PARTS
MANUAL
CHALLENGER
H135XL, H155XL
(F006)
CUSTOMER EDITION
852110
12/2001
2001 Hyster Company
UNIT CODE F006
NORTH AMERICA
12/2001
SECTIONS
FRAME
ENGINE ASSEMBLY
FUEL SYSTEM
ELECTRICAL SYSTEM
TRANSMISSION
STEERING SYSTEM
BRAKE SYSTEM
HYDRAULIC SYSTEM
MAST-TWO STAGE LIMITED FREE-LIFT
10
MAST-THREE STAGE FULL FREE-LIFT
11
OPTIONS
12
NUMERICAL INDEX
This Parts Manual is divided into 12 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.
12/2001
UNIT CODE F006
NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION
PAGE
A
ACTUATOR......................................................................................................................................................... 7-18
AIR FILTER
HEAVY DUTY
DIESEL........................................................................................................................................................ 3-72
GASOLINE AND LPG ................................................................................................................................. 3-68
STANDARD
S/N F006A-7082 ..................................................................................................................................... 3-62
S/N F006A-7083 , S/N F006D-1501 ................................................................................................... 3-64
ALTERNATOR
IDENTIFY BY "DELCO"
S/N F006D-3768..................................................................................................................................... 4-68
IDENTIFY BY "PRESTOLITE" ........................................................................................................................ 4-74
OPTIONAL...................................................................................................................................................... 4-78
S/N F006D-3769 S/N F006D-6520 ............................................................................................................ 4-72
ALTERNATOR MOUNTING
DIESEL 1004.42
WITH LOW EMISSIONS ............................................................................................................................. 4-80
AUXILIARY DRIVE ........................................................................................................................................... 2-200
AXLE HOUSING AND ATTACHING PARTS
S/N F6D-6398 ............................................................................................................................................ 5-54
B
BACKUP ALARM
OIL CLUTCH
S/N F006D-3779................................................................................................................................... 11-68
POWERSHIFT .............................................................................................................................................. 11-66
BRAKE
S/N F006A-3184......................................................................................................................................... 7-12
S/N F006A-1501 , S/N F006A-3185 , S/N F006A-4793 ...................................................................... 7-16
S/N F006A-3185 S/N F006A-4792............................................................................................................. 7-14
BRAKE LINES ...................................................................................................................................................... 7-4
BRAKE PEDAL LINKAGE
OIL CLUTCH
S/N F006D-3779....................................................................................................................................... 7-6
POWERSHIFT .................................................................................................................................................. 7-8
C
CAB
S/N F006A-8145, S/N F006D-2182 INC. 2237, 2257 ............................................................................ 11-2
S/N F006A-8146 , S/N F006D-2183 EXC. 2237, 2257........................................................................... 11-6
CAB GLASS ..................................................................................................................................................... 11-60
CAMSHAFT AND OIL PAN
GASOLINE AND LPG
2000 SERIES ENGINE ............................................................................................................................. 2-118
4LM 1994 SERIES ENGINE ..................................................................................................................... 2-110
5LM 1995 SERIES ENGINE ..................................................................................................................... 2-112
CAMSHAFT AND OIL SUMP
GASOLINE AND LPG................................................................................................................................... 2-114
CARBURETOR
GASOLINE
2001 HYSTER COMPANY
See Service Manual
for service procedures.
