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Hyster CHALLENGER H165-280XL (E007) Parts Manual – PDF DOWNLOAD
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Hyster CHALLENGER H165-280XL (E007) Parts Manual – PDF DOWNLOAD
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Description
Hyster CHALLENGER H165-280XL (E007) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster CHALLENGER H165-280XL (E007) 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 H165-280XL (E007) Parts Manual – PDF DOWNLOAD
Frame............................................................................................................................... 21 GENERAL TRUCK................................................................................................................... 24 OPERATOR COMPARTMENT WITHOUT CAB (→ S/N E007D03216U) .......................................................................... 26 OPERATOR COMPARTMENT WITHOUT CAB (S/N E007D03217U →) .......................................................................... 30 CAB............................................................................................................................. 34 CAB............................................................................................................................. 38 OPERATOR COMPARTMENT WITH CAB - SHEET 1 OF 2 (→ S/N E007D03216U) ............................................................. 40 OPERATOR COMPARTMENT WITH CAB - SHEET 1 OF 2 (S/N E007D03217U →) ............................................................. 44 OPERATOR COMPARTMENT WITH CAB - SHEET 2 OF 2 (→ S/N E007D03216U) ............................................................. 48 OPERATOR COMPARTMENT WITH CAB - SHEET 2 OF 2 (S/N E007D03217U →) ............................................................. 52 HEATER DIESEL................................................................................................................... 56 HEATER LPG...................................................................................................................... 60 FLOOR PLATES AND COVERS......................................................................................................... 64 HEATER CONTROL.................................................................................................................. 68 SUSPENSION SEAT................................................................................................................. 70 SEMI-SUSPENSION SEAT............................................................................................................ 72 LABELS.......................................................................................................................... 74 HOOD WITHOUT LOW EMISSIONS...................................................................................................... 77 HOOD WITH LOW EMISSIONS (S/N E007D03217 →) .................................................................................... 80 COUNTERWEIGHT................................................................................................................... 82 FAN............................................................................................................................. 84 WINDSHIELD WASHER............................................................................................................... 86 ENGINE ASSEMBLY..................................................................................................................... 89 POWERTRAIN MOUNT................................................................................................................ 94 EXHAUST NON TURBO DIESEL........................................................................................................ 96 EXHAUST TURBO DIESEL............................................................................................................ 98 EXHAUST LPG.....................................................................................................................100 COOLING TURBO DIESEL AND NON TURBO..............................................................................................102 COOLING LPG.....................................................................................................................106 FLYWHEEL DIESEL.................................................................................................................108 FLYWHEEL LPG....................................................................................................................110 CYLINDER BLOCK NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION .............................................................112 CYLINDER BLOCK TURBO DIESEL WITHOUT LOW EMISSIONS...............................................................................114 CYLINDER BLOCK TURBO DIESEL WITH LOW EMISSIONS (S/N E007E02673V →) (S/N E007D03217U →) .......................................116 CYLINDER BLOCK DIESEL NATURALLY ASPIRATED (S/N E007E02673V →) (S/N E007D03217U →) ............................................118 CRANKSHAFT AND PISTON NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ......................................................120 CRANKSHAFT AND PISTON TURBO DIESEL WITH AND WITHOUT LOW EMISSIONS - DIESEL NATURALLY ASPIRATED .................................122 CYLINDER HEAD NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ..............................................................126 CYLINDER HEAD TURBO DIESEL WITHOUT LOW EMISSIONS................................................................................128 CYLINDER HEAD TURBO DIESEL WITH EMISSIONS - NON TURBO DIESEL NATURALLY ASPIRATED (S/N E007E02673V →) (S/N E007D03217U →) ....130 TIMING GEAR NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ................................................................132 TIMING GEAR TURBO DIESEL WITH AND WITHOUT LOW EMISSIONS - NON TURBO DIESEL NATURALLY ASPIRATED .................................136 AUXILIARY DRIVE GEAR DIESEL (→ S/N E007D02050) ................................................................................140 AUXILIARY DRIVE GEAR DIESEL (S/N E007D02051 →) ................................................................................144 OIL PAN NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ....................................................................148 OIL PAN TURBO DIESEL WITHOUT LOW EMISSIONS......................................................................................152 OIL PAN TURBO DIESEL WITH LOW EMISSIONS - DIESEL NATURALLY ASPIRATED (S/N E007E02673V →) (S/N E007D03217U →) ................154 