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Summary of Contents for Xtreme Manufacturing Snorkel XR5519
- Page 1 XR5519 SR5519 OPERATOR’S OPERATOR’S MANUAL Pre-delivery Inspection Report must be completed upon plac- ing unit in service. Please use QR link or visit www.xmfg.com/warranty/pre-delivery-inspection-report Part Number 157-0070-000 to register online. August 2017 PROTOTYPE...
- Page 2 Xtreme Manufacturing, LLC (http://www.xmfg.com/) is headquartered in Las Vegas, Nevada, and has fabrication facilities in Selma, California. In October 2013, Xtreme Manufacturing became the majority shareholder in Snorkel International Holdings LLC, a global aerial work platform manufacturer, which has manufacturing facilities in the US, UK & New Zealand, as well as a global sales distribution network.
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Page 3: Table Of Contents
XR5519 Table of Contents Table of Contents Description Page Description Page Operator Seat Introduction Operator Seat Controls General Replacement Manuals Backrest Angle Adjustment Lever Fore and Aft Adjustment Lever Model/Serial Number Plate Seat Belt Orientation Safety Rear View Mirrors Safety Disclaimer Controls and Indicators Travel Select Lever Signal Words... - Page 4 XR5519 Table of Contents Table of Contents Description Page Description Page Fuel Types Place a Load Winter Operation With Diesel Fuel Load Shift Attachments Load Capacity Charts Preventive Maintenance Attachment Disclaimer Fork Ratings Establishing a Maintenance Program Standard Carriage Operation Maintenance Schedule Quick Attach System Boom Emergency Lower Down Valve...
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Page 5: Introduction
XR5519 Introduction General Model / Serial Plate This Operation and Safety Manual provides the information When contacting our parts department, please have the needed to safely operate the SR630 Reach Forklift. forklift serial number available. The serial number plate is located in the operator’s cab, at the base of the seat. -
Page 6: Safety
XR5519 Safety Warning Safety Disclaimer WARNING (Orange) used with the safety alert symbol Snorkel Manufacturing reserves the right to make technical indicates a potentially hazardous situation which, if not changes for product improvement. This manual may contain avoided, could result in death or serious injury. illustrations and photographs (for demonstration purposes), which slightly deviate from the actual product. - Page 7 XR5519 Safety Read Operator Read Maintenance General Safety Manual Before Manual Before Alert Symbol Operating This Working On Forklift This Forklift Read Material DO NOT OPERATE! Know First Aid Safety Data Instructions And/ Forklift Down Sheets (MSDS) For Or Locations On For Service Or Chemicals And Work site...
- Page 8 XR5519 Safety DO NOT DO NOT Fasten Jump While Allow Riders Seat Dismounting On Auxiliary Belt The Forklift Attachments Set Parking DO NOT Allow DO NOT Allow Brake To OFF Riders On Forklift Riders On Or In Disengage Frame Or Fenders The Operator Cab Parking Brake Set Parking Brake...
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Page 9: Employer Responsibility
XR5519 Safety Employer Responsibility Operator Qualifications Under Occupational Safety and Health Administration (OSHA) Operators must be in good physical and mental condition, rules, employers are required to train workers about hazards with appropriate reflexes, reaction time, vision, depth related to operating and maintaining the forklift. Successful perception, and hearing. -
Page 10: Mounting/Dismounting
XR5519 Safety Warning Mounting/Dismounting • Operate the forklift only on firm, stable surfaces. Holes, Warning obstructions, debris, loose fill, and other work site hazards could result in death or serious injury. Failure to use proper safety procedures when mounting • DO NOT allow bystanders in the work area. -
Page 11: Before Starting Forklift
XR5519 Safety Warning Warning Perform a pre-operation inspection and functional tests at the beginning of each work shift. Perform the pre-operation inspection first. DO NOT perform the pre-operation inspection with the engine running or hot. Wear appropriate protective clothing. Personal protective Allow the engine and associated components to cool before equipment can include, but is not limited to hardhat, performing an inspection. -
Page 12: Operation Safety
XR5519 Safety the forklift cannot be leveled using the frame sway control, Warning do not attempt to raise or place load. Reposition forklift or have the surface leveled. Operators must be properly trained and qualified to operate this specific forklift. Warning Know the location, learn the specific purpose, and demonstrate safe and proper use of all... - Page 13 XR5519 Safety • Slow down for turns. NEVER use crab or four wheel (4W) steering for traveling at high speeds. Use only two wheel • Slow down for rough, slippery, or select terrain. (2W) steering for higher speed travel and slow •...
