Xtreme Manufacturing XR5919 Operation And Safety Manual Download Page 1

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Operation and

Safety Manual

PN 24927-001

Tier 4 Final

Summary of Contents for XR5919

Page 1: ...Operation and Safety Manual PN 24927 001 DZ Tier 4 Final ...

Page 2: ...lifornia 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 Xtreme Manufacturing 1415 W Bonanza Road Las Vegas NV 89106 USA Contact Us T 1 800 497 1704 T 1 702 636 2969 F 1 702 636 49...

Page 3: ... Horn Button 31 Table of Contents Description Page Operator Seat 31 Operator Seat Controls 31 Backrest Angle Adjustment Lever 32 Fore and Aft Adjustment Lever 32 Seat Belt 32 Rear View Mirrors 33 Controls and Indicators 33 Travel Select Lever 33 Parking Brake Switch 33 Light Switches 34 Turn Signal and Hazard Switches 34 Steering Select Switch 34 Wiper Switch 34 Display Indicators 34 Display Featu...

Page 4: ...ling 60 Boom Lift Point 61 Suspended Loads 61 Pick Up a Load 61 Carry a Load 62 Place a Load 62 Load Shift 62 Load Capacity Charts 62 Preventive Maintenance Establishing a Maintenance Program 64 Maintenance Schedule 64 Boom Emergency Lower Down Valve 66 Lockout Tagout Do Not Operate Accident Prevention Tags 68 New or Additional Operators 68 Lockout Tagout Procedure 68 Do Not Operate Tags 69 ...

Page 5: ...nd practice safe use of forklift controls in a safe clear area BEFORE you operate this forklift on a work site It is your responsibility to observe applicable laws and regulations and to follow manufacturer s instructions on forklift operation and maintenance Replacement manuals for the XR5919 Reach Forklift can be obtained by contacting our parts department by phone or visiting our website Xtreme...

Page 6: ... or words that call attention to the safety sign and designate a degree or level of hazard seriousness ThesignalwordsusedinthismanualareDANGER WARNING and CAUTION DANGER Red used with the safety alert symbol indicates an imminently hazardous situation which if not avoided will result in death or serious injury Danger Signal Words Safety Disclaimer CAUTION Yellow with the safety alert symbol indica...

Page 7: ...e If Using Alcohol Drugs Or Medications Personal Protective Equipment Safety Shoes Lead Acid Batteries Create Explosive Gases Warning Hydraulic Oil Under Pressure Hot Oil DO NOT Open Unless Cap Is Cool To Touch Warning Rotating Belts Can Cut Or Entangle Replace Worn And Illegible Safety Labels And Labels Read Maintenance Manual Before Working On This Forklift Know First Aid Instructions And Or Loc...

Page 8: ... To ON Engage Parking Brake Warning Forklift Tip Over Can Cause Death Or Serious Injury DO NOT Raise Boom While Traveling On A Slope Danger Keep A Safe Distance From Electrical Lines Pinch Points Hands DO NOT Use Ether As A Starting Aid DO NOT Allow Riders On Auxiliary Attachments Set Parking Brake To OFF Disengage Parking Brake DO NOT Jump If Forklift Tips Keep Seat belt ON And Brace Yourself Tip...

Page 9: ...on or alter ation including welding or drilling can im pair and weaken the protective capability of the Rollover Protective Structure Falling Object Protective Structure ROPS FOPS and could result in death or serious injury Replace the ROPS FOPS if it is damaged before operating the forklift Under Occupational Safety and Health Administration OSHA rules employers are required to train workers abou...

Page 10: ...2 Electrical cables 3 Sewers Underground objects could cause death or serious in jury Warning Operate the forklift only on firm stable surfaces Holes obstructions debris loose fill and other work site hazards could result in death or serious injury DO NOT allow bystanders in the work area Avoid personnel machinery and forklifts in the work area Know the rules for movement of people and forklifts o...

