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Xtreme Manufacturing XR630 Operation And Safety Manual

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Operation and
Safety Manual
Deutz Tier 4F
Pre-delivery Inspection Report must be completed upon placing unit in
service. Please use QR link or visit
PN 24965-000 Rev C
www.xmfg.com/warranty/pre-delivery-inspection-report
August 2020
to register online.

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Summary of Contents for Xtreme Manufacturing XR630

  • Page 1 Operation and Safety Manual Deutz Tier 4F Pre-delivery Inspection Report must be completed upon placing unit in service. Please use QR link or visit PN 24965-000 Rev C www.xmfg.com/warranty/pre-delivery-inspection-report August 2020 to register online.
  • Page 2 Xtreme Manufacturing, LLC (w://www.xmfg.com/) is headquartered in Las Vegas, Nevada, and has fabrication facilities in Selma, California. In October 2013, Xtreme became the majority shareholder in Snorkel, a global aerial work platform manufacturer, which has manufacturing facilities in the US, UK & New Zealand, as well as a global sales distribution network. Find out more about Snorkel at www.snorkellifts.com.

  • Page 3: Table Of Contents

    XR630 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...
  • Page 4 XR630 Table of Contents Table of Contents Description Page Attachment Disclaimer Fork Ratings Standard Carriage Operation Quick Attach System Load Handling Boom Lift Point Suspended Loads Pick Up a Load Carry a Load Place a Load Load Shift Load Capacity Charts...

  • Page 5: Introduction

    Replacement Manuals RIGHT Telehandler operation and maintenance. Replacement manuals for the XR630 Telehandler can be ob- tained by contacting our parts department by phone or visit- ing our website: Xtreme Manufacturing LEFT Phone: (800) 497-1704 www.xmfg.com...

  • Page 6: Safety

    Warning Safety Disclaimer WARNING (Orange) used with the safety alert symbol Xtreme 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.
  • Page 7 XR630 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...
  • Page 8 XR630 Safety Operation Manual...

  • Page 9: Employer Responsibility

    XR630 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

    XR630 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 •...

  • Page 11: Before Starting Telehandler

    XR630 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...

  • Page 12: Operation Safety

    XR630 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.
  • Page 13 XR630 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

    XR630 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...

  • Page 15: Attachments

    XR630 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

    XR630 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...

  • Page 17: Dead Engine Towing

    XR630 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.

  • Page 18: Labels

    XR630 Labels Labels Labels INNER BOOM Fig 5. Label Legend (Left Side) and Front Left Right Side View Fig 6. Label Legend (Right Side) and Engine Compartment Operation Manual...
  • Page 19 XR630 Labels Labels Rear Right Quarter View Rear Left Quarter View Fig 7. Label Legend (Rear) Front View Cab View Fig 8. Label Legend (Front) Fig 9. Label Legend (Cab) Operation Manual...
  • Page 20 XR630 Labels Table 1. Labels Item Part No. Description Item Part No. Description 18008-000 DATA PLATE 18066-001 DECAL, XRM-CON-4-03* 18041-100 LABEL, WARNING PINCH POINT 10011170 LOAD CHART 18081-000 DECAL, XRM-QC-81CA* 18010-100 LABEL CAUTION SLIP/TRIP 18082-100 LABEL, WARNING INJECTION HAZARD* 18011-001...

  • Page 21: Replacement Labels

    XR630 Labels Replacement Labels XR630 LOAD CHART - STANDARD CARRIAGE Replacement labels can be obtained by contacting Xtreme LOAD RATINGS ARE 68° Manufacturing at (800) 497-1704. Please have the appropri- 65° FOR VEHICLE EQUIPPED 60° WITH AIR FILLED TIRES. ate label number available when you call.
  • Page 22 XR630 Labels 18016-100 7) 18015-001 8) 18016-100 9) 18017-001 10) 18018-002 18019-100 18018-100 12) 18019-100 11) 18018-100 Operation Manual...
  • Page 23 XR630 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 XR630 Labels 19) 18027-001 WARNING 20) 18031-001 21) 18032-001 22) 18067-100 18041-100 23) 18041-100 Operation Manual...
  • Page 25 XR630 Labels 18082-100 18083-100 25) 18082-100 26) 18083-100 18086-100 18086-101 27) 18086-100 28) 18086-101 18090-100 30) 18043-000 29) 18090-100 Operation Manual...
  • Page 26 XR630 Labels 31) 18232-000 32) 18300-001 33) 18312-000 18314-000 34) 18314-000 18315-000 35) 18315-000 36) 18044-000 18402-000 37) 18402-000 Operation Manual...
  • Page 27 XR630 Labels CONTROL CONTROL BOOM BOOM BOOM BOOM FORK TILT FORK TILT RETRACT RETRACT EXTEND EXTEND DOWN DOWN SWAY SWAY SWAY SWAY LEFT LEFT RIGHT RIGHT FORK TILT FORK TILT CONTROL CONTROL JOYSTICK JOYSTICK ENABLE ENABLE 18408-001 18408-001 38) 18408-000...

