Xtreme Forward Reach Forklift Xr4030 Parts Manual

Full download: http://manualplace.com/download/xtreme-forward-reach-forklift-xr4030-parts-manual/

2X
8

1415 W. Bonanza Rd Las Vegas, NV 89106 702-636-2969 www.XMFG.com

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XR4030

Table of Contents
Description Page No.
SECTION 1 - GENERAL INFORMATION 2
SECTION 2 - CHASSIS 6
SECTION 3 - LABELS 32
SECTION 4 - ENGINE 45
SECTION 5 - TRANSMISSION, AXLES, & DRIVESHAFTS 55
SECTION 6 - STEERING, BRAKES, WHEELS, & TIRES 66
SECTION 7 - HYDRAULIC SYSTEM 75
SECTION 8 - ELECTRICAL SYSTEM 97
SECTION 9 - BOOM 111
SECTION 10 - CAB 133
SECTION 11 - ATTACHMENTS 162
INDEXES 168
ADDENDUM 194

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XR4030 Section 1 - General Information

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XR4030 Section 1 - General Information

Abbreviations and Acronyms

Term Definition
A AMPERES
ASTM AMERICAN SOCIETY FOR TESTING AND MATERIALS
AWG AMERICAN WIRE GAUGE
BHC BUTTON HEAD CAP
BKDN BREAKDOWN
DIA DIAMETER
DPDT DOUBLE-POLE, DOUBLE-THROW
FSHC FLAT SOCKET HEAD CAP
FTG FITTINGS
HHC HEX HEAD CAP
ID INSIDE DIAMETER
LG LONG
MM MILLIMETER
NHA NEXT HIGHER ASSEMBLY
NPT NATIONAL PIPE THREAD
OD OUTSIDE DIAMETER
OHM OVAL HEAD MACHINE
PHM PAN HEAD MACHINE
PWH PAN WASHER HEAD
QD QUICK-DISCONNECT
REF REFERENCE
REG REGULAR
SAE SOCIETY OF AUTOMOTIVE ENGINEERS
SBHC SOCKET BUTTON HEAD CAP
SHC SOCKET HEAD CAP
SHS SOCKET HEAD SHOULDER
SPDT SINGLE-POLE, DOUBLE-THROW
SPST SINGLE-POLE, SINGLE-THROW
STR STRAIGHT
THD THREAD
UNC UNIFIED NATIONAL COARSE
UNF UNIFIED NATIONAL FINE
V VOLTS

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XR4030 Section 1 - General Information
Numerical List of Parts Breakdowns
Figure No. Description Page No.
2-1 FINAL ASSEMBLY 7
2-2 CHASSIS ASSEMBLY - CAB & COVERS 9
2-3 CHASSIS ASSEMBLY - ENGINE 15
2-4 CHASSIS ASSEMBLY - AXLES 23

3-1 LABELS AND LOAD CHARTS 33

4-1 ENGINE TRANSMISSION ASSEMBLY 46

4-2 RADIATOR ASSEMBLY 50
4-3 AIR CLEANER ASSEMBLY 52
4-4 FUEL TANK ASSEMBLY 54

5-1 TRANSMISSION & PUMP ASSEMBLY 56

5-2 FRONT AXLE ASSEMBLY 59
5-3 REAR AXLE ASSEMBLY 61
5-4 FRONT DRIVESHAFT ASSEMBLY 64
5-5 REAR DRIVESHAFT ASSEMBLY 65

6-1 STEERING COLUMN ASSEMBLY 67

6-2 STEER CYLINDER ASSEMBLY 68
6-3 STEERING SENSOR ASSEMBLY 69
6-4 BRAKE RETURN MANIFOLD ASSEMBLY 70
6-5 BRAKE RETURN FILTER ASSEMBLY 71
6-6 BRAKE CHARGE VALVE ASSEMBLY 72
6-7 ACCUMULATOR ASSEMBLY 73
6-8 WHEEL TIRE ASSEMBLY 74