VALVE COVER NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ................................................................156 VALVE COVER TURBO DIESEL WITHOUT LOW EMISSIONS..................................................................................160 VALVE COVER TURBO DIESEL WITH LOW EMISSIONS - DIESEL NATURALLY ASPIRATED (S/N E007D03217U →) (S/N E007E02673V →) ............164 OIL FILTER NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION, NATURALLY ASPIRATED ............................................168 OIL FILTER DIESEL TURBO WITHOUT LOW EMISSIONS (→ U647451C) ....................................................................170 OIL FILTER DIESEL TURBO WITHOUT LOW EMISSIONS (U647452C →) ....................................................................172 OIL FILTER DIESEL TURBO WITH LOW EMISSIONS......................................................................................174 MANIFOLDS NON TURBO DIESEL - WITH AND WITHOUT SOUND REDUCTION ..................................................................176 MANIFOLDS TURBO DIESEL WITHOUT LOW EMISSIONS....................................................................................178 MANIFOLDS TURBO DIESEL WITH EMISSIONS (S/N E007D03217U →) (S/N E007E02673V →) ................................................180 MANIFOLDS NON TURBO DIESEL NATURALLY ASPIRATED (S/N E007D03217U →) (S/N E007E02673V →) .......................................182 WATER PUMP DIESEL (→ S/N E007D02050) ..........................................................................................184 WATER PUMP DIESEL (S/N E007D02051 →) ..........................................................................................186 WATER PUMP TURBO DIESEL WITH LOW EMISSIONS - DIESEL NATURALLY ASPIRATED (S/N E007D03217U →) (S/N E007E02673V →) .............188 TURBOCHARGER TURBO DIESEL WITHOUT LOW EMISSIONS.................................................................................192 TURBOCHARGER WITH LOW EMISSIONS (S/N E007E02673V →) (S/N E007D03217U →) ......................................................194 AIR DUCTS TURBO DIESEL..........................................................................................................196 LUBE SYSTEM TURBO DIESEL........................................................................................................198 CYLINDER BLOCK LPG..............................................................................................................200 CYLINDER HEAD AND VALVES LPG....................................................................................................202 INTAKE MANIFOLD LPG.............................................................................................................206 OIL PUMP AND PAN LPG............................................................................................................208 WATER PUMP LPG..................................................................................................................210 FUEL SYSTEM.........................................................................................................................213 FUEL INTAKE DIESEL..............................................................................................................216 FUEL PRE-FILTER.................................................................................................................220 FUEL INJECTION NON TURBO DIESEL WITHOUT LOW EMISSIONS...........................................................................222 LOW PRESSURE SYSTEM NON TURBO DIESEL WITHOUT LOW EMISSIONS......................................................................224 LIFT PUMP.......................................................................................................................226 LPG TANK MOUNTING...............................................................................................................228 FUEL TANK LPG...................................................................................................................230 FUEL SYSTEM LPG.................................................................................................................232 CARBURETOR LPG..................................................................................................................234 LPG LOCK-OFF AND FILTER.........................................................................................................236 LPG CONVERTER...................................................................................................................237 AIR FILTER NON TURBO DIESEL.....................................................................................................238 AIR FILTER LPG..................................................................................................................240 FUEL INJECTION TURBO DIESEL WITHOUT LOW EMISSIONS...............................................................................242 FUEL INJECTION TURBO DIESEL WITH LOW EMISSIONS (S/N E007D03217 →) .............................................................246 FUEL INJECTION DIESEL NATURALLY ASPIRATED (S/N E007D03217 →) ..................................................................250 LOW PRESSURE SYSTEM TURBO DIESEL WITHOUT LOW EMISSIONS..........................................................................252 LOW PRESSURE SYSTEM TURBO DIESEL WITH LOW EMISSIONS AND NATURALLY ASPIRATED (S/N E007D03217 →) ................................254 FUEL FILTER TURBO DIESEL WITH LOW EMISSIONS - DIESEL NATURALLY ASPIRATED (S/N E007D03217 →) ..................................256 AIR FILTER TURBO DIESEL - WITHOUT LOW EMISSIONS ................................................................................258 AIR FILTER DIESEL TURBO WITH LOW EMISSIONS (S/N E007D03217 →) .................................................................260 THROTTLE LINKAGE DIESEL NON EMISSIONS...........................................................................................262 THROTTLE LINKAGE TURBO DIESEL WITH LOW EMISSIONS - DIESEL NATURALLY ASPIRATED (S/N E007D03217 →) .............................264 THROTTLE LINKAGE NON EMISSION DIESEL AND LPG WITH AUTOSHIFT (S/N E007D03325 →) ................................................266 THROTTLE LINKAGE LOW EMISSION DIESEL WITH AUTOSHIFT (S/N E007D03325 →) ........................................................268 THROTTLE LINKAGE LPG............................................................................................................270 THROTTLE PEDAL FORWARD/REVERSE LEVER............................................................................................272 