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Page 14: Load Safety
XR5519 Safety Load Safety DO NOT exit the forklift without following proper shut down procedures. Warning Engine fuel is flammable and Failure to follow proper safety procedures can cause a fire or explosion when lifting, lowering, and traveling with a resulting in death or serious in- load could result in death, serious injury, or jury. -
Page 15: Attachments
XR5519 Safety Attachments Forklift Maintenance Warning Warning Improper connection of an auxiliary attachment could re- Follow manufacturer’s instructions proper sult in death or serious injury. Attachments not locked into maintenance to make sure the forklift continues to meet place can become unstable and fall on the operator or other manufacturer’s specifications. -
Page 16: Jump Starting
XR5519 Safety IMPORTANT - In case of internal contact, DO NOT give fluids The parking brake can be manually released to tow the forklift. In this condition, it is pos- that induce vomiting. sible for the forklift to move suddenly when the brakes are released, which could result Warning in death, serious injury, or property damage. -
Page 17: Dead Engine Towing
XR5519 Safety Block all four wheels to prevent the vehicle from moving Dead Engine Towing once the parking brake is disabled. Position the towing vehicle in place. Attach any chain Parking Brake Release (Front Axle) needed to secure the disabled vehicle. Crawl under the front of the vehicle. -
Page 18: Labels
XR5519 Labels Labels Labels Left Side View INNER BOOM ON BOOM Fig 5. Label Legend (Left Side) Right Side View Fig 6. Label Legend (Right Side) Operation Manual... - Page 19 XR5519 Labels Labels Rear Right Quarter View Rear Left Quarter View Fig 7. Label Legend (Rear Left) Front View Cab View Fig 8. Label Legend (Front) Fig 9. Label Legend (Cab) Operation Manual...
- Page 20 XR5519 Labels Table 1. Labels Item Part No. Description Item Part No. Description 18008-000 DATA PLATE LABEL, WARNING INJECTION HAZ- 18082-100 ARD* 10010690 LOAD CHART LABEL, WARNING EXPLOSION HAZ- 18010-100 LABEL CAUTION SLIP/TRIP 18083-100 18011-001 LABEL, ENGINE DAMAGE 18086-100 LABEL, DEXRON III 18013-002 LABEL, DIESEL ONLY LOW SULFUR 18086-101...
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Page 21: Replacement Labels
XR5519 Labels Replacement Labels Replacement labels can be obtained by contacting Snorkel Manufacturing at (800) 497-1704. Please have the appropri- ate label number available when you call. 2) 10010690 1) 18008-000 18010-100 3) 18010-100 4) 18011-001 CHECK DIESEL ONLY ENGINE OIL Ultra Low Sulphur Fuel Only Minimum Oil Specification:... - Page 22 XR5519 Labels 18016-100 7) 18015-001 8) 18016-100 18018-100 9) 18017-001 10) 18018-100 18019-100 11) 18018-002 12) 18019-100 Operation Manual...
- Page 23 XR5519 Labels 18020-100 18021-100 13) 18020-100 14) 18021-100 15) 18022-001 16) 18023-001 18025-100 18026-100 17) 18025-100 18) 18026-100 Operation Manual...
- Page 24 XR5519 Labels 19) 18027-001 WARNING 20) 18031-001 18041-100 21) 18032-001 22) 18041-100 18082-100 18083-100 23) 18082-100 24) 18083-100 Operation Manual...
- Page 25 XR5519 Labels 18086-100 25) 18086-100 18086-101 26) 18086-101 18090-100 27) 18090-100 28) 18043-000 30) 18046-000 29) 18044-000 31) 18047-000 32) 18048-000 Operation Manual...
- Page 26 XR5519 Labels 18400-003 33) 18049-000 34) 18400-003 36) 18233-000 35) 18232-000 37) 18300-001 38) 18312-000 18314-000 18315-000 39) 18314-000 40) 18315-000 Operation Manual...
