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Hyster CHALLENGER H300-360XL H33-360XL-EC (D019) Parts Manual – PDF DOWNLOAD
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Hyster CHALLENGER H300-360XL H33-360XL-EC (D019) Parts Manual – PDF DOWNLOAD
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Description
Hyster CHALLENGER H300-360XL H33-360XL-EC (D019) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster CHALLENGER H300-360XL H33-360XL-EC (D019) 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 H300-360XL H33-360XL-EC (D019) Parts Manual – PDF DOWNLOAD
Frame................................................................................................ 21 GENERAL TRUCK.................................................................................... 24 OPERATOR COMPARTMENT WITHOUT CAB (→ S/N D019E02261) ............................................ 26 OPERATOR COMPARTMENT WITHOUT CAB (S/N D019E02262 →) ............................................ 30 OPERATOR COMPARTMENT WITH CAB - SHEET 1 OF 6 (→ S/N D019E02261) ............................... 34 OPERATOR COMPARTMENT WITH CAB - SHEET 2 OF 6 (S/N D019E02262 →) ............................... 38 OPERATOR COMPARTMENT WITH CAB - SHEET 3 OF 6 (→ S/N D019E02261) ............................... 40 OPERATOR COMPARTMENT WITH CAB - SHEET 4 OF 6 (S/N D019E02262 →) ............................... 44 OPERATOR COMPARTMENT WITH CAB - SHEET 5 OF 6 (→ S/N D019E02261) ............................... 48 OPERATOR COMPARTMENT WITH CAB - SHEET 6 OF 6 (S/N D019E02262 →) ............................... 52 HEATER DIESEL.................................................................................... 56 HEATER LPG....................................................................................... 60 FLOOR PLATES AND COVERS.......................................................................... 64 HEATER CONTROL................................................................................... 68 SUSPENSION SEAT.................................................................................. 70 SEMI-SUSPENSION SEAT............................................................................. 72 LABELS........................................................................................... 74 HOOD WITHOUT LOW EMISSIONS....................................................................... 78 HOOD WITH LOW EMISSIONS (S/N D019D02377 →) ..................................................... 82 COUNTERWEIGHT.................................................................................... 84 FAN.............................................................................................. 88 WINDSHIELD WASHER................................................................................ 90 ENGINE ASSEMBLY...................................................................................... 93 POWERTRAIN MOUNT................................................................................. 98 EXHAUST DIESEL NON TURBO.........................................................................100 EXHAUST DIESEL TURBO.............................................................................102 EXHAUST LPG......................................................................................104 COOLING DIESEL TURBO AND NON TURBO...............................................................106 COOLING LPG......................................................................................110 FLYWHEEL DIESEL..................................................................................112 FLYWHEEL LPG.....................................................................................114 CYLINDER BLOCK DIESEL NON TURBO..................................................................116 CYLINDER BLOCK DIESEL TURBO WITHOUT LOW EMISSIONS................................................118 CYLINDER BLOCK DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) (S/N D019E02328V →) .........120 CRANKSHAFT AND PISTON DIESEL NON TURBO...........................................................122 CRANKSHAFT AND PISTON DIESEL TURBO - WITH AND WITHOUT LOW EMISSIONS .............................124 CYLINDER HEAD DIESEL NON TURBO...................................................................126 CYLINDER HEAD DIESEL TURBO WITHOUT LOW EMISSIONS.................................................128 CYLINDER HEAD DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) ...............................130 TIMING GEAR DIESEL NON TURBO.....................................................................132 TIMING GEAR DIESEL TURBO - WITH AND WITHOUT LOW EMISSIONS .......................................136 TIMING COVER PERKINS - TIER II ENGINE ...........................................................140 AUXILIARY DRIVE GEAR DIESEL (→ S/N D019D01756 INC. 1758 EXC. 1753) .............................142 AUXILIARY DRIVE GEAR DIESEL (S/N D019D01757 → INC. 1753 EXC. 1758) .............................146 OIL PAN DIESEL NON TURBO.........................................................................150 OIL PAN DIESEL TURBO WITHOUT LOW EMISSIONS.......................................................154 OIL PAN DIESEL TURBO WITH LOW EMISSIONS..........................................................156 VALVE COVER DIESEL NON TURBO.....................................................................158 