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Hyster CHALLENGER H1050HD-CH H1150HD-CH (F117) Parts Manual – PDF DOWNLOAD
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Hyster CHALLENGER H1050HD-CH H1150HD-CH (F117) Parts Manual – PDF DOWNLOAD
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Description
Hyster CHALLENGER H1050HD-CH H1150HD-CH (F117) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster CHALLENGER H1050HD-CH H1150HD-CH (F117) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs correspond to descriptions found on the next page.
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. 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.
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. 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.
2. 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:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
4. 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:
5. Use the Numerical Index (Page 14-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 14-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session 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 (Figure 10)
7. 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.
TABLE OF CONTENTS:
Hyster CHALLENGER H1050HD-CH H1150HD-CH (F117) Parts Manual – PDF DOWNLOAD
Frame........................................................................................................ 21 COVERS................................................................................................... 26 COVERS................................................................................................... 28 DUST SHIELD.............................................................................................. 30 FLOORPLATES, STEPS, AND RAILS............................................................................ 32 COUNTERWEIGHT............................................................................................ 35 MIRRORS FRONT FENDER..................................................................................... 36 OVERHEAD GUARD WIRE MESH................................................................................. 38 CAB ATTACHING PARTS...................................................................................... 40 CAB DOOR RIGHT HAND...................................................................................... 42 CAB DOOR LEFT HAND....................................................................................... 44 CAB MAIN DOOR WINDOW - RIGHT AND LEFT HAND .............................................................. 46 CAB DOOR - ATTACHING PARTS .............................................................................. 48 MAIN WINDOW ASSEMBLY..................................................................................... 50 WINDOW WIPER SYSTEM SHEET 1 OF 2 (→ S/N F117E01646F) ................................................... 52 WINDOW WIPER SYSTEM SHEET 2 OF 2 (→ S/N F117E01646F) ................................................... 54 WINDOW WIPER SYSTEM WASHER BOTTLE KIT (S/N F117E01647F →) .............................................. 56 WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS - AND FRONT WIPER OPTIONS (S/N F117E01647F →) ............ 58 CAB FLOORMATS............................................................................................ 60 CAB MOUNTING............................................................................................. 62 CAB PANELS............................................................................................... 64 CAB SOUND REDUCTION...................................................................................... 66 CAB SUNSHADE - TOP ...................................................................................... 67 CAB SUNSHADE - REAR ..................................................................................... 68 CAB WINDOW INSTALLATION.................................................................................. 70 DASH AND AIR DUCT ASSEMBLY CAB........................................................................... 72 DELUXE SUSPENSION SEAT................................................................................... 74 SUSPENSION KIT ASSEMBLY.................................................................................. 76 SEAT ASSEMBLY WITH FABRIC COVER (→ 3/2010) ............................................................. 78 SEAT ASSEMBLY WITH FABRIC COVER (3/2010 →) ............................................................. 82 SEAT ASSEMBLY WITH VINYL COVER........................................................................... 86 SEAT AND SUSPENSION MOUNTING............................................................................. 89 SEAT SUSPENSION ASSEMBLY MECHANICAL...................................................................... 92 SEAT SUSPENSION ASSEMBLY AIR............................................................................. 96 SEAT PIVOT ARM ASSEMBLY..................................................................................100 AIR CONDITIONER SYSTEM WITH TWO-FAN CONDENSER SYSTEM - MCC ..............................................102 AIR CONDITIONER WITH TWO-FAN CONDENSER SYSTEM - MCC .....................................................104 CONDENSER ASSEMBLY TWO-FAN SYSTEM - MCC .................................................................106 AIR DUCT ASSEMBLY AIR CONDITIONING - WITH TWO-FAN CONDENSER SYSTEM, MCC .................................108 AIR CONDITIONER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM - MCC ............................................110 CONTROL PANEL ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM - MCC ..............................................112 HEATER AND AIR DUCT WITH TWO-FAN CONDENSER SYSTEM - MCC .................................................113 HEATER SYSTEM WITH TWO-FAN CONDENSER SYSTEM - MCC .......................................................114 AIR DUCT ASSEMBLY HEATER - WITH TWO-FAN CONDENSER SYSTEM, MCC ...........................................116 HEATER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM - MCC .....................................................118 AIR CONDITIONING SYSTEM MCC AND AURORA...................................................................120 AIR COMPRESSOR AND HOSES MCC (S/N F117E01647F →) .......................................................122 AIR CONDITIONING SYSTEM CONDENSER - AURORA ..............................................................124 HEATER HOSE ARRANGEMENT..................................................................................126 HEATER ASSEMBLY WITH THREE-FAN CONDENSER SYSTEM - AURORA ................................................128 HEATER AND AIR CONDITIONER ASSEMBLY WITH THREE-FAN CONDENSER SYSTEM - AURORA ............................130 HEATER AND AIR CONDITIONER MOUNTING WITH THREE-FAN CONDENSER SYSTEM - AURORA ............................132 LABELS...................................................................................................134 