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2004 Hyster Challenger H25-40XM H40XMS Parts Manual PDF Download
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2004 Hyster Challenger H25-40XM H40XMS Parts Manual PDF Download

Original price was: $39.95.Current price is: $24.95.

Complete illustrated parts manual for Hyster Challenger H25-40XM, H40XMS (E001) lift trucks. Covers H25XM, H30XM, H35XM, H40XM, H40XMS with gasoline, LPG, and diesel engines. 444-page PDF with exploded views, part numbers, and numerical index.

SKU: HD-HYS-CHAL-H25-40XM-E001-04 Category: Tags: , , , Vendor: OverhaulDocs
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Description

The 2004 Hyster Challenger H25-40XM H40XMS Parts Manual is the complete illustrated parts catalog for Hyster Challenger series lift trucks under Unit Code E001. Covering the H25XM, H30XM, H35XM, H40XM, and H40XMS models in gasoline, LPG, and diesel configurations, this 2004 Hyster Challenger H25-40XM H40XMS Parts Manual PDF gives you factory part numbers, exploded illustrations, and assembly breakdowns across all 13 major sections. Whether you are rebuilding an engine, replacing a hydraulic cylinder, or tracking down a single bearing, this Hyster Challenger H25-40XM H40XMS parts catalog organizes every component so you can find the right part the first time.

File Details

  • Manual Type: Illustrated Parts Manual
  • Brand: Hyster
  • Series: Challenger
  • Models Covered: H25XM, H30XM, H35XM, H40XM, H40XMS
  • Unit Code: E001
  • Date: 04/2004
  • Region: North America
  • Language: English
  • Page Count: 444
  • File Format: PDF
  • Parts Manual Number: 1492521

Chapters Covered

  • Frame – Frame and Floorplates, Overhead Guard, Engine Cover, Seats (Full Suspension and Non-Suspension), Labels, Load Backrest Extension, Counterweight
  • Engine Assembly – Cylinder Head and Cover, Cylinder Block, Crankshaft and Piston, Camshaft and Valves, Manifold Intake and Exhaust, Electrical System, Fuel System, Oil Pump and Filter, Cooling System, Radiator and Hoses, Engine Mounts, Exhaust Systems (Gasoline and LPG Standard, Low Emissions LPG and LPS, Overhead Gasoline and LPG, Standard Diesel Type DS, Type GS and LPS, Overhead Diesel, Low Emissions LPG and LPS)
  • Fuel System – Throttle Assembly, Monotrol Pedal, Throttle Linkage (Gasoline, LPG, Diesel), Carburetor (Gasoline, LPG Closed Loop, LPG Open Loop), Governor, Air Intake and Filter (Diesel, Gasoline, LPG), Fuel System (Diesel, Low Emissions LPG, EPA Compliant LPG), Regulator (LPG Closed Loop, LPG Open Loop), Fuel Filter (Diesel), Fuel Injection Pump (Diesel), Nozzle Holder (Diesel), Fuel Tank (Gasoline, LPG, Diesel)
  • Electrical System – Electrical System Chassis (Gasoline and LPG, Diesel), Electrical Cowl, Tail Lights, Lights LED Backup and Brake, Instrument Cluster, Forward and Reverse, Distributor, Starter (Gasoline and LPG, Diesel and DS), Alternator (Standard, Types GS LPS and DS), Wire Harnesses (Chassis, Engine, Cowl, Taillight, Rear Lights)
  • Transmission – Torque Converter, Gear Pump, Solenoid Valve, Transmission Housing, Transmission Gears, Transmission Hydraulic Lines, Clutch Hydraulic, Valve Control, Differential, Drive Axle, End Plate
  • Steering System – Steering Column, Steering Pump, Steering Axle, Steering Cylinder
  • Brake System – Brake Linkage, Brake Lines, Brake Assembly, Park Brake Lever, Master Cylinder
  • Hydraulic System – Hydraulics, Hydraulic Gear Pump, Hydraulic Gear Pump Drive, Valve Attaching Parts (Three Function, Four Function), Valve Control (Single Relief Three Function, Single Relief Four Function), Connecting Hoses, Tilt Cylinder (6 Forward/6 Backward, 6 Forward/10 Backward, 10 Forward/6 Backward)
  • Mast – Two Stage Limited Free-Lift – Outer Mast, Inner Mast, Free Lift, Lift Cylinder (LH, RH), Carriage, Mast Installation, Header Hose, Forks
  • Mast – Two Stage Full Free-Lift – Outer Mast, Inner Mast, Main Lift, Free Lift, Main Lift Cylinder (LH, RH), Free-Lift Cylinder, Carriage, Mast Installation, Header Hose, Forks
  • Mast – Three Stage Full Free-Lift – Outer Mast, Intermediate Mast, Inner Mast, Main Lift, Free Lift, Main Lift Cylinder (LH, RH), Free-Lift Cylinder, Carriage, Mast Installation, Header Hose, Forks
  • Options – Side-Shift Cylinder, Side-Shift Carriage, Integral Side-Shift Carriage, Integral Side-Shift Cylinder, Integral Side-Shift Hydraulic Hoses, Auxiliary Tubes, Wheel and Tire (Drive, Steering), Drive Wheel and Tire (Split Rim), Lifting Eye, Lights (Drive Lights and Rear), Back-Up Alarm
  • Numerical Index – Complete alphabetical part number lookup

