PARTS

MANUAL
CHALLENGER
H100XM, H110XM, H120XM,
H70XM, H80XM, H90XM
(K005)

CUSTOMER EDITION

1466307 ©2003 Hyster Company

01/2003
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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.
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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 See Service Manual i

for service procedures.
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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 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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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 See Service Manual iii

for service procedures.
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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 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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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 See Service Manual v

for service procedures.
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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 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

S (continued)

TWO STAGE LIMTED FREE-LIFT (60-INCH)

H70XM - H90XM ....................................................................................................................................... 13-44
SOUND REDUCTION ........................................................................................................................................ 1-16
STARTER
DIESEL ........................................................................................................................................................... 4-32
STEERING AXLE ................................................................................................................................................. 7-6
STEERING COLUMN........................................................................................................................................... 7-4
STEERING CYLINDER ...................................................................................................................................... 7-10
STEERING PUMP.............................................................................................................................................. 7-12
STEERING SYSTEM ........................................................................................................................................... 7-2

T
THROTTLE BODY GOVERNOR
GASOLINE AND DUAL FUEL ........................................................................................................................ 3-50
THROTTLE LINKAGE
DIESEL ........................................................................................................................................................... 3-60
GASOLINE AND LPG..................................................................................................................................... 3-58
TILT CYLINDER ................................................................................................................................................. 9-24
TIMING GEAR
DIESEL ........................................................................................................................................................... 2-66
TIRE AND WHEEL
DUAL DRIVE WHEEL..................................................................................................................................... 13-8
SINGLE DRIVE WHEEL
H100-120XM ............................................................................................................................................... 13-6
H70-90XM ................................................................................................................................................... 13-4
STEER WHEEL .............................................................................................................................................. 13-9
TORQUE CONVERTER....................................................................................................................................... 5-6
TRANSMISSION
SHEET 1 OF 2 .................................................................................................................................................. 5-8
SHEET 2 OF 2 ................................................................................................................................................ 5-12
TRANSMISSION LINES....................................................................................................................................... 5-4
TRANSMISSION MOUNT .................................................................................................................................... 5-2

U
UNDERCARRIAGE PAN .................................................................................................................................... 1-18

V
VALVE
HIGH AND LOW ............................................................................................................................................. 5-24
VALVE COVER AND INLET MANIFOLD
GASOLINE AND LPG..................................................................................................................................... 2-38
VALVE COVER AND ROCKER ARM SHAFT
DIESEL ........................................................................................................................................................... 2-70

W
WATER SEPARATOR ......................................................................................................................................... 3-12
WIRE HARNESS
ADAPTER
⇒S/N PENDING PER ECN 63634-01 ........................................................................................................ 4-93

©2003 HYSTER COMPANY See Service Manual vii

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

W (continued)

AUXILIARY LIGHTS
WORKLIGHTS .......................................................................................................................................... 13-71
CAB............................................................................................................................................................... 13-64
CLOSED LOOP
⇒S/N PENDING PER ECN 70700-65 ........................................................................................................ 4-79
CONVERSION, GAS TO LPG, GM 4.3L
SHEET 1 OF 2 ............................................................................................................................................ 4-40
SHEET 2 OF 2 ............................................................................................................................................ 4-42
DIESEL
S/N PENDING PER ECN 73766⇒ ............................................................................................................. 4-82
⇒S/N PENDING PER ECN 73766 ............................................................................................................. 4-80
DUAL FUEL SHUT OFF ................................................................................................................................. 4-84
DUAL FUEL, GM V6
SHEET 1 OF 2
S/N PENDING PER ECN 73766⇔S/N PENDING PER ECN 73891-01 ................................................. 4-62
⇒S/N PENDING PER ECN 92210-01..................................................................................................... 4-46
S/N PENDING PER ECN 92210-01⇔S/N PENDING PER ECN 73766 ................................................. 4-54
SHEET 2 OF 2
S/N PENDING PER ECN 73766⇔S/N PENDING PER ECN 73891-01 ................................................. 4-67
⇒S/N PENDING PER ECN 92210-01..................................................................................................... 4-51
S/N PENDING PER ECN 92210-01⇔S/N PENDING PER ECN 73766 ................................................. 4-58
ENGINE, GAS, GM V6
SHEET 1 OF 2
S/N PENDING PER ECN 92210-01⇔S/N PENDING PER ECN 73766 ................................................. 4-94
SHEET 2 OF 2
S/N PENDING PER ECN 92210-01⇔S/N PENDING PER ECN 73766 ................................................. 4-99
ENGINE, GM V6, 4.3L
SHEET 1 OF 2
⇒S/N PENDING PER ECN 92210-01..................................................................................................... 4-72
SHEET 2 OF 2
⇒S/N PENDING PER ECN 92210-01..................................................................................................... 4-74
ENGINE, LPG, GM V6, 4.3L
SHEET 1 OF 2
S/N PENDING PER ECN 73766⇒........................................................................................................ 4-114
S/N PENDING PER ECN 92110-01⇔S/N PENDING PER ECN 73766 ............................................... 4-108
SHEET 2 OF 2
S/N PENDING PER ECN 73766⇒........................................................................................................ 4-116
S/N PENDING PER ECN 92110-01⇔S/N PENDING PER ECN 73766 ............................................... 4-110
ESOS ADAPTER
⇒S/N PENDING PER ECN 63634-01 ........................................................................................................ 4-85
GAS ENGINE
⇒S/N PENDING PER ECN 92210-01 ........................................................................................................ 4-38
GAS, GM V6
SHEET 1 OF 2
S/N PENDING PER ECN 73766⇔S/N PENDING PER ECN 73891-01 ............................................... 4-102
SHEET 2 OF 2
S/N PENDING PER ECN 73766⇔S/N PENDING PER ECN 73891-01 ............................................... 4-104
LPG SWITCH.................................................................................................................................................. 4-77
MODULE, TYPE S POWERSHIFT
SHEET 1 OF 2
viii See Service Manual ©2003 HYSTER COMPANY
for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

