Hyster H70XM H80XM H90XM H100XM H110XM H120XM Challenger Parts Manual 2004

Description

File Details

• Manual Type: Illustrated Parts Manual
• Brand: Hyster
• Series: Challenger
• Models: H70XM, H80XM, H90XM, H100XM, H110XM, H120XM
• Unit Code: L005
• Publication Date: 01/2004
• Parts Manual Number: 1560144
• Language: English
• File Format: PDF
• Page Count: 502

Chapters Covered

This Hyster H70XM-H120XM Challenger Parts Manual is divided into 14 major sections, each loaded with exploded illustrations, part numbers, descriptions, and required quantities. Whether you are ordering a single replacement bolt or rebuilding an entire mast, every assembly is broken down to the detail-part level.

• 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, Undercarriage Pan, Labels and Decals, Load Backrest Extension, Forks
• 2 Engine Assembly — Cooling System, Fan Drive Assembly, Engine Belt Drive and Alternator Mounting, Exhaust (Gas and LPG), Exhaust (Diesel Tier II), Engine Mount (Diesel Tier II), Assembled Engine (Diesel Tier II), Cylinder Block (Diesel Tier II), Cylinder Head and Induction Manifold (Diesel Tier II), Valve Cover and Rocker Arm Shaft (Diesel Tier II), Crankshaft and Pistons (Diesel Tier II), Oil Pan and Pump (Diesel Tier II), Water Pump and Outlet (Diesel Tier II), Timing Gear (Diesel Tier II), Exhaust Manifold (Diesel Tier II), Oil Filter (Diesel Tier II), Oil Cooler (Diesel Tier II), Fuel Injection Pump (Diesel Tier II), Rotary Exhauster (Diesel Tier II), Engine Mounting (Gasoline and LPG), Engine Assembly (Gasoline 4.3L EPA / LPG 4.3L EPA), Exhaust Manifold (Gasoline and LPG 4.3L EPA), Cylinder Block (Gasoline and LPG 4.3L EPA), Cylinder Head (Gasoline and LPG 4.3L EPA), Camshaft and Oil Pan (Gasoline and LPG 4.3L EPA), Valve Cover and Inlet Manifold (Gasoline and LPG 4.3L EPA), Oil Pump (Gasoline and LPG 4.3L EPA), Drip Shield (Gasoline and LPG 4.3L EPA)
• 3 Fuel System — Air Intake and Filter System (Diesel Tier II), Air Filter (Diesel Tier II), Fuel Supply System (Diesel Tier II), Fuel Pump and Water Separator (Diesel Tier II), Water Separator (Diesel Tier II), Fuel Filter and Sender (Diesel Tier II), Fuel Filter (Diesel Tier II), Air Intake and Filter System (Gas and LPG), Air Filter (Gas and LPG), Fuel Supply System (LPG), Engine Fuel System (4.3L EPA LPG), Throttle Body and LPG Mixer (4.3L EPA), LPG Regulator (4.3L EPA), Fuel Supply System (Gasoline), Throttle Body Assembly (4.3L EPA Gasoline), LPG Tank Bracket (Fixed / Swing Out / Swing Out-Drop Down), Monotrol Pedal, Throttle Arm Assembly, Throttle Linkage (Diesel Tier II), Throttle Linkage (Gasoline and LPG), Forward and Reverse Lever
• 4 Electrical System — Cowl, Instrument Panel, Engine Compartment (Gasoline and LPG), Alternator and Battery (G, GS, LPG and LPS), Electrical System (Diesel Tier II), Type DS, Distributor Assembly (4.3L EPA Compliant), Alternator (Prestolite Brand GS, LPS, DS), Starter (Diesel Tier II), Wire Harness (Engine) (Diesel Tier II), Wire Harness Module (Sheet 1 of 2, Sheet 2 of 2), Wire Harness (Sealed Alternator)
• 5 Transmission — Transmission (1 of 2, 2 of 2), Flywheel and Torque Converter, Input Clutch (Reverse), Directional Clutch (Forward), Control Valve (Transmission), Manifold Valve, High and Low Valve, Transmission Lines, Transmission Mount
• 6 Drive Axle — Drive Axle, Differential Assembly, Drive Tires and Wheels (Single H70-H90XM, Single 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), Brake Assembly (H100-120XM), Park Brake
• 9 Hydraulic System — Hydraulic System, Hydraulic Control Lines (Three Function), Hydraulic Control Lines (Four Function), Hydraulic Control Valve and Attaching Parts (Three Function, Four Function), 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, Front Headlights (Without Cab), Rear Drive Light (Without Cab), Strobe Light (Amber, Without Cab), Dual Mirrors (Without Cab), Cab (Attaching Parts 1-6), Door Assembly (Left Hand, Right Hand), Wire Harnesses (Cab), Cab Wire Harness (Worklights and Strobe Light), Cab Wire Harness (Headlight and Handheld Light), Heater Installation (Gasoline, LPG, Diesel Tier II), Accumulator (Mast Load Dampening), Integral Side-Shift Assembly, Integral Side-Shift Carriage, Auxiliary Tube Extension Kit, Quick Disconnect Fittings, Lifting Eyes, Fender Extensions, Drive Tires and Wheels (Dual)
• 14 Numerical Index — A complete cross-reference listing every part number in the manual with its corresponding page and item number

What This Hyster Challenger Parts Manual Gives You

Every section opens with a detailed exploded-view illustration keyed to a parts list. The parts list gives you the item number, the exact Hyster part number, a full description, and the quantity required per assembly. The manual also uses keys, footnotes, serial number breaks, ECN numbers, and date breaks to identify which part applies to which truck variant. That level of detail is what separates a correct order from a return.

The Hyster H70XM H80XM H90XM H100XM H110XM H120XM Challenger Parts Manual covers all three engine families used across this model range: Diesel Tier II, Gasoline 4.3L EPA Compliant, and LPG 4.3L EPA Compliant. It also covers both single-speed and two-speed transmission configurations, all three mast types (two-stage limited free-lift, two-stage full free-lift, and three-stage full free-lift), and every optional attachment from side-shift carriages to cab assemblies and heater installations.

The numerical index alone is worth the download. If you already know the part number, you can jump straight to the correct illustration and item number without hunting through sections. If you only know the assembly, the table of contents and the section tabs guide you there fast.

Why This Matters for Hyster H70XM-H120XM Owners and Technicians

Ordering the wrong part costs time, money, and downtime. This parts manual eliminates that risk. The serial number breaks tell you exactly which version of a component was fitted to your truck. The shim and pressure plate options in the transmission section are listed with their thickness ranges. The mast cylinder pages reference specific cylinder group numbers and lift heights, so you can match your mast configuration precisely.

Whether you are maintaining a single H70XM in a warehouse or running a mixed fleet of Challenger lift trucks, having the correct parts manual means you can identify, order, and replace components with confidence. The exploded views also help when you are disassembling a complex assembly and need to know the order of parts, the location of hidden fasteners, or the quantity of each item.

Get Instant Access to the Hyster Challenger Parts Manual

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This Hyster H70XM-H120XM Challenger Parts Manual 2004 is delivered as an instant PDF download — no shipping, no waiting, no physical book to lose. Open it on any device: laptop in the workshop, tablet on the shop floor, or desktop in the office. Print the pages you need and take them right to the machine. With 502 pages covering 14 major sections and thousands of part numbers across six Challenger models, this is the most complete parts reference you can get for the H70XM through H120XM range.