Page 11: ...ons and functional tests may require assistance Keep the assistant visible and a safe distance from the forklift to prevent death or serious injury Become familiar with all safety and hazard labels regulations and procedures Make sure all proper safety and hazard labels are attached to the forklift and remain legible A brief description of controls indicators and instruments is provided as a conve...

Page 12: ... from electrical power lines Remain at least 10 feet plus an addition al 0 4 inches for each 1 000 volts over 50 000 volts from active power lines and other power sources Work site operating directives and or local or state codes might require a greater distance Know the maximum height and reach of this forklift Warning Use of the frame sway control with the boom raised above horizontal could caus...

Page 13: ...e gear select lever Allow the engine speed to slow down before shifting to the next lower gear Improper use of the gear select lever could cause transmission damage or forklift tip over roll over and result in death or serious in jury Operate the forklift for maximum stability Unstable forklifts can tip over resulting in death serious injury or property damage Keep the forklift stable by following...

Page 14: ...e stop Align all four 4 tires straight ahead or perpendicular to the axle before changing steering mode Load Safety Warning Failure to follow proper safety procedures when lifting lowering and traveling with a load could result in death serious injury or property damage DO NOT exceed forklift capacity of 5 900 pounds 2 676 ki lograms The total rated capacity of the forks being used must equal or e...

Page 15: ...quired Forklift Maintenance Warning Follow the manufacturer s instructions for proper maintenance to make sure the forklift continues to meet manufacturer s specifications Failure to properly maintain the forklift can result in improper performance which could cause death serious injury or property damage Attach Do Not Operate tags to the Ignition switch and steering wheel before beginning any ser...

Page 16: ...ause cancer birth defects or other reproductive harm Wash hands after Warning handling these items California Proposition 65 Warning Wear eye protection when connecting jump start cables Improper jump start procedures could cause the battery to explode which could result in death or serious injury Never jump start a frozen battery as it can explode Let the battery thaw out before charging NEVER ju...

Page 17: ... a time per side You do not need completely tighten the screws once re installed Just tighten then enough to release the parking brake then stop Fig 3 Parking Brake Screw Location Front Axle Fig 4 Parking Brake Screw Location Axle End Re Activating Parking Brakes Front Axle Warning Block all four wheels Failure to do so could result in death or serious injury from vehicle roll away 1 Block all fou...

Page 18: ...8 Labels Left Side View Right Side View Fig 5 Label Legend Left Side Fig 6 Label Legend Right Side 24 9 30 32 10 37 25 37 17 10 16 12 36 5 15 11 22 INNER BOOM 34 21 20 23 36 32 9 24 30 27 25 25 10 12 8 37 6 10 39 Labels ...

Page 19: ...Operation Manual 19 Labels Front View Cab View Fig 7 Label Legend Front Fig 9 Label Legend Cab Rear View Fig 8 Label Legend Rear 25 28 31 10 37 12 31 24 37 24 35 33 12 10 25 22 15 11 2 38 18086 101 39 ...

Page 20: ...Hazard 18 1 18026 100 Warning Unrestrained Operator Hazard 19 1 18027 001 Danger Rotating Equipment Hazard Table 1 Labels Item Qty Part No Description 20 1 18031 001 Warning Safe Operation Check list 21 1 18032 001 Warning Improper Use Hazard 22 1 18408 000 Boom Control Handle Function 23 1 18323 000 Boom Angle Indicator 24 6 18041 100 Warning Pinch Point Hazard 25 4 18318 000 Xtreme logo chassis ...

Page 21: ...5 18013 002 DIESEL ONLY 18013 002 Ultra Low Sulphur Fuel Only Maximum Sulphur Content 15ppm 18010 100 2 18004 040 4 18011 001 6 18014 002 CHECK ENGINE OIL 18014 002 Minimum Oil Specification API CJ 4 or higher 702 636 2969 800 497 1704 www XMFG com Parking Brake OFF ON 18004 040R01 Hazard Wiper Wash On Off Steering Crab 2W 4W Boom Rear Front On Off Lights Turn Front and Rear Wheels Must Be Centere...