THROTTLE PEDAL MONOTROL PEDAL...................................................................................................274 THROTTLE PEDAL MONOTROL PEDAL WITH AUTOSHIFT (S/N E007D03325 →) ...............................................................276 THROTTLE PEDAL FORWARD/REVERSE LEVER WITH AUTOSHIFT (S/N E007D03325 →) ........................................................278 ELECTRICAL SYSTEM...................................................................................................................281 ELECTRICAL SYSTEM DIESEL WITHOUT AUTOSHIFT......................................................................................284 ELECTRICAL SYSTEM DIESEL........................................................................................................287 ELECTRICAL DIESEL WITH AUTOSHIFT (S/N E007D03325 →) ...........................................................................288 INSTRUMENT PANEL DIESEL.........................................................................................................290 ELECTRICAL SYSTEM LPG WITHOUT AUTOSHIFT.........................................................................................294 STARTER.........................................................................................................................298 INSTRUMENT PANEL LPG............................................................................................................300 DISTRIBUTOR LPG.................................................................................................................304 ALTERNATOR OPTIONAL IDENTIFY BY "PRESTOLITE" (→ S/N E007D02133 DIESEL) ........................................................306 ALTERNATOR IDENTIFY BY "DELCO" (→ S/N E007D02133 DIESEL) ......................................................................310 ALTERNATOR LPG (S/N E007D02134 → DIESEL) ......................................................................................312 ALTERNATOR MOUNTING DIESEL WITHOUT LOW EMISSIONS................................................................................314 ALTERNATOR MOUNTING DIESEL WITH LOW EMISSIONS AND NATURALLY ASPIRATED (S/N E007D03217 →) ......................................316 ALTERNATOR MOUNTING LPG.........................................................................................................318 STARTER DIESEL..................................................................................................................320 WIRE HARNESS CONTROL PANEL (S/N E007D03265 →) .................................................................................322 WIRE HARNESS ENGINE COMPARTMENT (S/N E007D03325 ↔ S/N E007D04256X) ............................................................324 WIRE HARNESS ENGINE COMPARTMENT WITH AUTOSHIFT (S/N E007D04257X →) ............................................................326 WIRE HARNESS ENGINE COMPARTMENT WITHOUT AUTOSHIFT (S/N E007D04257X →) .........................................................328 WIRE HARNESS CONTROLLER AUTOSHIFT (S/N E007D03325 →) ..........................................................................330 WIRE HARNESS SHIFTER AUTOSHIFT (S/N E007D03325 →) .............................................................................332 WIRE HARNESS MONOTROL (S/N E007D03325 →) ......................................................................................333 TRANSMISSION........................................................................................................................335 TRANSMISSION ATTACHING PARTS....................................................................................................338 RANGE CONTROL WITHOUT AUTOSHIFT.................................................................................................340 RANGE CONTROL WITH AUTOSHIFT (S/N E007D03325 →) (T050M-6089 →) ...............................................................342 RANGE CONTROL WITH AUTOSHIFT (S/N E007D03736 ↔ S/N E007E02465X) (T050M-6089 →) ...............................................344 RANGE CONTROL WITH AUTOSHIFT (S/N E007E02466X →) ..............................................................................346 TRANSMISSION....................................................................................................................350 TRANSMISSION....................................................................................................................354 PUMP DRIVE GEARS................................................................................................................358 CLUTCH FORWARD AND LOW..........................................................................................................360 CLUTCH REVERSE AND SECOND.......................................................................................................362 SHAFT ASSEMBLY REVERSE AND SECOND CLUTCH SHAFT..................................................................................364 CLUTCH THIRD....................................................................................................................366 IDLER SHAFT.....................................................................................................................368 OUTPUT GEARS....................................................................................................................369 CHARGE PUMP.....................................................................................................................370 MODULATOR VALVE.................................................................................................................372 TRANSMISSION CONTROL VALVE......................................................................................................374 MONOTROL PEDAL..................................................................................................................376 Drive Axle..........................................................................................................................379 DRIVE AXLE DIESEL NON EMISSIONS (→ S/N E007D02862) ............................................................................382 DRIVE AXLE......................................................................................................................386 DIFFERENTIAL AND CARRIER........................................................................................................390 DIFFERENTIAL AND CARRIER........................................................................................................392 STEERING SYSTEM.....................................................................................................................395 