- Page 27 XR5519 Labels 18402-000 41) 18402-000 CONTROL BOOM BOOM FORK TILT RETRACT EXTEND DOWN SWAY SWAY LEFT RIGHT FORK TILT CONTROL JOYSTICK ENABLE 18408-001 42) 18408-001 CAUTION EQUIPMENT DAMAGE Wait at least two (2) minutes after shutting engine off before setting the battery disconnect switch to OFF.
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Page 28: Features Standard Equipment
XR5519 Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Two (2) section boom Options Enclosed cab with heat Boom equipped with slide pads Enclosed cab with heat & A/C Chassis Sealed pivot pins for extended service periods Heater/defroster/windshield wiper Side mounted engine Work light package... -
Page 29: Specifications
XR5519 Specifications Specifications Performance Standard Equipment Capacity ... . 5,500 lbs Heavy-duty Frame/Chassis Lift Height ... 30’ Frame Sway Heavy-duty Boom Forward Reach . -
Page 30: Operator Cab
XR5519 Operator Cab Operator Cab Warning Accessory Outlet A brief description of controls, indicators, and A 12 Volt accessory outlet is provided as a power source for instruments is provided as a convenience for personal items, such as a radio or cell phone (10 amps max). the operator. -
Page 31: Service Brake Pedal
XR5519 Operator Cab Service Brake Pedal Horn Button Press the service brake pedal to slow or stop the forklift. The Press the horn button to sound the horn. service brake pedal activates the service brakes on the front (2) wheels. Fig 13. -
Page 32: Backrest Angle Adjustment Lever
XR5519 Operator Cab Backrest Angle Adjustment Lever Seat Belt Pull the backrest angle adjustment lever up to release the seat Warning backrest lock. Adjust the angle of the backrest and release the lever to lock the backrest to the desired angle. Always check the condition of the seat belt and mounting hardware before operating the forklift. -
Page 33: Rear View Mirrors
XR5519 Operator Cab Grasp the free end of the seat belt (located on the left side of the seat) and make sure the belt webbing is not twisted or entangled in any portion of the seat assembly. Pull the retractable seat belt across your lap. Position the seat belt as low on your body as possible. -
Page 34: Display Indicators
XR5519 Operator Cab When the transmission is in Neutral, the Transmission Shift In- Display Indicators dicator highlights (N). D. TRANSMISSION RANGE INDICATORS The display allows the operator to view vital engine information and other critical functions, including gauge The machine starts up with the transmission in High Range display, engine diagnostics to monitor engine condition and mode, and the rabbit icon is displayed at B. - Page 35 XR5519 Operator Cab NOTE: Refer to the Operation section on Warning Indicators O. OIL PRESSURE GAUGE and Fault Codes. Displays the engine oil pressure on an analog gauge. G. ENGINE WARNING P. TACHOMETER The Engine Warning Indicator will be displayed when there is Indicates engine RPM on an analog gauge.
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Page 36: Display Features
XR5519 Operator Cab AVAILABLE MAIN MENU OPTIONS Display Features • System • Measure The display allows the operator to view vital engine • Adjust information and other critical functions, including gauge • Preferences display, engine diagnostics to monitor engine condition and performance, fault codes, and warning lights. - Page 37 XR5519 Operator Cab Fig 28. Modules Fig 31. New Event Log Logs MEASURE Selecting the Logs option allows for accessing the recorded Select Measure and then scroll down through this menu to events. Thus, you may view the recorded or new event logs. view the status of various engine or machine components.
- Page 38 XR5519 Operator Cab ADJUST Adjust is a password-protected menu that enables users to change the parameter values , such as temperature, angle of sway, etc. of different machine components. Fig 36. Auxiliary Valve Parameter Adjustment NOTE: The other available selection, Auxiliary output cmd is not implemented at this time.
- Page 39 XR5519 Operator Cab SETTINGS Touching the SETTINGS button will enter a mode where the user is able to select various suitable options. The (X) button will close the menu. Fig 40. Display Themes: High Tech (Default) Fig 38. Settings Menu AVAILABLE SETTINGS OPTIONS Background: The background themes are displayed on a drop-down list.
