Hyster D024 Service & Repair Manual Download | Manualshive

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Hyster D024 (S135FT S155FT) Forklift Service
Repair Manual

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Summary of Contents for D024

Page 1: ...Hyster D024 S135FT S155FT Forklift Service Repair Manual...

Page 2: ...80 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 120FT N005 P005 R005 S005 U005 H6 0 H7 0FT H135 155FT H006 J006 K006 L006 S6 0 7 0FT S135 155FT D024 E024...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...eparation 20 Engine Mounts Installation 21 Remove 21 Clean and Inspect 21 Install 21 Lubrication System Repair 22 Oil Pump Remove and Disassemble 22 Clean and Inspect 23 Oil Pump Assemble and Install...

Page 5: ...eel Install 46 Coolant Pump Repair 46 Remove 46 Clean and Inspect 47 Install 47 Thermostat Replacement 48 Remove 48 Thermostat Operation Check 48 Install 48 Starter Replacement 49 Remove 49 Install 52...

Page 6: ...5 5FT S5 5FTS S80 120FT S80 100FTBCS S120FTS S120FTPRS G004 H004 H4 0FT5 FT6 H4 5FTS5 H4 5FT6 H5 0 5 5FT H80 120FT N005 P005 R005 S005 U005 H6 0 H7 0FT H135 155FT H006 J006 K006 L006 S6 0 7 0FT S135 1...

Page 7: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 8: ...is connected Make sure a battery is the correct voltage and polarity before it is connected DO NOT check for current flow by making a spark because the electronic components can be damaged This SRM h...

Page 9: ...Ignition GM4 3L EPA Compliant Engines and GM5 7L LPG EPA Complicant Engine 2200SRM1097 3 Remove air cleaner distributor intake mani fold and exhaust manifolds Remove drive belt s and remove brackets...

Page 10: ...block in the sequence shown in Figure 3 Re move cylinder head and gasket Discard cylin der head gasket A FAN END Figure 3 Cylinder Head Capscrew Removal Sequence 11 Using a valve spring compressor rem...

Page 11: ...mended safety procedures WARNING Compressed air can move particles so they cause injury to the user or to other personnel Make sure the path of the compressed air is away from all personnel Wear prote...

Page 12: ...e cylinder head for warpage with a straight edge and feeler gauge See Figure 6 A cylinder head block deck with warpage in excess of 0 10 mm 0 004 in within a 152 4 mm 6 0 in area must be repaired or r...

Page 13: ...re placed it is not necessary to remove the cylinder head 1 UNDERSIZED MARGIN 2 PITTED SURFACE 3 BURNT OR ERODED AREAS 4 ACCEPTABLE EDGE MARGIN Figure 8 Valve Contact Surface Inspection Remove and Dis...

Page 14: ...l tube may indicate worn piston rings a damaged piston a worn or scored cylinder bore a damaged engine block or a damage cylinder head Remove piston from the suspect cylinder See Piston and Connecting...

Page 15: ...TE THIS LIST IS FOR 4 3L GASOLINE EN GINES A VARIATION FROM VERTICAL LESS THAN 1 6 mm 0 063 in B FREE LENGTH 51 3 mm 2 02 in C SPRING COMPRESSED TO 338 TO 374 N 76 TO 84 lbf AT 43 2 mm 1 70 in CLOSED...

Page 16: ...bolt at location 1 in Figure 12 b Finger start rocker arm bolt at location 2 in Figure 12 c Finger start rocker arm bolt at location 3 in Figure 12 d Finger start remaining three valve rocker arm bol...

Page 17: ...ce between valve stem and guide as follows 1 Clamp a dial indicator on exhaust port side of the cylinder head See Figure 14 2 Position dial indicator so that movement of valve stem from side to side c...

Page 18: ...ill meet specifications shown in Figure 16 Figure 16 Valve Head Measurements VALVE SEATS REPAIR NOTE Before any work is done on valve faces and seats make sure clearance of valve stems in their valve...

Page 19: ...springs These springs can come loose with enough force to cause an injury Always use equipment that was designed to test springs Always wear eye and face protection while testing valve springs Use a s...

Page 20: ...ove Install shim damper spring shield and cap or rotator Using a spring com pressor compress assembly and install retain ers Measure height of valve spring as shown in Figure 18 Measure from top of sh...

Page 21: ...AND REAR 2 REAR 3 FRONT Figure 20 Intake Manifold Sealant Locations 6 Install gaskets and intake manifold Tighten capscrews in sequence shown in Figure 21 Tighten capscrews on first pass to 3 N m 27 l...

Page 22: ...h rod socket Roller pivot Valve stem tip 1 VALVE PUSH ROD SOCKET 2 ROLLER PIVOT 3 VALVE STEM TIP 4 ROCKER ARM BOLT Figure 24 Lubricate Valve Rocker Arm Surfaces 10 See Figure 25 Install valve rocker a...

Page 23: ...alve rocker arm assemblies are in stalled and properly torqued no additional valve lash adjustment is required 1 CRANKSHAFT BALANCER ALIGNMENT MARK 2 ENGINE FRONT COVER ALIGNMENT TAB Figure 26 Rotate...

Page 24: ...ner and alternator Install drive belt s 16 Install exhaust manifolds Tighten capscrews in two steps first to 15 N m 133 lbf in then to 31 N m 274 lbf in If used bend lock tabs against heads of capscre...

Page 25: ...osits from coolant passages Engine block cylinder head bolt holes 5 After cleaning engine block spray or wipe cyl inder bores and machined surfaces with clean engine oil 6 Inspect following areas see...

Page 26: ...ARING BORES 8 ENGINE BLOCK HOLE PLUG BORE 9 ENGINE BLOCK 10 ENGINE MOUNT BOSSES Figure 28 Engine Block Inspection 7 Measure cylinder bores for taper and out of round See Figure 29 1 PISTON CYLINDER BO...

Page 27: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

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