Page 22: ...Operation Manual 22 Labels 7 18015 001 8 18016 100 18016 100 11 18018 002 12 18019 100 18019 100 9 18017 001 10 18018 100 18018 100 ...

Page 23: ...Operation Manual 23 Labels 13 18020 100 18020 100 14 18021 100 18021 100 17 18025 100 18025 100 18 18026 100 18026 100 15 18022 001 16 18023 001 ...

Page 24: ...31 001 23 18323 000 18323 000 0 10 20 30 40 50 60 24 18041 100 18041 100 21 18032 001 WARNING 22 18408 000 18408 000 JOYSTICK ENABLED AUX CONTROL AUX CONTROL FORK TILT DOWN FORK TILT UP BOOM RETRACT BOOM EXTEND BOOM LOWER BOOM RAISE JOYSTICK ENABLE ...

Page 25: ...Operation Manual 25 Labels 18082 100 18083 100 18086 100 18090 100 25 18318 000 26 18082 100 29 18090 100 30 18312 000 27 18083 100 28 18086 100 ...

Page 26: ...Operation Manual 26 Labels 18315 000 18044 000 18402 000 31 18315 000 32 18326 000 33 18325 000 34 18402 000 REQUIRED TIRE PRESSURE 80 PSI 18406 000R01 35 18406 000R01 18400 000 36 18400 000 ...

Page 27: ... 18086 101 18412 000R01 CAUTION EQUIPMENT DAMAGE Wait at least two 2 minutes after shutting engine off before setting the battery disconnect switch to OFF Equipment damage may occur if the engine control systems are not allowed to shutdown properly 39 18412 000R01 ...

Page 28: ...ndicator parking brake and engine warning indicators Easy access drop down electrical panel 12 Volt accessory power outlet Electric horn and backup alarm Rear view mirror Adjustable seat with seat belt Boom angle indicator Tires Air filled Hydraulics Auxiliary hydraulic circuit with quick attach Multifunction boom control handle Features Optional Equipment Feature Description Options Enclosed cab ...

Page 29: ...bs Power Train Engine Deutz 74 hp Fuel Capacity 17 gal Transmission Hydrostatic Brakes Inboard Wet Disc Parking Brake SAHR Tires Tires Standard Eq Air Filled 12 00 x 16 5 G2 Hydraulics GPM 26 PSI 3 200 Hydraulic Oil Capacity 24 gal Dimensions Length to fork face 12 1 5 Width 71 7 Height 6 6 Wheel Base 93 Ground Clearance 10 8 Turning Radius 11 Standard Equipment Heavy duty Frame Chassis Heavy duty...

Page 30: ...ch Position Purpose OFF Shuts down entire electrical system except the horn and accessory outlet RUN All controls and indicators are operable START Engages starter motor to crank engine NOTE The START position is spring loaded When the key is released the Ignition switch will automatically return to the RUN position Accessory Outlet A 12 Volt accessory outlet is provided as a power source for pers...

Page 31: ... Fig 13 Service Brake Pedal Steering Wheel Turn the steering wheel left or right to steer the forklift in the corresponding direction Fig 14 Steering Wheel Horn Button Press the horn button to sound the horn Fig 15 Horn Button Operator Seat Controls The operator seat can be adjusted two 2 ways fore and aft and backrest angle Fig 16 Operator Seat Operator Seat Operator Cab ...

Page 32: ...ective it may not properly restrain the operator which could result in death or serious injury DO NOT operate the forklift until the seat belt or mounting hardware is replaced if worn or damaged The seat belt MUST be worn while operating the forklift Failure to wear the seat belt could result in death or serious injury The reach forklift is equipped with a standard two inch 2 wide retractable seat...

Page 33: ...d REVERSE which change the direction of travel Fig 21 Travel Select Lever Controls and Indicators Travel Select Lever Position Purpose F Forward UP Position away from the operator N Neutral CENTER Position R Reverse DOWN Position toward the operator The travel select lever automatically locks when it is in the NEUTRAL position The operator must raise and move the travelselectleverwhenchangingtothe...