- Page 40 XR5519 Operator Cab CAN Switches Throttle Mode: Touching the CAN Switches opens the Master Switch cluster • TSC1 OFF display, which allows for viewing the status of the Steering, • TSC1 ON Lights, and Warning clusters. Fig 43. Throttle Mode Fig 45.
- Page 41 XR5519 Operator Cab DAY/NIGHT MODE This touch button allows for selecting the brightness of the screen: brighter, appropriate for day operation or dimmer, for operating the machine at night. MACHINE OPERATION MANUAL This touch button allows for viewing of all the available oper- ation and instructional documentation related to the current machine.
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Page 42: Transmission Range Selector Switch
XR5519 Operator Cab Transmission Range Selector Switch Select the desired mode by pushing the top of this switch to engage the High Range (rabbit), or the bottom to select the Low Range (turtle). The Low Range mode is used for climbing steep grades, or whenever slow speed is desired. -
Page 43: Windshield Wiper/Washer Switch
XR5519 Operator Cab Multifunction Joystick Controller (Joystick) Windshield Wiper / Washer Switch This switch is available only on enclosed cab models. The joystick is used to raise, lower, extend, retract the boom, tilt the carriage (or attachment), and sway the machine frame. Aux Button 1 Aux Button 2 Fig 58. - Page 44 XR5519 Operator Cab Boom Control Handle Functions Function Purpose Aux Button 1 Control auxiliary direction 1 Aux Button 2 Control auxiliary direction 2 Joystick Enable Depressed enables joystick functions. Trigger If not depressed, joystick is inert Sway Enable Trigger must be enabled for frame Trigger sway function Tilt Thumbstick...
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Page 45: Boom Angle Indicator
XR5519 Operator Cab Boom Maintenance Stand (Optional) Boom Angle Indicator The boom angle indicator is located on the left side of the The Boom Maintenance Stand is used to support the boom boom and is visible from the operator’s seat. Use the boom during any and maintenance activities where the boom is angle indicator to determine the boom angle when referring raised. -
Page 46: Operation
XR5519 Operation Operation Caution Pre-Operation Inspection Contact with hot surfaces and the exhaust To perform the pre-operation inspection make sure the pipe after the forklift has been operated forklift is NOT running, the engine is cool, the forklift is parked could result in serious personal injury. - Page 47 XR5519 Operation Warning Warning Wear eye protection when starting a forklift with jump start cables. Improper jump start procedures could cause the battery to ex- plode, which could result in death or serious injury. Lead-acid batteries produce flammable and potentially ex- •...
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Page 48: Pre-Operation Inspection Checklist
XR5519 Operation Pre-Operation Inspection Checklist Walk around the ENTIRE forklift while visually performing the pre-operation inspection. Check that “Do Not Operate” tags have not been placed on the forklift. Check that load capacity charts are legible. Check condition and operation of the seat belt and mounting hardware. Check that Operation and Safety Manual is in the protective case and legible. -
Page 49: Functional Tests
XR5519 Operation Release the parking brake. Functional Tests Operate the forklift in forward and reverse. Test the service and parking brakes. Warning • Apply the service brake pedal after the forklift Perform a pre-operation inspection and func- begins to move and the forklift should stop tional tests at the beginning of each work immediately. -
Page 50: Operator Maintenance
It is possible to use other cooling system corrosion protection cause death, serious injury, or property damage. agents (e.g. chemical corrosion protection agents) in excep- tional cases. Consult your Xtreme Manufacturing or DEUTZ NOTE: Keep the Operation and safety manual in the protective partner. - Page 51 XR5519 Operation In principle, all engine oils of the same specification can be mixed. However, mixing of engine oils should be avoided be- cause the worst properties of any of the components in the mixture are always dominant, affecting the result. The following lubricating oils are permissible for the engine in this operating manual: The ambient temperature at the installation site or in the ap-...
