Xtreme Manufacturing XR842/XR1045 Cummins T4F/ZF Service Manual
Type of machine: Forklift
Print No: 24961-000, August 2017
Language and Format: English/PDF
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The Service Manual will give you complete information on repair, servicing and preventative maintenance, for your Xtreme Manufacturing XR842/XR1045 Cummins T4F/ZF Forklift.
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Table of contents:
SECTION 1 – GENERAL INFORMATION
SECTION 2 – MAINTENANCE
SECTION 3 – TIRES & WHEELS
1-1 LUBRICANTS AND FLUIDS
1-2 TORQUE WRENCH USE
1-3 CAP SCREW TORQUE VALUES
2-1 PERIODIC MAINTENANCE
2-2 GREASE POINTS
3-1 CHECK WHEEL LUG NUT TORQUE
3-2 INSPECT WHEEL/TIRE ASSEMBLY
3-3 REPLACE WHEEL/TIRE ASSEMBLY
SECTION 4 – HYDRAULIC SYSTEM
4-1 GENERAL MAINTENANCE SAFETY
4-2 HYDRAULICS MAINTENANCE SAFETY AND PRECAUTIONS
4-3 HANDLING HYDRAULIC FLUID
4-4 MAKING LEAK-FREE CONNECTIONS
4-5 HOSE AND TUBING INSTALLATION PRACTICES
4-6 OPERATING CONDITIONS
4-7 MAINTENANCE PRACTICES
4-8 KEEPING THE HYDRAULIC SYSTEM CLEAN
4-9 CHECK HYDRAULIC FLUID LEVEL
4-10 CHANGE HYDRAULIC FLUID
4-11 REPLACE SUCTION STRAINER
4-12 CLEAN HYDRAULIC RESERVOIR STRAINER
4-13 REPLACE AIR BREATHER
4-14 REPLACE HIGH-PRESSURE FILTER
4-15 REPLACE RETURN LINE FILTER
4-16 TAKING HYDRAULIC FLUID SAMPLE
4-17 REPLACING A HOSE
4-19 REPLACE CARTRIDGE VALVE SOLENOID
4-19-1 LOCATION OF HYDRAULIC COMPONENTS
4-19-2 DISTRIBUTION MANIFOLD HOSE CONNECTIONS
SECTION 5 – ENGINE
5-1 GENERAL MAINTENANCE SAFETY
5-2 BATTERY DESCRIPTION
5-3 BATTERY CABLE DESCRIPTION
5-4 CHECK CONDITION OF BATTERY AND CABLES
5-5 REPLACE BATTERY
5-6 INSPECT AND CLEAN BATTERY
5-7 INSTALL AUXILIARY BATTERY
5-8 ELECTRICAL CENTER ASSEMBLY
5-9 REPLACE A FUSE
SECTION 6 – BOOM & ATTACHMENTS
6-1 GENERAL MAINTENANCE SAFETY
6-2 USING A GREASE GUN
6-3 BOOM AND ATTACHMENT LUBRICATION
6-4 LUBRICATE BOOM EXTEND CHAIN
6-5 INSPECT BOOM CHAINS
6-5-1 CHAIN NOMENCLATURE
6-5-2 VISUALLY INSPECT CHAIN
6-5-3 MEASURE CHAIN EDGE WEAR
6-5-4 MEASURE CHAIN ELONGATION
6-6 CHECK AND ADJUST BOOM CHAIN TENSION
6-7 SLIDE BLOCKS
6-8 INSPECT SLIDE BLOCKS
6-9 REPLACE SLIDE BLOCKS
6-10 INSPECT BOOM ROLLERS
6-11 FORK NOMENCLATURE
6-12 MEASURE FORK FLANK WEAR
6-13 FORK INSPECTION
6-14 MANUALLY RETRACT AND LOWER BOOM
SECTION 7 – CHECK-OUT PROCEDURES
7-1 CHECK OPERATION OF REAR AXLE STABILIZATION SYSTEM
SECTION 8 – STORAGE & TRANSPORT
8-1 GENERAL MAINTENANCE SAFETY
8-2 PREPARING ENGINE FOR LONG-TERM STORAGE
8-3 PREPARING FORKLIFT FOR LONG-TERM STORAGE
8-4 TRANSPORTING FORKLIFT
SECTION 9 – ELECTRICAL SYSTEM
9-1 GENERAL INFORMATION
9-2 ENGINE COMPONENTS DESCRIPTION
9-3 ENGINE IDENTIFICATION
9-4 ENGINE COMPONENTS
9-5 ENGINE MODEL IDENTIFICATION
9-6 GENERAL SERVICE INFORMATION
9-7 GENERAL ENGINE CARE
9-8 SCR GENERAL INFORMATION
9-9 ENGINE INDICATORS
9-10 ENGINE OPERATION
9-11 ECM
9-12 DIAGNOSTIC FAULT CODES
9-13 DIRECT FLOW AIR CLEANER
9-14 ENGINE MAINTENANCE
9-15 SYSTEM OPERATION REPORT
9-16 UNUSUAL SYSTEM NOISE
9-17 WATER FUEL SEPARATOR
9-18 OIL CHECK
9-19 COOLANT CHECK
9-20 COOLING FAN INSPECT
9-21 POLY-VEE BELT MAINTENANCE CHECK