ARMREST ASSEMBLY.........................................................................................136 AIR HORN.................................................................................................138 INSULATION MATS AND AIR DUCT CLIMATE CONTROL CAB.........................................................140 AIR DUCT LOUVER, CLIMATE CONTROL CAB.....................................................................142 SEAT ASSEMBLY CLIMATE CONTROL CAB........................................................................144 CLIMATE CONTROL SYSTEM MCC...............................................................................146 AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB - MCC ........................................................148 AIR CONDITIONER CLIMATE CONTROL CAB - MCC ...............................................................150 CAB ASSEMBLY CLIMATE CONTROL CAB.........................................................................152 TRAINING SEAT............................................................................................154 RADIO CONSOLE AND ATTACHING PARTS........................................................................156 ENGINE ASSEMBLY..............................................................................................159 ENGINE ASSEMBLY..........................................................................................163 ACCESSORY DRIVE PULLEY...................................................................................164 ACCESSORY DRIVE PULLEY...................................................................................165 LIFTING BRACKET..........................................................................................166 VALVE COVER..............................................................................................167 THERMOSTAT HOUSING.......................................................................................168 THERMOSTAT...............................................................................................170 CAMSHAFT.................................................................................................171 CAM FOLLOWER LEVERS......................................................................................172 ROCKER LEVERS............................................................................................174 FAN DRIVE AND SPACER.....................................................................................176 IDLER GEAR...............................................................................................178 CYLINDER HEAD............................................................................................180 CYLINDER BLOCK...........................................................................................182 CYLINDER LINER...........................................................................................184 PISTON AND CONNECTING ROD................................................................................186 PISTON COOLING NOZZLE....................................................................................188 CYLINDER BLOCK PLUMBING..................................................................................189 CRANKSHAFT...............................................................................................191 ENGINE CRANKSHAFT AND MAIN BEARINGS......................................................................192 ENGINE CRANKSHAFT AND MAIN BEARINGS - OPTIONAL ..........................................................194 AIR FILTER SYSTEM........................................................................................196 AIR FILTER ASSEMBLY......................................................................................198 AIR CLEANER PLUMBING.....................................................................................199 AIR TRANSFER CONNECTION..................................................................................200 BREATHER PLUMBING........................................................................................201 COOLANT HEATER STARTING AID..............................................................................202 TURBOCHARGER.............................................................................................204 TURBOCHARGER.............................................................................................208 TURBOCHARGER PLUMBING....................................................................................210 COMPRESSOR MOUNTING......................................................................................212 INTAKE CONNECTOR AIR COMPRESSOR..........................................................................214 DRIVE TRAIN FRONT........................................................................................215 FLYWHEEL.................................................................................................216 FLYWHEEL HOUSING.........................................................................................218 OIL FILTER AND COOLER HEAD...............................................................................220 OIL FILLER ARRANGEMENT...................................................................................222 OIL LEVEL GAUGE..........................................................................................223 OIL FILTER...............................................................................................224 OIL COOLER WATER PLUMBING................................................................................225 WATER PUMP...............................................................................................226 WATER PUMP...............................................................................................228 GEAR HOUSING.............................................................................................230 FRONT GEAR COVER.........................................................................................232 OIL PAN..................................................................................................234 OIL PAN..................................................................................................236 OIL PUMP AND ATTACHING PARTS.............................................................................238 VIBRATION DAMPER.........................................................................................239 COOLING..................................................................................................240 CORROSION RESISTER.......................................................................................242 RADIATOR ASSEMBLY........................................................................................244 RADIATOR PLUMBING........................................................................................246 INTAKE MANIFOLD..........................................................................................248 