Xtreme Manufacturing XR619 Operation And Safety Manual
  1. Manuals
  2. Brands
  3. Xtreme Manufacturing Manuals
  4. Compact Loader
  5. XR619
  6. Operation and safety manual

Xtreme Manufacturing XR619 Operation And Safety Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Operation and
Safety Manual
Tier 4 Final
Pre-delivery Inspection Report must be completed upon placing unit in
PROTOTYPE
service. Please use QR link or visit
www.xmfg.com/warranty/pre-delivery-inspection-report
PN 24978-000
to register online.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the XR619 and is the answer not in the manual?

Questions and answers

Summary of Contents for Xtreme Manufacturing XR619

  • Page 1 Operation and Safety Manual Tier 4 Final Pre-delivery Inspection Report must be completed upon placing unit in PROTOTYPE service. Please use QR link or visit www.xmfg.com/warranty/pre-delivery-inspection-report PN 24978-000 to register online.
  • 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.

  • Page 3: Table Of Contents

    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 Table of Contents Table of Contents Description Page Description Page Winter Operation With Diesel Fuel Load Shift Attachments Load Capacity Charts Attachment Disclaimer Preventive Maintenance Fork Ratings Establishing a Maintenance Program Standard Carriage Operation Maintenance Schedule Quick Attach System Boom Emergency Lower Down Valve Lockout / Tagout Load Handling Boom Lift Point...

  • Page 5: Introduction

    RIGHT Replacement Manuals Telehandler operation and maintenance. Replacement manuals for the XR619 Telehandler can be ob- tained by contacting our parts department by phone or visit- ing our website: LEFT Xtreme Manufacturing Phone: (800) 497-1704 Fig 2.

  • Page 6: Safety

    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 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 Safety Operation Manual www.xmfg.com...

  • Page 9: Employer Responsibility

    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 telehandler. Suc- perception, and hearing.

  • Page 10: Mounting/Dismounting

    Safety Warning Mounting/Dismounting • Operate the telehandler only on firm, stable surfaces. Warning Holes, 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. and dismounting the telehandler could result in death or •...

  • Page 11: Before Starting Telehandler

    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, gloves, performing an inspection.

  • Page 12: Operation Safety

    Safety If the telehandler cannot be leveled using the frame sway Warning control, do not attempt to raise or place load. Reposition telehandler or have the surface leveled. Operators must be properly trained and qualified to operate this specific telehandler. Warning Know the location, learn the specific purpose, and demonstrate safe and proper use of all...
  • Page 13 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 •...

  • Page 14: Load Safety

    Safety Load Safety DO NOT exit the telehandler without follow- ing 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

    Safety Attachments Telehandler 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 telehandler continues to meet place can become unstable and fall on the operator or other manufacturer’s specifications.

  • Page 16: Jump Starting

    Safety IMPORTANT - In case of internal contact, DO NOT give fluids The parking brake can be manually released to tow the telehandler. In this condition, it is that induce vomiting. possible for the telehandler to move sudden- ly when the brakes are released, which could Warning result in death, serious injury, or property damage.

  • Page 17: Dead Engine Towing

    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

    Labels Labels Labels Left Side View INNER BOOM Fig 5. Label Legend (Left Side) Right Side View Fig 6. Label Legend (Right Side) Operation Manual www.xmfg.com...
  • Page 19 Labels Labels Front View FULL 18069-000 Fig 7. Label Legend (Front) Cab View Rear View 18086-101 Fig 8. Label Legend (Rear) Fig 9. Label Legend (Cab) Operation Manual www.xmfg.com...
  • Page 20 18026-100 Warning, Unrestrained Operator 18412-000 Caution, Engine Control Damage Hazard 18069-000 Decal, XRM-HYD-LEVEL-04* 18027-001 Danger, Rotating Equipment 17517-000 Load Chart, XR619 Std. Carriage Hazard 18403-010 Fuse Box 5919 18031-001 Warning, Safe Operation Check- 18091-000 Decal, "X"-SX list 18081-000 Decal, XRM QC...