9-22 MECHANICAL RESTRICTION INDICATOR CHECK
9-23 EJECTION VALVE MAINTENANCE CHECK
9-24 DEF MAINTENANCE CHECK
9-25 CHARGE AIR COOLER MAINTENANCE CHECK
9-26 LUBRICATING OIL DRAIN
9-27 OIL FILTER
9-29 BATTERY
9-28 DRIVE BELT TENSIONER
9-29 DRIVE BELT TENSIONER
9-30 FUEL FILTER
9-31 COOLING SYSTEM
9-32 AFTERTREATMENT
9-33 VALVE CLEARANCE ADJUSTMENT
9-34 ALTERNATOR
9-35 THERMOSTAT
9-36 COOLING FAN DRIVE BELT
9-37 AIR FILTER
9-38 RT045 / XR1045 FILTER REPLACEMENT
9-39 ROTATION CHECK
9-40 STARTER MOTOR
9-41 FLOW DIAGRAMS – ENGINE
9-41-1 ENGINE FUEL FLOW DIAGRAM
9-41-2 ENGINE OIL FLOW DIAGRAM
9-41-3 ENGINE COOLANT FLOW DIAGRAM
9-41-4 ENGINE INTAKE AIR FLOW DIAGRAM
9-41-5 EXHAUST SYSTEM FLOW DIAGRAM
9-41-6 COMPRESSED AIR FLOW DIAGRAM
9-41-7 AFTERTREATMENT SYSTEM FLOW DIAGRAM
9-42 TROUBLESHOOTING
9-43 ENGINE SPECIFICATIONS
9-44 CUMMINS, INC. WARRANTY – ALL ENGINES (US & CANADA)
9-45 CUMMINS, INC. WARRANTY – ALL ENGINES (INTERNATIONAL)
9-46 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT, OFF-HIGHWAY
9-47 CALIFORNIA EMISSION CONTROL SYSTEM WARRANTY
SECTION 10 – TRANSMISSION
10-1 OPERATING MODE OF THE CONVERTER
10-2 POWERSHIFT TRANSMISSION
10-3 TRANSMISSION CONTROL
10-4 CONTROLLER DW-3
10-5 ELECTRONIC CONTROL UNIT TCU
10-6 ELECTRONIC CONTROLS FOR ZF POWERSHIFT TRANSMISSIONS
10-6-1 GENERAL
10-6-2 DESCRIPTION OF BASIC FUNCTIONS
10-6-3 AUTOMATIC CALIBRATION OF SHIFTING ELEMENTS (AEB)
10-6-4 ELECTRICAL INCHING
10-7 DESCRIPTION OF THE FAULT CODES FOR ERGO-CONTROL
10-7-1 ABBREVIATIONS
10-7-2 ZF – DISPLAY
10-7-3 DISPLAY DURING OPERATION
10-7-4 DISPLAY DURING AEB-MODE
10-7-5 DISPLAY DURING INCHPEDAL CALIBRATION
10-7-6 DEFINITION OF OPERATING MODES
10-8 TRANSMISSION MAINTENANCE
10-8-1 OIL GRADE
10-8-2 OIL LEVEL CHECK (MEASUREMENTS ONLY WITH RUNNING ENGINE) 10-8-3 OIL AND FILTER CHANGE INTERVALS
10-9 ZF-DIAGNOSIS SYSTEMS
10-10 LAPTOP-VERSION ZF-TESTMAN
10-11 ZF-MULTI-SYSTEM 5060
10-12 CONFIGURATION 3 WG-94 EC
10-13 INSTALLATION SHEET 3 WG-94 EC – DIRECT MOUNT – FRONT VIEW
10-14 INSTALLATION SHEET 3 WG-94 EC – DIRECT MOUNT – REAR VIEW
10-15 MEASURING POINTS, VALVES AND CONNECTIONS 3 WG-94 EC
10-16 OIL CIRCUIT DIAGRAM 3WG-94 EC-1ST GEAR FORWARD
10-17 POWER FLOW 3 WG-94 EC – FORWARD/REVERSE GEARS
10-18 CONTROLLER DW-3
10-19 3 WG-94 EC CONTROL EST-65 WIRING DIAGRAM
10-20 FAULT CODES FOR ERGOPOWER S WITH ZF TCU EC3A
10-20-1 INTRODUCTION
10-20-2 DEFINITION OF OPERATING MODES
10-20-3 NOTE REGARDING IGNITION KEY CYCLES
10-20-4 FAULT CODES
10-21 MEASURING THE RESISTANCE AT ACTUATOR/SENSORS AND CABLE
SECTION 11 – FRONT AXLE
11-1 OIL GRADE
11-2 OIL CHANGE
11-3 CONTROL OF STEERING ROD AND TIE ROD JOINTS
11-4 SERVICE BRAKE – BRAKE WEAR MEASUREMENT MS-T3060 II
SECTION 12 – REAR AXLE
12-1 OIL GRADE
12-2 OIL CHANGE
12-3 CONTROL OF STEERING ROD AND TIE ROD JOINTS
12-4 SERVICE BRAKE – BRAKE WEAR MEASUREMENT
MS-T 3045 II / MS-T 3055 II
APPENDIX – MAINTENANCE FORMS AND SAFETY TAGS
A-1 Preventive Maintenance and History Logs
A-2 Pre-Operation Checklist
A-3 Safety Tags
Maintenance Schedule
Maintenance History Log
Fork Inspection Log
Pre-Operation Checklist
Grease Fittings List
Danger Tags
Condition Tags
Notes