XTREME XR842/1045/1245/1254/1267 (Tier III) Forward Reach Forklift Service Manual PDF

XTREME XR842/1045/1245/1254/1267 (Tier III) Forward Reach Forklift Service Manual – PDF DOWNLOAD

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XTREME XR842/1045/1245/1254/1267 (Tier III) Forward Reach Forklift Service Manual – PDF DOWNLOAD

Language : English
Pages : 275
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

XTREME XR842/1045/1245/1254/1267 (Tier III) Forward Reach Forklift Service Manual – PDF DOWNLOAD

List of Effective Pages A
Service Bulletins B
Table of Contents i
List of Illustrations vi
List of Tables ix
SECTION 1 – GENERAL INFORMATION & SPECIFICATIONS 1-1
1-1 Scope of Manual 1-1
1-2 Applicability 1-1
1-3 Service Bulletins 1-1
1-4 Related Technical Documentation 1-2
1-5 Forklift Nomenclature 1-2
1-6 Component Data Plates 1-10
1-7 Lubricants and Fluids 1-14
1-8 Filters and Strainers 1-15
1-9 Forklift and Engine Specifications 1-16
1-10 Torque Wrench Use 1-24
1-11 Cap Screw Torque Values 1-24
SECTION 2 – MAINTENANCE & OPERATION SAFETY 2-1
2-1 General 2-1
2-2 Safety Signal Words 2-1
2-3 Notes 2-1
2-4 Safety Symbols 2-2
2-5 Lockout/Tagout Procedure 2-6
2-6 General Maintenance Precautions 2-7
2-7 Viton Seals 2-7
2-8 Using Compressed Air Safely 2-8
2-9 Battery Handling and Maintenance 2-8
2-10 Engine Operation and Maintenance 2-10
2-11 Fuel Handling and Maintenance 2-11
2-12 California Proposition 65 Warnings 2-11
2-13 Functional Tests 2-11
2-14 Safe Operation Checklist 2-12
2-15 Functional Test Checklist 2-13
2-16 Load Handling 2-14
Table of Contents Model XR842/1045/1245/1254/1267 Forklifts
Service Manual Rev 00 – (9/2/08) ii
Table of Contents – Cont
PARA TITLE PAGE
2-17 Picking Up a Load 2-16
2-18 Carrying a Load 2-16
2-19 Placing a Load 2-16
2-20 Load Shift 2-17
2-21 Proper Use of Forks 2-17
2-22 Prohibited Practices 2-17
2-23 Operator Hand Signals 2-18
2-24 Safety Decals 2-19
SECTION 3 – MAINTENANCE SCHEDULE 3-1
3-1 Establishing a Preventive Maintenance Program 3-1
3-2 Long-Interval Maintenance Requirements 3-5
SECTION 4 – AXLE CYLINDER AND OUTRIGGER LUBRICATION 4-1
4-1 General Maintenance Safety 4-1
4-2 Using a Grease Gun 4-1
4-3 Lubricate Axle Cylinders and Outriggers 4-2
SECTION 5 – ENGINE 5-1
5-1 General Maintenance Safety 5-1
5-2 Check Engine Oil Level 5-1
5-3 Check Engine Coolant Level 5-3
5-4 Check for Oil and Coolant Leaks 5-5
5-5 Check for Water in Fuel-Water Separator 5-6
5-6 Empty Air Filter Dust Cup 5-8
5-7 Check Condition and Tension of Drive Belts 5-10
5-8 Change Engine Oil 5-10
5-9 Replace Oil Filter 5-13
5-10 Replace Fuel Filter 5-15
5-11 Check Specific Gravity of Coolant 5-17
5-12 Drain and Flush Cooling System 5-19
5-13 Replace Air Filter 5-21
5-14 Check Air Filter 5-23
5-15 Check Condition and Tension of Drive Belts 5-24
5-16 Check and Adjust Valve Tip Clearances 5-26
5-17 Check Engine Hoses and Connections 5-28
Table of Contents Model XR842/1045/1245/1254/1267 Forklifts
Service Manual Rev 00 – (9/2/08) iii
Table of Contents – Cont
PARA TITLE PAGE
5-18 Check Radiator Hoses and Connections 5-29
5-19 Check Engine Wiring and Connections 5-30
5-20 Check for Oil, Coolant, and Fuel Leaks 5-31
SECTION 6 – TRANSMISSION, AXLES, & DRIVE SHAFTS 6-1
6-1 General Maintenance Safety 6-1
6-2 Using a Grease Gun 6-1
6-3 Lubricate Axle Grease Fittings 6-2
6-4 Lubricate Drive Shafts 6-4
