Xtreme Telehandler XR842 Forklift Parts Manual – PDF DOWNLOAD

Xtreme Telehandler XR842 Forklift Parts Manual – PDF DOWNLOAD

The Xtreme Telehandler XR842 Parts Manual in PDF format is essential for maintenance. Download for detailed insights into genuine replacement parts, ensuring effective repairs, and optimal forklift performance. Vital for comprehensive guidance in servicing your equipment.

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Xtreme Telehandler XR842 Forklift Parts Manual – PDF DOWNLOAD

Language : English
Pages : 793
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Xtreme Telehandler XR842 Forklift Parts Manual – PDF DOWNLOAD

GENERAL INFORMATION 9
XR842 GENERAL INFORMATION 9
COMPONENT IDENTIFICATION 13
XR842 COMPONENT IDENTIFICATION 13
CHASSIS 14
FUEL TANK ASSEMBLY, T4F CU 14
FUEL TANK ASSEMBLY, T4F 16
FUEL TANK ASSEMBLY 18
FUEL TANK ASSEMBLY, T3 20
BOOM 22
BOOM ASSEMBLY 22
OPTION – SOLARGIZER 12V ALDEN 27
INNER BOOM ASSEMBLY 31
MID BOOM ASSEMBLY 34
OUTER BOOM ASSEMBLY 40
ANGLE INDICATOR ASSEMBLY 43
ADAPTER ASSEMBLY 45
OUTER BOOM ROLLER ASSEMBLY 47
ROLLER ASSEMBLY 49
ROLLER ASSEMBLY 51
MID ROLLER ASSEMBLY 53
CHAIN SHEAVE ASSEMBLY 55
CHAIN SHEAVE ASSEMBLY 57
SLIDE BLOCK ASSEMBLY 59
TUBE CLAMP ASSEMBLY #2 61
HOSE CLAMP ASSEMBLY 63
ENGINE 65
CHASSIS ASSEMBLY – ENGINE ZF XR842 65
CHASSIS ASSEMBLY – ENGINE T3 ZF XR842 71
CHASSIS ASSEMBLY WITH ENGINE XR842 T4F 77
842 CHASSIS ASSEMBLY – ENGINE, T3-T4i 83
842 ASSEMBLY, ENGINE/TRANSMISSION, T3 91
ENGINE / TRANSMISSION ASSEMBLY CU 74HP 3 8 T3 12 V 96
ENGINE/TRANSMISSION ASSEMBLY 101
842 ASSEMBLY, ENGINE / TRANSMISSION, T4I 108
842 ASSEMBLY, ENGINE / TRANSMISSION, T4I WITH A/C 113
842 CHASSIS ASSEMBLY – ENGINE, PK T4F 116
ENGINE, 854 PERKINS, T4F 122
Cylinder Head Cover Base, Perkins 1104 126
Water Pump Kit, Perkins 1104 128
Alternator, Bracket and Fixings, Perkins 1104 130
TIMING CASE COVER, Perkins 1104 132
LEAK-OFF PIPES, Perkins 1104 134
TURBOCHARGER, Perkins 1104 136
FUEL LEAK OFF PIPES, Perkins 1104 138
LOW PRESSURE FUEL PIPES, Perkins 1104 140
FUEL FILTER, Perkins 1104 142
GLOW PLUGS, Perkins 1104 144
PIPEWORK AND CONNECTIONS, Perkins 1104 146
Flywheel Housing, Perkins 1104 148
FLYWHEEL ASSY, Perkins 1104 150
Cylinder Head Cover, Perkins 1104 152
Fuel Rail, Perkins 1104 154
High Pressure Fuel Pump, Perkins 1104 156
CRANKSHAFT SPEED SENSOR, Perkins 1104 158
Engine Control Module, Perkins 1104 160
INJECTOR ASSY, Perkins 1104 162
Rocker Arm Assy, Perkins 1104 164
REAR END OIL SEAL, Perkins 1104 166
Cylinder Head Assembly, Perkins 1104 168
