Hyster Diesel Forklift Troubleshooting

@all,

I'm having a somewhat unusual problem today:

I acquired an old Hyster forklift from a company.

It started running initially.

A few days ago, it stopped working while in operation and now it won't start.

The following was observed:

1.) There is a leak in the gasket on the cylinder where it connects to the exhaust manifold. Air is escaping from there when the starter is engaged.

2.) When you pull out the dipstick, it also blows air out from there. (In my opinion, the piston rings are no longer in good condition.)

3.) The diesel filter was clogged (possibly with metallic particles/wear debris?). It has now been replaced with a new one.

What can be done/tested? We don't want to invest a lot of money, but the forklift was working before.

Thank you very much.

Greetings.
Peter.

Hi,

I'm not sure which model of forklift you have, but you should clean the fuel tank if the filter is clogged. Also, blow out the tube that draws diesel from the tank with compressed air. A friend's Hyster forklift had the same problem. It would run for only a few seconds before stopping.

Regards,
arne

@Arne,

Thanks again for your reply.

The pre-filter probably hasn't been replaced yet.

Black liquid is coming from the diesel line, and there are also non-metallic particles present.

It is quite possible that there is liquid and other things in the tank that do not belong there . At least, it doesn't necessarily only smell like diesel .

What is the approximate cost (in €) for cleaning everything, including the fuel tank, lines, fuel injection pump, injectors, etc.?

Is it worth it?

Greetings.
Peter.

@all,

After various self-proclaimed experts have tried to fix it, the forklift still doesn't work.

Sometimes it starts up, but then it shuts down automatically after running for a while.

The so-called experts believe that the compression is not working correctly. However, everyone wants to buy the broken forklift.

How does low compression manifest itself? Can compression be measured in a diesel engine?

Greetings.
Peter.

Hello,

It's difficult to draw many conclusions from the previous post. If the diesel engine starts and then dies, it's unlikely to be a compression issue. What type of engine and fuel injection pump is installed? Is it a pre-chamber diesel or a Perkins direct injection engine? Is it a rotary fuel injection pump or a distributor pump, possibly from Bosch? If it dies while running, check the fuel shut-off valve, especially if it's electric. Otherwise, the diesel supply might be drawing air (try attaching a clear hose to the fuel injection pump), or the diesel filter might be clogged or contaminated.

Best regards,
Christian.