Hyster Challenger H170-280HD (F007) Forklift Service Manual

Name: Hyster Challenger H170-280HD (F007) Forklift Service Manual
Brand: MidWestTech
SKU: 1506708
Price: 139.59 USD
Availability: InStock

1,342 pages · Publication 1506708

$139.59

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Models: Challenger H170-280HD (F007)
Manual type: Service Manual
Pages: 1,342
Publication: 1506708
Condition: Brand new

Hyster Challenger H170-280HD (F007) Forklift Service Manual, publication 1506708

What's inside

From the manual's own table of contents: 325 sections, 700 entries. See sample pages (PDF, 273 KB)

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Steering Axle

Safety Precautions Maintenance and Repair

General

Description

Steering Axle Assembly Repair

Wheels and Hubs Repair (All Units)4 topics

Remove and Disassemble
Clean
Inspect
Assemble and Install

Spindles and Bearings Repair (All Units)1 topic

Remove

Tie Rods Repair (All Units)1 topic

Install

Steering Cylinder Repair1 topic

Clean and Inspect

Troubleshooting

Masts

Safety Procedures When Working Near Mast

Operation2 topics

Two-Stage Mast
Three-Stage Mast

Forks Repair

Carriage Repair6 topics

Sideshift Carriage, Disassemble
Sideshift Carriage, Assemble
Sideshift Cylinder, Disassemble
Sideshift Cylinder, Assemble
Fork Positioner Cylinder, Disassemble
Fork Positioner Cylinder, Assemble

Mast Repairs4 topics

Two-Stage Mast, Disassemble
Three-Stage Mast, Disassemble
Two-Stage Mast, Assemble
Three-Stage Mast, Assemble

Lift Cylinders Description2 topics

Piston-Type Cylinders
Displacement-Type Cylinders

All Lift Cylinders Repair2 topics

Disassemble
Assemble

Mast Operation Check

Lift and Tilt System Leak Checks2 topics

Lift System
Tilt System

Tilt Cylinder Stroke and Backward Tilt Angle Adjustment

Lift Chain Adjustments

Mast Adjustments3 topics

Bearing Blocks
Wear Plates
Load Roller Adjustments

Carriage Adjustment

Show all 325 sections

Table 1. Carriage and Fork Weights

Table 2. Mast Weights

Table 3. Allowable Mast Movement from Internal Leakage

Cooling System5 topics

Radiator
Radiator Cap
Thermostat
Water Pump
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning2 topics

Drain
Fill

Alternator with Regulator

Alternator Repair2 topics

Alternator Type A
Alternator Type B

General Check and Adjustment

Low Output Check (Type A or Type B)

High Output Check (Type A or Type B)

Brushes Circuit Check2 topics

Delco Alternators
Motorola Alternators

Diodes Check

Diode Bridge Check1 topic

Delco and Leece-Neville Alternators

Rotor Field Winding Check

Stator Windings Check

Voltage Regulator Check

Differential

Differential Repair

Specifications

Table 1. Ring Gear Backlash Adjustment Specifications

Table 2. Ring and Pinion Tooth Contact Adjustment

Table 3. General Specifications

Table 4. Rivet Installation Pressure

Table 5. Pinion Adjustment

Table 6. Pinion Preload Pressure

Table 7. Torque Specifications

Table 8. Torque Specifications for Metric Hardware

Table 9. Torque Specifications for Metric (Fine) Hardware

Tilt Cylinders

Tilt Cylinder Repair

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

Torque Specifications2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Starter

Description and Operation

Starter Repair

General Checks and Adjustments

Lift Cylinders3 topics

Lowering Control Valve
Cylinders (General)
Cylinders (Two-Speed)

Lift Cylinder Repair3 topics

Lift Cylinder Removal Without Removing Mast
Lift Cylinder Installation in Mast
Chevron-Style Packing

Lift Cylinders for VISTA® Masts1 topic

Description

Lift System Leak Check

Table 1. Lift Trucks with Two-Speed Lift Cylinders

Table 2. Cylinder Retainer Torque Specifications and Weight Guid

Metric and Inch (SAE) Fasteners6 topics

Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table

Table 1. Bolts and Screws

Table 2. Studs and Nuts

Table 3. Torque Nuts

Table 4. Torque Nuts With Nylon Insert

Table 5. Torque Values for Metric Fasteners*

Table 6. Torque Values for Inch Fasteners*

Table 7. Conversion Table for Metric and English units

Table 8. Cotter Pin Dimensional Data

Perkins Diesel Engines3 topics

General Safety Rules
Engine Serial Number Codes
Engine Data

Engine Removal and Installation1 topic

Lift Engine

Cylinder Head Assembly Repair8 topics

Valve Cover
Rocker Arm Assembly
Valve Clearance Adjustments
Valve Springs
Cylinder Head Assembly
Valves and Valve Springs
Valve Guides
Cylinder Head and Valve Seats

