Hyster S135FT, S155FT (F024) 4-Wheel Cushion Tire Forklifts Pdf Repair Service Manual

Hyster S135FT, S155FT (F024) 4-Wheel Cushion Tire Forklifts PDF Repair Service Manual

The Hyster F024 Repair Service Manual covers the S135FT and S155FT in their 4-wheel cushion tire configuration — rated at 13,500 lb and 15,500 lb for indoor heavy industrial use. The S135FT and S155FT model names also appear under the G024 series code, but the G024 covers pneumatic tire variants built for outdoor and mixed-surface applications. The F024 is a distinct generation serving a different operating environment entirely — smooth concrete floors in steel fabrication plants, large-format warehouses, paper processing facilities, and heavy manufacturing buildings where cushion tire fitment is appropriate and outdoor yard operation is not part of the machine's role. If your data plate shows F024, this is the correct document. G024 procedures applied to an F024 machine will produce incorrect results across hydraulic, tyre, and brake systems.

At this capacity on cushion tires, the machines carry heavy loads across indoor floor surfaces where brake balance, mast hydraulic integrity, and drivetrain condition directly affect both productivity and floor safety. The 2,000 lb step between the two variants produces real differences in brake wear limits, hydraulic relief settings, and drivetrain tolerances — both sets of values are documented within this manual, each applied to the correct machine.

Manual Technical Specifications

Systems and Repair Coverage

Complete diagnostic, disassembly, and rebuild procedures for both F024 variants:

• Engine Overhaul and Fuel System: Cylinder bore and wear measurement, valve clearance per variant, cylinder head surface flatness and valve seat recession, head bolt torque sequence — LPG regulator pressure and mixer calibration, diesel injection pump static and dynamic timing, nozzle return rate testing, and fuel bleed sequence each documented independently reflecting F024 engine installation specifications
• Hydraulic Mast and Lift Circuit: Mast channel wear measurement and roller clearance adjustment, lift cylinder bore condition and drift test under working load to assess seal condition before disassembly, seal kit replacement, tilt cylinder rod seal service, main relief valve calibration with S135FT and S155FT values documented separately where they differ, load-hold valve leak test, and hydraulic pump output pressure and flow testing
• Powershift Transmission and Torque Converter: Stall test and rpm deviation interpretation, forward and reverse clutch circuit pressure testing per capacity variant, clutch pack disc and plate wear measurement, pack clearance specification, transmission disassembly from F024 chassis layout, modulation valve spool inspection, and fault diagnosis covering engagement hesitation, direction change harshness, and converter temperature faults
• Drive Axle and Differential: Shaft spline wear assessment, ring and pinion backlash and depth setting, carrier bearing preload procedure, axle housing inspection at weld stress points, hub bearing end-float specification, and seal replacement — S155FT load tolerances identified where the higher capacity produces different values from the S135FT
• Electrical System and Safety Interlock Diagnosis: Alternator output and starter current draw testing, hydraulic solenoid coil resistance per F024 specification, seat switch and directional lever interlock tested as individual component checks, parking brake circuit continuity, engine protection sender test values, and instrument panel and warning circuit fault tracing
• Cushion Tyre, Steering, and Brake Repair: Cushion tyre removal and pressing procedure with F024 rim specification, seating depth and post-press inspection criteria, king pin bore wear limit and toe-in specification after steering axle rebuild, service brake drum wear limit and minimum lining thickness documented per capacity variant, wheel cylinder bore inspection and bleed sequence, pedal travel adjustment, and parking brake holding force test at rated machine weight

Why This Manual Matters for F024 Service

• F024 and G024 share model names but serve fundamentally different applications — cushion tire indoor operation versus pneumatic tire outdoor use — meaning tyre procedures, brake specifications, and certain hydraulic values differ between the two series documents
• Cushion tyre pressing at 13,500 to 15,500 lb requires correct rim specification and seating depth data — neither is present in the G024 pneumatic tire documentation or carried over from lighter cushion tire series
• Hydraulic relief values and brake drum wear limits at this indoor capacity class carry direct consequence for floor safety — the factory figures for each variant are the only reliable reference, not approximations from adjacent models
• The 2,000 lb capacity step between S135FT and S155FT produces variant-specific drivetrain tolerances and clutch pressure values — both documented separately so each machine is serviced to its own rated standard
• Stall test and clutch pressure checks are structured as diagnostic steps before disassembly — on heavy indoor machines running near-rated loads, identifying the fault location before pulling the transmission avoids unnecessary rebuild work

Download the Hyster S135FT S155FT F024 Service Manual PDF

The complete Hyster S135FT S155FT F024 cushion tire factory repair manual is available immediately at Manualskart.com — find the F024, G024, and the full range of medium-heavy Hyster documentation in the Hyster Service Manual Collection. This Hyster F024 service manual PDF is an 865+ page factory document covering both cushion tire variants with generation-specific procedures and capacity-specific values that apply to F024 machines only.

Frequently Asked Questions

My machine is an S155FT — how do I know if I need the F024 or G024 manual?
Check the series code on your machine's data plate — not the model name. F024 identifies the cushion tire indoor generation covered by this document. G024 identifies the pneumatic tire variant requiring a separate publication. Tyre procedures, certain hydraulic values, and brake specifications differ between the two series and are not interchangeable.

Does the cushion tyre pressing procedure apply at this capacity class?
Yes. The F024 includes the full cushion tyre removal and pressing procedure with rim specification, seating depth data, and post-press inspection criteria appropriate for the 13,500 to 15,500 lb machine weight. This procedure is absent from the G024 pneumatic documentation covering the same model names.

Are the S135FT and S155FT specifications genuinely different within this manual?
Yes. The 2,000 lb capacity difference produces distinct clutch circuit pressure values, brake drum wear limits, and axle load tolerances between the two variants. Where specifications are shared across the F024 platform a single procedure covers both — where they differ each variant's values are identified separately.

What fuel configurations are covered?
LPG and diesel configurations are both covered with independent fuel system procedures — regulator and mixer calibration for LPG, injection pump timing and nozzle return testing for diesel. Engine mechanical procedures common to both fuel types are covered under a shared section.