STEERING........................................................................................................................398 STEER PUMP......................................................................................................................402 VALVE BLOCK.....................................................................................................................404 STEERING AXLE...................................................................................................................406 STEERING CYLINDER...............................................................................................................410 BRAKE SYSTEM........................................................................................................................413 BRAKE LINES.....................................................................................................................416 BRAKE LINES LPG AND DIESEL (S/N E007D01549 ↔ S/N E007D04256X (Turbo)) (S/N E007D01548 ↔ S/N E007D04275X (Non-Turbo)) .........420 BRAKE LINES.....................................................................................................................424 AIR TANK DIESEL (S/N E007D01615 →) ............................................................................................428 AIR TANK DIESEL AND LPG (S/N E007D01616 →) ....................................................................................430 AIR TANK WITH AUTOSHIFT (S/N E007D03325 →) ....................................................................................432 BRAKE LINE WITH AUTOSHIFT.......................................................................................................434 PNEUMATIC SOLENOID VALVE........................................................................................................436 AIR COMPRESSOR..................................................................................................................438 AIR COMPRESSOR..................................................................................................................440 AIR COMPRESSOR..................................................................................................................442 AIR COMPRESSOR..................................................................................................................444 AIR COMPRESSOR..................................................................................................................446 AIR COMPRESSOR AND ATTACHING PARTS..............................................................................................450 AIR COMPRESSOR SHEET 1 OF 2 (S/N E007D04276X → Non Turbo) (S/N D007D04257X → Turbo) ..........................................452 AIR COMPRESSOR SHEET 2 OF 2 (S/N D007D04276X → Non Turbo) (S/N D007D04257X → Turbo) ..........................................454 AIR COMPRESSOR 366 LPG ENGINE...................................................................................................456 COMPRESSOR MOUNTING LPG.........................................................................................................458 TREADLE VALVE AND ATTACHING PARTS SERVICE BRAKE (→ S/N E007D01548) ............................................................460 TREADLE VALVE AND ATTACHING PARTS SERVICE BRAKE (S/N E007D01549 →) ............................................................462 VALVE AND ATTACHING PARTS PARK BRAKE (→ S/N E007D01548) .......................................................................464 VALVE AND ATTACHING PARTS PARK BRAKE (S/N E007D01549 →) .......................................................................466 BRAKE SYSTEM....................................................................................................................468 BRAKE SYSTEM....................................................................................................................470 BRAKE CHAMBER...................................................................................................................472 TREADLE VALVE...................................................................................................................474 PARK BRAKE VALVE................................................................................................................476 PARK BRAKE VALVE................................................................................................................478 HYDRAULIC SYSTEM....................................................................................................................479 HYDRAULIC SYSTEM................................................................................................................482 HYDRAULIC TANK..................................................................................................................486 HYDRAULIC PUMP..................................................................................................................488 VALVE ATTACHING PARTS TWO FUNCTION..............................................................................................492 CONTROL VALVE TWO FUNCTION (→ S/N E007D02707) .................................................................................494 CONTROL VALVE TWO FUNCTION (S/N E007D02708 →) .................................................................................496 VALVE ATTACHING PARTS THREE FUNCTION............................................................................................500 VALVE ATTACHING PARTS DUAL FUNCTION SIDE-SHIFT (S/N E007D03265 →) .............................................................504 CONTROL VALVE THREE FUNCTION (→ S/N E007D02707) ...............................................................................508 CONTROL VALVE THREE FUNCTION (S/N E007D02708 →) ...............................................................................512 VALVE ATTACHING PARTS FOUR FUNCTION.............................................................................................516 CONTROL VALVE FOUR FUNCTION (→ S/N E007D02707) ................................................................................520 CONTROL VALVE FOUR FUNCTION (S/N E007D02708 →) ................................................................................524 VALVE ATTACHING PARTS FIVE FUNCTION.............................................................................................528 CONTROL VALVE FIVE FUNCTION (→ S/N E007D02707) ................................................................................532 CONTROL VALVE FIVE FUNCTION (S/N E007D02708 →) ................................................................................536 