EXHAUST..................................................................................................250 EXHAUST MANIFOLD.........................................................................................252 EXHAUST OUTLET CONNECTION................................................................................254 NOISE PANEL..............................................................................................255 FRONT ENGINE SUPPORT.....................................................................................256 ENGINE MOUNTS............................................................................................258 HAND HOLE COVER..........................................................................................260 FUEL SYSTEM..................................................................................................263 FUEL SYSTEM..............................................................................................266 FUEL SYSTEM..............................................................................................268 FUEL PUMP DRIVE..........................................................................................271 FUEL PUMP INTAKE FITTING.................................................................................273 FUEL PUMP ASSEMBLY.......................................................................................274 FUEL PUMP COUPLING.......................................................................................276 FUEL PUMP PLUMBING.......................................................................................278 FUEL INJECTOR............................................................................................280 FUEL FILTER PLUMBING.....................................................................................282 FUEL FILTER AND WATER SEPARATOR..........................................................................284 THROTTLE PEDAL LINKAGE...................................................................................286 ELECTRICAL SYSTEM............................................................................................289 ELECTRICAL SYSTEM........................................................................................294 TRANSMISSION CONTROLLER AND SHIFT LEVER..................................................................298 CONSOLE INDICATOR DISPLAY AND CONTROLS...................................................................300 CONTROL PANEL HEATER.....................................................................................302 CONTROL PANEL AIR CONDITIONER............................................................................304 DC-DC CONVERTER AND ATTACHING PARTS......................................................................306 ARMREST SWITCHES HYDRAULIC LEVERS........................................................................307 ARMREST SWITCHES JOYSTICK................................................................................308 ENGINE CONTROL SYSTEM....................................................................................310 ELECTRICAL ACCESSORIES...................................................................................312 WIRING ACCESSORIES ELECTRONIC CONTROL MODULE.............................................................314 ALTERNATOR...............................................................................................316 ALTERNATOR MOUNTING......................................................................................318 ALTERNATOR DRIVE PULLEY..................................................................................320 WIRE HARNESS MAST (→ S/N F117E01610F) ..................................................................321 WIRE HARNESS MAST (S/N F117E01611F →) ..................................................................322 STARTER MOTOR............................................................................................324 STARTER MOTOR............................................................................................325 LIGHT BAR AND MOUNT TWISTLOCK MODULE.....................................................................326 FUSE BOX SEALED..........................................................................................328 RELAYS AND FUSES OPERATOR COMPARTMENT (→ 3/2010) .......................................................330 RELAYS AND FUSES OPERATOR COMPARTMENT (3/2010 →) .......................................................334 WIRE HARNESS SIDE CONSOLE - SHEET 1 OF 2 (→ 3/2010) ...................................................338 WIRE HARNESS SIDE CONSOLE - SHEET 2 OF 2 (→ 3/2010) ...................................................344 WIRE HARNESS SIDE CONSOLE - SHEET 1 OF 2 (3/2010 →) ...................................................348 WIRE HARNESS SIDE CONSOLE - SHEET 2 OF 2 (3/2010 →) ...................................................354 WIRE HARNESS REAR........................................................................................357 WIRE HARNESS EXTENSION (S/N F117E01647F →) .............................................................358 WIRE HARNESS CHASSIS - SHEET 1 OF 2 (→ S/N F117E01610F) ...............................................360 WIRE HARNESS CHASSIS - SHEET 2 OF 2 (→ S/N F117E01610F) ...............................................364 WIRE HARNESS CHASSIS - SHEET 1 OF 2 (S/N F117E01611F →) ...............................................368 WIRE HARNESS CHASSIS - SHEET 2 OF 2 (S/N F117E01611F →) ...............................................372 WIRE HARNESS POWER PILE SLOPE (→ S/N F117E01610F) ......................................................376 WIRE HARNESS SWITCHES - HYDRAULIC LEVERS ................................................................378 WIRE HARNESS STAIR LIGHT.................................................................................380 WIRE HARNESS LIGHT SWITCH................................................................................381 WIRE HARNESS CLOSED CAB..................................................................................382 WIRE HARNESS REAR WIPER EXTENSION........................................................................385 WIRE HARNESS CAB LIGHT...................................................................................386 WIRE HARNESS STEERING COLUMN.............................................................................388 WIRE HARNESS UNDER FLOOR.................................................................................390 WIRE HARNESS POWERTRAIN (→ S/N F117E01610F) ............................................................392 WIRE HARNESS POWERTRAIN (S/N F117E01611F →) ............................................................396 WIRE HARNESS ARMREST.....................................................................................400 WIRE HARNESS JOYSTICK....................................................................................402 WIRE HARNESS FRONT