Hyster CHALLENGER H100XL Service & Repair Manual Download | Manualshive

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Hyster G005 (H70XL, H80XL, H90XL, H100XL,
H110XL, H90XLS) Forklift

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Summary of Contents for CHALLENGER H100XL

Page 1: ...Hyster G005 H70XL H80XL H90XL H100XL H110XL H90XLS Forklift ...

Page 2: ...ASTS DESCRIPTION AND REPAIRS FOR LIFT TRUCKS WITH 3 500 TO 6 000 KG 7 000 TO 12 000 LB CAPACITIES H3 50 5 00XL H70 110XL G005 S3 50 5 50XL S70 120XL D004 E3 50 5 50XL E70 120XL C098 PART NO 897122 4000 SRM 340 ...

Page 3: ...d condition Always use HYSTER APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follo...

Page 4: ...mble 10 Assemble 11 Install 14 Sideshift Carriage 1993 and Later Design 14 Remove 14 Repairs 14 Install 14 Weight of Mast Parts 17 Two Stage Mast With Limited Free Lift Repair 17 Remove 17 Disassemble 17 Clean and Inspect 19 Assemble 19 Install 21 Two Stage Mast With Full Free Lift Repair 21 Remove 21 Disassemble 21 Clean and Inspect 23 Assemble 23 Install 23 Three Stage Mast With Full Free Lift 2...

Page 5: ...more information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions please write to me admin servicemanualperfect com ...

Page 6: ... Masts TABLE OF CONTENTS Continued Mast Adjustments 31 Carriage Adjustment 33 Troubleshooting 34 This section is for the following models H3 50 5 00XL H70 110XL G005 S3 50 5 50XL S70 120XL D004 E3 50 5 50XL E70 120XL C098 ii ...

Page 7: ...nner weld ment Forks or other types of load handling equip ment are attached to the carriage A load backrest extension is installed on the carriage A sideshift carriage permits the operator to hydrauli cally change the lateral position of the load handling device on the carriage TWO STAGE MAST WITH LIMITED FREE LIFT The Vista Two Stage mast has two weldments an outer weldment and an inner weldment...

Page 8: ...s load roller and strip bearing arrangements sim ilar to the two stage mast The two main lift cylinders are installed at the back of the outer weldment The base of each lift cylin der sits in a mount at the bottom of the outer weld ment The hydraulic fitting for each lift cylinder goes through a hole in the mount The top of each lift cylinder cylinder rod fits into guides at the top of the inner w...

Page 9: ...e used on the mast to raise the carriage and extend the weldments The weldments are telescopic and have load roller and strip bearing arrangements similar to the two stage mast The two main lift cylinders are installed at the back of the outer weldment The base of each lift cylinder is held on a mount at the bottom of the outer weldment The hydraulic fittings for the lift cylin ders go through hol...

Page 10: ...NDER 2 2 OUTER LIFT CHAIN 3 FREE LIFT CYLINDER 4 INNER LIFT CHAIN 5 INNER WELDMENT 6 INTERMEDIATE WELDMENT 7 OUTER WELDMENT 8 FROM MAIN CONTROL VALVE 9 EXTERNAL LOWERING CONTROL VALVE 10 INTERNAL LOWERING CONTROL VALVE Figure 4 Three Stage Mast With Full Free Lift 4 ...

Page 11: ... or personnel lift to work on the mast DO NOT use blocks to support the mast weld ments nor to restrain their movement Mast repairs require disassembly and re moval of parts and can require removal of the mast or carriage Follow the repair pro cedures in the correct Service Manual for the mast WHEN WORKING NEAR THE MAST ALWAYS Lower the mast and carriage completely Push the lift lower control leve...

Page 12: ...M 340 A TWO STAGE LFL MAST B TWO STAGE FFL MAST C THREE STAGE FFL MAST 1 OUTER WELDMENT 2 INNER WELDMENT 3 INTERMEDIATE WELDMENT 4 HOOK 5 FREE LIFT CYLINDER 6 CROSSMEMBER 7 CROSSMEMBER Figure 5 Two Stage LFL Two Stage FFL and Three Stage FFL Masts 6 ...

