parts.

Modification of masts and carriages by SPED

(Special Products Engineering Department) are
identified by a model prefix code beginning with
the letter "S". contact your dealer for Hyster lift
trucks for information on these assemblies.

twelve See Service Manual ©2004 HYSTER COMPANY

for service procedures.
 UNIT CODE E117
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IDENTIFICATION OF ATTACHMENT AND

SIDE-SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Hyster lift trucks.

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to
identify the attachment.

Always refer to the group, serial, or part number when ordering service parts.

Modificaciones de accesorios y carretillas de desplazamiento lateral por SPED (Departamento de Ingeniería de Productos Especiales)
are identified by a model prefix code beginning with the letter 'S'. Contact your dealer for Hyster lift trucks for
information on these assemblies.

©2004 HYSTER COMPANY See Service Manual thirteen

for service procedures.
 UNIT CODE E117
EUROPE 07/2004

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 HYSTERPART NUMBER

Operating Manual

Service Manual (Complete) .................................................................................................. 1546437

Parts Manual

fourteenth See Service Manual ©2004 HYSTER COMPANY

for service procedures.
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07/2004 EUROPE

1 FRAME

1 FRAME
Hyster Challenger H40 00xm16ch 52 00xm16ch E117 Parts Manual
Full download:http://manualplace.com/download/hyster-challenger-h40-00xm16ch-52-00xm16ch-e117-parts-manual/

This is the cut pages sample. Download all 522 page(s) at: ManualPlace.com