  • Page 21: Replacement Labels

    Labels Replacement Labels Parking Brake Lights Boom Rear Front Hazard Turn Steering Front and Rear Wheels Must Be Centered Before Engaging. Crab Wash Wiper 18004-040R01 702-636-2969 www.XMFG.com 800-497-1704 1) 18008-000 2) 18004-040 18010-100 3) 18010-100 4) 18011-001 CHECK DIESEL ONLY ENGINE OIL Ultra Low Sulphur Fuel Only...
  • Page 22 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 www.xmfg.com...
  • Page 23 Labels 18020-100 18021-100 13) 18020-100 14) 18021-100 15) 18022-001 16) 18023-001 18026-100 18025-100 18) 18026-100 17) 18025-100 Operation Manual www.xmfg.com...
  • Page 24 Labels 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 22) 18408-004 18041-100 18323-000 23) 18323-000 24) 18041-100 Operation Manual www.xmfg.com...
  • Page 25 Labels 18082-100 25) 18318-000 26) 18082-100 25A) 18318-100 18086-100 18083-100 27) 18083-100 28) 18086-100 18090-100 29) 18090-100 30) 18312-000 Operation Manual www.xmfg.com...
  • Page 26 Labels 18315-000 31) 18315-000 32) 18326-000 18044-000 33) 18325-000 18402-000 34) 18402-000 REQUIRED TIRE PRESSURE 80 PSI 18400-100 18406-000R01 35) 18406-000R01 36) 18400-100 36A) 18400-200 Operation Manual www.xmfg.com...
  • Page 27 OFF. Equipment damage may occur if the engine control systems are not allowed to shutdown properly. 18412-000R01 39) 18412-000R01 18069-000 40) 18069-000 4.00 XR619 LOAD CHART - STANDARD CARRIAGE MAIN AUX (2) LOAD RATINGS 2 FT RELAY RELAY SHOWN ARE FOR...

  • Page 28: Features

    Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Two (2) section boom Options Enclosed cab with heat Boom equipped with rollers Enclosed cab with heat & A/C Chassis Sealed pivot pins for extended service periods Heater/defroster/windshield wiper Side mounted engine Work light package Lights...

  • Page 29: Specifications

    Specifications Specifications Performance Standard Equipment Capacity ... . 6,000 lbs Heavy-duty Frame/Chassis Lift Height ... 19’ Roller Boom Forward Reach ..11’ Robust Wiring Frame Leveling L/R .

  • Page 30: Operator Cab

    Operator Cab Operator Cab Warning A brief description of controls, indicators, and instruments is provided as a convenience for the operator. These descriptions DO NOT pro- vide complete operation instructions. Read and understand the entire manual to prevent death, serious injury, or equipment damage. Ignition Switch A key is required to operate the ignition switch.

  • Page 31: Service Brake Pedal

    Operator Cab Operator Seat Operator Seat Controls The operator seat can be adjusted two (2) ways: fore and aft, and backrest angle. Fig 13. Service Brake Pedal Steering Wheel Turn the steering wheel left or right to steer the forklift in the corresponding direction.

  • Page 32: Backrest Angle Adjustment Lever

    Operator Cab Grasp the free end of the seat belt (located on the right Backrest Angle Adjustment Lever side of the seat) and make sure the belt webbing is not twisted or entangled in any portion of the seat assembly. Pull the backrest angle adjustment lever up to release the seat Pull the retractable seat belt across your lap.

  • Page 33: Controls And Indicators

    Operator Cab Parking Brake Switch Controls and Indicators The Parking Brake switch (A) has two (2) positions: ON and Travel Select Lever OFF. The travel select lever has three (3) positions: FORWARD, NEUTRAL, and REVERSE, which change the direction of travel. Travel Select Lever Position Purpose...
  • Page 34 Operator Cab The Steering Select switch has three (3) steering positions: Light Switches Crab, Two Wheel Steering (2W), and Four Wheel Steering (4W). The Light Switches control the boom and cab lights. Fig 20. Light Switches Fig 22. Steering Select and 2-Wheel Rear Switches Turn Signal and Hazard Switches Wiper Switch The optional Turn Signal Switch controls the turn signals...