Page 13: ...ion after the width adjustment is made REMOVE AND INSTALL WARNING Do not try to move a fork without a lifting de vice Each fork for these lift trucks can weigh 66 to 183 kg 145 to 402 lb for a hook fork and 128 to 226 kg 281 to 498 lb for a pin fork A fork can be removed from the carriage for replace ment of the fork or other maintenance Hook Fork Remove Slide a hook fork to the fork removal notch...

Page 14: ...ce to lift fork away from carriage Install Install fork pin in carriage Align eyes of forks so forks will be installed on fork pin When fork pin is installed in carriage so it holds forks install load backrest extension Engage fork with lock pin 1 CARRIAGE 2 FORK 3 FORK PIN 4 LOCK PIN 5 LOAD BACKREST EXTENSION Figure 8 Pin Forks Carriage Repair REMOVE WARNING Do not work under a raised carriage Lo...

Page 15: ...ility and will not fall over when the inner weldment is raised above the load rollers of the carriage 4 Use lift cylinders to raise inner weldment until it is above load rollers of carriage If the hy draulic system cannot be used connect lifting de vice to top of inner weldment Carefully raise in ner weldment until it is above load rollers of car riage 5 Move lift truck from carriage Connect lifti...

Page 16: ...emble WARNING Make sure any lifting devices have the correct capacity for the parts being moved See Weight of Mast Parts 1 Disconnect hydraulic lines at sideshift cylinder Disconnect sideshift cylinder at carriage and at apron Remove sideshift cylinder See Figure 10 Figure 11 Figure 12 and Figure 13 2 Remove keeper plates or carriage hooks at bot tom of carriage Use lifting device and lift apron f...

Page 17: ...ckup ring in groove of retainer b Install piston on rod Tighten nut for rod to 122 to 149 N m 90 to 110 lbf ft c Install piston seal and backup ring on piston Install rod and piston in shell Install gland into cylinder tube Tighten gland to 140 to 160 N m 103 to 118 lbf ft 2 Install guide rollers on brackets at carriage When used install bearing segments as shown in Figure 12 and Figure 13 Make su...

Page 18: ...Sideshift Carriage Repair 4000 SRM 340 Figure 12 Sideshift Carriages 12 ...

Page 19: ... RING 13 BEARING SEGMENT A S H3 50 4 50XL S H70 110XL 1 CARRIAGE 2 APRON 3 SIDESHIFT CYLINDER 4 LOAD ROLLER 5 SHIMS 6 SNAP RING 7 CARRIAGE HOOK 8 CYLINDER MOUNT 9 SIDE ROLLER 10 BEARING SEGMENT 11 BEARING BLOCK Figure 13 Sideshift Carriages 6 Install sideshift cylinder in carriage Install an chor pins or nuts at both ends of the cylinder Af ter the nut at the apron is just tight loosen nut 1 4 tur...

Page 20: ...ge bar to move down so the sideshift carriage can be removed Carefully lift sideshift carriage from standard carriage The sideshift cylinder mounting bracket and cylinder will stay on the standard carriage Remove bushings 4 Disconnect hydraulic lines at sideshift cylinder Put caps on open lines Remove cylinder mount bracket from carriage If necessary remove threaded rods and shims to remove sidesh...

Page 21: ...ft Cylinder 5 Make sure standard carriage is completely low ered Connect lifting device to lifting eye In stall sideshift carriage on standard carriage Put blocks under bottom bar of sideshift carriage so bottom bushing is moved tight against standard carriage 6 Install two top capscrews On 2 00 to 2 75 ton 4 000 to 5 000 lb lift trucks tighten all cap screws to 435 N m 320 lbf ft On 3 00 to 3 20 ...

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