CUSTOMER EDITION
PARTS
MANUAL
CHALLENGER
H100XM, H110XM, H120XM,
H70XM, H80XM, H90XM
(K005)
1466307 ©2003 Hyster Company
01/2003
01/2003
UNIT CODE K005
NORTH AMERICA
SECTIONS
1 FRAME
2 ENGINE ASSEMBLY
3 FUEL SYSTEM
4 ELECTRICAL SYSTEM
5 TRANSMISSION
6 DRIVE AXLE
7 STEERING SYSTEM
8 BRAKE SYSTEM
9 HYDRAULIC SYSTEM
10 MAST-TWO STAGE LIMITED FREE-LIFT
11 MAST-TWO STAGE FULL FREE-LIFT
12 MAST-THREE STAGE FULL FREE-LIFT
13 OPTIONS
14 NUMERICAL INDEX
This Parts Manual is divided into 14 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the
pages to the corresponding tab.
01/2003
UNIT CODE K005
NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCUMULATOR .............................................................................................................................................. 13-22
AIR FILTER ......................................................................................................................................................... 3-56
AIR FILTER SYSTEM ......................................................................................................................................... 3-54
ALTERNATOR
GAS/LPG AND DIESEL .................................................................................................................................. 4-26
PRESTOLITE BRAND
GS, LPS, DS ............................................................................................................................................... 4-28
ALTERNATOR MOUNTING
DIESEL
D/B 07/2001 ⇒ ............................................................................................................................................. 2-52
⇒ D/B 07/2001 ............................................................................................................................................. 2-50
AMBER STROBE REVERSE LIGHTS
WITHOUT CAB ............................................................................................................................................. 13-28
AUDIBLE ALARM ............................................................................................................................................. 13-54
AUXILIARY TUBE EXTENSION KIT
TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-20
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 13-18
B
BACKUP AND BRAKE LIGHTS ......................................................................................................................... 4-36
BAFFLE AND ATTACHING PARTS ...................................................................................................................... 2-6
BRAKE ASSEMBLY
H100-120XM ................................................................................................................................................... 8-10
H70-90XM ......................................................................................................................................................... 8-6
BRAKE LINKAGE ................................................................................................................................................. 8-2
C
CAB .................................................................................................................................................................. 13-57
CAB ATTACHING PARTS ................................................................................................................................. 13-32
SHEET 1 OF 3 .............................................................................................................................................. 13-58
SHEET 2 OF 3 .............................................................................................................................................. 13-60
SHEET 3 OF 3 .............................................................................................................................................. 13-62
CAMSHAFT AND OIL PAN
GASOLINE AND LPG ..................................................................................................................................... 2-32
CARBURETOR (LPG)
WITH LOW EMISSIONS ................................................................................................................................. 3-31
CARRIAGE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-32
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-18
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 10-20
CONTROL VALVE
(1 OF 2)
S/N PENDING PER ECN 63639 ⇒ ............................................................................................................. 9-16
(2 OF 2)
S/N PENDING PER ECN 63639 ⇒ ............................................................................................................. 9-20
⇒ S/N PENDING PER ECN 63639 ................................................................................................................. 9-14
TRANSMISSION ............................................................................................................................................. 5-20
CONTROL VALVE AND ATTACHING PARTS
FOUR FUNCTION WITH DETENTED LEVERS ............................................................................................ 9-12
THREE FUNCTION ........................................................................................................................................ 9-10
©2003 HYSTER COMPANY i
See Service Manual
for service procedures.
UNIT CODE K005
NORTH AMERICA 01/2003
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
C (continued)
COOLANT PUMP
DIESEL
D/B 09/2001 ⇒ ............................................................................................................................................. 2-80
⇒ D/B 09/2001 ............................................................................................................................................. 2-78
COOLING ............................................................................................................................................................. 2-4
COUNTERWEIGHT ........................................................................................................................................... 1-24
CRANKSHAFT AND PISTON
DIESEL
D/B 07/2001 ⇒ ............................................................................................................................................. 2-60
⇒ D/B 07/2001 ............................................................................................................................................. 2-58
CYLINDER BLOCK
DIESEL
D/B 07/2001 ⇒ ............................................................................................................................................. 2-56
⇒ D/B 07/2001 ............................................................................................................................................. 2-54
GASOLINE AND LPG ..................................................................................................................................... 2-28
CYLINDER HEAD
DIESEL ........................................................................................................................................................... 2-68
GASOLINE AND LPG ..................................................................................................................................... 2-36
D
DIFFERENTIAL ASSEMBLY ................................................................................................................................ 6-2
DIRECTIONAL CLUTCH .................................................................................................................................... 5-18
DISTRIBUTOR ................................................................................................................................................... 4-30
DOOR ASSEMBLY
LEFT HAND .................................................................................................................................................. 13-68
RIGHT HAND ................................................................................................................................................ 13-66
DRIVE AXLE ........................................................................................................................................................ 6-4
DUAL FUEL SYSTEM
⇒ S/N K005D-5482 ......................................................................................................................................... 3-32
S/N K005D-5483 ⇒ ......................................................................................................................................... 3-36
DUAL MIRROR
WITHOUT CAB ............................................................................................................................................. 13-30
E
ELECTRICAL SYSTEM
ALTERNATOR AND BATTERY
G, GS, LPG, LPS, AND DUAL FUEL ............................................................................................................ 4-8
COWL ............................................................................................................................................................... 4-4
DIESEL ........................................................................................................................................................... 4-22
GASOLINE, GASOLINE SAFETY, AND DUAL FUEL .................................................................................... 4-12
LPG AND LPS ................................................................................................................................................ 4-18
ENGINE AND ATTACHING PARTS
DIESEL ........................................................................................................................................................... 2-48
GASOLINE AND LPG ..................................................................................................................................... 2-24
ENGINE MOUNT
DIESEL ........................................................................................................................................................... 2-46
GASOLINE AND LPG ..................................................................................................................................... 2-22
EXHAUST
3-WAY CATALYTIC CONVERTER
ii ©2003 HYSTER COMPANY
See Service Manual
for service procedures.