6-5 Replace Transmission Filters and Fluids (XR1045/1245/1254) 6-6
6-6 Replace Transmission Filters and Fluids (XR842/1267) 6-8
6-7 Check Axle Oil Level 6-10
6-8 Check Wheel-End Oil Level 6-12
6-9 Drain and Fill Axle Wheel-End 6-14
SECTION 7 – WHEELS & TIRES 7-1
7-1 General Maintenance Safety 7-1
7-2 Check Wheel Lug Nut Torque 7-1
7-3 Inspect Wheel/Tire Assembly 7-3
7-4 Replace Wheel/Tire Assembly 7-4
7-5 Replace Tire 7-7
SECTION 8 – HYDRAULIC SYSTEM 8-1
8-1 General Maintenance Safety 8-1
8-2 Hydraulics Maintenance Safety and Precautions 8-1
8-3 Handling Hydraulic Fluid 8-2
8-4 Making Leak-Free Connections 8-2
8-4-1 Hose and Tubing Installation Practices 8-2
8-4-2 Operating Conditions 8-2
8-4-3 Maintenance Practices 8-3
8-5 Keeping the Hydraulic System Clean 8-4
8-6 Check Hydraulic Fluid Level 8-6
8-7 Change Hydraulic Fluid 8-8
8-8 Replace Suction Strainer 8-10
8-9 Clean Hydraulic Reservoir Strainer 8-13
8-10 Replace Air Breather 8-15
8-11 Replace High-Pressure Filter 8-17
Table of Contents Model XR842/1045/1245/1254/1267 Forklifts
Service Manual Rev 00 – (9/2/08) iv
Table of Contents – Cont
PARA TITLE PAGE
8-12 Replace Return Line Filter 8-20
8-13 Taking Hydraulic Fluid Sample 8-22
8-14 Replacing a Hose 8-25
8-15 Tightening Loose Fittings 8-28
8-16 Replace Cartridge Valve 8-28
8-17 Replace Cartridge Valve Solenoid 8-31
8-18 Location of Hydraulic Components 8-33
8-19 Distribution Manifold Hose Connections 8-33
8-20 Maintenance Requirements for Failed Pump 8-50
SECTION 9 – ELECTRICAL SYSTEM 9-1
9-1 General Maintenance Safety 9-1
9-2 Battery Safety 9-1
9-3 Battery Description 9-3
9-4 Battery Cable Description 9-3
9-5 Check Condition of Battery and Cables 9-3
9-6 Replace Battery 9-4
9-7 Inspect and Clean Battery 9-7
9-8 Install Auxiliary Battery 9-9
9-9 Electrical Center Assembly 9-11
9-10 Engine Relay Assembly 9-16
9-11 Replace a Relay 9-18
9-12 Replace a Fuse 9-20
SECTION 10 – BOOM & ATTACHMENTS 10-1
10-1 General Maintenance Safety 10-1
10-2 Using a Grease Gun 10-1
10-3 Boom and Attachment Lubrication 10-2
10-4 Lubricate Boom Extend Chain 10-6
10-5 Inspect Boom Chains 10-7
10-5-1 Chain Nomenclature 10-8
10-5-2 Visually Inspect Chain 10-8
10-5-3 Measure Chain Edge Wear 10-11
10-5-4 Measure Chain Elongation 10-13
10-6 Check and Adjust Boom Chain Tension 10-15
10-7 Slide Blocks 10-16
10-8 Slide Block Inspection 10-16
Table of Contents Model XR842/1045/1245/1254/1267 Forklifts
Service Manual Rev 00 – (9/2/08) v
Table of Contents – Cont
PARA TITLE PAGE
10-9 Replace Slide Blocks 10-20
10-10 Inspect Boom Rollers 10-21
10-11 Fork Nomenclature 10-24
10-12 Measure Fork Flank Wear 10-26
10-13 Fork Inspection 10-28
10-14 Manually Retracting and Lowering Boom 10-29
SECTION 11 – CHECK-OUT PROCEDURES 11-1
11-1 Check Operation of Rear Axle Stabilization System 11-1
SECTION 12 – STORAGE & TRANSPORTATION 12-1
12-1 General Maintenance Safety 12-1
12-2 Preparing Engine for Long-Term Storage 12-1
12-3 Preparing Forklift for Long-Term Storage 12-4
12-4 Transporting Forklift 12-5
APPENDIX – MAINTENANCE FORMS AND SAFETY TAGS A-1
A-1 Preventive Maintenance and History Logs A-1
A-2 Pre-Operation Checklist A-1
A-3 Safety Tags A-1
Maintenance Schedule A-2
Maintenance History Log A-8
Fork Inspection Log A-11
Pre-Operation Checklist A-13
Grease Fittings List A-15
Danger Tags A-16
Condition Tags A-17
Notes A-18