Piston and Connecting Rod Assemblies Repair5 topics

Rod Bearings
Piston and Connecting Rod Assembly
Piston Rings
Piston and Connecting Rod
Piston Cooling Jets

Crankshaft Assembly Repair8 topics

General
Crankshaft Pulley
Rear Oil Seal
Main Bearings
Thrust Washers
Crankshaft
Flywheel
Flywheel Housing

Timing Case and Timing Gears Repair10 topics

Timing Case Cover
Front Oil Seal
Crankshaft Pulley Wear Sleeve
Idler Gear and Hub
Air Compressor Drive, Bendix
Fuel Injection Pump Gear
Camshaft Gear
Crankshaft Gear
Timing Case
Camshaft and Tappets

Cylinder Block Assembly Repair3 topics

Cylinder Block
Cylinder Bore (Four-Cylinder Engines)
Cylinder Liner (Six-Cylinder Engines)

Engine Timing

Turbocharger - Engine YH Repair

Lubrication System Repair6 topics

Oil Filter, Replace
Filter Head
Oil Sump
Oil Pump
Relief Valve
Idler Gear Shaft, Replace

Fuel System Repair5 topics

Fuel Injection Pump
Fuel System, Remove Air
Fuel Filter, Replace
Fuel Injectors
Fuel Pump

Cooling System Repair3 topics

Coolant Pump
Fan and Fan Drive
Oil Cooler (Six-Cylinder Engines)

Electrical Equipment Repair4 topics

Drive Belts
Alternator
Starter Motor
Cold Start Aid

Air Compressor - Engines YG and YH1 topic

Repair

Rotary Exhauster Replacement

Engine Specifications12 topics

Piston and Connecting Rods
Crankshaft Assembly
Timing Case and Drive Assembly
Engine Block Assembly
Turbocharger
Lubrication System
Fuel System
Cooling System
Flywheel and Housing
Electrical Equipment
Piston and Connecting Rod Assemblies
Auxiliary Equipment

Special Torque Specifications

Special Tools

Table 1. Cylinder Head

Table 2. Valve Guides

Table 3. Inlet Valves

Table 4. Exhaust Valves

Table 5. Valve Springs

Table 6. Tappets

Table 7. Rocker Arm Shaft

Table 8. Rocker Arms and Bushings

Table 9. Pistons (Engine AR)

Table 10. Pistons (Engines YG and YH)

Table 11. Piston Rings (Engine AR)

Table 12. Piston Rings (Engines YG and YH)

Table 13. Piston Pins

Table 14. Connecting Rods

Table 15. Small End Bushings

Table 16. Connecting Rod Bearings (Engines AR and YG)

Table 17. Connecting Rod Bearings (Engine YH)

Table 18. Piston Cooling Jets

Table 19. Crankshaft

Table 20. Main Bearings

Table 21. Crankshaft Thrust Washers

Table 22. Crankshaft Heat Treatment

Table 23. Crankshaft Overhaul Specifications

Table 24. Maximum Variation (Run-out)

Table 25. Camshaft

Table 26. Camshaft Thrust Washer

Table 27. Camshaft Gear

Table 28. Gear for Fuel Injection Pump

Table 29. Crankshaft Gear

Table 30. Idler Gear and Hub

Table 31. Cylinder Block (Engine AR)

Table 32. Cylinder Bore Specifications

Table 33. Cylinder Block (Engines YG and YH)

Table 34. Cylinder Liners (Engines YG and YH)

Table 35. Cylinder Liner Specifications (Partially Finished)

Table 36. Oil Pump (Engine AR)

Table 37. Oil Pump (Engines YG and YH)

Table 38. Idler Gear for Oil Pump

Table 39. Relief Valve

Table 40. Oil Filter

Table 41. Lucas Fuel Injection Pump

Table 42. Fuel Pump (Engine AR)

Table 43. Fuel Pump (Engines YG and YH)

Table 44. Fuel Filter

Table 45. Fuel Injector Codes

Table 46. Coolant Pump

Table 47. Thermostat

Table 48. Fan Drive Housing

Table 49. Limits for Flywheel Run Out and Alignment (Total Indic

Table 50. Alternator

Table 51. Starter Motor

Table 52. Cold Start Aid

Table 53. List of Possible Causes

Three-Speed Powershift Transmission

Mechanical Description2 topics

Torque Converter
Clutch Assemblies

Hydraulic Operation5 topics

Sump, Filter and Pump
Transmission Control Valve
Modulator Valve
Transmission Control System
Hydraulic Circuits