7-1 HYDRAULIC TANK ASSEMBLY 76

7-2 HYDRAULIC TANK LID ASSEMBLY 77
7-3 HIGH-PRESSURE FILTER / STEERING VALVE ASSEMBLY 78
7-4 DISTRIBUTION MANIFOLD ASSEMBLY 79
7-5 ISOLATION MANIFOLD ASSEMBLY 81
7-6 BOOM MANIFOLD ASSEMBLY 83
7-7 FORK POSITIONING MANIFOLD ASSEMBLY 84
7-8 OPERATOR CONTROL VALVE ASSEMBLY 85
7-9 FRONT HANDLE ASSEMBLY 87
7-10 SWAY HANDLE ASSEMBLY 88
7-11 MASTER CYLINDER ASSEMBLY 89
7-12 LIFT CYLINDER ASSEMBLY 90
7-13 EXTEND CYLINDER ASSEMBLY 91

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XR4030 Section 1 - General Information
Numerical List of Parts Breakdowns
Figure No. Description Page No.
7-14 EXTEND CYLINDER HOUSING ASSEMBLY 92
7-15 FRONT AXLE CYLINDER ASSEMBLY 93
7-16 REAR AXLE CYLINDER ASSEMBLY 94
7-17 REAR AXLE LOCK MANIFOLD ASSEMBLY 96

8-1 ELECTRICAL ASSEMBLY 98

8-2 ELECTRICAL CENTER ASSEMBLY 101
8-3 RELAY PANEL ASSEMBLY 102
8-4 TERMINAL STRIP ASSEMBLY 104
8-5 TERMINAL STRIP ASSEMBLY 105
8-6 TERMINAL STRIP ASSEMBLY 106
8-7 BATTERY DISCONNECT SWITCH ASSEMBLY 107
8-8 FUSE BLOCK ASSEMBLY 108
8-9 SOLENOID ASSEMBLY 109

9-1 BOOM ASSEMBLY 112

9-2 INNER BOOM ASSEMBLY 119
9-3 OUTER BOOM ASSEMBLY 126
9-4 ANGLE INDICATOR ASSEMBLY 129
9-5 SLIDE BLOCK ASSEMBLY 130
9-6 OUTER BOOM ROLLER ASSEMBLY 131
9-7 ROLLER ASSEMBLY 132

10-1 CAB ASSEMBLY 134

10-2 FRONT CONTROL CONSOLE ASSEMBLY 141
10-3 FRONT CONTROL PANEL ASSEMBLY 145
10-4 CONTROL ENCLOSURE SUBASSEMBLY 146
10-5 CONTROL VALVE COVER ASSEMBLY 147
10-6 CONTROL VALVE COVER SUBASSEMBLY 149
10-7 ACCELERATOR PEDAL ASSEMBLY 150
10-8 FRONT COVER ASSEMBLY 151
10-9 ENGINE COVER ASSEMBLY 153
10-10 RADIATOR COVER ASSEMBLY 155
10-11 BATTERY COVER ASSEMBLY 157
10-12 REAR LIGHT ASSEMBLY 159
10-13 RADIATOR SHROUD ASSEMBLY 160

11-1 FORK POSITIONING CARRIAGE ASSEMBLY 163

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XR4030 Section 2 - Chassis

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XR4030 Section 2 - Chassis
2

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FIGURE 2-1. FINAL ASSEMBLY (32000-000)

ITEM PART NUMBER DESCRIPTION QTY
- 32000-000 FINAL ASSEMBLY -
1 32002-000 ASSY, CHASSIS CAB/COVERS 1
2 32005-000 ASSY, BOOM 4030 1
3 32095-000 ASSY, 96” ADJ CRG GRP E 1
4 27063-000 LIFT CYLINDER PIN ASSY 2
5 29728-071 KIT, HDWR-BOOM INST 1
5.1 11001-008 WASHER 1/2 SAE FLAT 4
5.2 10004-008 SCREW 1/2-13UNC HHC X 1 4
6 27076-001 PIN ASSY 2
7 32020-000 LIFT CYLINDER ASSY 2

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 XR4030 Section 2 - Chassis

2X
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7
5.1 5.2
2X
9
6 2X ONE SPACER ON EACH
SIDE OF BEARING BEFORE
INSTALLING MASTER
CYLINDER AND PIN
(BOTH SIDES OF CHASSIS)
4 2X

5.1 5.2
2X

FIGURE 2-1. FINAL ASSEMBLY (32000-000)

ITEM PART NUMBER DESCRIPTION QTY
8 32019-000 MASTER CYLINDER ASSY 2
9 32195-000 SPACER RING 4

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XR4030 6
Section 2 - Chassis