ALTERNATOR, 854 PERKINS 170
DEF TANK, 854 PERKINS 172
Starter Motor 174
Fuel Pre-Lift Pump, 854 PERKINS 176
INJECTOR ASSY, 854 PERKINS 178
Dipstick & Tube 180
Cylinder Head Cover, 854 Pk 182
Water Outlet Housing, 854 PERKINS 184
Clean Emissions Module, 854 PERKINS 186
Breather, 854 Pk 188
Injector, Cummins 190
Injector Plumbing, Cummins 192
Turbocharger Assembly 194
Aftertreatment Device 196
Oil Pan 198
Lubricating Oil Pump, Cummins 200
Air Intake Manifold, Cummins 202
Fuel Plumbing, Cummins 204
Fuel System Accessories, Cummins 206
Engine Oil Cooler, Cummins 208
Engine Control Module, Cummins 210
Valve Cover, Cummins 212
Water Pump Drive, Cummins 214
Belt Tensioner, Cummins 216
COOLER ASSEMBLY, 854 PK 218
RADIATOR ASSEMBLY 220
RADIATOR SHROUD ASSEMBLY 222
RADIATOR SHROUD ASSEMBLY, T4F 224
RADIATOR SHROUD ASSEMBLY T-4 226
RADIATOR SHROUD ASSEMBLY, T4F CUMMINS 228
OVERFLOW TANK ASSEMBLY 230
EXPANSION TANK ASSEMBLY 232
AIR CLEANER ASSEMBLY, 854 PERKINS T4F 234
AIR CLEANER ASSEMBLY, CUMMINS 237
AIR CLEANER ASSY 239
SCR/FLEX PIPE/SENSOR TUBE ASSEMBLY, T4F PERKINS 241
A/C COMPRESSOR SUB ASSEMBLY 243
CABIN AND COVERS 245
CAB MOUNTING ASSEMBLY, CUMMINS T4F WITH ENCLOSED CAB AND A/C 245
FINAL ASSEMBLY WITH ENCLOSED CAB AND A/C – Perkins T4F 249
FINAL ASSEMBLY WITH ENCLOSED CAB AND A/C – 854 Perkins T4i 252
842 FINAL ASSEMBLY, T3 255
842 FINAL ASSEMBLY, EARLY MODELS 257
842 BASIC (CHASSIS) ASSEMBLY: EARLY MODEL 259
CAB ASSEMBLY – OPEN XR842 261
CAB ASSEMBLY – ENCLOSED XR842 264
CAB ASSEMBLY – ENCLOSED W/AC XR842 267
ENCLOSED CAB WITH HEATER AND AIR CONDITIONING, TYP 270
842 CAB ASSEMBLY, OPEN T4i 292
842 CAB ASSEMBLY, OPEN T3 294
ENCLOSED CAB ASSEMBLY 300
COMP DOOR ASSEMBLY – NEW STYLE 309
842 BASIC (CHASSIS) ASSEMBLY, T3 311
CAB ASSEMBLY, OPEN 313
CAB ASSEMBLY 316
SEAT ASSEMBLY 322
FRONT CONTROL ASSEMBLY 324
FRONT CONSOLE ASSEMBLY 326
FRONT CONSOLE ASSEMBLY TIER 4 FINAL 328
FRONT CONTROL CONSOLE ASSEMBLY, T4F ZF 331
FRONT CONTROL CONSOLE ASSEMBLY 335
SIDE CONTROL CONSOLE ASSEMBLY 8K>12K T4F 337
SIDE CONTROL CONSOLE ASSEMBLY 8K>12K 339
FRONT HANDLE ASSEMBLY, KAWASAKI, 12MM 341
SWAY HANDLE ASSEMBLY 343
REAR HANDLE ASSEMBLY 345
REAR HANDLE ASSEMBLY 347
ACCELERATOR PEDAL ASSEMBLY 349
ACCELERATOR PEDAL ASSEMBLY 351
ACCELERATOR PEDAL ASSEMBLY 353
842 CHASSIS ASSEMBLY – COVERS, T4I 355
842 CHASSIS ASSEMBLY- COVERS ZF 359
CHASSIS ASSEMBLY- COVERS XR842 T4F 362
SIDE CONSOLE COVER ASSEMBLY 366
SIDE CONSOLE TOP COVER ASSEMBLY 368
FRONT COVER ASSEMBLY 370
FRONT COVER ASSEMBLY, STEEL, LONG 372
FRONT COVER ASSEMBLY, PK 374
ENGINE COVER ASSEMBLY, T4i 376
