Hyster S70-120XL, S120XLS [S3.50-5.50XL, S5.50XLS] (D004 B818) Forklift Index:

PERKINS DIESEL ENGINES, SERIFS 1000
1.1 GENERAL
GENERAL SAFETY RULES
Viton Seals
1.2 DESCRIPTION
1.3 Engine Serial NumberCodes .
I -4 Engine Data
1.5 Iou-4 ENGINE .
1.6 ENGINE
1.7 1006-6 ENGINE
1-8 1006-6T ENGINE ..
I .9 REMOVAL AND INSTALLATION
CYLINDER HEAD ASSEMBLY
I.IOVALVECOVER ….. ….. ……
1.11 Removal
1.121nsta11ation
1.13 ROCKER ARM ASSEMBLY .
1.14 Removal…. .
1.15 Installation
1.16 Disassembly
17 Inspection
1.18 Assembly
1.19 VALVE CLEARANCE ADJUSTMENTS
.20 Four Cylinder Engines
1,21 Six Cylinder Engines ,
1.22 VALVE SPRINGS
1.23 CYLINDER HEAD ASSEMBLY
1.24 Removal….
1.25 Installation •
1.26 VALVES AND VALVE SPRINGS ,
1,27 Removal
I .28 Inspection .
I .29 Installation
1.30 VALVE GUIDES
I -31 Inspection
1.32 Removal….

1.33 Installation
1.34 CYLINDER HEAD AND VALVE SEATS .
1.35 Inspection
I Repair
Valve Seats .
PISTON AND CONNECTING ROD ASSEMBLIES
1.38 ROD BEARINGS .
1.39 Removal….
1.40 Installation .
1.41 PISTON AND CONNECTING ROD ASSEMBLY
I .42 Service Note
I -43 Removal
1.44 Installation .
1.45 PISTON RINGS .
1.46
1,47 Ins-V*ction
1.4* Installation
1.49 PISTON AND CONNECTING ROD
Disassembly , , , ,
IS I Inspection
1S21nstallation .
1.53 PISTON COOLING JETS (Engines AB and YB)
Removal .
I .55 Installation
CRANKSHAFT ASSEMBLY …. .
1.56 GENERAL
1.57 CRANKSHAFT PULLEY .
I Removal. Engines AA and AB .
1.59 Installation, Engines AA and AB
I .60 Removal. Engines YA and YB .
Installation, Engines YA and YB
1.62 REAR OIL SEAL .
1.63 Replacement
1.64 MAIN BEARINGS ..
1.66 Installation….
1.67 THRUST WASHERS
.68 Check The Axial Movement Of The Crankshaft

1.69 Removal
1.70 Installation
1.71 CRANKSHAFT’ .
1.72 Removal .
73 Inspection
1.74 Installation …………..„,.
TIMING CASE AND TIMING GEARS .
1.75 GENERAL
1.76 TIMING CASE COVER
1.77 Removal
1.78 Installation
I .79 FRONT OIL SEAL
1.80 Removal…„……..
1.81 Installation ….. ….. ….
I IDLER GEAR AND HUB
1.83 Removal….
1.84 Installation .
1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
Removal
1.87 Installation
1.88 CRANKSHAFT GEAR
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 .97 DESCRIPTION
1.98 .
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
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…. .
I. 118 Inspection
1.119 Installation .
1.120 RELIEF VALVE
1.121 Removal….
1.122 Disassembly
1.123 Inspection
1.124 Installation ,
FUEL SYSTEM .
1.125 DESCRIPTION .
1.126 CAV FUEL INJECI’ION PUMP
1.127 Removal….
1.128 Installation
1.129 CAV FUEL INJECr10N PUMP. CHECKS AND ADJUSTMENTS
I. 130 Timing Gear Marks
1.131 How To Set Number I Piston To TDC On The Compression Stroke ,
1.132 Check The Valve Tuning .
l. 133 Cheek Ilie Timing Fuel Injection Pump .
I. 134 Check The Timing Mark Of The Fuel lnÉction Pump .
1.135 Check lhe Engine Timing Mark .
1.136 REMOVE AIR FROM THE FUEL SYSTEM
1,137 Fuel Injection Pump With Tube
1,138 Fuel Injection Pump With Vent Screw
1.139 FUEL FILTER (REPLACEMENT) .

