Hyster S135-S155XL2 [S6.00-7.00XL] (B024 A879) Forklift Index:

PERKINS DIFSEL ENGINES, SERIFS 1000
1.1 GENERAL
GENERAL SAFETY RULES
Viton Seals
1.2 DESCRIPTION
1.3 Engine Serial Number Codes .
I -4 Engine Data ,
1.5 1004-4 ENGINE .
1.6 ENGINE .
1.7 1006-6 ENGINE .
1-8 1006-6T ENGINE .
I .9 REMOVAL AND INSTALLATION
CYLINDER HEAD ASSEMBLY
1.10 VALVECOVER .
1.11 Removal
1.121nstallation…………………………………..„.
1.13 ROCKER ARM ASSEMBLY .
1.14 Removal
1.15 Installation .
I. 17 Inspection
1.18 Assembly
1.19 VALVECLEARANCEADJUSTMENTS
.20 Four Cylinder Engines
1,21 Six Cylinder Engines .
.22 VALVE SPRINGS
1.23 CYLINDER HEAD ASSEMBLY
1.24 Removal…. ….. ..
1.25 Installation .
1.26 VALVES AND VALVE SPRINGS
1,27 Removal . , , . ,
1.28 Inspection .
I .29 Installation
130 VALVE GUIDES
131 Inspection
1.32 Removal…. ….. ….. .. . . .

1.33 Installation
1.34 CYLINDER HEAD AND VALVE SEATS
.35
136 Repair
1.37 Installation Of New Valve Seats
PISTON AND CONNECTING ROD ASSEMBLIES .
1.38 ROD BEARINGS .
1.39 .
1.40 Installation
1.41 PISTON AND CONNECTING ROD ASSEMBLY
1,42 Service Note
1.43 Removal .
1.44 Installation …
1.45 PISTON RINGS .
1.47 Inspection
1.48 Installation
1.49 PISTON AND CONNECTING ROD
ISO Disassembly , , , , , , ,
I Inspection
152 Installation .
1.53 PISTON COOLING JETS (Engines AB YEI) …………
1.54
155 Installation
CRANKSHAFT ASSEMBLY .
1.56 GENERAL
1.57 CRANKSHAFT PULLEY
1.58 Removal. Engines AA and AB .
I .59 Installation, Engines AA and AB
160 Removal. Engines YA and YB .
Installation, Engines YA and YB
1.62REAR01LSEAL……..
I .63 Replacement
1.64 MAIN BEARINGS
Removal . , ,
1.66 Installation
1.67 THRUST WASHERS
I .68 Check The Axial Movement Of The Crankshaft

1.70 Installation
1.71 CRANKSHAFr
1.72Remova1…………………
1.73 Inspection .
1.74 Installation
TIMING CASE AND TIMING GEARS .
1.75 GENERAL .
1.76 TIMING CASE COVER
1.78 Installation
1.79 FRONT OIL SF A1
L81 Installation .
.82 IDLER GEAR AND HUB
1.83 Removal….
I -84 Installation .
1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
1.86 Removal… ….
1.87 Installation
1.8* CRANKSHAFT GEAR .
1.89 Removal
1.90 Installation
1,91 TIMING CASE ..
1.92 Removal
1.93 Installation
1.94 CAMSHAFT AND TAPPETS
1.95 Removal
1.96 Installation .
ENGINE BLOCK ASSEMBLY
I DESCRIPTION
1.98 ENGINE BLOCK
1.99 Disassembly
l. 100 Inspection
1.101 Assembly .
1.102CYLINDER LINER
1.103 Inspection
1,104 Hone

1.105 Removal…„…………..w………………. .
1.106 Installation .
TURBOCHARGER, ENGINES AB AND YB
1,107 GENERAL
1.108 Removal .
1.109 Installation
I I O Clean The Impeller And Compressor Housing
LUBRICATION SYSTEM .
1.111 GENERAL .
1.112 OIL FILTER, REPLACEMENT
1,113 OIL SUMP
1.114 Removal….
1.115 Installation .
1.11601LPUMP .
1.117 Removal
1.118 Inspectic*l
1.119 Installation ….
1.120RELIEFVALVE
1.121 Removal……,..,..
1.122 Disassembly
1.123 Inspection
124 Installation
FUELSYSTEM
1,125 DESCRIPTION
1.126 CAV FUEL INJECTION PUMP
1.127
1,128 Installation
1.129 CAV FUEL INJECTION PUMP. CHECKS AND ADJUSTMENTS
l. 130 Timing Gear Marks .
l. 131 HOW TO Set Number I Piston TO TDC On The Compression Stroke .
1.132 Check The Valve Timing .
l. 133 Cheek The Timing Of Fuel Injection Pump .
I. 134 Check ‘lhe Timing Mark Of The Fuel Injection Pump
l. 135 Check •me Engine Timing Mark .
1.136 REMOVE AIR FROM THE FUEL SYSTEM
1.137 Fuel Injection Pump With Vent Tube .
1.138 Fuel Injection Pump With Vent Screw .
1.139 FUEL FILTER (REPLACEMENT) .

