H8.00-12.00XM
CUSTOMEREDITION
CHALLENGER
PARTS MANUAL
(G007) 1557030 ©2005HysterCompany 03/2005
ThisPartsManualisdividedinto14majorsectionswhicharelistedabove.Quickreferencetothesesectionscan bemadebyplacingtherightthumbonthetabofthedesiredsection,bendingthebookbackandthumbingthe pagestothecorrespondingtab.
03/2005 UNITCODEG007 EUROPE SECTIONS 1 FRAME 2 ENGINES 3 FUELSYSTEM 4 ELECTRICALSYSTEM 5 TRANSMISSION 6 DRIVEAXLE 7 STEERINGSYSTEM 8 BRAKESYSTEM 9 HYDRAULICSYSTEM 10 MAST-TWOSTAGELIMITEDFREE-LIFT 11 MAST-THREESTAGEFULLFREE-LIFT 12 ATTACHMENTS 13 OPTIONS 14 NUMERICALINDEX
03/2005 UNITCODEG007 EUROPE 1 FRAME
SECTION1 FRAME
03/2005 UNITCODEG007 EUROPE
DESCRIPTION PAGE AIRCONDITIONINGSYSTEM CUMMINS.......................................................................................................................................................1-36 PERKINS........................................................................................................................................................1-34 AIRDUCTANDACCESSORIES CAB.................................................................................................................................................................1-62 ARMREST PIVOT-UP.......................................................................................................................................................1-68 CABANDATTACHINGPARTS..........................................................................................................................1-12 CABANDTILTCYLINDERMOUNTING............................................................................................................1-20 CABHARDWAREANDCONTROLCOVER......................................................................................................1-58 CONDENSER.....................................................................................................................................................1-44 COUNTERWEIGHT...........................................................................................................................................1-10 DASHDISPLAY CAB.................................................................................................................................................................1-64 ELECTRICALPUMP CABTILT.........................................................................................................................................................1-28 FLOORPLATESANDCOVERS..........................................................................................................................1-8 GENERALTRUCK...............................................................................................................................................1-2 HANDPUMP CABTILT.........................................................................................................................................................1-26 HEATERANDAIRCONDITIONERASSEMBLY................................................................................................ 1-42 HEATERANDAIRCONDITIONERATTACHMENT...........................................................................................1-38 HEATERASSEMBLY................................................................................................................. ........................1-40 HEATERHOSEARRANGEMENT CUMMINS.......................................................................................................................................................1-32 PERKINS........................................................................................................................................................1-30 HOOD...................................................................................................................................................................1-4 INCHINGPEDALANDACCESSORIES CAB.................................................................................................................................................................1-60 LABELS..............................................................................................................................................................1-56 SEATASSEMBLY AIR..................................................................................................................................................................1-46 MECHANICAL................................................................................................................................................1-48 STEELDOOR LEFTHAND....................................................................................................................................................1-18 RIGHTHAND..................................................................................................................................................1-16 TILTCYLINDER CAB.................................................................................................................................................................1-24 TRAININGSEAT................................................................................................................................................1-54 WINDOWWASHERANDARMRESTASSEMBLY............................................................................................1-66 ©2005HYSTERCOMPANY 1-1 SeeServiceManual forserviceprocedures.
GENERALTRUCK(Figure1-1)
UNITCODEG007 EUROPE03/2005
1-2 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.