W (continued)

S/N PENDING PER ECN 63571⇔S/N PENDING PER ECN 73675-01 ............................................... 4-120
POWERSHIFT
SHEET 1 OF 2
⇒S/N PENDING PER ECN 63571.......................................................................................................... 4-86
SHEET 2 OF 2
⇒S/N PENDING PER ECN 63571.......................................................................................................... 4-90
REVERSE ALARM ....................................................................................................................................... 13-56
TYPE "S" GAS AND LPG
⇒S/N PENDING PER ECN 73766 ............................................................................................................. 4-45
TYPE S
GAS AND LPG
S/N PENDING PER ECN 73766⇒.......................................................................................................... 4-78

©2003 HYSTER COMPANY See Service Manual ix

for service procedures.
 UNIT CODE K005
NORTH AMERICA 01/2003

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

TERM DEFINITION TERM DEFINITION

Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment
MSTS Microprocessor Spark Timing System
D/B Date Break
NPT National Pipe Threads
dbA Decibel "A" Scale
O/S Oversize
DE Drive End
PTO Power Take Off
ECH Empty Container Handler
RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High
S/N Serial Number
Stacking
TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High
Stacking UL Type D Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High UL Type DS Diesel-Powered Safety Rating
Stacking UL Type E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating
Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking
UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module
UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice
UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable
U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPROM Electrically Programmable Read Only
Memory V Volts

x See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE K005
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HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.

©2003 HYSTER COMPANY See Service Manual xi

for service procedures.
 UNIT CODE K005
NORTH AMERICA 01/2003

HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT previous page, BEARING CAP (Item 2) is a
HIGHER ASSEMBLY IS NOT KNOWN: subpart of the major assembly CASE.

1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASE assembly.

2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly which parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629 ⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553 ⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.

3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on. Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243 ⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.

5. Use the Numerical Index on Page 14-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 ⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00 ⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.

xii See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE K005
01/2003 NORTH AMERICA

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957 and 1980.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

©2003 HYSTER COMPANY See Service Manual xiii

for service procedures.
 UNIT CODE K005
NORTH AMERICA 01/2003

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code

letter, and date of manufacture are stamped
approximately six inches below the top of most
forks.

2. The carriage group number is stamped on the

right hand side of the top crossmember (pin type)
or on the back of the right hand end of the bottom
crossmember (hook type). A date code has two
letters in line with or below the carriage group
number.

3. The mast identification number has a unit code,

a letter indicating the plant of manufacture, and
a serial number. Underneath the production
sequence number is a four digit number that
indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped

on the cylinder shell.

Always refer to the group, serial, or part number

when ordering service parts.

Modification of masts and carriages by SPED

(Special Products Engineering Department) are
identified by a model prefix code beginning with
the letter "S". contact your dealer for Hyster lift
trucks for information on these assemblies.

xiv See Service Manual ©2003 HYSTER COMPANY

for service procedures.