UNIT CODE F006
NORTH AMERICA
12/2001
TABLE OF CONTENTS (Continued)
DESCRIPTION
PAGE
C (continued)
S/N F006A-7082 ..................................................................................................................................... 3-40
LPG
S/N F006D-2947 INC. 2960, 2976 EXC. 2936 ....................................................................................... 3-34
S/N F006D-2948 INC. 2936 EXC. 2960, 2976 ....................................................................................... 3-36
CARRIAGE
HOOK TYPE
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-24
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-16
PIN TYPE
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-22
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-12
CLUSTER GAUGE ............................................................................................................................................. 4-56
CLUTCH
OIL CLUTCH
S/N F006D-3779..................................................................................................................................... 5-10
CLUTCH LINKAGE
OIL CLUTCH
S/N F006D-3779..................................................................................................................................... 5-18
CLUTCH PACK
POWERSHIFT ................................................................................................................................................ 5-26
CONTROL LINKAGE
OIL CLUTCH
FORWARD/REVERSE LEVER
S/N F006A-3790 ................................................................................................................................. 5-12
S/N F006A-3791 , S/N F006D-1501 S/N F006D-3779.................................................................... 5-14
POWERSHIFT
S/N F006A-3790 ..................................................................................................................................... 5-34
S/N F006A-3791 , S/N F006D-1501 ................................................................................................... 5-38
CONTROL VALVE
FOUR FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................ 8-50
TWO AND THREE FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................. 8-48
CONTROL VALVE ATTACHING PARTS
FOUR FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................ 8-42
THREE FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................ 8-36
TWO FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................ 8-30
CONTROL VALVE ATTACHING PARTS WITH FITTINGS
FOUR FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................. 8-56
TWO AND THREE FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................. 8-52
CONTROL VALVE ATTACHING TUBES
FOUR FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................. 8-60
TWO AND THREE FUNCTION
S/N PENDING PER ECN 63408 ............................................................................................................. 8-58
ii
See Service Manual
for service procedures.
2001 HYSTER COMPANY
UNIT CODE F006
NORTH AMERICA
12/2001
LOCK-OFF FILTER (Figure 3-16)
LPG
ITEM
1
1
2
3
4
5
6
7
PART NO.
DESCRIPTION
258321
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
Filter and Lock-Off Valve .............................................................................................
Washer ....................................................................................................................
Screw ......................................................................................................................
Diaphragm...............................................................................................................
O-Ring .....................................................................................................................
Screw ......................................................................................................................
Valve Seat ...............................................................................................................
Filter ........................................................................................................................
Gasket .....................................................................................................................
1
2
8
1
1
1
1
1
1
263958
Repair Kit (Includes Items 1-7) ....................................................................................
2001 HYSTER COMPANY
QTY
See Service Manual
for service procedures.
3-47
UNIT CODE F006
NORTH AMERICA
12/2001
LPG CONVERTER (Figure 3-17)
( S/N F006D-1884)
3-48
See Service Manual
for service procedures.
2001 HYSTER COMPANY
UNIT CODE F006
NORTH AMERICA
12/2001
LPG CONVERTER
( S/N F006D-1884)
ITEM
1
1
2
3
4
4
5
6
7
8
9
10
11
11
12
13
14
15
16
17
18
19
20
20
PART NO.
DESCRIPTION
196193
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
204829
204830
.. . . .
.. . . .
204831
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
204835
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
Converter Assembly ....................................................................................................
Capscrew ................................................................................................................
Lockwasher .............................................................................................................
Cover .......................................................................................................................
Diaphragm...............................................................................................................
Screw ......................................................................................................................
Lockwasher .............................................................................................................
Lever Assembly .......................................................................................................
Pin ...........................................................................................................................
Seat .........................................................................................................................
Pin ...........................................................................................................................
Spring ......................................................................................................................
Body ........................................................................................................................
Screw ......................................................................................................................
Lockwasher .............................................................................................................
Seat .........................................................................................................................
Gasket .....................................................................................................................
Plate ........................................................................................................................
Plug .........................................................................................................................
Spring ......................................................................................................................
Pin ...........................................................................................................................
Diaphragm...............................................................................................................
Cover .......................................................................................................................
Screw ......................................................................................................................
Lockwasher .............................................................................................................
1
6
6
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
7
7
204837
Converter Repair Kit (Includes Items 1, 3-4, 7-8, 13, 17-18, 20) .................................
2001 HYSTER COMPANY
QTY
See Service Manual
for service procedures.
3-49
UNIT CODE F006
NORTH AMERICA
12/2001
LPG CONVERTER (Figure 3-18)
(S/N F006D-1885 S/N F006D-4317)
3-50
See Service Manual
for service procedures.
2001 HYSTER COMPANY