1.140 FUEL INJECTORS
1.141 Removal…. , .
142 Inspection
1.143 Installation .
1.144 FUEL PUMP
1.145 Removal…. ,
1.146Disassemb1y
1.147 Assembly .
1.148 Installation .
1.149 Test
COOLING SYSTEM .
1.150 GENERAL
1,151 THERMOSTAT ,
I. 152 Replacement
1.153 COOLANT PUMP .
1.155Disassemb1y
I.IS6Assembly
1.157 Installation .
1.158 FAN AND FAN DRIVE
1.159 Removal….
1.160 Disassembly
1.161 Assembly .
, 162 Installation
1.163 OIL COOLER
l. 164 Removal. Engine AB .
l, 165 Removal, Engines YA and YB
1.166 Disassembly And Assembly …..
l. 167 Installation, Engine AB .
1.168 Installation. Engines YA and YB
1.169 By-Pass Valve. Oil Cooler
FLYWHEEL AND FLYWHEEL HOUSING ….. ….. ….. ….. ….
l. 170 GENERAL
1.171 FLYWHEEL , , ……….„
1.172
1.173 Ring Gear (Replacement) . .
1.174 Installation
1.175 FLYWHEEL HOUSING

1.176
1.177 Installation .
ELECTRICAL EQUIPMENT .
1.178 DRIVE BELTS .
1.179 ALTERNATOR .
1.180 STARTER MOTOR
1.182 Installation .
1.183 COLD START AID
AIR COMPRESSOR, ENGINES YA AND YB
1,184 GENERAL
l. 185 Air Compressor. Removal. WABCO .
1.186 Compressor Drive, Inspection ……
l. 187 Air Compressor. Installation. WABCO
1.188 Compressor Drive. Disassembly. WABCO
1.189 Compressor Drive, Assembly, WABCO .
1.190 Air Compressor, Removal, BENDIX .
Air Compressor, Installation, BENDIX
1.192 Compressor Drive. Disassembly. BENDIX
l, 193 Compressor Drive, Assembly, BENDIX .
ENGINE SPECIFICATIONS
1.194 CYLINDER HEAD ASSEMBLY
1.195 Cylinder Head .
196 Valve Guides
1.1971n1etVa1ves .
l, 198 Exhaust Valves
1.199 Double Valve Springs TO Outer
I Double Valve Springs TO Inner
1.201 Single Valve Springs
1202 Tappets….
1203 Rocker Arm Shaft
1.204 Rcx•ker Arms And Bushings
1.205 PISTON AND CONNECTING RODS .
1206 Pistons, Engines AA And YA .
14207 Pistons. Engines AB And YB
1,208 Piston Rings, Engines AA And YA
1.209 Piston Rings, Engines AB And YB
1.210 Connecting R«ls. Engines AA And YA

1.211 Connecting Rods. Engines AB And YB .
1.212 Piston Pins, Engines AA And YA
1.213 Piston Pins, Engines AB and YB
1,214 Small End Bushings. Engines AA And YA
1.215 Small End Bushings, Engines AB And YB
1.216 Connecting Rod Bearings, Engines AA And YA .
1.217 Connecting Rod Bearings. Engines AB And YB .
1,218 Piston Cooling Jets, AB And YB
1.219 CRANKSHAFr ASSEMBLY .
1.220Crankshaft .
1.221 Crankshaft Heat Treatment ,
1.222 Crankshaft Overhaul
1.223 Main Bearings .
1.224 Crankshaft Thrust Washers
1.225 TIMING CASE AND DRIVE ASSEMBLY .
1.226 Camshaft .
1.227 Camshaft Washer
1,228 Camshaft Gear , , , , ,
1.229 Gear For Fuel Injection Pump
1.230 Crankshaft Gear
1.231 Idler Gear And Hub
1-232 ENGINE BLOCK ASSEMBLY .
1.233 Engine Bl«k
1.234 Cylinder Liners
1.235 TURBOCHARGER
1.236 LUBRICATION SYSTEM….
1237 Oil Pump, Engines AAAndAB .
1,238 Oil Pump, Engines YA And YB
1239 Relief Valve
1.2400il Filter .
1.241 FUEL SYSTEM .
1242 Cav Fuel Injection pump
1243 FUEL INJECTORS
1244 Fuel Pump, Engines AA And AB
1245 Foel Pump. Engines YA And YB
1246 Fuel Filter .
1.247 COOLING SYSTEM .
1.248 Coolant Pump .

I , 249 ,
1.250 Fan Drive Housing
1.251 FLYWHEEL AND HOUSING .
1-252 Limits for flywheel out” and alignment (total indicator . ,
1.253 ELECTRICAL EQUIPMENT
1.2S4A1ternator
1.255 Starter Motor
1.256C01dStaItAid ,
TORQUE SPECIFICATIONS
SPECIAL TOOLS .