VALVE COVER DIESEL TURBO WITHOUT LOW EMISSIONS...................................................162 VALVE COVER DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) .................................166 OIL FILTER DIESEL NON TURBO (→ S/N D019D01756 INC. 1758 EXC. 1753) .............................168 OIL FILTER DIESEL NON TURBO (S/N D019D01757 → INC. 1753 EXC. 1758) .............................169 OIL FILTER DIESEL TURBO WITHOUT LOW EMISSIONS (→ U647451C) .....................................172 OIL FILTER DIESEL TURBO WITHOUT LOW EMISSIONS (U647452C →) .....................................174 OIL FILTER DIESEL TURBO WITH LOW EMISSIONS.......................................................176 MANIFOLD DIESEL NON TURBO........................................................................178 MANIFOLD DIESEL TURBO WITHOUT LOW EMISSIONS......................................................180 MANIFOLD DIESEL TURBO WITH LOW EMISSIONS.........................................................182 WATER PUMP DIESEL (→ S/N D019D01756 INC. 1758 EXC. 1753) .......................................184 WATER PUMP DIESEL (S/N D019D01757 → INC. 1753 EXC. 1758) .......................................186 WATER PUMP DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) ..................................188 TURBOCHARGER DIESEL TURBO........................................................................190 TURBOCHARGER DIESEL TURBO (S/N D019D02377 →) ...................................................192 AIR DUCTS DIESEL TURBO...........................................................................194 LUBRICANT SYSTEM DIESEL TURBO....................................................................196 CYLINDER BLOCK LPG...............................................................................198 CYLINDER HEAD AND VALVES LPG.....................................................................200 INTAKE MANIFOLD LPG..............................................................................204 OIL PUMP AND PAN LPG.............................................................................206 WATER PUMP LPG...................................................................................208 FUEL SYSTEM..........................................................................................211 FUEL INTAKE DIESEL...............................................................................214 FUEL PRE-FILTER DIESEL...........................................................................218 FUEL INJECTION DIESEL WITHOUT LOW EMISSIONS......................................................220 LOW PRESSURE SYSTEM DIESEL WITHOUT LOW EMISSIONS.................................................222 LIFT PUMP........................................................................................224 LPG TANK MOUNTING................................................................................226 FUEL TANK LPG....................................................................................228 FUEL SYSTEM LPG..................................................................................230 CARBURETOR LPG...................................................................................232 LOCK-OFF FILTER LPG..............................................................................234 CONVERTER LPG....................................................................................235 AIR FILTER DIESEL NON TURBO......................................................................236 AIR FILTER LPG...................................................................................238 FUEL INJECTION DIESEL TURBO WITHOUT LOW EMISSIONS................................................240 FUEL INJECTION DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) ..............................244 LOW PRESSURE SYSTEM DIESEL TURBO WITHOUT LOW EMISSIONS...........................................248 LOW PRESSURE SYSTEM DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) .........................250 FUEL FILTER DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) .................................252 AIR FILTER DIESEL TURBO WITHOUT LOW EMISSIONS....................................................254 AIR FILTER DIESEL TURBO WITH LOW EMISSIONS (S/N D019D02377 →) ..................................256 THROTTLE LINKAGE DIESEL NON EMISSIONS............................................................258 THROTTLE LINKAGE DIESEL WITH LOW EMISSIONS (S/N D019D02377 →) ..................................260 THROTTLE LINKAGE NON EMISSION DIESEL AND LPG WITH AUTOSHIFT (S/N D019D12439 →) .................262 THROTTLE LINKAGE LOW EMISSION DIESEL WITH AUTOSHIFT (S/N D019D12439 →) .........................264 THROTTLE LINKAGE LPG.............................................................................266 THROTTLE PEDAL FORWARD AND REVERSE LEVER.........................................................268 THROTTLE PEDAL MONOTROL PEDAL....................................................................270 THROTTLE PEDAL MONOTROL PEDAL WITH AUTOSHIFT (S/N D019D12439 →) ................................272 THROTTLE PEDAL FORWARD AND REVERSE LEVER - WITH AUTOSHIFT (S/N D019D12439 →) ..................274 ELECTRICAL SYSTEM....................................................................................277 ELECTRICAL SYSTEM DIESEL WITHOUT