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Page 52: Before Starting Forklift
XR5519 Operation Before Starting Forklift Warning Failure to use proper safety procedures when mounting and dismounting the forklift could result in death or serious injury. • Keep steps clear of dirt, mud, snow, ice, debris, and oth- er hazards. Face the forklift for mounting or dismount- ing. -
Page 53: Starting Forklift
XR5519 Operation Release key immediately after the engine starts. The Starting Forklift Ignition Switch will automatically return to RUN. Caution Normal Starting Release the key immediately once the engine starts. If the Warning engine does not start, DO NOT crank the starter motor con- tinuously for more than 15 seconds. -
Page 54: Forklift Travel
XR5519 Operation Two Wheel Front Steering (2W) Forklift Travel Two wheel (2W) steering allows the front wheels to turn in the same direction as the Steering Modes steering wheel. The rear wheels remain in a fixed forward position. Two wheel (2W) steering is useful for traveling at higher speeds. -
Page 55: Warning And Fault Indicators
XR5519 Operation Warning and Fault Indicators Low Fuel Level Indicator Warning Critically Low Fuel Level Warning A fault condition may trigger a popup dialog box on the display describing the nature of High Hydraulic Temperature Indicator the fault during operation. Corresponding red or amber warning lights will illuminate to indicate the severity of the fault. -
Page 56: Starting Travel
XR5519 Operation Warning Starting Travel To prevent death, serious injury, or property damage, apply service brakes until the forklift Warning comes to a complete stop, move travel select lever to NEUTRAL (N), set the Parking Brake Use proper safety procedures and avoid switch to ON (engaged), lower and retract the hazardous situations while operating the boom, and shut off the engine before exiting the forklift. -
Page 57: Refueling
XR5519 Operation If the forklift is parked on an incline, block the wheels. Warning Depending on the situation, you may choose to use California Proposition 65 the Battery Disconnect Switch. However, you should wait 2 minutes after the engine is shut down before Diesel and gasoline engine exhaust and some disconnecting the battery with the switch. -
Page 58: Attachments
XR5519 Operation Attachments Attachment Disclaimer Warning DO NOT exceed the manufacturer’s rated load for any auxiliary attachment. Any attempt to lift or carry loads in excess of the manufactur- er’s rated load may cause forklift tip over, loss of load, or structural damage which could re- sult in death, serious injury, or property damage. -
Page 59: Standard Carriage Operation
XR5519 Operation Quick Attach System Standard Carriage Operation The standard carriage uses manually adjustable forks and can This forklift includes a quick attach system that allows for easy be tilted up or down by using the thumb stick on the control attachment changes. - Page 60 XR5519 Operation 4. Raise the boom until pivot pins (A) have seated fully in at- 7. Insert quick attach pin keeper. tachment hooks (B). Fig 79. Quick Attach Pin Keeper Warning Fig 77. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment Hooks (B) Hydraulic attachments have a maximum 5.
- Page 61 XR5519 Operation Attachment Removal NOTE: To remove a standard carriage with forks, spread the forks apart on the carriage shaft. This provides adequate sup- port for the carriage to stand alone. 1. Bring the forklift to a complete stop. 2. Move the travel select lever to NEUTRAL (N). 3.
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Page 62: Load Handling
XR5519 Operation Failure to keep personnel clear of the load Load Handling area while the load is being raised or lowered could result in death or serious injury. DO NOT lift, swing, or move a load over anyone. Danger • Review the rated load capacity of each auxiliary attach- Death or serious injury by electrocution ment before performing any operation. -
Page 63: Boom Lift Point
XR5519 Operation Pick Up A Load Use correct load chart to review the rated load capacity of the carriage or auxiliary attachment being used. NEVER exceed specified weights and load centers. Approach the load slowly and squarely with the fork tips straight and level. -
Page 64: Load Capacity Charts
XR5519 Operation NOTE: For example, when letter “A” first appears, the boom Load Capacity Charts extension corresponds to the arc of line “A” throughout all the load capacity charts. Warning The boom angle indicator is located on the left side of the boom and is visible from the operator’s seat. - Page 65 XR5519 Operation 5. Operator reads load capacity chart for attachment carriage The Sway Enable button on the joystick is used to enable to learn it will be safe to place the load at any boom angle with the machine frame sway before lifting any loads. This button the boom extend letter “D”...
