Hyster Challenger K005 (H100XM, H110XM, H120XM, H70XM, H80XM, H90XM) Forklift Parts Manual

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.

Hyster Challenger K005 (H100XM, H110XM, H120XM, H70XM, H80XM, H90XM) Forklift Parts Manual

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