LIGHTS................................................................................404 WIRE HARNESS FRONT LIGHTS - ALTERNATE PART ..............................................................406 WIRE HARNESS CLOSED CAB..................................................................................408 START AID................................................................................................411 SECOND 12V SOCKET OPTION CLIMATE CONTROL CAB.............................................................412 WIRE HARNESS WINDOW WASH PUMPS (→ S/N F117E01646F) .....................................................413 SPEED LIMITING GANTRY CARRIAGE...........................................................................414 PROXIMITY SWITCH.........................................................................................416 WIRE HARNESS PROXIMITY SWITCH - GANTRY ..................................................................417 WIRE HARNESS PROXIMITY SWITCH - LIFT AND TILT ...........................................................418 WIRE HARNESS ADD-ON SPEED LIMITING.......................................................................420 TRANSMISSION.................................................................................................423 TRANSMISSION LINES AND ATTACHING PARTS (→ S/N F117E01677G) .............................................426 TRANSMISSION LINES AND ATTACHING PARTS (S/N F117E01678G →) .............................................430 TRANSMISSION ASSEMBLY....................................................................................434 TRANSMISSION PUMP DRIVE..................................................................................436 TRANSMISSION INPUT DRIVE GEARS...........................................................................438 TRANSMISSION TURBINE SHAFT, STATOR SUPPORT, AND OIL BAFFLE..............................................440 TRANSMISSION CASE AND REAR COVER.........................................................................442 TRANSMISSION SPEED SENSORS...............................................................................444 TRANSMISSION FORWARD, REVERSE AND SECOND, - AND THIRD OR FOURTH CLUTCH SHAFTS ...........................445 TRANSMISSION FORWARD CLUTCH SHAFT........................................................................446 TRANSMISSION REVERSE AND SECOND CLUTCH SHAFT.............................................................448 TRANSMISSION FIRST SPEED GEARS...........................................................................450 TRANSMISSION FIRST SPEED SHAFT AND IDLER GEAR............................................................451 TRANSMISSION FIRST SPEED CLUTCH SHAFT....................................................................452 TRANSMISSION THIRD SPEED GEARS...........................................................................455 TRANSMISSION THIRD SPEED CLUTCH SHAFT....................................................................456 TRANSMISSION FOURTH SPEED CLUTCH SHAFT...................................................................460 TRANSMISSION OUTPUT SHAFT................................................................................462 TRANSMISSION REGULATOR VALVE AND HYDRAULIC PUMP ARRANGEMENT..............................................464 TRANSMISSION TORQUE CONVERTER AND DRIVE PLATE............................................................466 TRANSMISSION TORQUE CONVERTER HOUSING....................................................................468 TRANSMISSION CONTROL VALVE MOUNTING......................................................................472 TRANSMISSION CONTROL VALVE ASSEMBLY......................................................................474 TRANSMISSION REMOTE FILTER AND ADAPTOR...................................................................478 TRANSMISSION UNIVERSAL SHAFT.............................................................................480 Drive Axle...................................................................................................481 AXLE HOUSING.............................................................................................484 DIFFERENTIAL AND CARRIER.................................................................................486 DIFFERENTIAL AND CARRIER ALTERNATE PART..................................................................490 HUB AND SHAFT............................................................................................494 HUB AND SHAFT............................................................................................498 PARK BRAKE ASSEMBLY......................................................................................502 STEERING SYSTEM..............................................................................................505 STEERING AXLE AND ATTACHING PARTS........................................................................508 STEERING AXLE ASSEMBLY...................................................................................510 STEERING CYLINDER........................................................................................512 STEERING CYLINDER........................................................................................513 STEERING COLUMN AND ATTACHING PARTS......................................................................514 STEER COLUMN ASSEMBLY....................................................................................516 STEERING COLUMN..........................................................................................518 STEERING CONTROL UNIT....................................................................................520 STEERING CONTROL VALVE...................................................................................522 BRAKE SYSTEM.................................................................................................525 BRAKE SYSTEM.............................................................................................528 BRAKE ASSEMBLY SERVICE BRAKES - WET BRAKE (S/N F117E01547D → (TE-27)) (S/N F117E01546D → (TE-32)) ....532 BRAKE AND INCHING PEDAL LINKAGE..........................................................................534 HYDRAULIC SYSTEM.............................................................................................537 HYDRAULIC SUPPLY AND RETURN SHEET 1 OF 2.................................................................540 HYDRAULIC SUPPLY AND RETURN SHEET 2 OF 2.................................................................544 HYDRAULIC TANK AND ATTACHING PARTS.......................................................................548 HYDRAULIC SYSTEM LIFT AND TILT (→ 11/2009) .............................................................552 HYDRAULIC SYSTEM LIFT AND TILT (11/2009 →) .............................................................554 HYDRAULIC VALVES AND ATTACHING PARTS.....................................................................556 CONTROL VALVE ASSEMBLY