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Hyster D024 (S135FT.S155FT) Forklift Service Manual

3,791 pages · Publication 1652520

$379.77
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Models
D024 (S135FT.S155FT)
Manual type
Service Manual
Pages
3,791
Publication
1652520
Condition
Brand new
Hyster D024 (S135FT.S155FT) Forklift Service Manual, publication 1652520

What's inside

From the manual's own table of contents: 72 sections, 325 entries. See sample pages (PDF, 335 KB)

Cooling System
Safety Precautions Maintenance and Repair
General
Cooling System Checks4 topics
  • Exhaust Leaks Into Cooling System
  • Water Flow Restrictions in Radiator
  • Radiator Hoses
  • Water Pump
Flushing the Cooling System1 topic
  • Cooling System, Clean
Radiator Replacement6 topics
  • Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0
  • Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S
  • Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H
  • Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0
  • Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT
  • Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT
Fan Assembly Replacement3 topics
  • Fan Removal
  • Inspect
  • Fan Installation
Steering Axle
Steering Axle Assembly Repair5 topics
  • Remove
  • Disassemble
  • Clean
  • Assemble
  • Install
Spindles, Bearings, and Tie Rods Repair2 topics
  • Spindles and Bearings
  • Tie Rods
Steering Cylinder Repair3 topics
  • Remove and Disassemble
  • Clean and Inspect
  • Assemble and Install
Torque Specifications
LPG Fuel System
Hoses Replacement
LPG Tank and Bracket Replacement13 topics
  • Remove
    • Install
  • LPG Tank Bracket, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S
    • Remove
    • Install
  • LPG Tank Bracket Alignment Pin, Lift Truck Models S4.0, 4.5, 5.5
    • Remove
    • Install
    • Remove
    • Install
  • LPG Tank Bracket, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155
    • Remove
    • Install
High Pressure Fuel Filter Unit Repair9 topics
  • Fuel Filter Element
    • Remove
    • Clean/Inspect
    • Install
  • Fuel Filter Housing
    • Remove
    • Disassemble
    • Assemble
    • Install
Electronic Throttle Body Repair1 topic
  • Clean/Inspect
Fuel Injector Repair11 topics
  • Fuel Rail
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • Fuel Injectors and Adapters
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Clean
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
LPG Regulator Repair11 topics
  • LPG Regulator
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • LPG Regulator Fuel Filter
    • Remove
    • Install
  • Lock-Off Solenoid and Cartridge
    • Remove
    • Install
Control System19 topics
  • Electronic Control Unit (ECU) and Injector Driver Modules Assemb
    • Remove
    • Install
  • Electronic Control Unit (ECU)
    • Remove
    • Install
  • Injector Driver Modules
    • Remove
    • Install
  • Fuel Pressure Sensor
    • Remove
    • Install
  • Low LPG Pressure Switch
    • Remove
    • Install
  • LPG Pressure Sensor
    • Remove
    • Install
  • Oxygen Sensor
Exhaust System Repair25 topics
  • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models H6.0FT, H7.0FT (H135FT, H15
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models S6.0FT, S7.0FT (S135FT, S15
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove
    • Install
Gasoline Fuel System4 topics
  • Electronic Throttle Body
    • Remove
    • Clean/Inspect
    • Install
Fuel System Repair34 topics
  • Before Repair Procedure
  • After Repair Procedure
    • Fuel Leakage Check for Lift Trucks Built Before January, 2010
    • Fuel Leakage Check for Lift Trucks Built After January, 2010
  • Fuel Line Pressure Check
  • Fuel Injector Repair
    • Remove
    • Install
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove
    • Install
Brake System2 topics
  • Dry Brake System
  • Wet Brake System
Show all 72 sections
Service Brakes Repair (Dry Brake)1 topic
  • Adjust
Parking Brake Repair3 topics
  • Dry Brake System
    • Wet Brake System
    • Lift Trucks With a MONOTROL® Pedal or Forward Reverse Lever
Master Cylinder Repair1 topic
  • Install and Adjust
Accumulator1 topic
  • Pre-Charge Check
Modulating Brake Valve, Accumulator Charge Valve, and Accumulato11 topics
  • Modulating Brake Valve
    • Disassemble
    • Clean and Inspect
    • Assemble
  • Accumulator Charge Valve
    • Disassemble
    • Clean and Inspect
    • Assemble
  • Pressure Checks
    • Accumulator Charge Valve Check
    • Accumulator Check
Service Brakes Adjustment (Dry Brake)1 topic
