Hyster D024 Service & Repair Manual
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Hyster D024 Service & Repair Manual

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Hyster D024 (S135FT S155FT) Forklift Service
Repair Manual

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Summary of Contents for Hyster D024

  • Page 1 Hyster D024 (S135FT S155FT) Forklift Service Repair Manual...
  • Page 2 GM 4.3L V-6 ENGINES S4.0-5.5FT, 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; (S135-155FT) [D024, E024, F024, G024] PART NO. 1627339 0600 SRM 1251...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 4: Table Of Contents

    Valve Lifters ..............................34 Remove ................................34 Clean and Inspect ............................34 Install ................................35 Crankshaft Repair ..............................36 Remove ................................36 Inspect and Repair ............................36 How to Check Clearance Between Main Bearings and Their Journals ............37 Install .................................38 ©2015 HYSTER COMPANY...
  • Page 5 Table of Contents TABLE OF CONTENTS (Continued) Piston and Connecting Rod Assemblies Repair ....................40 Connecting Rod Bearings, Replace ........................40 Piston and Connecting Rod Assemblies, Remove ....................41 Disassemble ...............................41 Piston, Clean and Inspect ..........................42 Cylinder Bores, Inspect and Repair ......................... 42 Piston Rings ..............................
  • Page 6 Table of Contents This section is for the following models: S4.0-5.5FT, 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; (S135-155FT) [D024, E024, F024, G024]...
  • Page 7 "THE QUALITY KEEPERS" HYSTER APPROVED PARTS...

  • Page 8: General

    0600 SRM 1251 General General • DO NOT cause a short circuit by connection CAUTION of the electric wires to the wrong terminals. Make sure a correct identification of the Disconnect the battery cables before doing any wire is made before it is connected. disassembly and repair of the engine or parts of the electrical system.

  • Page 9: Cylinder Head Repair

    Cylinder Head Repair 0600 SRM 1251 Cylinder Head Repair 7. Remove valve rocker arms. Organize rocker REMOVE AND DISASSEMBLE arms so they can be installed in their original positions. See Figure 2. WARNING Disconnect the battery cables before making re- pairs to the engine.
  • Page 10 0600 SRM 1251 Cylinder Head Repair 8. Remove valve rocker arm supports. 10. Remove capscrews that hold cylinder head to block in the sequence shown in Figure 3. Re- 9. Remove valve push rods. move cylinder head and gasket. Discard cylin- der head gasket.

  • Page 11: Clean And Inspect

    Cylinder Head Repair 0600 SRM 1251 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 protective goggles or a face shield to prevent injury to the eyes.
  • Page 12 0600 SRM 1251 Cylinder Head Repair 3. Clean valve guides. CAUTION To prevent possible gouging of the cylinder head surfaces, use care when removing gasket mate- rial. 4. Remove all gasket material from surfaces of cylinder head. 5. Inspect cylinder head for following defects: •...

  • Page 13: Valve Oil Seals

    Cylinder Head Repair 0600 SRM 1251 1. UNDERSIZED MARGIN 1. BURNT OR DAMAGED AREAS 2. PITTED SURFACE 2. UNDERSIZED MARGIN 3. BURNT OR ERODED AREAS 3. BENT STEM 4. ACCEPTABLE EDGE MARGIN 4. SCORING/DAMAGE TO THE STEM 5. WORN KEY GROOVE Figure 8.

  • Page 14: Cylinder Leak Down Test

    Inspect cylinder head. See Cylinder Head 1. Install the J 35667-A Cylinder Head Leakdown Repair, Clean and Inspect. Tester (Hyster P/N 4060759) tester in the spark plug port on cylinder to be tested. Clean and Inspect 2. Apply shop air pressure to J 35667-A Cylinder...