Page 34: ... steering modes at higher travel speeds can make the forklift unstable and cause a loss of control which could result in death serious injury or property damage Operator Cab Display Indicators The display allows the operator to view vital engine information and other critical functions including gauge display engine diagnostics to monitor engine condition and performance fault codes and warning in...

Page 35: ...ngine Fig 27 Display Indicators Style A A B C D G H I J K M N O L D HIGH HYDRAULIC OIL TEMP The hydraulic oil temperature indicator illuminates when the oil temperature is above 1800 F If the hydraulic oil temperature indicator illuminates stop and idle the engine to allow time for cooling If the hydraulic oil temperature indicator does not go out after five 5 minutes stop the forklift follow prop...

Page 36: ...lays a required maintenance information If there is no warning it displays the clock Fig 28 P WATER IN FUEL The Water in Fuel Indicator will be displayed when water is detected in the fuel filter Drain the water by opening the petcock on the bottom of the fuel filter In reference to the display Style B if there is no alert the top row indicators disappear E ENGINE SHUTDOWN The Engine Shutdown Indi...

Page 37: ...ab Fig 34 Main Menu Display Style A MAIN MENU Pressing the MENU button will bring up the MAIN MENU Pressing the MENU button again brings up the SERVICE REMINDER screen depicted on the next page in Fig 43 display style A or in Fig 44 display style B ENGINE DIAGNOSTICS Pressing the ENGINE DIAGNOSTICS soft button will display engine information Pressing the MENU button will return to the GAUGE DISPLA...

Page 38: ...lities Display Style A For machines equipped with the display style B the UTILITIES menu screenshot is depicted in Fig 42 At any time pressing the MENU button will return to the GAUGE DISPLAY mode For example the display style B has the following adjustable user settings Ambient light day or night Brightness Units Language The display style A has similar user adjustable settings Pressing the MENU ...

Page 39: ...t meant for regular end users hence Hidden The HIDDEN UTILITIES is accessed from the MAIN MENU by pressing the lower left menu soft button Fig 35 and then on the next screen pressing the middle upper soft button twice and then the middle lower button twice Pressing the MENU button will return to the UTILITIES mode Fig 45 Edit Service Reminders Screenshot Display Style B The service reminders may b...

Page 40: ...CE RE MINDERS in the MAIN MENU Fig 43 44 where users can check on the status of the service reminders to see how many hours until the next service is required Fig 48 Edit Service Reminders PDM DIAGNOSTICS Pressing the PDM DIAGNOSTICS soft button from the HIDDEN UTILITIES menu will display the status of the Power Distribu tion Module Pressing the MENU button will return to the UTILITIES mode This s...

Page 41: ...increase boom lift extend and carriage tilt speeds NOTE Two 2 boom functions can be performed at the same time by moving the joystick into the corner between 2 individual functions Positions B D F or H Fig 51 Enable Trigger Tilt Thumbstick Aux Button 1 Aux Button 2 Enable LED Boom Control Handle Functions Function Purpose Aux Button 1 Control auxiliary direction 1 Aux Button 2 Control auxiliary di...

Page 42: ...erator 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 NOTE The boom angle indicator is a plumb arrow with angular graduations from 2 30 to 690 Fig 53 Boom Angle Indicator A B C D E F G H Fig 52 Joystick Functions ...

Page 43: ... These letters indicate boom extension as it corresponds to the load capacity charts Fig 54 Boom Extend Letters Frame Level Indicator The frame level indicator is mounted on the upper right corner of the operator s cab The frame level indicator allows the operator to view if the forkllift has been positioned in a level condition Fig 55 Frame Level Indicator ...

Page 44: ...the seat belt or mounting hardware is defective it may not properly restrain the operator resulting in death or serious injury DO NOT operate the forklift until the seat belt or mount ing hardware is replaced if worn or damaged The seat belt MUST be worn while operating the fork lift Failure to wear the seat belt could result in death or serious injury Pre Operation Inspection To perform the pre o...