  • Page 35: Display Indicators

    Operator Cab D. WATER IN FUEL Display Indicators The Water in Fuel Indicator will be displayed when water is detected in the fuel filter. Drain the water by opening the pet- The display allows the operator to view vital engine cock on the bottom of the fuel filter.

  • Page 36: Display Features

    Operator Cab K. FUEL GAUGE S. MENU BUTTON INDICATOR Indicates the approximate quantity of fuel in the tank. The Use the soft button to the left of this indicator to access the total capacity of the fuel tank is 17 gallons. Main Menu screen.
  • Page 37 Operator Cab UTILITIES • Clock Setup The Utilities Menu is accessed from the Main Menu by pressing Pushing the top right select button will enter the CLOCK SET- the top left selection button. UP MENU, where the digital clock may be adjusted. Fig 30.
  • Page 38 Operator Cab When the "EZcal" button is pressed, the TCU (Transmission Control Unit) enters transmission calibration mode and it checks first for all the machine conditions necessary for a successful transmission calibration. It displays a green check symbol to the right of the condition if it is met. When all of the machine conditions for calibration are met, the TCU enters clutch calibration mode.
  • Page 39 Operator Cab This area is for editing or resetting the service reminders once a service has been completed and is different than the SER- VICE REMINDERS in the MAIN MENU where users can check on the status of the service reminders to see how many hours until the next service is required.

  • Page 40: Multifunction Jiystick Controller

    Operator Cab Fig 44. Boom Control Multifunction Joystick Controller (Joystick) Joystick Functions (1) The joystick is used to raise, lower, extend, retract the boom, tilt the carriage (or attachment). NOTE: The joystick is a variable speed control. Function speed is proportional to handle movement. The more the joystick is moved in the appropriate direction, the faster the correspond- ing function will occur.

  • Page 41: Boom Angle Indicator

    Operator Cab Boom Extend Letters As the boom is extended, the boom extend letters on the left side of the boom are visible to the operator. These letters indicate boom extension as it corresponds to the load capacity charts. Fig 46. Joystick Functions Boom Maintenance Stand (Optional) This machine is equipped with a Boom Maintenance Stand, which is used during any and maintenance activities where...

  • Page 42: Operation

    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 telehandler has been operated telehandler is NOT running, the engine is cool, the telehandler could result in serious personal injury. is parked on level ground, the boom is completely retracted, and the frame is level.
  • Page 43 Operation Warning Warning Wear eye protection when starting a telehan- dler with jump start cables. Improper jump start procedures could cause the battery to explode, which could result in death or seri- ous injury. Lead-acid batteries produce flammable and potentially ex- •...

  • Page 44: Pre-Operation Inspection Checklist

    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 45: Functional Tests

    Operation Release the parking brake. Functional Tests Operate the telehandler in forward and reverse. Test the service and parking brakes. Warning • Apply the service brake pedal after the telehandler Perform a pre-operation inspection and func- begins to move and the telehandler should stop tional tests at the beginning of each work immediately.

  • Page 46: Operator Maintenance

    (e.g. chemi- The ambient temperature cal corrosion protection agents) in exceptional cases. Consult at the installation site or in the application area of the engine your Xtreme Manufacturing or DEUTZ partner. Operation Manual www.xmfg.com...
  • Page 47 Operation is decisive for choosing the right vis- cosity class. Too high a viscosity can lead to starting difficulties, too low a viscosity can endanger the lubrication effect and cause a high lubricating oil consumption. Depending on the ambient tempera- ture, the following common viscosity classes are recommended: Check the engine oil level by pulling...
  • Page 48 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 49: Starting Telehandler

    Operation Release key immediately after the engine starts. The Starting the Telehandler 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 50: Telehandler Travel

    Operation Two Wheel Front Steering (2W) Telehandler 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 51: Warning And Fault Indicators

    Operation Engine Load Indicator (yellow, above 90%) or Warn- Warning and Fault Indicators ing (red, at or above 99%). Dark gray at normal op- erating range. Warning Hydraulic Oil Pressure Indicator, above 20 psi. En- gine must be running above 500 RPM A fault condition may trigger a popup dialog box on the display describing the nature of the fault during operation.

