Hyster Challenger H70XM-H120XM (L005) Parts Manual 1560144 – 2005 PDF Download

Description

Hyster Challenger H70XM-H120XM (L005) Parts Manual – Complete Illustrated Parts Catalog

The Hyster Challenger H70XM-H120XM (L005) Parts Manual 1560144 is the full factory parts catalog for the H70XM, H80XM, H90XM, H100XM, H110XM and H120XM Challenger lift trucks, published by Hyster in March 2005 for the North America market. Every assembly, subassembly and detail part required for service replacement across the whole truck is catalogued here, with part numbers, descriptions, quantities, keys, footnotes and serial-number breaks attached to each item.

If you own, service or restore one of these Challenger trucks, the Hyster H70XM-H120XM parts manual answers the question that stops every repair cold: which exact part number do I order? Instead of guessing at a dealer counter or sorting through generic aftermarket listings, you can go straight to the illustrated breakdown for the assembly in front of you and read the number off the page.

File Details

• Manual type: Illustrated Parts Manual (Parts Catalog)
• Brand: Hyster
• Series: Challenger
• Models covered: H70XM, H80XM, H90XM, H100XM, H110XM, H120XM
• Unit code: L005
• Document number: 1560144
• Edition / date: 03/2005, North America
• Language: English
• Format: PDF
• Pages: 580

Chapters Covered

This Hyster Challenger parts catalog is divided into fourteen major sections, each tabbed for quick reference. The full contents are:

• 1 — Frame
  • General Truck, Operator Module, Hood and Covers, Floor Plates and Covers
  • Non-Suspension Seat, Full Suspension Seat, Counterweights
  • Rear Access Screen, Overhead Guard, Sound Reduction, Labels and Decals
  • Load Backrest Extension, Forks (Standard Taper Hook, Polished Full Bottom Taper Hook)
• 2 — Engine Assembly
  • Cooling System, Fan Drive Assembly, Engine Belt Drive and Alternator Mounting
  • Exhaust and Exhaust Manifold, Engine Mount, Diesel Tier II Engine Assemblies
  • Cylinder Block, Cylinder Head and Induction Manifold, Valve Cover and Rocker Arm Shaft
  • Crankshaft and Pistons, Oil Pan and Pump, Oil Filter, Oil Cooler, Timing Gear
  • Water Pump and Outlet, Fuel Injection Pump (with and without bleed back system)
  • Rotary Exhauster, Gasoline and LPG 4.3L EPA Compliant assemblies
  • Intake Manifold and Fuel Rail, Valve Cover and Inlet Manifold, Camshaft and Oil Pan
  • Coil Assembly, Cylinder Head, Oil Pump, Drip Shield
• 3 — Fuel System
  • Air Intake and Filter System (Diesel Tier II, Gas and LPG)
  • Air Filter, Fuel Supply System, Fuel Pump and Water Separator
  • Water Separator, Fuel Sender, Fuel Filter and Attaching Parts
  • Engine Fuel System, LPG Regulator, Fuel Supply System for Gasoline and LPG
  • Throttle Body and LPG Mixer, Throttle Body Assembly, LPG Tank Bracket
  • Throttle Linkage (Diesel, Gasoline, LPG), Forward and Reverse Lever, Monotrol Pedal, Throttle Arm Assembly
• 4 — Electrical System
  • Cowl, Instrument Panel, Engine Compartment, Alternator and Battery
  • Alternator and Battery Safety (GS and LPS), Diesel Tier II electrical system, Type DS
  • Distributor Assembly, Alternator and Mounting, Prestolite Alternator
  • Starter Motor (Gasoline and LPG GM 4.3L), Starter (Diesel Tier II)
  • Wire Harnesses: Diesel Engine, Gasoline GM 4.3L, LPG GM 4.3L, Fuel Injector, LPG Regulator
  • Interface Harness, Module and Powershift Transmission Harnesses
  • Sealed Alternator Harness, Alternator to Circuit Breaker, Brake Pressure Switch
  • Powershift Transmission Control Harnesses (early and late serial ranges)
• 5 — Transmission
  • T086, T088, T089 Transmission assemblies (Sheet 1 and 2)
  • T118, T120, T121 Transmission assemblies (Sheet 1 and 2)
  • Flywheel and Torque Converter, Clutch Packs (Input/Reverse, Counter/Forward, Single Speed, Two Speed)
  • Control Valve, Manifold Valve, High and Low Valve
  • Transmission Lines, Transmission Mounting
• 6 — Drive Axle
  • Drive Axle assembly, Differential Assembly
  • Drive Tires and Wheels (Single, H70-H90XM and H90-H120XM)
• 7 — Steering System
  • Steering System, Steer Column, Shift Lever, Steer Axle
  • Steer Cylinder, Steer Pump, Steer Tires and Wheels
• 8 — Brake System
  • Brake System, Master Cylinder and Booster Assembly
  • Brake Assembly (H70-90XM and H100-120XM)
  • Park Brake, Brake Relay Assembly
• 9 — Hydraulic System
  • Hydraulic System, Hydraulic Control Lines (Three Function and Four Function)
  • Hydraulic Control Valve Attaching Parts, Hydraulic Control Valve (Three and Four Function)
  • Hydraulic Filter Housing, Hydraulic Pump, Mast Installation, Tilt Cylinders
• 10 — Mast, Two Stage Limited Free-Lift
  • Outer Mast, Inner Mast, Main Lift
  • Main Lift Cylinders, Carriage, Header Hose
• 11 — Mast, Two Stage Full Free-Lift
  • Outer Mast and Main Lift, Inner Mast and Free Lift
  • Main Lift Cylinders, Free-Lift Cylinder, Carriage, Header Hose
• 12 — Mast, Three Stage Full Free-Lift
  • Outer Mast, Intermediate Mast, Inner Mast, Main Lift, Free-Lift
  • Main Lift Cylinders, Free-Lift Cylinder, Carriage, Header Hose
• 13 — Options
  • Back-Up Alarm and Wire Harness, Front Headlights, Rear Drive Light, Rear Drive Lights with Amber Strobe
  • Strobe Light (Amber), Amber Strobe Reverse Lights, Dual Mirrors
  • Cab Attaching Parts (Sheets 1–6), Door Assembly (LH and RH), Cab Wire Harnesses
  • Heater and Heater Installation (Gasoline, LPG, Diesel Tier II)
  • Accumulator (Mast Load Dampening), Integral Side-Shift Assembly and Carriage
  • Auxiliary Tube Extension Kit, Quick Disconnect Fittings, Lifting Eyes, Fender Extensions
  • Drive Tires and Wheels (Dual), Lights Back-Up and Brake (Incandescent and LED)
  • Wire Harness for Pressure Switch LED Brake Lights
• 14 — Numerical Index
  • Full alphanumeric part-number index with cross-reference to section and item number