  • Page 28: Features

    XR630 Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Three (3) 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...

  • Page 29: Specifications

    XR630 Specifications Specifications Performance Standard Equipment Capacity ... . 6,000 lbs Heavy-duty Frame/Chassis Frame Sway Lift Height ... 30’ Heavy-duty Boom Forward Reach .

  • Page 30: Operator Cab

    XR630 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).

  • Page 31: Service Brake Pedal

    XR630 Operator Cab Service Brake Pedal Horn Button Press the service brake pedal to slow or stop the Telehandler. Press the horn button to sound the horn. The service brake pedal activates the service brakes on the front (2) wheels.

  • Page 32: Backrest Angle Adjustment Lever

    XR630 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.

  • Page 33: Rear View Mirrors

    XR630 Operator Cab 1. 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. 2. Pull the retractable seat belt across your lap. Position the seat belt as low on your body as possible.

  • Page 34: Display Indicators

    XR630 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 XR630 Operator Cab G. ENGINE WARNING shows abnormal readings, stop the Telehandler, follow proper shut down procedures, tag Telehandler with “Do Not Operate” The Engine Warning Indicator will be displayed when there is tags, and have a qualified mechanic service or repair the an engine fault.

  • Page 36: Display Features

    XR630 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 XR630 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.
  • Page 38 XR630 Operator Cab ADJUST SETTINGS Touching the SETTINGS button will enter a mode where the Adjust is a password-protected menu that enables users to user is able to select various suitable options. The (X) button change the parameter values , such as temperature, angle of will close the menu.
  • Page 39 XR630 Operator Cab Fig 38. Display Theme: High Tech (Default) Fig 41. General Units Throttle Mode: • TSC1 OFF • TSC1 ON Fig 39. Other Available Display Theme: Chrome Fig 42. Throttle Mode Throttle Response: LOAD • Regular SPEED •...
  • Page 40 XR630 Operator Cab CAN Switches Touching the CAN Switches opens the Master Switch cluster display, which allows for viewing the status of the Steering, Lights, and Warning clusters. Fig 47. Engine Status, Page 3 MVEC FUSE SCREEN Select this option to view the status of the Multiplexed Vehicle Electrical Center (MVEC) fuse panel.

  • Page 41: Light Switches

    XR630 Operator Cab DAY/NIGHT MODE Light Switches This touch button allows for selecting the brightness of the screen: brighter, appropriate for day operation or dimmer, for The Light Switches control the boom and cab lights. It operating the machine at night.

  • Page 42: Steering Select Switch

    XR630 Operator Cab Steering Mode Select Switch Warning DO NOT change steering modes until the Telehandler comes to a complete stop. Align all four (4) wheels perpendicular to the axle, before changing steering mode. Changing steering modes at higher travel speeds can make the Telehandler unstable, and cause a loss of control, which could result in death, serious injury, or property damage.

  • Page 43: Multifunction Joystick Controller (Joystick)

    XR630 Operator Cab Boom Control Handle Functions Multifunction Joystick Controller (Joystick) Function Purpose Aux Button 1 Control auxiliary direction 1 The joystick is used to raise, lower, extend, retract the boom, Aux Button 2 Control auxiliary direction 2 tilt the carriage (or attachment).

  • Page 44: Frame Sway Control

    XR630 Operator Cab Auxiliary Attachment Control Frame Sway Control The Sway Enable button on the joystick is used to enable the machine frame sway before lifting any loads. This button needs to be depressed at all times while the joystick is moved sideways for frame sway purposes.