TILT CYLINDER ATTACHING PARTS...................................................................................................540 TILT CYLINDER...................................................................................................................542 TILT LOCK VALVE.................................................................................................................545 FLOW REGULATOR..................................................................................................................546 Mast-Two Stage Limited Free-Lift....................................................................................................547 OUTER MAST TWO STAGE LIMITED FREE-LIFT..........................................................................................550 INNER MAST TWO STAGE LIMITED FREE-LIFT..........................................................................................553 LIFT TWO STAGE LIMITED FREE-LIFT................................................................................................555 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT (→ S/N E007D02580S) .................................................................560 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT (S/N E007D02581S →) .................................................................564 CARRIAGE TWO STAGE LIMITED FREE-LIFT............................................................................................568 HEADER HOSES TWO STAGE LIMITED FREE-LIFT........................................................................................570 Mast-Three Stage Full Free-Lift.....................................................................................................575 OUTER MAST THREE STAGE FULL FREE-LIFT...........................................................................................578 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT....................................................................................580 INNER MAST THREE STAGE FULL FREE-LIFT...........................................................................................582 MAIN LIFT THREE STAGE FULL FREE-LIFT............................................................................................584 MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT...................................................................................588 FREE LIFT THREE STAGE FULL FREE-LIFT............................................................................................590 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT...................................................................................594 CARRIAGE WITH SIDE-SHIFT - THREE STAGE FULL FREE-LIFT ..........................................................................598 CARRIAGE WITH SIDE-SHIFT AND FORK POSITIONER - THREE STAGE FULL FREE-LIFT ......................................................600 FORK POSITIONER CYLINDER THREE STAGE FULL FREE-LIFT.............................................................................604 FORK POSITIONER VALVE THREE STAGE FULL FREE-LIFT................................................................................606 HEADER HOSE THREE AND FOUR FUNCTION ONLY - THREE STAGE FULL FREE-LIFT ..........................................................608 OPTIONS.............................................................................................................................611 TIRE AND WHEEL H165-210XL - SHEET 1 OF 2 .......................................................................................614 TIRE AND WHEEL H165-280XL - SHEET 2 OF 2 .......................................................................................616 SIDE-SHIFT CARRIAGE.............................................................................................................618 SIDE-SHIFT CARRIAGE DUAL FUNCTION PIN QUICK DISCONNECT (S/N E007D03265 →) .....................................................622 HYDRAULIC CYLINDER DUAL FUNCTION PIN QUICK DISCONNECT (S/N E007D03265 →) ......................................................626 SELECTOR VALVE..................................................................................................................628 FORKS...........................................................................................................................629 FORKS PIN (S/N E007D03265 →) ..................................................................................................630 FORKS QUICK DISCONNECT (S/N E007D03265 →) .....................................................................................631 HEADER HOSE FIVE FUNCTION - DUAL FUNCTION SIDE-SHIFT FORK POSITIONER (S/N E007D03265 →) ......................................632 FLOODLIGHTS.....................................................................................................................636 FRONT, BRAKE/BACK-UP AND REAR WORK LIGHTS.......................................................................................638 STROBE LIGHT....................................................................................................................642 ROTATING BEACON.................................................................................................................644 SIDE-SHIFT CYLINDER.............................................................................................................646 FIRE EXTINGUISHER...............................................................................................................648 BACK-UP ALARM...................................................................................................................650 FIELD CONVERSION KITS...............................................................................................................653 AUDIBLE ALARM CONVERSION KITS...................................................................................................656 LIGHT CONVERSION KITS...........................................................................................................656 CONTROL VALVE CONVERSION KITS...................................................................................................656 MISCELLANEOUS CONVERSION KITS...................................................................................................656 NUMERICAL INDEX.....................................................................................................................659
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HYSTER CHALLENGER H165-280XL (E007) PARTS MANUAL – PDF DOWNLOAD:
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