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Hyster CHALLENGER H135XL, Service & Repair Manual

The Hyster CHALLENGER H135XL is a reliable and powerful forklift that is perfect for handling heavy loads. To ensure smooth operation and maintenance, make sure to download the free Service & Repair Manual from manualshive.com. This manual provides detailed instructions and diagrams to help keep your machine in top condition.

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"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

Summary of Contents for CHALLENGER H135XL

Page 1: ...Hyster F006 H135XL H155XL Forklift...

Page 2: ...FRAME H6 00 7 00XL H135 155XL F006 G006 PART NO 897104 100 SRM 322...

Page 3: ...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...

Page 4: ...5 Small Leaks Repair 5 Large Leaks Repair 5 Clean 5 Steam Method 6 Chemical Solution Method 6 Other Methods of Preparation for Repair 6 Install 6 Fuel Tank Repair 7 Remove 7 Repair 7 Install 7 Radiat...

Page 5: ...ore 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 pl...

Page 6: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 7: ...f tanks and replacement of safety labels are included Description The frame is one weldment and includes the hy draulic tank and the fuel tank for gasoline and diesel fuel There is a counterweight for...

Page 8: ...counterweight can fall from the lift truck 1 Remove the grille and the cover for the hydraulic pump 2 Remove the bracket for the rear hood mount from the frame Put a block between the hood and the ra...

Page 9: ...mbly so the lift truck cannot fall forward The surface must be solid even and level when the lift truck is put on blocks Make sure that any blocks used to support the lift truck are solid one piece un...

Page 10: ...ng are all part of the operator restraint sys tem Each item must be checked to make sure it is attached securely functions correctly and is in good condition The end of the seat belt must fasten corre...

Page 11: ...eck for wet areas accumulation of dirt and loose or miss ing paint caused by leakage Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved fo...

Page 12: ...s given by the manufacturer WARNING Compressed air can move particles so that they cause injury to the user or to other personnel Make sure that the path of the compressed air is away from all personn...

Page 13: ...uel from the tank is put in a closed container 2 Remove the drain plug and drain the fuel from the tank Disconnect the fuel lines at the tank and put caps on the openings 3 Remove the filler neck from...

Page 14: ...ith a powershift transmission remove the capscrews that hold the torque converter to the flywheel Put blocks under the output end of the transmission Remove the capscrews that connect the engine to th...

Page 15: ...Figure 5 NOTE A 40 N m 30 lbf ft TORQUE B 56 N m 41 lbf ft TORQUE C 50 N m 37 lbf ft TORQUE D 165 N m 122 lbf ft TORQUE A FAN END OF ENGINE DIESEL SHOWN B FLYWHEEL END OF ENGINE 1 FRAME 2 MOUNT BRACK...

Page 16: ...nameplate Cleaning solvents can be flammable and toxic and cause skin irritation When using cleaning solvents always follow the recommendations of the manufacturer If a label must be replaced use the...

Page 17: ...100 SRM 322 Safety Labels Figure 6 Label Positions 11...

Page 18: ...and window frames are replaced as single units A window and frame are not available as separate units The top window has no frame WARNING All windows installed in the cab are made of special material...

Page 19: ...100 SRM 322 Cab Repair 1 CAB FRAME ASSEMBLY 2 WIPER ASSEMBLY FRONT 3 WINDSHIELD 4 TOP WINDOW 5 WIPER ASSEMBLY REAR 6 DOOR WINDOW RH 7 DOOR ASSEMBLY RH 8 REAR WINDOW 9 SIDE WINDOW Figure 7 Cab 13...

Page 20: ...o 0 30 Rear 1319365 Clear Laminated Tempered Safety Glass per ANSI Z26 1 AS2 5 6 to 6 8 0 22 to 0 27 Side 1319364 Clear Laminated Tempered Safety Glass per ANSI Z26 1 AS2 5 6 to 6 8 0 22 to 0 27 Doors...

Page 21: ......

Page 22: ...TECHNICAL PUBLICATIONS 100 SRM 322 11 03 3 97 4 90 5 86 Printed in U S A...

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