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Hyster CHALLENGER H25-40XM 40XMS (D001) Parts Manual – PDF DOWNLOAD
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Hyster CHALLENGER H25-40XM 40XMS (D001) Parts Manual – PDF DOWNLOAD
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Description
Hyster CHALLENGER H25-40XM 40XMS (D001) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster CHALLENGER H25-40XM 40XMS (D001) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs correspond to descriptions found on the next page.
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
4. Locate the assembly the required part is used on and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 13-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 13-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (Figure 10)
7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, “A”, “B”, “C”, “D”, or “E” and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.
TABLE OF CONTENTS:
Hyster CHALLENGER H25-40XM 40XMS (D001) Parts Manual – PDF DOWNLOAD
Frame................................................................................. 19 FRAME AND FLOORPLATES............................................................. 22 OVERHEAD GUARD.................................................................... 26 ENGINE COVER...................................................................... 28 SUSPENSION SEAT................................................................... 30 NON-SUSPENSION SEAT............................................................... 32 FULL SUSPENSION SEAT SHEET 1 OF 2................................................. 34 FULL SUSPENSION SEAT SHEET 2 OF 2................................................. 38 LABELS............................................................................ 40 COUNTERWEIGHT..................................................................... 44 NOISE REDUCTION FRAME............................................................. 46 NOISE REDUCTION ENGINE COVER...................................................... 48 FORKS............................................................................. 50 LOAD BACKREST EXTENSION........................................................... 52 ENGINE ASSEMBLY....................................................................... 53 CYLINDER HEAD AND COVER GASOLINE AND LPG.......................................... 56 CYLINDER BLOCK GASOLINE AND LPG................................................... 58 OIL PAN AND TIMING GEAR COVER GASOLINE AND LPG.................................... 60 CRANKSHAFT AND PISTON GASOLINE AND LPG............................................ 62 CAMSHAFT AND VALVES GASOLINE AND LPG.............................................. 64 MANIFOLD INTAKE AND EXHAUST - GASOLINE AND LPG ................................... 66 ELECTRICAL SYSTEM ENGINE - GASOLINE AND LPG ...................................... 68 OIL PUMP AND FILTER GASOLINE AND LPG.............................................. 70 COOLING GASOLINE AND LPG.......................................................... 72 RADIATOR AND HOSES GASOLINE AND LPG............................................... 74 ENGINE MOUNT GASOLINE AND LPG (→ S/N D001H03001) ................................ 76 ENGINE MOUNT GASOLINE AND LPG (S/N D001H03002 →) ................................ 77 CYLINDER HEAD DIESEL.............................................................. 78 CYLINDER BLOCK DIESEL............................................................. 80 OIL PAN AND TIMING GEAR COVER DIESEL.............................................. 82 CRANKSHAFT AND PISTON DIESEL...................................................... 84 CAMSHAFT AND VALVES DIESEL........................................................ 86 INTAKE AND EXHAUST MANIFOLD DIESEL................................................ 88 ELECTRICAL SYSTEM DIESEL ENGINE................................................... 90 OIL PUMP AND FILTER DIESEL........................................................ 92 COOLING DIESEL.................................................................... 94 RADIATOR AND HOSES DIESEL......................................................... 96 ENGINE MOUNT DIESEL............................................................... 