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Page 66: Preventive Maintenance
XR5519 Preventive Maintenance Check condition and tension of drive belts (use Establishing a Maintenance Program tension meter to check belt tension) Lubricate front and rear driveshaft grease fittings Lubricate front and rear axle grease fittings Check wheel lug nuts torqued to 250 ft lbs Lubricate boom pivot point grease fittings Lubricate slide block contact areas Replace hydraulic return line filter... - Page 67 XR5519 After Every 1,000 Hours of Operation After Every 250 Hours of Operation Comply with 50-Hour Maintenance Requirements Comply with 50-Hour Maintenance Requirements Comply with 250-Hour Maintenance Requirements Change engine oil and filter Comply with 500-Hour Maintenance Requirements Check air filter (replace if necessary) Change axle wheel-end and differential oil &...
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Page 68: Boom Emergency Lower Down Valve
XR5519 Locate needle valve on extend cylinder. Loosen nut on Boom Emergency Lower Down Valve valve, then loosen valve with hex wrench. Both of the lift and extend cylinders are equipped with a needle valve which allows the cylinder to retract without the direct assist of the machine’s hydraulic power. - Page 69 XR5519 Do Not Operate Tags ON TOP Fig 97. Lift Cylinder Lower Down Valve 11. Thread a 125mm long M8-1.25 capscrew into the manual operator of the lift/lower section on the proportional control valve (first section from boom side, on top of the valve) and use it to manually operate the valve to lower the boom.
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Page 70: Lockout / Tagout
XR5519 Lockout / Tagout Lockout/Tagout THROWING THE BATTERY DISCONNECT SWITCH TOO EARLY MAY CONFUSE THE ECU IF THE WRITING PROCESS IS NOT Do Not Operate - Accident Prevention Tags COMPLETED. Before beginning any maintenance or service, place a Do Not Operate Tag on both the starter key switch and the steering wheel, stating that the vehicle should not be operated. -
Page 71: Do Not Operate Tags
XR5519 Lockout / Tagout Do Not Operate Tags Operation Manual... -
Page 72: Warranty
(15) days after delivery of the Xtreme Manufacturingproduct to the Customer or Dealer’s demonstration/ rental eet. Xtreme Manufacturing must be noti ed, in writing, within ten (10) days, of any machine sold to a Customer from a Dealer/SSC’s rental eet duringthe warranty period. - Page 73 XR5519 Xtreme Manufacturing Product Warranty Policy 6) All parts claimed under warranty must be held available for return and inspectionupon request for a period of 90 days from date of claim submission, it is necessary that all parts are individuallytagged or marked with their part number and the warranty claim number.
- Page 74 Customer /SSC / Distributor to allocate a warranty claim number to the repair. • All correspondencein respect of the claim to be on an o cial Xtreme Manufacturingwarranty claim form as suppliedby Xtreme Manufacturing’s warranty department. • All warranty claims must be submittedwithin 30 days of the date of the machine repair.
- Page 75 This warranty is expressly in lieu of all other warranties, representations or liabilities of Xtreme Manufacturing, either expressed or implied, unless otherwise amendedin writing by Xtreme Manufacturing.
- Page 76 Xtreme Manufacturing Product Warranty Policy Distributor/SSC/ Customer. XTREME MANUFACTURING MAKES NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THIS LIMITED WARRANTY. XTREME MANUFACTURING MAKES NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND DISCLAIMS ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO INJURY TO PERSONS OR PROPERTY.
- Page 77 XR5519 Xtreme Manufacturing Product Warranty Policy XTREME MANUFACTURING WARRANTY SCHEDULE Limited Warranty Periods Item Warranty Period 10 years or 10,000 hours, parts Main Frame and Chassis replacement or repair 5 years or 5,000 hours, parts replacement Boom weldment and rollers...
- Page 78 LOCAL DISTRIBUTOR LOKALER VERTIEBSHÄNDLER DISTRIBUTEUR LOCAL EL DISTRIBUIDOR LOCAL EUROPE, MIDDLE EAST IL DISTRIBUTORE LOCALE AFRICA & ASIA PHONE: +44 (0) 845 1550 058 FAX: +44 (0) 845 1557 756 NORTH & SOUTH AMERICA PHONE: +1 785 989 3000 TOLL FREE: +1 800 255 0317 FAX: +1 785 989 3070 AUSTRALIA PHONE: +61 1300 700 450...