AUXILIARY.........................................................................560 CONTROL VALVE ASSEMBLY LIFT..............................................................................562 CONTROL VALVE ASSEMBLY LIFT AND TILT.....................................................................564 CONTROL VALVE ASSEMBLY CAP AND SUPPORT KIT...............................................................566 ACCUMULATOR AND ATTACHING PARTS LIFT.....................................................................567 ACCUMULATOR BRAKE........................................................................................570 MAIN MANIFOLD............................................................................................572 MAIN MANIFOLD............................................................................................574 MAIN MANIFOLD............................................................................................576 MAIN MANIFOLD AND ATTACHING PARTS........................................................................578 MAIN MANIFOLD ASSEMBLY PAGE 1 OF 2 (S/N F117E01724J →) .................................................580 MAIN MANIFOLD ASSEMBLY PAGE 2 OF 2 (S/N F117E01724J →) .................................................582 MANIFOLD LIFT AND TILT...................................................................................584 MANIFOLD CAB.............................................................................................586 HYDRAULIC PUMP MAIN......................................................................................588 HYDRAULIC PUMP STEERING..................................................................................590 FLOW AMPLIFIER...........................................................................................592 FLOW AMPLIFIER...........................................................................................594 JOYSTICK INSTALLATION....................................................................................596 JOYSTICK ASSEMBLY........................................................................................598 PILOT VALVE ASSEMBLY JOYSTICK............................................................................600 HAND LEVER INSTALLATION..................................................................................602 TILT CYLINDERS AND ATTACHING PARTS.......................................................................604 TILT CYLINDERS...........................................................................................606 SOLENOID VALVE...........................................................................................608 MAST WITH CONTAINER HANDLER..................................................................................611 MAST ASSEMBLY WITH GANTRY CARRIAGE.......................................................................614 LIFT CYLINDER 7010 MM (275.9 IN.), AND 9754 MM (384.0 IN.) LIFT HEIGHT...................................618 LIFT CYLINDER 12650 MM (498.0 IN.) LIFT HEIGHT...........................................................620 MAST INSTALLATION........................................................................................622 Attachments..................................................................................................623 HEADER HOSE..............................................................................................626 HEADER HOSE..............................................................................................630 GANTRY CARRIAGE WITH MECHANICAL PILE SLOPE...............................................................634 HANGER ASSEMBLY..........................................................................................637 GANTRY CARRIAGE WITH POWER PILE SLOPE....................................................................638 CYLINDER POWER PILE SLOPE................................................................................641 BUMPERS..................................................................................................642 OPTIONS......................................................................................................643 OPTIONAL MOUNTING EQUIPMENT (HANDLE).....................................................................646 FRONT, BRAKE/BACK-UP, AND REAR WORK LIGHTS...............................................................648 STAIR LIGHT..............................................................................................652 MAP LIGHT................................................................................................654 CAB RECIRCULATING FAN....................................................................................655 ROTATING BEACON..........................................................................................656 BACK-UP ALARM............................................................................................658 TIRES AND WHEELS DRIVE - 18.00 X 25 .....................................................................660 TIRES AND WHEELS STEER - 16.00 X 25 AND 18.00 X 25 ......................................................662 TIRES AND WHEELS DRIVE AND STEER - 18.00 X 33 X 36 PLY ..................................................664 DRIVE TIRES AND WHEELS 18.00 X 33........................................................................666 HEATED TOP WINDOW........................................................................................668 EMPTY SEAT ENGINE SHUTDOWN...............................................................................669 ENGINE BLOCK HEATER 240V.................................................................................670 3-POINT SEAT BELT........................................................................................672 FIELD CONVERSION KITS........................................................................................673 MAST HOSE SHEAVE KIT.....................................................................................676 BRAKE TEMPERATURE SWITCH KIT.............................................................................676 WATER COOLED TURBOCHARGER................................................................................676 DRIVE AXLE CONVERSION KIT................................................................................676 EMPTY SEAT ENGINE SHUTDOWN OVERRIDE......................................................................676 LOUVER - HEAVY DUTY AIRCO................................................................................676 TELEMETRY KITS...........................................................................................676 PARK BRAKE KIT...........................................................................................676 NUMERICAL INDEX..............................................................................................679
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HYSTER CHALLENGER H1050HD-CH H1150HD-CH (F117) PARTS MANUAL – PDF DOWNLOAD:
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