10

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

ITEM PART NUMBER DESCRIPTION QTY
- 32002-000 CHASSIS ASSEMBLY - CAB & COVERS -
1 32003-000 ASSY, ENGINE INSTALL 1
2 32013-000 ASSY, ENCLOSED CAB 4030 1
3 32107-000 BRKT, HOSE SEAL/CLAMP 2
4 25758-001 FRONT COVER ASSY 1
5 13552-001 DRAW LATCH (REF 13552-000) 1
6 29708-000 ASSY, ENGINE COVER 1270 TIER IV 1
7 32017-000 ASSY, RAD SHROUD 4030 1
8 25843-003 ASSY, RADIATOR COVER TIER IV 1
9 26998-000 BATTERY COVER ASSY 1

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 XR4030 Section 2 - Chassis

7 1

10

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

ITEM PART NUMBER DESCRIPTION QTY
10 29010-000 HYDRAULIC TANK ASSY 1
11 27524-003 ASSY, CONTROL VALVE COVER 1
12 27121-000 ISOLATER RETAINER PLATE 4
13 25064-018 KIT, HDWR-HYD TANK 1
13.1 11001-008 WASHER 1/2 SAE FLAT 4
13.2 10004-024 SCREW 1/2-13UNC HHC X 3 4
14 11252-001 GAS SPRING 2
15 11253-000 BALL END-GAS SPRING 2
16 29725-024 KIT, HDWR-CAB 1
16.1 11001-020 WASHER 1-1/4 SAE FLAT 6

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XR4030 Section 2 - Chassis
17.2 6X
1 6X 17.1
REF
7
REF

6
REF

8
REF

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

ITEM PART NUMBER DESCRIPTION QTY
16.2 10909-020 NUT 1-1/4-12UNF HEX LOCK REG 2
16.3 10031-040 SCREW 1-1/4 12 UNF HHC GR8 X 5 LG 2
16.4 10031-026 SCREW 1-1/4-12 UNF HHC GR8 X 3.25 LG 2
17 29728-025 KIT, HDWR-RADIATOR SHROUD 1
17.1 11001-005 WASHER FW 0.3125 6
10
17.2 10001-005 SCREW 5/16-18UNC HHC X 5/8 REF 6
18 29728-034 KIT, HDWR-DRAW LATCH 1
12 4X
18.1 11001-003 WASHER #10 SAE FLAT 2
18.2 10253-003 SCREW #10-24 UNC PHD X 3/8” LG 13.1 4X 2
19 29728-035 KIT, HDWR-BATTERY COVER 13.2 1

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 17.2 6X

1 6X 17.1
REF
7
REF

XR4030 Section 2 - Chassis

6
REF
2
REF

4
REF

18.2 2X

10
REF 18.1 2X

12 4X

13.1 4X

13.2

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

ITEM PART NUMBER DESCRIPTION QTY
19.1 11001-003 WASHER #10 SAE FLAT 10
19.2 10908-003 NUT #10-24UNC HEX LOCK 5
19.3 10253-005 SCREW #10-24UNC PHM X 5/8 5
20 29728-036 KIT, HDWR-CONTROL PANEL 1
20.1 11001-006 WASHER 3/8 SAE FLAT ASTM 6
20.2 10002-006 SCREW 3/8-16UNC HHC X 3/4 6
21 13253-000 POWER DIST BLOCK 1
22 29728-044 KIT, HDWR HOSE GUIDE 1
22.1 11001-006 WASHER 3/8 SAE FLAT 4
22.2 10900-006 NUT 3/8-16UNC REG HEX 2

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XR4030 Section 2 - Chassis

4X 20.2

4X 20.1

2X 20.1

2X 20.2

4X 22.1

4X 22.2

2X 16.2
2X 16.1

4X 22.4
2X 16.3
2X 16.1 4X 22.5

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

ITEM PART NUMBER DESCRIPTION QTY
22.3 10002-040 SCREW 3/8-16UNC HHC x 5 2
22.4 11001-005 WASHER FW 0.3125 8
22.5 10908-005 NUT 5/16-18 UNC HEX LOCK REG 4
22.6 10002-013 HBOLT 0.3750-16x1.625x1-N 4

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 XR4030 Section 2 - Chassis
8
REF