Page 45: ...compounds chemicals known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after Warning handling these items California Proposition 65 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 Never jump start a frozen bat...

Page 46: ...n inspection Check that Do Not Operate tags have not been placed on the forklift Check that load capacity charts are legible Check mirrors for cracks cleanliness and proper adjustment Check engine compartment for Loose or damaged belts hoses and radiator fan blades Check hydraulic reservoir for proper fluid level Add hydraulic fluid if necessary Check condition and operation of the seat belt and m...

Page 47: ...should stop immediately Apply the parking brake The forklift should not move unless the parking brake is released Test each steering function Operate the forklift in forward and reverse at low speed and turn the steering wheel approximately 1 2 turn in each direction for each of the following modes Align the wheels and set the Steering Select switch to crab steering Align the wheels and set the St...

Page 48: ... Keep the Operation and safety manual in the protective case provided inside the operator cab as shown below Check the engine oil level by pulling out the yellow oil dipstick handle A located adjacent to the fuel filter can Unscrew the oil fill cap B and add engine oil API CJ 4 if necessary Check the battery the case and the battery terminals Warning Lead acid batteries produce flammable and poten...

Page 49: ...ngaging a control DO NOT jump from the forklift Clothing can get caught on pedals levers or other protrudingparts Landingonunevensurfaces could result in death or serious personal injury Before starting the reach forklift 1 Make sure the master battery disconnect is ON Fig 62 Travel Select Lever Must Be in NEUTRAL N AND Parking Brake Switch A Must Be ON Engaged to Start the Reach Forklift F R N A ...

Page 50: ... motor con tinuously for more than 15 seconds Failure to release the key after the engine has started or continuous cranking can damage the starter motor 4 Release key immediately after the engine starts The Ignition Switch will automatically return to RUN Fig 65 Ignition Switch Automatically Returns to RUN NOTE If the engine fails to start on the first try wait until the engine and starter come t...

Page 51: ...odes Crab steering allows all four 4 wheels to turn in the same direction as the steering wheel allowing the forklift to move sideways Crab steering is useful in a congested work site to line up to a loading location Crab Steering Two wheel 2W steering allows the front wheels to turn in the same direction as the steering wheel The rear wheels remain in a fixed forward position Two wheel 2W steerin...

Page 52: ... Starting Travel Warning Indicators and Fault Codes Warning A fault condition may trigger a popup dialog box on the display describing the nature of the fault during operation Corresponding red or amber warning lights will illuminate to indicate the severity of the fault If an Engine Shutdown fault condition is present stop the forklift follow proper shut down procedures tag the forklift with Do N...

Page 53: ...uced power A flashing Engine Warning Indicator is displayed with the Engine Stop Indicator when the engine is either shut down or an automatic engine shutdown is imminent A flashing Engine Warning Indicator displayed with both the Oil Pressure Indicator and Engine Stop Indicator shows the oil pressure is low The engine should be shutdown Automatic engine shutdown is imminent ENGINE STOP INDICATOR ...

Page 54: ...d of time Engine is either shutdown or automatic shut down is imminent ON High Exhaust Temperature Active or manual regeneration Engine operating with no power de rate or during forced regeneration ON Excessive Soot Loading Manual regeneration recommended Engine operating with no de rate ON Regeneration Disabled Regeneration disabled by operator or machine Engine operating with no de rate ON Serio...

Page 55: ... the volatile memory after the engine is off THROWING THE BATTERY DISCONNECT SWITCH TOO EARLY MAY CONFUSE THE ECU IF THE WRITING PROCESS IS NOT COMPLETED 8 Turn the Fuel Shut off Valve to the OFF Closed position It is located in the center of the chassis on the cab side towards the rear Engine fuel is flammable and can cause a fire or explosion resulting in death or serious in jury DO NOT smoke wh...