03/2005 UNITCODEG007 EUROPE GENERALTRUCK ITEMPARTNO.DESCRIPTION QTY 1.....Frame(☞ Figure1-2)................................................................................................ 1 2.....EngineAssembly (☞ Figure2-1)............................................................................... 1 3.....FuelSystem(☞ Figure3-1)....................................................................................... 1 4.....ElectricalSystem(☞ Figure4-1)............................................................................... 1 5.....Transmission(☞ Figure5-1)...................................................................................... 1 6.....DriveAxle(☞ Figure6-1).......................................................................................... 1 7.....SteeringSystem(☞ Figure7-1)................................................................................ 1 8.....BrakeSystem(☞ Figure8-1).................................................................................... 1 9.....HydraulicSystem(☞ Figure9-1)............................................................................... 1 10.....Mast-TwoStageLimitedFree-Lift(☞ Figure10-1).................................................... 1 11.....Mast-ThreeStageFullFree-Lift(☞ Figure11-1)....................................................... 1 12.....Attachments (☞ Figure12-1)..................................................................................... 1 13.....Options(☞ Figure13-1)............................................................................................ 1 14.....NumericalIndex........................................................................................................... 1 ©2005HYSTERCOMPANY 1-3 SeeServiceManual forserviceprocedures.
HOOD(Figure1-2)
UNITCODEG007 EUROPE03/2005
1-4 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.
03/2005 UNITCODEG007 EUROPE HOOD ITEMPARTNO.DESCRIPTION QTY 1362030Handle.........................................................................................................................2 21477508Bracket.........................................................................................................................1 3292501Capscrew.....................................................................................................................4 4320156Washer........................................................................................................................4 5292680Lockwasher..................................................................................................................4 6136687Nut...............................................................................................................................4 7292528Capscrew.....................................................................................................................4 81479870Screw(Stop)................................................................................................................4 9136692Nut...............................................................................................................................4 10320157Washer........................................................................................................................2 11292681Lockwasher..................................................................................................................4 121489092Screw(Stop) ................................................................................................................ 2 13216877Nut...............................................................................................................................10 14239503Nut...............................................................................................................................4 15376397Nut...............................................................................................................................2 1618498Capscrew.....................................................................................................................2 171479871Washer........................................................................................................................2 18292535Capscrew............................................................................................................... ......AR 19300088Seal(Door) (Door)....................................................................................................... 8 20320162Washer........................................................................................................................8 21292683Lockwasher.................................................................................................................. 10 22 b .....Channel .......................................................................................................................1 22 a .....Channel .......................................................................................................................1 23 b 1478957Hood(RH)...................................................................................................................1 23 a 1478958Hood(RH)...................................................................................................................1 24376300GasSpring................................................................................................................... 2 25 b 1479059Hood(LH) 1 25 a 1479060Hood(LH) 1 26 b 1476660Rod..............................................................................................................................1 26 a 1476661Rod..............................................................................................................................1 271489401Support 1 281477512Bracket ......................................................................................................................... 1 291494868Plug(WithoutAirConditioner)..................................................................................... 4 301494869Plug(WithoutAirConditioner)..................................................................................... 3 311382332 Latch............................................................................................................................2 321494480 Bracket......................................................................................................................... 2 33320155Washer 4 34296155Capscrew..................................................................................................................... 4 35292679Lockwasher.................................................................................................................. 4 36292668Nut...............................................................................................................................4 37320160 Washer........................................................................................................................ 4 38292682 Lockwasher.................................................................................................................. 4 39136692 Nut...............................................................................................................................4 40 c 1382766 Wrench........................................................................................................................ 1 41309666 Plug(Non-EEC)........................................................................................................... 2 421494642 Shim AR 421494643 Shim AR ©2005HYSTERCOMPANY 1-5 SeeServiceManual forserviceprocedures.
UNITCODEG007 EUROPE03/2005
ITEMPARTNO.DESCRIPTION QTY 421494645Shim............................................................................................................................AR 43320158Washer........................................................................................................................AR FOOTNOTES:
H10.00XM-H12.00XM
H8.00XM-H9.00XM
NotIllustrated 1-6 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.
HOOD
a
b
c
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1-7
NOTES
FLOORPLATESANDCOVERS(Figure1-3)
UNITCODEG007 EUROPE03/2005
1-8 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.