AUTOSHIFT.......................................................280 ELECTRICAL DIESEL WITH AUTOSHIFT (S/N D019D12439 →) ............................................284 INSTRUMENT PANEL DIESEL..........................................................................286 ELECTRICAL SYSTEM LPG WITHOUT AUTOSHIFT..........................................................290 STARTER..........................................................................................294 INSTRUMENT PANEL LPG.............................................................................296 DISTRIBUTOR LPG..................................................................................300 ALTERNATOR SHEET 1 OF 2 (→ S/N D019D01796 (DIESEL)) ............................................302 ALTERNATOR SHEET 2 OF 2 (→ S/N D019D01796 (DIESEL)) ............................................306 ALTERNATOR LPG (S/N D019D01797 → (DIESEL)) .....................................................310 ALTERNATOR MOUNTING DIESEL WITHOUT LOW EMISSIONS.................................................312 ALTERNATOR MOUNTING DIESEL WITH LOW EMISSIONS (S/N D019D02377 →) ...............................314 ALTERNATOR MOUNTING LPG..........................................................................316 STARTER DIESEL...................................................................................318 WIRE HARNESS CONTROL PANEL (S/N D019D02394U →) .................................................320 WIRE HARNESS ENGINE COMPARTMENT (S/N D019D12439 ↔ S/N D019D02996X) .............................322 WIRE HARNESS ENGINE COMPARTMENT WITH AUTOSHIFT (S/N D019D02997X →) .............................324 WIRE HARNESS ENGINE COMPARTMENT WITHOUT AUTOSHIFT (S/N D019D02997X →) ..........................326 WIRE HARNESS CONTROLLER AUTOSHIFT (S/N D019D12439 →) ...........................................328 WIRE HARNESS SHIFTER AUTOSHIFT (S/N D019D12439 →) ..............................................330 WIRE HARNESS MONOTROL (S/N D019D12439 →) .......................................................331 WIRE HARNESS OPERATOR COMPARTMENT - WITH OPTIONAL ROTATING BEACON ...............................332 TRANSMISSION.........................................................................................335 TRANSMISSION ATTACHING PARTS.....................................................................338 RANGE CONTROL WITHOUT AUTOSHIFT..................................................................340 RANGE CONTROL WITH AUTOSHIFT (S/N D019D02439 ↔ S/N D019D02720) (T050M-6089 →) .................342 RANGE CONTROL WITH AUTOSHIFT (S/N D019D02721 ↔ 9/1999) (T050M-6089 →) .........................344 RANGE CONTROL WITH AUTOSHIFT (9/1999 →) ........................................................346 TRANSMISSION.....................................................................................348 TRANSMISSION.....................................................................................352 PUMP DRIVE GEAR..................................................................................356 CLUTCH FORWARD AND REVERSE.......................................................................358 CLUTCH REVERSE AND SECOND........................................................................360 SHAFT ASSEMBLY REVERSE AND SECOND CLUTCH SHAFT...................................................362 CLUTCH THIRD.....................................................................................364 IDLER SHAFT......................................................................................366 OUTPUT GEAR......................................................................................367 CHARGE PUMP......................................................................................368 MODULATOR VALVE..................................................................................370 CONTROL VALVE....................................................................................372 MONOTROL PEDAL...................................................................................374 DRIVE AXLE EC-4 (→ S/N D019D01965) .............................................................376 DRIVE AXLE NON-EC AND EC-3 (→ S/N D019D01619) ..................................................380 DRIVE AXLE NON-EC AND EC-3 (S/N D019D01620 ↔ S/N D019D01781) ...................................384 DRIVE AXLE NON-EC AND EC-3 (S/N D019D01782 →) ..................................................388 DIFFERENTIAL.....................................................................................392 DRIVE AXLE EMPTY CONTAINER HANDLER-4 (S/N D019D01966 →) ........................................394 DIFFERENTIAL.....................................................................................398 STEERING SYSTEM......................................................................................401 STEERING.........................................................................................404 STEER PUMP.......................................................................................408 VALVE BLOCK......................................................................................410 STEERING AXLE....................................................................................412 STEERING CYLINDER................................................................................416 BRAKE