ENGINE COVER ASSY – ROLLER 378
ENGINE COVER ASSEMBLY 381
ENGINE COVER ASSEMBLY, T4F PK 383
ENGINE COVER ASSEMBLY 1045 T4F ZF 385
ENGINE COVER, SUBASSEMBLYCUMMINS XR842 387
HOOD ROLLER ASSEMBLY SMALL HOOD 389
RADIATOR COVER ASSEMBLY, LARGE CUTOUTS 391
RADIATOR COVER ASSEMBLY, CUMMINS 393
BATTERY COVER ASSEMBLY 395
REAR LIGHT ASSEMBLY 397
LIGHT MOUNT ASSEMBLY 399
OPTION – TOOLBOX ASSEMBLY, PINTLE 401
OPTION, XR842-1045 FENDERS, ZF 13 X 24 TIRES 403
HYDRAULIC SYSTEM 405
HYDRAULIC PUMP ASSEMBLY 405
HYDRAULIC PUMP ASSEMBLY, HENGLI 410
TORQUE LIMITER CONTROL VALVE ASSEMBLY, HENGLI 414
CONTROL VALVE ASSEMBLY, HYDRAULIC PUMP, HENGLI 416
PUMP SEALS SERVICE KIT, HYDRAULIC PUMP, HENGLI 418
HYDRAULIC TANK ASSEMBLY 420
HYDRAULIC TANK ASSEMBLY 422
HYDRAULIC TANK ASSEMBLY 424
HYDRAULIC / DEF TANK ASSEMBLY 426
ASSEMBLY HYDRAULIC / DEF TANK PURCHASED 430
HIGH-PRESSURE FILTER / STEERING VALVE ASSEMBLY 432
DISTRIBUTION MANIFOLD ASSEMBLY 434
DISTRIBUTION MANIFOLD ASSEMBLY 437
DISTRIBUTION MANIFOLD ASSEMBLY 439
ISOLATION MANIFOLD ASSEMBLY 441
ISOLATION MANIFOLD ASSEMBLY, T3/3Flex 443
BOOM MANIFOLD ASSEMBLY 445
OPERATOR CONTROL VALVE ASSEMBLY 8K>12K T4F 447
OPERATOR CONTROL VALVE ASSEMBLY 8K>12K 449
OPERATOR CONTROL VALVE ASSEMBLY 451
MASTER CYLINDER ASSEMBLY 453
BOOM LIFT CYLINDER ASSEMBLY 455
LIFT CYLINDER ASSEMBLY 457
LIFT CYLINDER ASSEMBLY, HENGLI 459
EXTEND CYLINDER ASSEMBLY 461
EXTEND CYLINDER ASSEMBLY, HENGLI 463
EXTEND CYLINDER SUB-ASSEMBLY 465
EXTEND CYLINDER HOUSING ASSEMBLY 467
EXTEND CYLINDER COLLAR ASSEMBLY 469
EXTEND CYLINDER SUPPORT ASSEMBLY 471
LIFT CYLINDER PIN ASSEMBLY 473
LIFT CYLINDER PIN ASSEMBLY 475
MASTER CYLINDER PIN ASSEMBLY 477
MASTER CYLINDER PIN ASSEMBLY 479
EXTEND CYLINDER PIN ASSEMBLY 481
CARRIAGE TILT CYLINDER ASSEMBLY 483
CARRIAGE TILT CYLINDER SUB-ASSEMBLY 485
ROTATE CYLINDER ASSEMBLY – OPTIONAL 487
ROTATE CYLINDER SUB-ASSEMBLY 489
SWAY CYLINDER ASSEMBLY-FRONT 491
SWAY CYLINDER ASSEMBLY, FRONT AXLE 493
REAR SWAY CYLINDER ASSEMBLY – ZF 495
SWAY CYLINDER ASSEMBLY – REAR 497
SWAY CYLINDER ASSEMBLY, REAR AXLE 499
AXLE CYLINDER SUB-ASSEMBLY 501
REAR AXLE LOCK MANIFOLD ASSEMBLY 503
CHASSIS HOSE KIT, 842, T3 505
CHASSIS HOSE KIT T4 509
CHASSIS HOSE KIT, XR842 T4F 512
BOOM HOSE KIT 515
HYDRAULIC SCHEMATIC, 842 517
ELECTRICAL SYSTEM 518
OPTION BOOM LIGHTS ASSEMBLY 518
ENGINE HARNESS 74HP 3 8 CUMMINS 521
ENGINE RELAY ASSEMBLY 525
ELECTRICAL CONSOLE ASSEMBLY, T4F 527
CONSOLE – ELECTRICAL ASSEMBLY, T4I 529
FRONT CONTROL PANEL ASSEMBLY T4F 531
FRONT CONTROL PANEL ASSEMBLY 534
ELECTRICAL ASSEMBLY 536