Transmission Repair

Control Valve Repair1 topic

Disassemble and Assemble

Modulator Valve Repair

Transmission Pump Repair

Monotrol Pedal Repair

Inching/Brake Pedal Linkage Adjustment

Stall Test

Transmission Oil Pressure Check

Table 1. Transmission Pressures

Autoshift Transmission Controller

Autoshift Control Module

Transmission Shift Control Valve

Autoshift Functions19 topics

System Interaction with Operator Display
Error Code Descriptions
System Audible Alarm
Park Brake Interlock
System Reset/Override
System Degraded Operating Mode
System Failure Mode
Transmission Oil High-Temperature Fault
Loss of Transmission Oil Pressure Fault
Controller Bypass
Automatic/Manual Shift Mode
Automatic Transmission Shifting
Manual Transmission Shifting
Direction Change
Direction Change Inhibit
Downshift Inhibit
Driveshaft Engagement Inhibit
Lift Height Transmission Interrupt (Optional)
Engine Dethrottle (Optional)

Autoshift Hardware2 topics

Autoshift Lever
Speed Sensors

Transmission System Monitor Diagnostics

Controller Parameter Adjustment Software User Interface13 topics

User Interface Description
Components Required to Communicate with Controller
Userlink Installation Instructions
Start Procedures
Controller Product Codes
Main Menu Description
Language Selection
Help Menu
PC Serial Communication Port
Monitor Screen
Event Log
Parameter Adjustment
Exit Menu

Controller Connector Pin-Out Tables

Table 1. Error Code Descriptions

Table 2. Automatic Transmission Upshift

Table 3. Automatic Transmission Downshift

Table 4. Event Log Descriptions and Values

Table 5. Parameter Descriptions and Values

Table 6. J2 Controller Connector (Black)

Table 7. J1 Controller Connector (Blue)

Frame

Counterweight Repair2 topics

Fenders
Side Counterweight, Replace

Hood and Air Cleaner Repair

Hydraulic Tank Repair2 topics

Repairs, All Units
Other Methods of Preparation for Repair

Fuel Tank Repair1 topic

Repairs

Cooling System and Radiator Repair

Engine and Transmission Repair3 topics

Hyster T-50 Transmission, Remove
Hyster T-50 Transmission, Install
TE-10 Transmission

Label Replacement

Operators Cab

Cab Repair4 topics

Rear Cab Assembly
Bottom Cab Assembly
Raising and Lowering Cab
Cab Repair

Oil Filling for Tilt System

Inching and Brake Pedals2 topics

Pedal Adjustment
Inching Cable Adjustment

Throttle Cable Adjustment2 topics

Mechanical
Electronic

Seat Assembly Removal

Power Assist Armrest1 topic

Adjust

Steering Column Repair

Window Wipers Replacement4 topics

Wiper Assembly, Replace
Front Window Wiper Motor Assembly, Replace
Rear Wiper Motor Assembly, Replace
Top Window Wiper Motor Assembly, Replace

Window Washer Motors and Pumps1 topic

Wiper and Washer Operating Switches

Window Replacement4 topics

Front Window, Replace
Rear Window, Replace
Top Window, Replace
Door Window, Replace

Heater and Air Conditioning Assembly7 topics

Heater Parts, Replace
Heat Control Knob/Cable
Heater Control Switches
Air Control Knob/Cable
Air Filter, Replace
Air Conditioning Condenser Fan(s), Standard
Air Conditioning Condenser Fan(s), Tropical

Instruments, Switches, and Controls2 topics

Switches
Controls

Fuses and Relays3 topics

Fuse Panel
Fuses
Relays

Electrical Schematics

Steering System

Steering Wheel and Column Assembly1 topic

Steering Wheel and Horn

Steering Control Unit Repair1 topic

Operation

Steering System Air Removal

Steering Relief Pressure Check

Dry Brake System2 topics

Service Brakes
Parking Brake

Air Tank Repair1 topic

Drain Valve

Brake Pedal Valve Repair1 topic

Disassemble, Inspect, and Assemble

Air Chambers Repair

Actuator Arms Repair

Brake Assemblies Repair4 topics

Brake Shoe, Remove
Camshaft, Remove
Camshaft, Install
Brake Shoe, Install

Air Dryer2 topics

Cartridge
Filter

Quick-Release Valve

Governor Check and Adjustment for Air Compressor

Brake Shoes Adjustment1 topic

Service Brakes, Park Function

Table 1. Air Chambers Operation

Hydraulic System5 topics

Hydraulic Pump
Main Control Valve
Steering Control Unit
Pilot Block
Tilt Relief Valve