This 2004 Hyster Challenger H25-40XM H40XMS Parts Manual PDF also includes an Abbreviations Quick Reference, a How to Use the Illustrated Parts Manual guide, step-by-step instructions for finding the desired part number, truck serial number locations, lift equipment identification, attachment and side-shift carriage serial number identification, and a publications list.

What This Parts Manual Gives You

The Hyster Challenger H25-40XM H40XMS parts manual is built for anyone who needs to identify, order, or replace components on these lift trucks. Each section opens with a contents page, followed by exploded-view illustrations where every part is called out with an item number, part number, description, and required quantity. Keys and footnotes handle the variations between gasoline, LPG, and diesel models, as well as the differences between mast configurations. Serial number breaks and Engineering Change Notice (ECN) references are printed directly on the pages, so you can confirm you are looking at the correct part for your specific truck.

Whether you are working on the engine assembly, the transmission, the brake system, or the hydraulic system, the 2004 Hyster Challenger H25-40XM H40XMS parts manual PDF covers all 13 major sections. The numerical index at the end lets you look up a part number and jump straight to the page and item number where it appears. For anyone maintaining, repairing, or restoring Hyster Challenger H25XM, H30XM, H35XM, H40XM, or H40XMS lift trucks, this 2004 Hyster Challenger H25-40XM H40XMS Parts Manual is the reference that connects every part number to its illustration.

Why This Hyster Challenger Parts Manual Matters

Ordering the wrong part costs time and money. The 2004 Hyster Challenger H25-40XM H40XMS parts manual removes that guesswork by giving you the exact part numbers and quantities for every assembly, subassembly, and detail part. The exploded views show how components fit together, which is invaluable when you are disassembling a mast, rebuilding a brake assembly, or tracing a hydraulic circuit. With model-specific and serial-number-specific information, this Hyster Challenger H25-40XM H40XMS parts catalog helps you get the right part for your exact machine.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “2004 Hyster Challenger H25-40XM H40XMS Parts Manual PDF Download” are as follows:

tocp. 1
1 FRAMEp. 19
FRAME AND FLOORPLATES (Figure 1-1)p. 22
OVERHEAD GUARD (Figure 1-2)p. 25
ENGINE COVER (Figure 1-3)p. 26
SEAT (Figure 1-4)p. 28
SEAT (Figure 1-5)p. 30
SEAT (Figure 1-6)p. 32
LABELS (Figure 1-7)p. 34
LOAD BACKREST EXTENSION (Figure 1-8)p. 37
COUNTERWEIGHT (Figure 1-9)p. 38
2 ENGINE ASSEMBLYp. 41
CYLINDER HEAD AND COVER (Figure 2-1)p. 46
CYLINDER BLOCK (Figure 2-2)p. 48
OIL PAN AND TIMING GEAR COVER (Figure 2-3)p. 50
CRANKSHAFT AND PISTON (Figure 2-4)p. 52
CAMSHAFT AND VALVES (Figure 2-5)p. 54
MANIFOLD (Figure 2-6)p. 56
ELECTRICAL SYSTEM (Figure 2-7)p. 58
ELECTRICAL SYSTEM (Figure 2-8)p. 60
FUEL SYSTEM (Figure 2-9)p. 62
FUEL SYSTEM (Figure 2-10)p. 64
ENGINE FUEL SYSTEM (Figure 2-11)p. 66
OIL PUMP AND FILTER (Figure 2-12)p. 68
COOLING SYSTEM (Figure 2-13)p. 70
RADIATOR AND HOSES (Figure 2-14)p. 72
ENGINE MOUNTS (Figure 2-15)p. 74
CYLINDER HEAD (Figure 2-16)p. 76
CYLINDER BLOCK (Figure 2-17)p. 78
OIL PAN AND TIMING GEAR COVER (Figure 2-18)p. 80
CRANKSHAFT AND PISTON (Figure 2-19)p. 82
CAMSHAFT AND VALVES (Figure 2-20)p. 84
MANIFOLD (Figure 2-21)p. 86
ELECTRICAL SYSTEM (Figure 2-22)p. 88
OIL PUMP AND FILTER (Figure 2-23)p. 90
COOLING SYSTEM (Figure 2-24)p. 92
RADIATOR AND HOSES (Figure 2-25)p. 94
ENGINE MOUNTS (Figure 2-26)p. 96
EXHAUST (Figure 2-27)p. 98
EXHAUST (Figure 2-28)p. 100
EXHAUST (Figure 2-29)p. 102
EXHAUST (Figure 2-30)p. 104
EXHAUST (Figure 2-31)p. 106
EXHAUST (Figure 2-32)p. 108
3 FUEL SYSTEMp. 111
THROTTLE ASSEMBLY (Figure 3-1)p. 114
MONOTROL PEDAL (Figure 3-2)p. 116
THROTTLE LINKAGE (Figure 3-3)p. 118
THROTTLE LINKAGE (Figure 3-4)p. 120
THROTTLE LINKAGE (Figure 3-5)p. 121
CARBURETOR (Figure 3-6)p. 122
GOVERNOR (Figure 3-7)p. 124
AIR INTAKE AND FILTER (Figure 3-8)p. 126
AIR INTAKE AND FILTER (Figure 3-9)p. 128
AIR INTAKE AND FILTER (Figure 3-10)p. 130
FUEL SYSTEM (Figure 3-11)p. 132
FUEL SYSTEM (Figure 3-12)p. 136
CARBURETOR (Figure 3-13)p. 140
REGULATOR (Figure 3-14)p. 142
CARBURETOR (Figure 3-15)p. 144
REGULATOR (Figure 3-16)p. 146
FUEL SYSTEM (Figure 3-17)p. 148
NOZZLE HOLDER (Figure 3-18)p. 150
FUEL FILTER (Figure 3-19)p. 152
FUEL INJECTION PUMP (Figure 3-20)p. 154
FUEL TANK (Figure 3-21)p. 156
FUEL TANK (Figure 3-22)p. 158
FUEL TANK (Figure 3-23)p. 160
4 ELECTRICAL SYSTEMp. 163
ELECTRICAL SYSTEM (Figure 4-1)p. 166
ELECTRICAL SYSTEM (Figure 4-2)p. 170
ELECTRICAL (Figure 4-3)p. 174
CONTROL UNIT (Figure 4-4)p. 178
TAIL LIGHTS (Figure 4-5)p. 180
LIGHTS, LED BACKUP AND BRAKE (Figure 4-6)p. 182
BATTERY (Figure 4-7)p. 184
INSTRUMENT CLUSTER (Figure 4-8)p. 186
INSTRUMENT CLUSTER (Figure 4-9)p. 188
LEVER (Figure 4-10)p. 190
WIRE HARNESS (Figure 4-11)p. 191
WIRE HARNESS (Figure 4-12)p. 192
WIRE HARNESS (Figure 4-13)p. 194
WIRE HARNESS (Figure 4-14)p. 195
WIRE HARNESS (Figure 4-15)p. 196
WIRE HARNESS (Figure 4-16)p. 197
WIRE HARNESS (Figure 4-17)p. 198
WIRE HARNESS (Figure 4-18)p. 199
WIRE HARNESS (Figure 4-19)p. 200
WIRE HARNESS (Figure 4-20)p. 202
WIRE HARNESS (Figure 4-21)p. 204
WIRE HARNESS (Figure 4-22)p. 205
WIRE HARNESS (Figure 4-23)p. 206
WIRE HARNESS (Figure 4-24)p. 207
WIRE HARNESS (Figure 4-25)p. 208
DISTRIBUTOR (Figure 4-26)p. 210
STARTER (Figure 4-27)p. 212
STARTER (Figure 4-28)p. 214
ALTERNATOR (Figure 4-29)p. 216
ALTERNATOR (Figure 4-30)p. 218
5 TRANSMISSIONp. 221