  • Page 52: Starting Travel

    Operation Warning Starting Travel To prevent death, serious injury, or property damage, apply service brakes until the Warning telehandler comes to a complete stop, move travel select lever to NEUTRAL (N), set the Use proper safety procedures and avoid Parking Brake switch to ON (engaged), lower hazardous situations while operating the and retract the boom, and shut off the engine before exiting telehandler to prevent death, serious injury,...

  • Page 53: Refueling

    Operation If the telehandler 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 54: Attachments

    Operation Warning Attachments DO NOT exceed telehandler capacity of 6,000 Attachment Disclaimer pounds (2,721.5 kilograms). The total rated capacity of the forks being used must equal or exceed telehandler capacity. Forks can Warning bend or break causing loss of load and could result in death or serious injury.

  • Page 55: Standard Carriage Operation

    Operation Quick Attach System Standard Carriage Operation The standard carriage uses manually adjustable forks and can This Telehandler includes a quick attach system that allows for be tilted up or down by using the thumb stick on the control easy attachment changes. Perform attachment connection handle.
  • Page 56 Operation 4. Raise the boom until pivot pins (A) have seated fully in at- tachment hooks (B). Fig 66. Quick Attach Pin Keeper Fig 64. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment Warning Hooks (B) Hydraulic attachments have a maximum 5.
  • Page 57 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.

  • Page 58: Load Handling

    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 59: Suspended Loads

    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 60: Load Capacity Charts

    Operation Boom extend letters are located on the left side of the boom Load Capacity Charts and visible to the operator as the boom is extended. These letters indicate boom extension as it corresponds to the load capacity charts. Warning DO NOT exceed rated capacity.
  • Page 61 “D” showing. the telehandler or its parts which could result in death or serious injury if the telehandler is not properly operated or maintained. XR619 LOAD CHART - STANDARD CARRIAGE Read the Operation and Safety LOAD RATINGS 2 FT...

  • Page 62: Preventive Maintenance

    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 boom roller grease fittings and chains Replace hydraulic return line filter...
  • Page 63 Check specific gravity of engine coolant After Every 250 Hours of Operation Replace hydraulic reservoir air breather Comply with 50-Hour Maintenance Requirements Replace hydraulic return line filter Change engine oil and filter Replace hydraulic high-pressure filter Check air filter (replace if necessary) Replace hydraulic filter on drive pump Check tension and condition of drive belts (use tension meter to check belt tension)

  • Page 64: Boom Emergency Lower Down Valve

    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 65 Fig 83. Lift Cylinder Lower Down Valve 10. Thread a 125mm long M8-1.25 cap screw into the manual operator of the lift/lower section on the proportional control valve (the first (1) section from boom side, on top of the valve) and use it to manually operate the valve to lower the boom.

  • Page 66: Lockout / Tagout

    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 67: Do Not Operate Tags

    Lockout / Tagout Do Not Operate Tags Operation Manual www.xmfg.com...
  • Page 68 (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 69 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 70 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 71 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 72 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 73 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 or repair...
  • Page 74 8350 EASTGATE ROAD HENDERSON, NV 89015 (702) 636-2969 (800) 497-1704 www.XMFG.com OPERATION & SAFET Y OPERATION & SAFET Y MANUAL Pre-delivery Inspection Report must be completed upon placing unit in service. Please use QR link or visit www.xmfg.com/warranty/pre-delivery-inspection-report to register online. Part Number 24978-000...

Table of Contents