Xtreme Manufacturing XR842/XR1045 Cummins T4F/ZF Service Manual

Xtreme Manufacturing XR842/XR1045 Cummins T4F/ZF Service Manual

Type of machine: Forklift
Print No: 24961-000, August 2017
Language and Format: English/PDF
Instant Download after payment. Please make sure your email address is correct.

The Service Manual will give you complete information on repair, servicing and preventative maintenance, for your Xtreme Manufacturing XR842/XR1045 Cummins T4F/ZF Forklift.

__________________
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