Hyster S135FT, S155FT (G024) Forklift Trucks Pdf Repair Service Manual

Hyster S135FT, S155FT (G024) Forklift Trucks PDF Repair Service Manual

The Hyster G024 Repair Service Manual covers the S135FT and S155FT — two sit-down pneumatic tire counterbalance forklifts rated at 13,500 lb and 15,500 lb respectively. This capacity range occupies a specific position in industrial operations — heavier than general warehouse machines but not the specialist territory of large-capacity plant equipment. Steel service centers, lumber yards, precast concrete suppliers, heavy distribution operations, and paper handling facilities are where these machines typically work, often running extended shifts under near-rated loads on surfaces that range from warehouse concrete to outdoor hardstand.

With only two variants sharing the same G024 platform, the service differences between the S135FT and S155FT are narrower than many multi-variant series — but they exist. The 2,000 lb capacity step between the two models affects brake system wear limits, drivetrain load tolerances, and hydraulic relief settings. Where those values differ, this manual documents each variant separately. Where the platform is shared, a single procedure covers both.

Manual Technical Specifications

Systems and Repair Coverage

Complete diagnostic, disassembly, and rebuild procedures for both G024 variants:

• Engine Overhaul and Fuel System: Cylinder bore measurement, valve clearance per variant, cylinder head surface and valve seat service, head bolt torque sequence — LPG regulator and mixer calibration, diesel injection pump timing, nozzle return rate testing, and fuel system bleed each covered with independent procedures
• Hydraulic Mast and Lift Circuit: Mast channel wear and roller clearance adjustment, lift cylinder bore condition and drift test under load, seal kit replacement, tilt cylinder rod seal service, main relief valve calibration with S135FT and S155FT values documented where they differ, load-hold valve leak test, and hydraulic pump output testing
• Powershift Transmission and Torque Converter: Stall test procedure and speed reading interpretation, clutch circuit pressure testing per capacity variant, clutch pack disc and plate measurement, pack clearance specification, transmission disassembly from G024 chassis layout, valve body spool inspection, and fault diagnosis covering engagement hesitation, range hunting, and converter temperature faults
• Drive Axle and Differential: Axle shaft spline condition assessment, ring and pinion backlash and depth setting, carrier bearing preload, axle housing inspection at weld stress points, hub bearing end-float specification, and seal replacement — with S155FT load tolerances noted where the higher capacity affects values
• Electrical System and Interlock Fault Tracing: Alternator output and starter current draw testing, hydraulic solenoid coil resistance values, safety interlock circuit testing for seat switch, directional lever, and parking brake as individual component checks, engine sender test values, and instrument and warning circuit diagnosis
• Steering Axle Repair: King pin bore wear limit and replacement procedure, thrust bearing condition, toe-in specification after reassembly, and hub bearing preload adjustment
• Brake System and Tyre Service: Drum wear limit and lining thickness minimum documented separately for S135FT and S155FT, wheel cylinder inspection and bleed sequence, pedal travel specification, parking brake adjustment and holding force test, pneumatic tyre inflation per load rating, and wheel nut torque sequence

Why This Manual Matters for G024 Service

• At 13,500 to 15,500 lb, hydraulic relief settings and brake wear limits carry more consequence than on lighter machines — applying an approximated value at this capacity class is not an acceptable substitute for the correct factory figure
• The 2,000 lb step between S135FT and S155FT produces real differences in drivetrain tolerances and brake specifications — both sets of values are documented so each machine is serviced to its own rated standard
• Transmission stall test and clutch pressure check procedures allow condition assessment before any disassembly — particularly relevant on machines that run extended shifts under heavy loads where early fault detection avoids costly unplanned downtime
• Diesel and LPG fuel system procedures are documented independently — not merged into a shared reference that requires interpretation for each fuel type

Getting This Manual From Manualskart

The G024 is listed by series code on Manualskart. Both the S135FT and S155FT are covered in a single document — there is no need to purchase separate publications for each capacity variant on this platform.

• Download available immediately after purchase with no waiting period
• Single payment, permanent access — no renewal or expiry
• Keyword-searchable PDF — find any torque value, pressure specification, or wiring reference instantly
• Printable at workshop scale for bench use
• 30-day refund if the series code does not match your machine
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Frequently Asked Questions

Does one manual genuinely cover both the S135FT and S155FT?
Yes. Both variants are on the same G024 platform and are documented together. Where the 2,000 lb capacity difference produces different specifications — brake wear limits, drivetrain tolerances, hydraulic relief values — the manual identifies each variant's values separately. Shared procedures use a single entry for both.

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

Are the transmission specifications the same across both variants?
Most transmission procedures are common to the G024 platform, but clutch circuit pressure values are documented per capacity variant. The S155FT carries different clutch pressure specifications from the S135FT — the manual identifies where each variant's values apply.

How do I confirm this is the right manual for my machine?
Check the series code on your machine's data plate or parts record. If it shows G024 alongside either S135FT or S155FT, this document contains the correct factory procedures and specifications for your machine.

Download the Hyster S135FT S155FT G024 Service Manual PDF

Both G024 variants are covered in a single 870+ page factory document — access the complete Hyster S135FT S155FT G024 repair manual immediately at Manualskart.com, and find additional medium-heavy capacity forklift documentation in the Hyster Service Manual Collection.