01/2003
UNIT CODE K005
NORTH AMERICA
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
E (continued)
LPG WITH LOW EMISSIONS
S/N PENDING PER ECN 73989 ⇒ .......................................................................................................... 2-18
⇒ S/N PENDING PER ECN 73989 .......................................................................................................... 2-16
DIESEL ........................................................................................................................................................... 2-20
GASOLINE AND LPG
WITHOUT LOW EMISSIONS
S/N PENDING PER ECN 73989 ⇒ .......................................................................................................... 2-14
⇒ S/N PENDING PER ECN 73989 .......................................................................................................... 2-12
EXHAUST MANIFOLD
GASOLINE AND LPG
S/N PENDING PER ECN 73989 ⇒ ............................................................................................................. 2-42
⇒ S/N PENDING PER ECN 73989 ............................................................................................................. 2-40
F
FAN DRIVE ASSEMBLY ....................................................................................................................................... 2-8
FENDER EXTENSIONS ................................................................................................................................... 13-10
FLOOR PLATES AND COVERS ........................................................................................................................ 1-22
FORK
POLISHED FORK WITH FULL BOTTOM TAPER HOOK TYPE
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-40
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-26
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 10-26
STANDARD TAPER HOOK TYPE (H100-120XM)
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-39
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-25
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 10-25
STANDARD TAPER HOOK TYPE (H70-90XM)
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-38
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-24
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 10-24
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-24
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-14
FRONT HEAD LIGHTS
WITHOUT CAB ............................................................................................................................................. 13-24
FUEL FILTER
LOW PRESSURE SYSTEM
DIESEL .......................................................................................................................................................... 3-8
FUEL SYSTEM
DIESEL ............................................................................................................................................................. 3-2
GASOLINE ...................................................................................................................................................... 3-16
LPG
CLOSED LOOP ........................................................................................................................................... 3-28
OPEN LOOP
⇒ S/N K005D-5482 .................................................................................................................................. 3-20
S/N K005D-5483 ⇒ .................................................................................................................................. 3-24
FULL SUSPENSION SEAT
©2003 HYSTER COMPANY iii
See Service Manual
for service procedures.
UNIT CODE K005
NORTH AMERICA 01/2003
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
F (continued)
SHEET 1 OF 2 .................................................................................................................................................. 1-6
SHEET 2 OF 2 .................................................................................................................................................. 1-8
G
GENERAL TRUCK ............................................................................................................................................... 1-2
GOVERNOR
LPG ................................................................................................................................................................. 3-49
H
HARNESS KIT
DUAL FUEL .................................................................................................................................................... 4-15
HEADER HOSE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-28
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-28
TWO STAGE LIMITED FREE-LIFT
⇒ S/N A749L-3337, ⇒ S/N A750L-2645 .................................................................................................... 10-14
S/N A749L-3338 ⇒ , S/N A750L-2646 ⇒ .................................................................................................... 10-16
HEATER INSTALLATION
DIESEL ......................................................................................................................................................... 13-12
GASOLINE .................................................................................................................................................... 13-14
LPG ............................................................................................................................................................... 13-16
HIGH PRESSURE FUEL INJECTION AND PUMP
DIESEL ........................................................................................................................................................... 3-10
HOOD AND COVERS ........................................................................................................................................ 1-14
HYDRAULIC CONTROL LINES
FOUR FUNCTION ............................................................................................................................................ 9-8
THREE FUNCTION .......................................................................................................................................... 9-6
HYDRAULIC PUMP
⇒ S/N K005D-02086 ....................................................................................................................................... 9-26
S/N K005D-02087 ⇒ ....................................................................................................................................... 9-28
HYDRAULIC SYSTEM ......................................................................................................................................... 9-2
I
INJECTOR THROTTLE BODY
GASOLINE ...................................................................................................................................................... 3-52
INNER AND FREE LIFT MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-6
INNER MAST
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-10
TWO STAGE LIMITED FREE-LIFT ................................................................................................................. 10-4
INPUT CLUTCH ................................................................................................................................................. 5-16
INSTRUMENT PANEL .......................................................................................................................................... 4-7
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-6
iv ©2003 HYSTER COMPANY
See Service Manual
for service procedures.