How This Hyster Parts Manual Is Organized

Each assembly breakdown in the Hyster Challenger H70XM-H120XM parts manual is presented as an exploded illustration with numbered callouts, followed by a matching table listing every item: part number, description, required quantity, and any key or footnote that applies. Keys distinguish similar assemblies such as left-hand and right-hand brake parts, single-speed and two-speed transmissions, or standard versus heavy-duty air cleaner configurations. Quantities are given per assembly, and where a subpart sits inside a larger assembly, indentations in the description column show the hierarchy. Serial-number breaks and ECN (Engineering Change Notice) references appear where a part changed mid-production, so a truck built before or after a break gets the correct item. Date breaks indicate changes where a serial break was never recorded. Five periods in the part-number column mean the item is not serviced separately — a pointing-hand figure reference directs you to the assembly that contains it.

The fourteen-section structure of this Hyster Challenger parts book means you can go from a general area — say, Brake System — straight to the specific assembly without reading through the whole truck. The Numerical Index in Section 14 is the fast path when you already know the part number and just need to know which figure and page to open.

What You Can Do With This Manual

The practical value of the Hyster Challenger H70XM-H120XM L005 parts manual is in the jobs it lets you complete correctly the first time:

• Look up the exact part number for a failed component on an H70XM through H120XM truck, including year- and serial-specific variants.
• Build a complete parts list for a planned repair — engine overhaul, transmission clutch pack replacement, brake rebuild, mast cylinder reseal, hydraulic control valve service — before ordering anything.
• Confirm how many of a given fastener, seal, shim, bearing or clip are used per assembly so nothing is short mid-job.
• Identify which options and attachments are installed on a particular truck by comparing the figure number against the build.
• Source the correct item on the first attempt when using the Hyster numerical index for a part number you already have.
• Confirm superseded or changed part numbers using the serial-number and ECN breaks printed against each affected item.

Ordering the wrong part number on a forklift is expensive in both money and downtime. A Challenger H70XM through H120XM covers six rated capacities, three transmission families (T086–T089 and T118–T121), diesel Tier II plus gasoline and LPG 4.3L engines, and three different mast configurations — so parts commonality is far from universal. The serial-number breaks in this manual, such as the cutoff between L005V02272B and L005V02273B for fuel injection pumps, or between L005V02564B and L005V02565B for clutch pack families, exist precisely so a technician can land on the right component rather than a near-match.

Delivery

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The Hyster Challenger H70XM-H120XM (L005) Parts Manual 1560144 is delivered as an instant PDF download immediately after payment. There is no shipping, no waiting, and no physical book to lose in a workshop. Open it on a laptop or desktop in the bay, print the specific assembly pages you need, or email a parts list to a supplier from the same device. The document covers the full range of working conditions a service technician faces: exploded views for disassembly and reassembly, complete part-number tables for ordering, and a single consolidated index for when you already have the number in hand.