98 EXHAUST STANDARD - GASOLINE AND LPG ..............................................100 EXHAUST STANDARD - DIESEL ........................................................102 EXHAUST TYPE GS AND LPS...........................................................104 EXHAUST TYPE DS...................................................................106 EXHAUST OVERHEAD - GASOLINE AND LPG ..............................................108 EXHAUST OVERHEAD - DIESEL ........................................................110 FUEL SYSTEM...........................................................................113 THROTTLE..........................................................................116 MONOTROL PEDAL....................................................................118 THROTTLE LINKAGE GASOLINE.........................................................120 THROTTLE LINKAGE LPG..............................................................121 THROTTLE LINKAGE DIESEL...........................................................122 CARBURETOR GASOLINE...............................................................124 CARBURETOR LPG....................................................................126 GOVERNOR GASOLINE AND LPG.........................................................128 AIR INTAKE AND FILTER GASOLINE AND LPG............................................130 AIR INTAKE AND FILTER DIESEL (→ 11/1996) ........................................132 AIR INTAKE AND FILTER DIESEL (11/1996 →) ........................................134 TANK MOUNTING LPG.................................................................136 FUEL SYSTEM GASOLINE AND LPG......................................................138 FUEL SUPPLY SYSTEM LPG............................................................140 FILTER AND LOCK-OFF VALVE LPG.....................................................142 CONVERTER LPG - IDENTIFY BY VENDOR MODEL CODE "J" ................................144 CONVERTER LPG - IDENTIFY BY VENDOR MODEL CODE "K" (→ S/N D001H04636) ...........146 CONVERTER LPG - IDENTIFY BY VENDOR MODEL CODE "K" (S/N D001H04637 →) ...........148 FUEL SYSTEM DIESEL................................................................150 NOZZLE HOLDER DIESEL..............................................................152 FUEL FILTER DIESEL................................................................154 INJECTION PUMP DIESEL.............................................................156 FUEL TANK AND LINES GASOLINE......................................................158 FUEL TANK AND LINES DIESEL........................................................160 ELECTRICAL SYSTEM.....................................................................163 ELECTRICAL SYSTEM GASOLINE AND LPG................................................166 ELECTRICAL SYSTEM TYPE GS AND LPS.................................................170 ELECTRICAL SYSTEM DIESEL..........................................................172 ELECTRICAL SYSTEM TYPE DS.........................................................176 TAIL LIGHTS EARLY PRODUCTION......................................................178 TAIL LIGHTS LATE PRODUCTION.......................................................180 BATTERY...........................................................................182 INSTRUMENT CLUSTER................................................................184 SHIFT LEVER.......................................................................186 ELECTRICAL COWL...................................................................188 WIRE HARNESS COWL (→ S/N D001H02209) ............................................192 WIRE HARNESS COWL (S/N D001H02210 →) ............................................194 WIRE HARNESS CLUSTER PANEL........................................................195 WIRE HARNESS CLUSTER POWER........................................................196 WIRE HARNESS FORWARD/REVERSE......................................................197 WIRE HARNESS MONOTROL PEDAL.......................................................198 WIRE HARNESS SEAT SWITCH..........................................................199 WIRE HARNESS ENGINE - GASOLINE AND LPG ...........................................200 WIRE HARNESS ENGINE - TYPE GS AND LPS ............................................201 WIRE HARNESS CHASSIS - DIESEL ....................................................202 WIRE HARNESS ENGINE - TYPE DS ....................................................203 WIRE HARNESS TAIL LIGHT...........................................................204 DISTRIBUTOR GASOLINE AND LPG......................................................206 STARTER GASOLINE AND LPG (→ 4/1999) .............................................208 STARTER GASOLINE AND LPG (4/1999 →) .............................................210 STARTER DIESEL....................................................................212 ALTERNATOR GASOLINE, LPG AND DIESEL - STANDARD ...................................214 ALTERNATOR TYPE GS, LPS, AND DS...................................................216 TRANSMISSION..........................................................................219 TRANSMISSION HOUSING..............................................................222 TRANSMISSION HOUSING..............................................................224 TRANSMISSION HOUSING..............................................................226 TRANSMISSION GEARS................................................................230 