FLOORPLATESANDCOVERS
03/2005 UNITCODEG007 EUROPE
ITEMPARTNO.DESCRIPTION QTY 1320162Washer........................................................................................................................18 2296173Capscrew.....................................................................................................................6 3287837Capscrew.....................................................................................................................6 4216735Grommet......................................................................................................................6 5320160Washer........................................................................................................................6 61491360Seal.............................................................................................................................AR 7320158Washer........................................................................................................................4 8296167Capscrew.....................................................................................................................14 91480237ClipNut........................................................................................................................14 10325983Trim..............................................................................................................................AR 11320157Washer........................................................................................................................38 12296013Capscrew............................................................................................................... ......8 13302402Nut...............................................................................................................................6 14136749Capscrew............................................................................................................... ......4 151532341GasSpring...................................................................................................................1 16302400Locknut........................................................................................................................10 172071326Cover...........................................................................................................................1 1891946Grommet......................................................................................................................8 191529665Capscrew.....................................................................................................................2 20 c 1529813RunningBoard(LH)..................................................................................................... 1 20 a 1529815RunningBoard(LH)..................................................................................................... 1 21 c 1529814RunningBoard(RH).................................................................................................... 1 21 a 1529816RunningBoard(RH).................................................................................................... 1 22 c 1532189Extension (RH)............................................................................................................ 1 22 a 1532448Extension (RH)............................................................................................................ 1 23 c 1532188Extension(LH)............................................................................................................. 1 23 a 1532446Extension(LH)............................................................................................................. 1 241485265Cover...........................................................................................................................1 251485263Panel(LH).................................................................................................................... 1 261485264Panel(RH)................................................................................................................... 1 271529751Cover(BatteryBox)..................................................................................................... 1 281532202Battery Box.................................................................................................................. 1 29 b 136692Nut...............................................................................................................................8 30 b 292682Lockwasher.................................................................................................................. 8 31 b 320160Washer 8 32 b 1515431 Cover...........................................................................................................................1 33 b 1562200 Cover...........................................................................................................................1 34 b 1516035 Liner.............................................................................................................................1 35 b 1516036 Liner.............................................................................................................................1 36 b 1516037 Liner.............................................................................................................................1 37 b 1516038 Liner 1 FOOTNOTES: a H10.00XM-H12.00XM b H12.00XM c H8.00XM-H9.00XM ©2005HYSTERCOMPANY 1-9 SeeServiceManual forserviceprocedures.
COUNTERWEIGHT(Figure1-4)
UNITCODEG007 EUROPE03/2005
1-10 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.
03/2005 UNITCODEG007 EUROPE
ITEMPARTNO.DESCRIPTION QTY 11467696TowPin........................................................................................................................2 21495368Grip..............................................................................................................................2 3376319Capscrew.....................................................................................................................2 4149531Washer........................................................................................................................2 515168Lockwasher..................................................................................................................2 61475214Shim............................................................................................................................2 7280472Sealant........................................................................................................................2 8292597Capscrew.....................................................................................................................4 91475872Washer........................................................................................................................4 10316829Nut...............................................................................................................................4 111301086Washer........................................................................................................................4 1215189Washer.................................................................................................................. ......2 13302440Pin...............................................................................................................................2 14 b 2038853Fender(LH).................................................................................................................1 14 a 2038855Fender(LH).................................................................................................................1 151475211Shim............................................................................................................................2 161475212Shim............................................................................................................................2 171475213Shim............................................................................................................................2 18 b 1467624Counterweight............................................................................................................. 1 18 a 1467625Counterweight............................................................................................................. 1 19 b 2038854Fender(RH)................................................................................................................. 1 19 a 2038856Fender(RH)................................................................................................................. 1 201532632Liner(LH) 1 211532633Liner(RH) 1 FOOTNOTES: a H10.00XM-H12.00XM b H8.00XM-H9.00XM ©2005HYSTERCOMPANY 1-11 SeeServiceManual forserviceprocedures.
COUNTERWEIGHT
CABANDATTACHINGPARTS(Figure1-5)
UNITCODEG007 EUROPE03/2005
1-12 ©2005HYSTERCOMPANY SeeServiceManual forserviceprocedures.