01/2003
UNIT CODE K005
NORTH AMERICA
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
L
LABELS AND PAINT .......................................................................................................................................... 1-31
LIFT PUMP
DIESEL ........................................................................................................................................................... 3-14
LIFTING EYE .................................................................................................................................................... 13-70
LOAD BACKREST EXTENSION
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-36
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-22
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 10-22
LOCK-OFF FILTER
LPG ................................................................................................................................................................. 3-46
LOW PRESSURE SYSTEM
DIESEL
⇒ D/B 07/2001 ............................................................................................................................................... 3-4
LOW PRESSURE SYSTEM (DIESEL)
D/B 07/2001 ⇒ .................................................................................................................................................. 3-6
LPG CONVERTER
OPEN LOOP
⇒ S/N K005D-5482 ...................................................................................................................................... 3-47
S/N K005D-5483 ⇒ ...................................................................................................................................... 3-48
LPG TANK AND BRACKET
SWING OUT ................................................................................................................................................... 3-42
LPG TANK BRACKET
FIXED ............................................................................................................................................................. 3-40
SWING OUT/DROP DOWN ............................................................................................................................ 3-44
M
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-20
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 10-10
MAIN LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-12
TWO STAGE LIMITED FREE-LIFT ................................................................................................................. 10-6
MAIN LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-10
MANIFOLD VALVE ............................................................................................................................................. 5-23
MANIFOLDS
DIESEL
D/B 07/2001 ⇒ ............................................................................................................................................. 2-74
⇒ D/B 07/2001 ............................................................................................................................................. 2-72
MAST INSTALLATION ........................................................................................................................................ 9-22
MASTER CYLINDER AND BOOSTER ASSEMBLY .......................................................................................... 8-12
MONOTROL PEDAL .......................................................................................................................................... 3-64
MONOTROL PEDAL LINKAGE .......................................................................................................................... 3-62
N
NON-SUSPENSION SEAT ................................................................................................................................... 1-4
©2003 HYSTER COMPANY v
See Service Manual
for service procedures.
UNIT CODE K005
NORTH AMERICA 01/2003
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
O
OIL FILTER
DIESEL ........................................................................................................................................................... 2-76
OIL PAN AND PUMP
DIESEL ........................................................................................................................................................... 2-62
OIL PUMP
GASOLINE AND LPG ..................................................................................................................................... 2-44
OPERATOR MODULE
⇒ S/N K005D-05972 ....................................................................................................................................... 1-10
S/N K005D-05973 ⇒ EXC. 6018 ..................................................................................................................... 1-12
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-2
TWO STAGE LIMITED FREE-LIFT ................................................................................................................. 10-2
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-2
OVERHEAD GUARD .......................................................................................................................................... 1-20
P
PARK BRAKE ..................................................................................................................................................... 8-14
R
REAR ACCESS SCREEN
S/N PENDING PER ECN 70712-24 ⇒ ............................................................................................................ 1-28
⇒ S/N PENDING PER ECN 70712-24 ............................................................................................................ 1-26
REAR DRIVE LIGHTS
WITHOUT CAB ............................................................................................................................................. 13-26
ROTARY EXHAUSTER
DIESEL ........................................................................................................................................................... 2-82
S
SHIFT LEVER .................................................................................................................................................... 4-34
SIDE-SHIFT CARRIAGE
TWO AND THREE STAGE FULL-FREE-LIFT (48 AND 60-INCH)
H70-90XM ................................................................................................................................................. 13-38
TWO AND THREE STAGE FULL-FREE-LIFT (54 AND 60-INCH)
H100XM-H120XM ..................................................................................................................................... 13-40
TWO STAGE LIMITED FREE-LIFT (48 AND 60-INCH)
H70XM - H90XM ....................................................................................................................................... 13-34
TWO STAGE LIMITED FREE-LIFT (54 AND 60-INCH)
H100XM - H120XM ................................................................................................................................... 13-36
SIDE-SHIFT CARRIAGE FRAME
TWO AND THREE STAGE FULL FREE-LIFT (48-INCH)
H70XM - H90XM ....................................................................................................................................... 13-48
TWO AND THREE STAGE FULL FREE-LIFT (54 AND 60-INCH)
H100XM-H120XM ..................................................................................................................................... 13-52
TWO AND THREE STAGE FULL FREE-LIFT (60-INCH)
H70XM - H90XM ....................................................................................................................................... 13-50
TWO STAGE LIMITED FREE-LIFT (54 AND 60-INCH)
H100XM - H120 XM .................................................................................................................................. 13-46
TWO STAGE LIMTED FREE-LIFT (48-INCH)
H70XM - H90XM ....................................................................................................................................... 13-42
vi ©2003 HYSTER COMPANY
See Service Manual
for service procedures.
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