ELECTRICAL CENTER ASSEMBLY 540
ELECTRICAL CENTER ASSEMBLY W/OR 542
STRIP TERMINAL ASSEMBLY #8 X 12 544
STRIP TERMINAL ASSEMBLY #6 X 16 546
STRIP TERMINAL ASSEMBLY #6 X 18 548
FUSE BLOCK ASSEMBLY 550
SOLENOID ASSEMBLY 552
BATTERY DISCONNECT SWITCH ASSEMBLY 554
ELECTRICAL SCHEMATIC, 854 PERKINS T4F 556
ELECTRICAL SCHEMATIC, CUMMINS QSF3 8 / ZF 560
LIGHT-RED LED ASSEMBLY 563
LIGHT – GREEN LED ASSEMBLY 565
LIGHT – AMBER LED ASSEMBLY 567
TRANSMISSIONS, AXLES, & DRIVESHAFTS 569
TRANSMISSION ASSEMBLY, ZF 3WG94 569
TRANSMISSION AND PUMP ASSEMBLY ZF 571
TRANSMISSION FILTER ASSEMBLY 573
OUTPUT ASSEMBLY 575
CONTROL UNIT 577
PRESSURE OIL PUMP 579
ENGINE CONNECTION, ZF 581
TRANSMISSION HOUSING, ZF 583
TRANSMISSION AND PUMP ASSEMBLY 585
TRANSMISSION AND PUMP ASSEMBLY T3 587
GROUP-TRANSMISSION CASE AND PLATE 589
ASSEMBLY-TORQUE CONVERTER 592
GROUP-CHARGING PUMP 593
GROUP-FORWARD & REVERSE SHAFT 596
GROUP-CONTROL 598
ASSEMBLY-DRIVE PLATE 600
842 CHASSIS ASSEMBLY – AXLES 602
CHASSIS ASSEMBLY – AXLES ZF XR842 610
842 CHASSIS ASSEMBLY – AXLES, T4I 618
842 CHASSIS ASSEMBLY – AXLES, T3 625
CHASSIS ASSEMBLY – AXLES T3 ZF XR842 629
FRONT AXLE ASSEMBLY, DANA 637
CENTRAL HOUSING 639
DIFFERENTIAL 641
TRUNNION 644
HUB REDUCTION 646
FRONT AXLE ASSEMBLY ZF 649
INPUT ASSEMBLY, FRONT AXLE, ZF 651
INPUT, FRONT AXLE, ZF 656
LIMIT SLIP DIFFERENTIAL ASSEMBLY, FRONT AXLE, ZF 658
AXLE CASING ASSEMBLY, ZF 660
JOINT HOUSING ASSEMBLY, ZF 662
JOINT HOUSING 665
STEERING LIMITER, FRONT/REAR AXLE 667
PLANETARY DRIVE ASSEMBLY, ZF 669
STEERING CYLINDER 671
REAR AXLE ASSEMBLY ZF 673
INPUT ASSEMBLY, ZF 675
DIFFERENTIAL ASSEMBLY, ZF 680
REAR AXLE ASSEMBLY, DANA 682
CENTRAL HOUSING, DANA (14610-001-A) 684
DIFFERENTIAL, DANA 686
HUB REDUCTION, REAR AXLE, DANA 688
STEERING, REAR AXLE, DANA (14610-001-E) 691
TRUNNION, REAR AXLE, DANA (14610-001-F) 693
STEERING, BRAKES, WHEELS, & TIRES 695
14609-001 _ STEERING 695
STEERING COLUMN ASSEMBLY 697
ACCUMULATOR ASSEMBLY 699
ACCUMULATOR CHARGE VALVE ASSEMBLY 701
BRAKE VALVE ASSEMBLY, MICO 703
14609-001 _ BRAKES 706
PARKING BRAKE 708
MULTI-DISK BRAKE ASSEMBLY, ZF 710
MULTI-DISK BRAKE 712
BRAKES, DANA 714
BRAKE CHARGE VALVE ASSEMBLY 716
BRAKE PRESSURE SWITCH ASSEMBLY 719
WHEEL AND TIRE ASSEMBLY 721
WHEEL AND TIRE ASSEMBLY 723
LABELS 725
LABEL KIT XR842 725
LABEL KIT XR842 ZF 733
ATTACHMENTS 741
PINTLE HOOK ASSEMBLY 741
HITCH PIN ASSEMBLY 743
BRACKET ASSEMBLY, ECM MOUNT CUMMINS 745
STANDARD CARRIAGE ASSEMBLY HEAVY-DUTY W-DBLRS 747
CARRIAGE STANDARD HD ASSEMBLY 749
CARRIAGE PIN ASSEMBLY 751
Appendix A:Pages Index 753
Appendix B:Parts Index 758