  • Page 45: Boom Angle Indicator

    XR630 Operator Cab Boom Angle Indicator The boom angle indicator is located on the left side of the boom and is visible from the operator’s seat. Use the boom angle indicator to determine the boom angle when referring to load capacity charts. Refer to the LOAD CAPACITY CHARTS section of this manual for more information.

  • Page 46: Operation

    XR630 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.
  • Page 47 XR630 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 48: Pre-Operation Inspection Checklist

    XR630 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.

  • Page 49: Functional Tests

    XR630 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 50: Operator Maintenance

    It is possible to use other cooling system corrosion protection could 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 partner.
  • Page 51 XR630 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.

  • Page 52: Before Starting Telehandler

    XR630 Operation Before Starting Telehandler Warning Failure to use proper safety procedures when mounting and dismounting the Telehandler could result in death or serious injury. • Keep steps clear of dirt, mud, snow, ice, debris, and oth- er hazards. Face the Telehandler for mounting or dis- mounting.

  • Page 53: Starting Telehandler

    XR630 Operation Caution Starting Telehandler Release the key immediately once the engine starts. If the Normal Starting engine does not start, DO NOT crank the starter motor con- tinuously for more than 15 seconds. Failure to release the key after the engine has started or continuous cranking can Warning damage the starter motor.

  • Page 54: Telehandler Travel

    XR630 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 55: Warning And Fault Indicators

    XR630 Operation Warning and Fault Indicators Hydraulic Oil Pressure Indicator, above 20 psi. En- gine must be running above 500 RPM Warning Low Hydraulic Oil Pressure Indicator, between 10 and 20 psi. Engine 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 56: Starting Travel

    XR630 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...

  • Page 57: Refueling

    XR630 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 58: Attachments

    This Telehandler is not intended to be used and should not be used with an attachment that would alter the center of gravity or stability of this Telehandler. Xtreme Manufacturing Because forks are always used in multiples, the total rating...

  • Page 59: Standard Carriage Operation

    XR630 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.
  • Page 60 XR630 Operation 4. Raise the boom until pivot pins (A) have seated fully in at- tachment hooks (B). Fig 82. Quick Attach Pin Keeper Fig 80. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment Warning Hooks (B) Hydraulic attachments have a maximum 5.
  • Page 61 XR630 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 Telehandler to a complete stop. 2. Move the travel select lever to NEUTRAL (N).

  • Page 62: Load Handling

    XR630 Operation Warning Load Handling DO NOT exceed the manufacturer’s rated load Danger for any auxiliary attachment. Any attempt to lift or carry loads in excess of the manufac- turer’s rated load may cause Telehandler tip Death or serious injury by electrocution...

  • Page 63: Boom Lift Point

    XR630 Operation Boom Lift Point Suspended Loads Warning Warning DO NOT exceed rated capacities. Any attempt Avoid carrying a suspended load. If necessary, to lift or carry loads in excess of those shown secure the load by attaching it to the...

  • Page 64: Carry A Load

    XR630 Operation The load capacity charts pop up on the screen every time Carry A Load there's a load on the forks. The load charts are provided to assist the operator in determining how to safely operate 1. Carry the load as low as possible while maintaining good the boom to pick up, carry, and set down a load with the ground clearance and visibility.
  • Page 65 Operator reads load capacity chart for attachment carriage to learn it will be safe to place the load at any boom angle with the boom extend letter “E” showing. XR630 LOAD CHART - STANDARD CARRIAGE LOAD RATINGS ARE 68° FOR VEHICLE EQUIPPED 65°...

  • Page 66: Preventive Maintenance

    XR630 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...
  • Page 67 XR630 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 &...

  • Page 68: Boom Emergency Lowering

    XR630 Boom Emergency Lowering In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact a local Xtreme Authorized Distributor for specific instructions.

  • Page 69: Lockout/Tagout

    XR630 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 70: Do Not Operate Tags

    XR630 Lockout / Tagout Do Not Operate Tags Operation Manual...
  • Page 71 XR630 Lockout / Tagout Operation Manual...
  • Page 72 (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 XR630 Warranty 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 XR630 Warranty 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 8350 EASTGATE ROAD HENDERSON, NV 89015 (702) 636-2969 (800) 497-1704 www.XMFG.com 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. PN 24965-000 Rev C...

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