SYSTEM.........................................................................................419 BRAKE LINES......................................................................................422 BRAKE LINES......................................................................................426 BRAKE LINES......................................................................................430 AIR TANK.........................................................................................434 AIR TANK.........................................................................................436 AIR TANK WITH AUTOSHIFT (S/N D019D12439 →) .....................................................438 BRAKE LINES WITH AUTOSHIFT (S/N D019D12439 →) ..................................................440 SOLENOID VALVE PNEUMATIC (S/N D019D12439 →) ....................................................442 AIR COMPRESSOR...................................................................................444 AIR COMPRESSOR...................................................................................446 AIR COMPRESSOR...................................................................................448 AIR COMPRESSOR...................................................................................450 AIR COMPRESSOR...................................................................................452 AIR COMPRESSOR AND ATTACHING PARTS...............................................................454 AIR COMPRESSOR SHEET 1 OF 2 (S/N D019D02998X →) ................................................456 AIR COMPRESSOR SHEET 2 OF 2 (S/N D019D02998X →) ................................................458 AIR COMPRESSOR 366 LPG ENGINE....................................................................460 COMPRESSOR MOUNTING LPG..........................................................................462 TREADLE VALVE SHEET 1............................................................................464 PARK BRAKE ATTACHING PARTS.......................................................................466 PARK BRAKE ATTACHING PARTS.......................................................................468 BRAKE SYSTEM.....................................................................................470 BRAKE CHAMBER....................................................................................474 TREADLE VALVE SHEET 2............................................................................476 PARK BRAKE VALVE.................................................................................478 PARK BRAKE VALVE.................................................................................480 HYDRAULIC SYSTEM.....................................................................................481 HYDRAULIC SYSTEM DIESEL AND LPG NON-EC...........................................................484 HYDRAULIC SYSTEM EMPTY CONTAINER HANDLER - SHEET 1 ..............................................488 HYDRAULIC TANK...................................................................................492 HYDRAULIC PUMP WITHOUT LOW EMISSIONS.............................................................494 HYDRAULIC PUMP WITH LOW EMISSIONS (S/N D019D02377U →) (S/N D019E02328V →) .....................496 VALVE ATTACHING PARTS TWO FUNCTION...............................................................498 CONTROL VALVE TWO FUNCTION (→ S/N D019D02127) ..................................................500 CONTROL VALVE TWO FUNCTION (S/N D019D02128 →) ..................................................502 VALVE ATTACHING PARTS THREE FUNCTION.............................................................506 VALVE ATTACHING PARTS DUAL FUNCTION SIDE-SHIFT (S/N D019D02394U →) .............................510 CONTROL VALVE THREE FUNCTION (→ S/N D019D02127) ................................................514 CONTROL VALVE THREE FUNCTION (S/N D019D02128 →) ................................................518 VALVE ATTACHING PARTS FOUR FUNCTION..............................................................522 CONTROL VALVE FOUR FUNCTION (→ S/N D019D02127) .................................................526 CONTROL VALVE FOUR FUNCTION (S/N D019D02128 →) .................................................530 VALVE ATTACHING PARTS FIVE FUNCTION..............................................................534 CONTROL VALVE FIVE FUNCTION (→ S/N D019D02127) .................................................538 CONTROL VALVE FIVE FUNCTION (S/N D019D02128 →) .................................................542 TILT CYLINDER ATTACHING PARTS....................................................................546 TILT CYLINDER TWO STAGE LIMITED FREE-LIFT - H300XL-H360XL NON-EC ................................548 TILT CYLINDER TWO STAGE LIMITED FREE-LIFT - EMPTY CONTAINER HANDLER .............................552 TILT CYLINDER THREE STAGE FULL FREE-LIFT.........................................................555 TILT LOCK VALVE..................................................................................556 Mast-Two Stage Limited Free-Lift.....................................................................557 OUTER MAST TWO STAGE LIMITED FREE-LIFT...........................................................560 INNER MAST TWO STAGE LIMITED FREE-LIFT...........................................................564 