TRANSMISSION GEARS................................................................232 TRANSMISSION GEARS................................................................234 HYDRAULIC CLUTCH..................................................................236 HYDRAULIC CLUTCH..................................................................238 HYDRAULIC CLUTCH..................................................................240 HYDRAULIC CLUTCH..................................................................242 HYDRAULIC CLUTCH..................................................................244 SOLENOID VALVE....................................................................246 CONTROL VALVE.....................................................................248 CONTROL VALVE.....................................................................250 CONTROL VALVE.....................................................................252 CONTROL VALVE.....................................................................254 FLYWHEEL AND TORQUE CONVERTER.....................................................256 FLYWHEEL AND TORQUE CONVERTER.....................................................258 FLYWHEEL AND TORQUE CONVERTER.....................................................260 GEAR PUMP.........................................................................262 GEAR PUMP.........................................................................263 DIFFERENTIAL......................................................................264 DRIVE AXLE........................................................................266 TRANSMISSION HYDRAULIC LINES......................................................268 TRANSMISSION HYDRAULIC LINES......................................................270 TRANSMISSION HYDRAULIC LINES......................................................272 END PLATE.........................................................................274 STEERING SYSTEM.......................................................................277 STEERING COLUMN...................................................................280 STEERING CONTROL VALVE............................................................282 STEERING AXLE.....................................................................284 STEERING CYLINDER.................................................................286 STEERING CYLINDER.................................................................288 BRAKE SYSTEM..........................................................................291 BRAKE LINKAGE.....................................................................294 BRAKE LINKAGE.....................................................................296 BRAKE LINES.......................................................................300 BRAKE ASSEMBLY....................................................................302 BRAKE ASSEMBLY....................................................................306 PARK BRAKE LEVER..................................................................310 MASTER CYLINDER...................................................................312 HYDRAULIC SYSTEM......................................................................315 HYDRAULICS........................................................................318 HYDRAULICS........................................................................322 HYDRAULIC PUMP GASOLINE AND LPG (→ S/N D001H03304) ..............................326 HYDRAULIC PUMP DIESEL (→ S/N D001H03304) ........................................328 HYDRAULIC PUMP GASOLINE AND LPG (S/N D001H03305 →) ..............................330 PUMP DRIVE GASOLINE AND LPG.......................................................332 PUMP DRIVE DIESEL.................................................................333 CONTROL VALVE ATTACHING PARTS THREE FUNCTION (→ S/N D001H03395) .................334 CONTROL VALVE ATTACHING PARTS THREE FUNCTION (S/N D001H03396 →) .................338 CONTROL VALVE THREE FUNCTION - SINGLE RELIEF (→ S/N D001H03395) ................342 CONTROL VALVE THREE FUNCTION - SINGLE RELIEF (S/N D001H03396 →) ................346 CONTROL VALVE THREE FUNCTION - DUAL RELIEF (→ S/N D001H03395) ..................350 CONTROL VALVE THREE FUNCTION - DUAL RELIEF (S/N D001H03396 →) ..................354 CONTROL VALVE ATTACHING PARTS FOUR FUNCTION (→ S/N D001H03395) ..................358 CONTROL VALVE ATTACHING PARTS FOUR FUNCTION (S/N D001H03396 →) ..................360 CONTROL VALVE FOUR FUNCTION - SINGLE RELIEF (→ S/N D001H03395) .................362 CONTROL VALVE FOUR FUNCTION - SINGLE RELIEF (S/N D001H03396 →) .................366 CONTROL VALVE FOUR FUNCTION - DUAL RELIEF (→ S/N D001H03395) ...................370 CONTROL VALVE FOUR FUNCTION - DUAL RELIEF (S/N D001H03396 →) ...................374 MAST INSTALLATION.................................................................378 