  • Service Brakes Adjustment
Brake System Air Removal4 topics
  • Using Pressure Bleed System
  • Using Brake Pedal Pressure
    • Lift Truck Models with Master Cylinder
    • Lift Truck Models with Modulating Brake Valve
Brake Pedal Adjustment
Free Pedal Adjustment
Table 1. Accumulator Charge Valve Pressure
Table 2. Accumulator Specifications
Frame
Description
Hood, Seat, Dash, and Side Covers Replacement
Steering Column8 topics
  • Description
  • Steering Column Repair
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
Counterweight Replacement3 topics
  • Tow Pin
    • Remove and Install
    • Remove and Install For Lift Truck Models S5.5FTS (S80FTBCS, S100
Overhead Guard Replacement1 topic
  • LED Tail, Backup, and Brake Lights, Replace
Operator Restraint System Replacement
Engine Replacement4 topics
  • Remove Engine Only
  • Install Engine only
  • Remove Engine and Transmission
  • Install Engine and Transmission
Electronic Throttle Replacement5 topics
  • Cummins 4.5L Diesel Engine With Electronic Throttle
    • Remove
    • Install
    • Pull Actuator Linkage Adjustment
    • Low Idle Adjustment
Throttle Pedal and Cable Adjustment16 topics
  • Cummins 4.5L Diesel Engine
  • Cummins QSB 3.3L Engine for Lift Truck Models S6.0FT, S7.0FT (S1
    • Remove
    • Inspect
    • Install
  • Cummins 4.5L Diesel Engine for Lift Truck Models S6.0FT, S7.0FT
    • Remove
    • Inspect
    • Install
  • Kubota 3.8L Diesel Engine for Lift Truck Models S6.0FT, S7.0FT (
    • Remove
    • Inspect
    • Install
    • Remove
    • Inspect
    • Install
Hydraulic Filter Assembly Repair
Fuel and Hydraulic Tanks Repair6 topics
  • Steam Method of Cleaning
    • Chemical Solution Method of Cleaning
  • Additional Preparations for Repair
  • Small Leaks, Repair
  • Large Leaks, Repair
  • Preparations for Use After Repair
Safety Labels
Table 1. Gas Spring Installation, Holes for Installing Rod Ends
Table 2. Weight of Counterweights
Three-Speed Powershift Transmission Repair
Transmission Repair28 topics
  • Torque Converter, Remove
    • Torque Converter Housing, Disassemble
    • Transmission Case, Disassemble
    • FORWARD 1, Disassemble
    • RANGE 2, Disassemble
    • REVERSE, Disassemble
    • RANGE 1, Disassemble
    • FORWARD 2, Disassemble
    • Stator Support, Disassemble
    • Turbine Shaft, Disassemble
    • Pump Drive Gear, Disassemble
    • Idler Gear, Disassemble
    • Housings
    • Oil Seals and Gaskets
    • Bearings
    • Gears and Shafts
    • RANGE 2, Assemble
    • FORWARD 1, Assemble
    • REVERSE, Assemble
    • RANGE 1, Assemble
    • FORWARD 2, Assemble
    • Stator Support, Assemble
    • Turbine Shaft, Assemble
    • Pump Drive Gear, Assemble
    • Idler Gear, Assemble
    • Torque Converter Housing, Assemble
    • Transmission Case, Assemble
  • Torque Converter, Install
Control Valve Repair
Torque Specification
Capacities and Specifications
Lift Truck Lifting Capacity
Counterweight Weights
Tire Sizes
Capacities
Electrical System
Transmission Oil Pressures
Hydraulic System Relief Pressures
Steering System
Stall Speeds (in RPM ±100 rpm)
Mast Speeds
Tilt Angles
Front End Equipment - Mast Creep1 topic
  • Mast Creep
Engine Specifications6 topics
  • Frame
  • Hang On Sideshift Carriage With Fork Positioner, Lift Truck Mode
  • Steering System
  • Transmission
  • Engine - GM 4.3L
  • Engine - Cummins 4.5L and QSB 3.3L Diesel
Table 5. 3-Speed Transmission, Lift Trucks Manufactured BEFORE O
Table 6. 2-Speed Transmission, Lift Trucks Manufactured BEFORE J
Table 7. 3-Speed Transmission, Lift Trucks Manufactured AFTER Oc
Table 8. 2-Speed Transmission, Lift Trucks Manufactured AFTER Ju

Inside this manual

Real pages from this service manual (3,791 pages). Open the sample pages (PDF, 334 KB)

Sample pages from the Hyster D024 (S135FT.S155FT) Forklift Service Manual: Troubleshooting, Specifications, Diagram, Color page, Color page
  • Troubleshooting, page 1,604: Wrong Actuation Operates or Actuation is Backward (E-Valve)
  • Specifications, page 1,894: Fan Assembly Replacement
  • Diagram, page 2,474: Legend for Figure 28
  • Color page, page 1,469: STEERING CONTROL UNIT (SCU)
  • Color page, page 1,720: Figure 9060-10-25. Cab Component Locations

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 3,791 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster E024 (S135FT, S155FT)Service Manual · E024 · $399.77Hyster F024 (S135FT, S155FT)Service Manual · F024 · $389.57Hyster G024 (S135FT, S155FT)Service Manual · G024 · $389.81

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).