Hydraulic Pump Repair

Priority Valve Repair

Pilot Valve Repair

Control Levers and Joystick Repair

Pump Output Check2 topics

First Method
Second Method

Steering Relief Pressure Check and Adjustment

Calibration Procedure for Hydraulic Controls7 topics

General and Calibration Startup
Joystick/Lever Calibration
Valve Flow Adjustment
PWM Board Readouts/PV3 Readouts
I/O Board Readouts
Diagnostics
Calibration System Shutdown

Diagnostics2 topics

Lift, Lower, Tilt, and Attachment Circuits (Also see Main Contro
Steering Circuit (Also see Steering System 1600 SRM 936 )

Table 1. Error Code Display

Table 2. Altering PT FLT (Old Logic)

Table 3. Altering PT FLT (New Logic)

Table 4. Fixed PT Logic

Table 5. ECH

Instrument Panel Indicators and Senders4 topics

Instrument Panel Meters, Indicators, and LCD Display
Error Code Display, Transmission
Error Code Display, Engine
Connector

Instrument Panel Component Replacement2 topics

Instrument Panel, Remove
Light, Replace

Sender Replacement7 topics

Fuel Level Sender
Transmission Pressure and Temperature Sender, Tier 1
Pressure Sender, Tier 2
Temperature Sender, Tier 2
Low Coolant Sender
Vacuum Switch
Crankshaft Position Sensor

Table 1. Instrument Panel and Indicators

Table 2. Engine Error Code Descriptions

Table 3. Pin Description

Table 4. Sender Description

Capacities and Specifications

Lift Truck Weights

Capacities3 topics

Perkins Diesel
Cummins Diesel
Perkins

Electrical System

Tire Sizes

Mast Speeds

Torque Specifications, Cummins Diesel

Torque Specifications, Perkins Diesel1 topic

Engine

Torque Specifications - Perkins, Tier 2

Torque Specifications, General12 topics

Transmission
Driveline and Axle
Differential
Brakes - Wet
Brakes - Dry
Steering
Hydraulic System
Mast
Carriage
Tilt Cylinders
Frame
Wiper Arms, Front

Hyster T-50 Transmission Pressures (Powershift and Automatic)

TE-10 Transmission Specifications3 topics

Electrical
Hydraulic Cooler Lines
Torque Specifications for Lubricated or Plated Screw Threads

Table 1. Temperature Sensor (In Speed Sensor) Resistance Versus

Table 2. Grade 5

Table 3. Grade 8

Table 5. O-ring Port Plug Torque Chart

Table 6. Pipe Plug Torque Chart

Diagrams

Planetary Drive Axle1 topic

Identification

Removal

Disassembly4 topics

Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)
Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD
Wheel End
Spindle and Piston Housing

Cleaning4 topics

Clean Ground or Polished Parts
Clean Parts With Rough Finish
Clean Axle Assemblies
Drying Cleaned Parts

Corrosion Prevention

Parts Inspection9 topics

Tapered Roller Bearings
Bevel Pinion and Ring Gear Sets
Main Differential Assembly
Axle Shafts
Yoke
Brakes
Repair or Replace Parts
Repair Welding
Apply Silicone Gasket Material

Assembly4 topics

Spindle and Piston Housing to Axle Housing
Wet Disc Brakes
Adjust Wheel Bearing Preload
Planetary Spider Assembly

Installation1 topic

Fill Wet Disc Brakes With Hydraulic Fluid

Lubrication Specification

Main Control Valve4 topics

Lift Section
Tilt/Auxiliary Section
Relief Valves
Unloader Valve

Main Control Valve Repair

Pressure Relief Valve Check and Adjustment9 topics

Check and Adjust
Replace
Brake Drum
Dry Brakes
Spindle and Brake Spider
Ground or Polished Parts
Parts With Rough Finish
Axle Assemblies
Spindle, Brake Spider, and Brake