TILT CYLINDER.....................................................................380 Mast-Two Stage Limited Free-Lift......................................................383 OUTER MAST TWO STAGE LIMITED FREE-LIFT............................................386 INNER MAST TWO STAGE LIMITED FREE-LIFT............................................388 LIFT TWO STAGE LIMITED FREE-LIFT (→ S/N A550L01566) .............................390 LIFT TWO STAGE LIMITED FREE-LIFT (S/N A550L01567 →) .............................392 LIFT CYLINDER LEFT HAND - TWO STAGE LIMITED FREE-LIFT ............................396 LIFT CYLINDER RIGHT HAND - TWO STAGE LIMITED FREE-LIFT ...........................398 CARRIAGE TWO STAGE LIMITED FREE-LIFT..............................................400 HEADER HOSE THREE FUNCTION - TWO STAGE LIMITED FREE-LIFT .........................402 HEADER HOSE FOUR FUNCTION - TWO STAGE LIMITED FREE-LIFT ..........................404 Mast-Two Stage Full Free-Lift.........................................................407 OUTER MAST TWO STAGE FULL FREE-LIFT...............................................410 INNER MAST TWO STAGE FULL FREE-LIFT...............................................412 MAIN LIFT TWO STAGE FULL FREE-LIFT (→ S/N A558L01559) ...........................414 MAIN LIFT TWO STAGE FULL FREE-LIFT (S/N A558L01560 →) ...........................416 FREE-LIFT TWO STAGE FULL FREE-LIFT................................................418 MAIN LIFT CYLINDER LEFT HAND - TWO STAGE FULL FREE-LIFT (→ S/N A558L03214) .....422 MAIN LIFT CYLINDER LEFT HAND - TWO STAGE FULL FREE-LIFT (S/N A558L03215 →) .....424 MAIN LIFT CYLINDER RIGHT HAND - TWO STAGE FULL FREE-LIFT (→ S/N A558L03214) ....426 MAIN LIFT CYLINDER RIGHT HAND - TWO STAGE FULL FREE-LIFT (S/N A558L03215 →) ....428 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT.......................................430 CARRIAGE TWO STAGE FULL FREE-LIFT.................................................432 HEADER HOSE THREE FUNCTION - TWO STAGE FULL FREE-LIFT ............................434 HEADER HOSE FOUR FUNCTION - TWO STAGE FULL FREE-LIFT .............................438 Mast-Three Stage Full Free-Lift.......................................................441 OUTER MAST THREE STAGE FULL FREE-LIFT.............................................444 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT......................................446 INNER MAST THREE STAGE FULL FREE-LIFT.............................................448 MAIN LIFT THREE STAGE FULL FREE-LIFT (→ S/N A554L18550) .........................450 MAIN LIFT THREE STAGE FULL FREE-LIFT (S/N A554L01856 →) .........................454 FREE-LIFT THREE STAGE FULL FREE-LIFT..............................................458 MAIN LIFT CYLINDER LEFT HAND - THREE STAGE FULL FREE-LIFT ........................462 MAIN LIFT CYLINDER RIGHT HAND - THREE STAGE FULL FREE-LIFT .......................464 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT.....................................466 CARRIAGE THREE STAGE FULL FREE-LIFT...............................................468 HEADER HOSE THREE FUNCTION - THREE STAGE FULL FREE-LIFT ..........................470 HEADER HOSE FOUR FUNCTION - THREE STAGE FULL FREE-LIFT ...........................474 OPTIONS...............................................................................477 SIDE-SHIFT CARRIAGE...............................................................480 SIDE-SHIFT CYLINDER...............................................................482 FENDER............................................................................484 LIFTING EYE.......................................................................486 DRIVE TIRE AND WHEEL DISC WHEEL...................................................488 DRIVE TIRE AND WHEEL SPLIT WHEELS.................................................490 STEER TIRE AND WHEEL DISC WHEEL...................................................492 STEER TIRE AND WHEEL SPLIT WHEELS.................................................494 DRIVE LIGHTS AND REAR LIGHTS......................................................496 STROBE LIGHT......................................................................498 FIRE EXTINGUISHER.................................................................500 MIRROR............................................................................502 BACK-UP ALARM.....................................................................504 AUXILIARY FUNCTION TUBE TWO STAGE LIMITED FREE-LIFT...............................506 AUXILIARY FUNCTION TUBE TWO AND THREE STAGE FULL FREE-LIFT........................508 NUMERICAL INDEX.......................................................................511
IMAGES PREVIEW OF THE MANUAL:
HYSTER CHALLENGER H25-40XM 40XMS (D001) PARTS MANUAL – PDF DOWNLOAD:
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