  • Page 15: Assemble And Install

    Assemble and Install A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) 1. Using GM tool J-42073 (Hyster P/N 4622265), B. FREE LENGTH: 50 mm (2.0 in.) install oil seal in lower groove. Install shim, C. SPRING COMPRESSED TO 265 N (59.5 lbf) AT damper, spring, shield, and cap or rotator.
  • Page 16 0600 SRM 1251 Cylinder Head Repair 2. Apply a molybdenum grease or equivalent to c. Finger start rocker arm bolt at location 3 following valve rocker arm contact surfaces: in Figure 12. • Valve push rod socket d. Finger start remaining three valve...

  • Page 17: Valve Guides And Seats, Repairs

    Cylinder Head Repair 0600 SRM 1251 VALVE GUIDES AND SEATS, REPAIRS Measure clearance 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, crosswise to cyl- inder head, will cause a direct movement of dial indicator stem.

  • Page 18: Valves, Repair

    0600 SRM 1251 Cylinder Head Repair VALVES, REPAIR Before any work is performed on valve NOTE: faces and seats, make sure clearance of valve stems in their valve guides is within specifications. A correction for minimum wear and damage to valve and seat can be done by a process called lap- ping.

  • Page 19: Valve Springs

    Cylinder Head Repair 0600 SRM 1251 A. EXHAUST VALVE B. INTAKE VALVE 1. CYLINDER HEAD 2. VALVE Figure 17. Valve Seat Widths and Valve/Valve Seat Overlap Use a special tool to check tension of valve springs. VALVE SPRINGS Compress the spring to correct height and check tension.

  • Page 20: Assemble And Install

    Make sure cylinder head is aligned with pins in GINES. block. A. VARIATION FROM VERTICAL: LESS THAN 4. Use sealant Hyster P/N 1451215 on threads of 1.6 mm (0.063 in.) B. FREE LENGTH: 51.3 mm (2.02 in.) capscrews for cylinder head. Install capscrews C.
  • Page 21 Cylinder Head Repair 0600 SRM 1251 5. Apply RTV sealant (Hyster P/N 280472) to front and rear surfaces between intake mani- fold and engine block. See Figure 20. The bead of sealant must be 5 mm (0.2 in.) thick and ex- tend up sides of heads 13 mm (0.5 in.) to seal...
  • Page 22 0600 SRM 1251 Cylinder Head Repair CAUTION Be sure that the arrow on the valve rocker arm support is in the up position. See Figure 23. 8. Install valve rocker arm supports. 1. VALVE PUSH ROD SOCKET 2. ROLLER PIVOT 3.
  • Page 23 Cylinder Head Repair 0600 SRM 1251 1. BOLT AT LOCATION 1 1. CRANKSHAFT BALANCER ALIGNMENT MARK 2. BOLT AT LOCATION 2 2. ENGINE FRONT COVER ALIGNMENT TAB 3. BOLT AT LOCATION 3 Figure 26. Rotate Crankshaft Balancer Figure 25. Install Valve Rocker Arm Assemblies 12.
  • Page 24 0600 SRM 1251 Cylinder Head Repair 14. Install spark plugs. 15. Install throttle body, air cleaner, and distribu- tor. Install brackets for drive belt tensioner 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).

  • Page 25: Engine Block Cleaning And Inspection

    Engine Block Cleaning and Inspection 0600 SRM 1251 Engine Block Cleaning and Inspection 5. After cleaning engine block, spray or wipe cyl- CLEAN AND INSPECT inder bores and machined surfaces with clean engine oil. CAUTION 6. Inspect following areas, see Figure 28: To prevent possible gouging of the engine block •...
  • Page 26 0600 SRM 1251 Engine Block Cleaning and Inspection 7. Measure cylinder bores for taper and out-of- round. See Figure 29. 1. PISTON CYLINDER BORE 2. BORE MEASURING DEVICE Figure 29. Cylinder Bore Taper and Out-of-Round Inspection 1. COOLANT JACKET 2. CYLINDER BORE 3.

  • Page 27: Piston Bore Preparation

    Thanks very much for your reading, Want to get more 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 please write to me: admin@servicemanualperfect.com...

This manual is also suitable for:

S135ftS155ft

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