TORQUE CONVERTOR (Figure 5-1)p. 224
GEAR PUMP (Figure 5-2)p. 226
SOLENOID VALVE (Figure 5-3)p. 227
TRANSMISSION HOUSING (Figure 5-4)p. 228
TRANSMISSION GEARS (Figure 5-5)p. 232
TRANSMISSION HYDRAULIC LINES (Figure 5-6)p. 234
CLUTCH (Figure 5-7)p. 236
VALVE (Figure 5-8)p. 238
DIFFERENTIAL (Figure 5-9)p. 240
DRIVE AXLE (Figure 5-10)p. 242
END PLATE (Figure 5-11)p. 244
6 STEERING SYSTEMp. 247
STEERING COLUMN (Figure 6-1)p. 250
STEERING PUMP (Figure 6-2)p. 252
STEERING AXLE (Figure 6-3)p. 254
STEERING CYLINDER (Figure 6-4)p. 256
7 BRAKE SYSTEMp. 257
BRAKE LINKAGE (Figure 7-1)p. 260
BRAKE LINES (Figure 7-2)p. 262
BRAKE ASSEMBLY (Figure 7-3)p. 264
PARK BRAKE LEVER (Figure 7-4)p. 266
MASTER CYLINDER (Figure 7-5)p. 268
8 HYDRAULIC SYSTEMp. 271
HYDRAULICS (Figure 8-1)p. 274
HYDRAULIC GEAR PUMP (Figure 8-2)p. 278
HYDRAULIC GEAR PUMP DRIVE (Figure 8-3)p. 280
VALVE ATTACHING PARTS (Figure 8-4)p. 282
VALVE (Figure 8-5)p. 286
VALVE ATTACHING PARTS (Figure 8-6)p. 290
VALVE (Figure 8-7)p. 292
CONNECTING HOSES (Figure 8-8)p. 296
TILT CYLINDER (Figure 8-9)p. 298
TILT CYLINDER (Figure 8-10)p. 300
TILT CYLINDER (Figure 8-11)p. 302
9 MAST-TWO STAGE LIMITED FREE-LIFTp. 305
OUTER MAST (Figure 9-1)p. 308
INNER MAST (Figure 9-2)p. 310
FREE LIFT (Figure 9-3)p. 312
LIFT CYLINDER (Figure 9-4)p. 314
LIFT CYLINDER (Figure 9-5)p. 316
CARRIAGE (Figure 9-6)p. 318
MAST INSTALLATION (Figure 9-7)p. 320
HEADER HOSE (Figure 9-8)p. 322
FORKS (Figure 9-9)p. 324
FORKS (Figure 9-10)p. 325
10 MAST-TWO STAGE FULL FREE-LIFTp. 327
OUTER MAST (Figure 10-1)p. 330
INNER MAST (Figure 10-2)p. 332
MAIN LIFT (Figure 10-3)p. 334
FREE LIFT (Figure 10-4)p. 336
MAIN LIFT CYLINDER (Figure 10-5)p. 338
MAIN LIFT CYLINDER (Figure 10-6)p. 340
MAIN LIFT CYLINDER (Figure 10-7)p. 342
MAIN LIFT CYLINDER (Figure 10-8)p. 344
FREE-LIFT CYLINDER (Figure 10-9)p. 346
CARRIAGE (Figure 10-10)p. 348
MAST INSTALLATION (Figure 10-11)p. 350
HEADER HOSE (Figure 10-12)p. 352
HEADER HOSE (Figure 10-13)p. 356
FORKS (Figure 10-14)p. 359
FORKS (Figure 10-15)p. 360
11 MAST-THREE STAGE FULL FREE-LIFTp. 361
OUTER MAST (Figure 11-1)p. 364
INTERMEDIATE MAST (Figure 11-2)p. 366
INNER MAST (Figure 11-3)p. 368
MAIN LIFT (Figure 11-4)p. 370
FREE LIFT (Figure 11-5)p. 372
MAIN LIFT CYLINDER (Figure 11-6)p. 374
MAIN LIFT CYLINDER (Figure 11-7)p. 376
FREE-LIFT CYLINDER (Figure 11-8)p. 378
CARRIAGE (Figure 11-9)p. 380
MAST INSTALLATION (Figure 11-10)p. 382
HEADER HOSE (Figure 11-11)p. 384
FORKS (Figure 11-12)p. 387
FORKS (Figure 11-13)p. 388
12 OPTIONSp. 389
SIDE-SHIFT CYLINDER (Figure 12-1)p. 392
SIDE-SHIFT CARRIAGE (Figure 12-2)p. 394
INTEGRAL SIDE-SHIFT CARRIAGE (Figure 12-3)p. 396
INTEGRAL SIDE-SHIFT CARRIAGE (Figure 12-4)p. 398
INTEGRAL SIDE-SHIFT CYLINDER (Figure 12-5)p. 400
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES (Figure 12-6)p. 401
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES (Figure 12-7)p. 402
AUXILIARY TUBES (Figure 12-8)p. 404
AUXILIARY TUBES (Figure 12-9)p. 406
AUXILIARY TUBES (Figure 12-10)p. 408
WHEEL AND TIRE (Figure 12-11)p. 410
DRIVE WHEEL AND TIRE (Figure 12-12)p. 412
WHEEL AND TIRE (Figure 12-13)p. 414
WHEEL AND TIRE (Figure 12-14)p. 416
LIFTING EYE (Figure 12-15)p. 417
LIGHTS (Figure 12-16)p. 418
BACK-UP ALARM (Figure 12-17)p. 420


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