Wet Brake System1 topic

Oil Cooler Circuit

Pressure Switch Replacement

Accumulators Replacement

Brake Treadle Valve Repair

Parking Brake Valve Repair

Parking Brake Caliper Repair

Brake Pad Repair

Seals Repair

Service Brake Repair12 topics

Minimum Brake Disc Thickness
Hydraulic Fluid for Brake Actuation
Brake Coolant Specifications
Coolant Change Intervals
Hydraulic Fluid Specifications
Brake Does Not Apply
Brake Does Not Release
Brake Performance
Brake Leaks Actuation Fluid
Brake Cooling Fluid Leakage
Brake Noise and Vibration
Brake Overheats

Table 1. Brake Pad Adjustment

Table 2. Minimum Brake Disc Thickness

Table 3. Formed Seal Wear Chart

Empty Container Handling Attachment8 topics

Selector Valves
Sideshift Circuit
Extend and Retract Circuit
Twist Lock Circuit and Control
Lifting Hooks
Indicator Lights and LEDs
Lift Interrupt and Override
Overlowering Interrupt and Override

Carriage and Attachment Repair

Attachment Without Carriage Repair

Sideshift Cylinders Repair

Extension Cylinders Repair

Vertical End Beams Repair1 topic

Hose Replacement in End Beams

Twist Locks Repair for Model 553

Hooks Replacement for Model 555

Twist Locks Repair for Model 558

Bleed the System

Valve Assembly

Slide Pad Replacement

Adjustments5 topics

Twist Lock Angle Adjustment
LOCKED/NOT LOCKED Sensors Adjustment
Seated Sensor Adjustment
Overlowering Protection Sensor Adjustment (Models 553 and 558)
Torque Chart

Maintenance2 topics

Additional Attachment Maintenance
Interface Boxes

Table 1. Torque Chart

Table 2. Maintenance Schedule

Periodic Maintenance2 topics

How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule1 topic

Empty Container Attachment Maintenance

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

Maintenance Procedures Every 250 Hours or Every 2 Months1 topic

Empty Container Handler

Maintenance Procedures Every 500 Hours or Every 3 Months13 topics

Lift Chains
Drive Shaft
Steering Axle
Wheel Nuts
Shafts for Brake Actuators
Drive Axle and Differential
Hydraulic Tank Breather
Air Filter, Engine, and Air Compressor
Cabin Air Filter, Heater
Engine Oil and Filter
General Lubrication
Fork Wear and Damage Check
Lift Chains Wear Check

Maintenance Procedures Every 1000 Hours or 6 Months4 topics

Transmission Oil and Filter, Change
Fuel Filter
Fuel Injection Pump Timing
Valve Adjustment

Maintenance Procedures Every 2000 Hours or Yearly2 topics

Differential and Drive Axle
Wheel Bearings

Fuel Injectors Check

Lift and Tilt System Leak Check

Welding Repairs

Wheel and Tire Replacement5 topics

Remove Wheels From Lift Truck
Pneumatic Tires
Add Air to Tires
Solid Rubber Tires
Wheels, Install

Table 1. Daily Inspections − Condition Check

Table 2. Daily Inspections − Fluid Level Check

Table 3. Daily Inspections − Checks With the Engine Running

Table 4. First Inspection After First 100 Hours of Operation

Table 5. Periodic Maintenance Schedule − Inspect and Adjust

Table 6. Periodic Maintenance Schedule − Lubricate

Table 7. Periodic Maintenance Schedule − Change

Table 8. Empty Container Attachment Maintenance − Inspect and

Table 9. Empty Container Attachment Maintenance − Lubricate

Table 10. Allowable Mast Movement from Internal Leakage

Perkins Tier 2 Diesel Engines1 topic

Cylinder Liner

Turbocharger13 topics

Impeller and Compressor Housing, Clean
Waste-Gate Valve Check
Closed Circuit Breather System (CCB)
Oil Filter Head
Oil Filter Head Bypass Valve
Fuel System Air Removal
Fuel Lift Pump
Oil Cooler
Electronic Control Module (ECM)
Voltage Load and Protection Module (VLPM)
Engine Speed and Timing Sensor
Pressure Sensors (Engine Oil and Air Intake)
Temperature Sensor

Air Compressor

Turbocharger Troubleshooting

Table 9. Pistons

Table 10. Piston Rings

Table 11. Piston Pins

Table 12. Connecting Rods

Table 13. Small End Bushings

Table 14. Connecting Rod Bearings

Inside this manual

Real pages from this service manual (1,342 pages). Open the sample pages (PDF, 273 KB)

Sample pages from the Hyster Challenger H170-280HD (F007) Forklift Service Manual: Specifications, Troubleshooting, Diagram

Specifications, page 236: General
Troubleshooting, page 616: Troubleshooting
Diagram, page 776: Diagrams, Schematics, or Arrangements

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,342 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).