1.140 FUEL INJECTORS
1.141 Removal
I. 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
Removal
1.155Disassemb1y
l. 156 Assembly ,
1.157 Installation .
1.158 FAN AND FAN DRIVE ,
1.159 Removal…. ………………….„…
1.160 Disassembly…. .
1.161 Assembly .
I. 162 Installation
1.163011-COOLER…………………
l. 164 Removal. Engine AB .
, 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
FLYWHEEL AND FLYWHEEL HOUSING
1.170 GENERAL
1.171 H-YWHEEL , ,
1.172Remova1…………..„………
1.173 Ring Gear (Replacement) .
1.174
1.175 FLYWHEEL HOUSING .

1.176 Removal .
1.177 Installation
ELECTRICAL EQUIPMENT .
1.178 DRIVE BELTS .
1,179
1.180 STARTER MOTOR
1.181 Removal .
1.182 Installation .
1,183 COLD START AID
AIR COMPRESSOR, ENGINES YA AND YB .
1.184GENERAL .
1.185 Air Compressor. Removal. WABCO .
I 186 Compressor Drive, Inspection
1.187 Air Compressor, Installation. WABCO .
l. 188 Compressor Drive. Disassembly, WABCO … .
1.189 Compressor Drive, Assembly, WABCO
1, 190 Air Compressor, Removal. BENDIX
1,191 Air Compressor, Installation, BENDIX .
1.192 Compressor Drive, Disassembly. BENDIX .
I. 193 Cornpressor Drive, Assembly, BENDIX .
ENGINE SPECIFICATIONS
l. 194 CYLINDER HEAD ASSEMBLY
1.195Cy1inderHead .
1.196 Valve Guides .
1.197 Inlet Valves …………..„..
1.198 Exhaust Valves
1.199 muble Valve Springs To Outer
1200 Double Valve Springs TO Inner
1201 Single Valve Springs .
Tappets .
1.203 Rocker Shaft .
1.204 Rocker Arms And Bushings
1.205 PISTON AND CONNECTING RODS
I ,206 Pistons, Engines AA And YA
I .207 Pistons. Engines AB And YB
1.208 Piston Rings, Engines AAAndYA . .
1.209 Piston Rings, Engines AB And YB , , , , , , , , ,
1,210Connecting Rods, Engines AAAndYA

I .211 Connecting Rods, Engines AB And YB
1.212 Piston mns, EnginesAAAndYA ….. ….. …..
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
I .217 Connecting Rod Bearings. Engines AB And YB
I .218 Piston Cooling Jets, Engines AB And YB
1.219 CRANKSHAFT ASSEMBLY .
I .220 Crankshaft
1.221 Crankshaft Heat Treatment .
I .222 Crankshaft Overhaul .
1.223 Main Bearings
I .224 Crankshaft Thrust Washers
1.225 TIMING CASE AND DRIVE ASSEMBLY .
I. 226 Camshaft
1.227 Camshaft nu•ust 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 Block .
1.234 Cylinder Liners
1.235 TURBOCHARGER
1.236 LUBRICATION SYSTEM
1.237 Oil pump, Engines AA And AB .
1.238 Oil Pump, Engines YA And YB
1.239 Relief Valve .
1.240 Oil Filter .
1.241 FUEL SYSTEM
1,242 Cav Fuel Injection pump
1.243 FUEL INJECTORS .
.244 Fuel Pump, Engines AA And AB .
1.245 Fuel Pump. Engines YA And YB
1.246 Fuel Filter
1247 COOLING SYSTEM .
I .24* Coolant Pump

1.249 Thermostat .
I. Fan Drive Housing
1.251 FLYWHEEL AND HOUSING
1.252 Limits for flywheel • ‘run out” and alignment (total indicator reiKling) .
1253 ELECTRICAL EQUIPMENT .
1,254 Alternator
1.255 Starter Motor
1.256 cold stut Aid
TORQUE SPECIFICATIONS .
SPECIAL TOOLS