LIFT TWO STAGE LIMITED FREE-LIFT.................................................................566 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - NON-EMPTY CONTAINER HANDLER (→ S/N D019D02025) ....570 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - NON-EMPTY CONTAINER HANDLER (S/N D019D02026 →) ....572 LIFT CYLINDER EMPTY CONTAINER HANDLER 3 AND 4 - TWO STAGE LIMITED FREE-LIFT .....................574 CARRIAGE TWO STAGE LIMITED FREE-LIFT.............................................................576 HEADER HOSE TWO STAGE LIMITED FREE-LIFT..........................................................578 Mast-Three Stage Full Free-Lift......................................................................581 OUTER MAST THREE STAGE FULL FREE-LIFT............................................................584 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT.....................................................586 INNER MAST THREE STAGE FULL FREE-LIFT............................................................588 MAIN LIFT THREE STAGE FULL FREE-LIFT.............................................................590 MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT....................................................594 FREE-LIFT THREE STAGE FULL FREE-LIFT.............................................................596 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT....................................................600 CARRIAGE WITH SIDE-SHIFT AND FORK POSITIONER - THREE STAGE FULL FREE-LIFT .......................602 CARRIAGE HYDRAULICS WITH SIDE-SHIFT AND FORK POSITIONER - THREE STAGE FULL FREE-LIFT ............604 FORK POSITIONER CYLINDER THREE STAGE FULL FREE-LIFT..............................................606 SIDE-SHIFT CYLINDER THREE STAGE FULL FREE-LIFT...................................................608 FORK POSITIONER VALVE THREE STAGE FULL FREE-LIFT.................................................610 HEADER HOSE THREE AND FOUR FUNCTION - THREE STAGE FULL FREE-LIFT ................................612 EMPTY CONTAINER HANDLER..............................................................................615 CONTAINER HANDLING ATTACHMENT EMPTY CONTAINER HANDLER............................................618 ENDBEAM EMPTY CONTAINER HANDLER..................................................................620 HYDRAULIC HOSES EMPTY CONTAINER HANDLER..........................................................622 HYDRAULIC SYSTEM EMPTY CONTAINER HANDLER - SHEET 2 ..............................................626 AIR SYSTEM EMPTY CONTAINER HANDLER...............................................................628 EXTENSION EMPTY CONTAINER HANDLER................................................................630 ELECTRICAL CONTROL EMPTY CONTAINER HANDLER.......................................................632 ELECTRICAL SYSTEM EMPTY CONTAINER HANDLER........................................................634 SIDE-SHIFT CYLINDER EMPTY CONTAINER HANDLER......................................................636 LIGHTS EMPTY CONTAINER HANDLER...................................................................638 OPTIONS..............................................................................................641 SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT..................................................644 SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT...................................................646 SIDE-SHIFT CYLINDER..............................................................................648 SIDE-SHIFT CARRIAGE DUAL FUNCTION PIN OR QUICK DISCONNECT (S/N D019D02394U →) ..................650 HYDRAULIC CYLINDER DUAL FUNCTION PIN OR QUICK DISCONNECT (S/N D019D02394U →) ...................654 SELECTOR VALVE...................................................................................656 FORK.............................................................................................657 PIN FORK STANDARD TAPER (S/N D019D02394U →) ....................................................658 FORK HOOK TYPE QUICK DISCONNECT - DUAL FUNCTION (S/N D019D02394U →) ...........................659 TIRE AND WHEEL H300XL............................................................................660 TIRE AND WHEEL H300XL-H360XL.....................................................................662 HEADER HOSE FIVE FUNCTION - DUAL FUNCTION SIDE-SHIFT FORK POSITIONER ............................664 STROBE LIGHT.....................................................................................668 ROTATING BEACON..................................................................................670 LIGHTS...........................................................................................672 FLOODLIGHTS......................................................................................676 FIRE EXTINGUISHER................................................................................678 BACK-UP ALARM....................................................................................680 NUMERICAL INDEX......................................................................................683
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HYSTER CHALLENGER H300-360XL H33-360XL-EC (D019) PARTS MANUAL – PDF DOWNLOAD:
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