9
REF

5X 19.2

5X 19.1

5X 19.1
19.3 5X

22.6 4X

22.4 4X

22.3 4X

1 22.1 4X
3 2X
4X 22.4
2X 16.3
4X 22.5
2X 16.1

2X 16.4

FIGURE 2-2. CHASSIS ASSEMBLY - CAB & COVERS (32002-000)

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XR4030 Section 2 - Chassis

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FIGURE 2-3. CHASSIS ASSEMBLY - ENGINE (32003-000)

ITEM PART NUMBER DESCRIPTION QTY
- 32003-000 CHASSIS ASSEMBLY - ENGINE -
1 32004-000 ASSY, CHASSIS AXLES/VALVES/CYL’S 1
2 12353-000 ISOLATOR MOUNT - ENGINE/TRANS 4
3 32117-000 PLATE, HEAT SHIELD 1
4 12350-000 ISOLATOR MOUNT 2
5 32063-000 PLATE, EXHAUST MNT 1
6 A13964-011 PERKINS TIER IV SECONDARY FUEL FILTER 1
7 A13964-013 FUEL FILTER PERKINS IN-LINE 1
8 A14112-010 FILTER, TRANS REMOTE MNT 1
9 32102-000 BRKT, TRANS FILTER 1

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XR4030 Section 2 - Chassis
1

13

FIGURE 2-3. CHASSIS ASSEMBLY - ENGINE (32003-000)

ITEM PART NUMBER DESCRIPTION QTY
10 32166-000 ASSY, VALVE TRANS HI/LO SHIFT 1
11 32116-000 COVER, ACCESS A/T CONN 1
12 32120-000 PIPE, EXHAUST 1
13 32012-000 ASSY, ENGINE-PERKINS 173 HP 1
14 32106-000 BRKT, AFTER TREATMENT 1
15 14401-001 ASSY, AFTER TREATMENT 1
16 32174-000 ASSY, FUEL FILTER 1
17 29728-019 KIT, HDWR-AFTER TREATMENT 1
17.1 11001-008 WASHER 1/2 SAE FLAT 6
17.2 11001-005 WASHER FW 0.3125 2

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XR4030 Section 2 - Chassis

1
REF

22

30

13
REF
31

23.1

22

23.2

12

FIGURE 2-3. CHASSIS ASSEMBLY - ENGINE (32003-000)

ITEM PART NUMBER DESCRIPTION QTY
17.3 11001-006 WASHER 3/8 SAE FLAT 3
17.4 11015-011 WASHER M10 FLAT METRIC 4
17..5 10405-030 SCREW M10-1.5 HHC X 30mm LG 4
17.6 10001-005 SCREW 5/16-18UNC HHC X 5/8 2
17.7 10004-009 HBOLT 0.5000-13x1.125x1.125-N 6
17.8 10002-006 SCREW 3/8-16UNC HHC X 3/4 3
18 29728-020 KIT, HDWR-ENG ACCESS 1
18.1 11015-011 WASHER M10 FLAT METRIC 4
18.2 10405-016 SCREW M10-1.50m HHC X 16mm 4
18.3 11001-006 WASHER 3/8 SAE FLAT 10

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Xtreme Forward Reach Forklift Xr4030 Parts Manual
Full download: http://manualplace.com/download/xtreme-forward-reach-forklift-xr4030-parts-manual/
XR4030 Section 2 - Chassis

30
2X 34
18.2 18.1
9

24.3 18.5

24.1

18.3
13
REF

10

16

18.6

18.3

24.1 18.3

18.4
24.2

8
18.3 18.4

FIGURE 2-3. CHASSIS ASSEMBLY - ENGINE (32003-000)

ITEM PART NUMBER DESCRIPTION QTY
18.4 10908-006 NUT 3/8-16UNC HEX LOCK REG 8
18.5 10002-011 SCREW 3/8-16UNC X 1-3/8 REG HEX 2
18.6 10002-008 SCREW 3/8-16UNC HHC X 1 2
18.7 11001-004 PREFERRED NARROW FW 0.25 2
18.8 10901-004 NUT 1/4-28UNF REG HEX 1
18.9 10002-007 SCREW 3/8-16UNC HHC X 7/8 GR8 2
18.10 10002-010 SCREW 3/8-16UNC HHC X 1-1/4 4
19 29728-003 KIT, HRDWR-TRANS ISOLATOR 2
19.1 11001-006 WASHER 3/8 SAE FLAT 8
19.2 10908-006 NUT 3/8-16UNC HEX LOCK REG 4

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