Page 56: ... forklift capacity Forks can bend or break causing loss of load and could result in death or serious injury All approved forks for this forklift are marked with a maximum load capacity rating A This rating is stamped on the left edge of the fork just below the fork pivot shaft The rating listed is in U S pounds and is based upon a 24 inch 610 mm load center B This rating specifies the maximum load...

Page 57: ...y Attachments not locked into place could become unstable and fall on the operator or other personnel near the forklift which could result in death or serious injury Make sure attachment locking devices are always in place DO NOT operate the forklift until you have positive indicationthatthecarriageattachmentisfullyengaged Attachment Connection 1 Position the forklift directly behind the attachmen...

Page 58: ...g 74 Insert Quick Attach Pin Through Attachment and Quick Attach Adapter Fig 75 Quick Attach Pin Keeper 7 Insert quick attach pin keeper Hydraulic attachments have a maximum hydraulic pressure rating Failure to make sure the attachment is equipped with a pressure reducing valve or is rated to be equal or greater than 3 200 psi 220 6 bar which is the maximum pressure of the forklift auxiliary hydra...

Page 59: ...t the attachment backward 6 Disconnect the quick attach couplers this only applies to attachments with a quick attach hydraulic system Fig 77 Disconnect Quick Attach Couplers Fig 78 Remove Quick Attach Pin Keeper 7 Remove the quick attach pin keeper Fig 79 Remove Pin from Attachment 8 Remove the pin at the bottom of the adapter Fig 80 Lower Attachment to Ground in Level Position 9 Lower the attach...

Page 60: ...forklift tip over loss of load or structural damage which could re sult in death serious injury or property damage Warning Review the rated load capacity of each auxiliary attach ment before performing any operation Use the correct load chart and NEVER exceed specified weights and load centers DO NOT exceed the manufacturer s recommended load capacity DO NOT operate the forklift with an unsafe loa...

Page 61: ...Avoid carrying a suspended load If necessary secure the load by attaching it to the forklift tie downs and or have another person assist with safely steadying the load The handling of suspended loads can introduce dynamic forces drastically affecting the stability of the forklift Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not stabilized Swinging loa...

Page 62: ... side of the boom and visible to the operator as the boom is extended These letters indicate boom extension as it corresponds to the load capacity charts Load capacity charts located in the center of the dash panel are provided to assist the operator in determining how to safely operate the boom to pick up carry and set down a load with the reach forklift including what angle how high and how for ...

Page 63: ... BO O M A N G LE 5 900 LBS MAX LOAD WITH BOOM FULLY RETRACTED ONLY 69 65 55 50 45 30 25 20 15 10 5 0 25 40 35 60 2 3 5 5 0 0 L B S 5 1 5 0 L B S 4 5 0 0 L B S 3 5 5 0 L B S 2 9 0 0 L B S 2 3 5 0 L B S 2 FT 2 FT Fig 86 Load Capacity Chart For example 1 The operator determines load weight and makes sure load does not exceed fork attachment or boom capacity The load is 3 000 pounds 1 360 kg 2 The ope...

Page 64: ...rical cables leads and connections for damage and tightness Check for oil and coolant leaks Check condition and tension of drive belts use 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 Repla...

Page 65: ... Change axle wheel end and differential oil clean magnetic drain plugs After Every 1 000 Hours of Operation Comply with 50 Hour Maintenance Requirements Comply with 250 Hour Maintenance Requirements Comply with 500 Hour Maintenance Requirements Comply with 1000 Hour Maintenance Requirements Change hydraulic fluid After Every 2 000 Hours of Operation After Every 4 000 Hours of Operation Top off axl...

Page 66: ...f the load is in a position where it can be removed safely completely remove the load from the carriage and or attachment Otherwise leave the load in place 5 Remove boom access cover on back of boom Fig 89 Boom Access Cover Fig 90 Extend Cylinder Lower Down Valve Warning Keep fingers and feet away from moving parts or pinch points to prevent pinching or crushing Failure to do so can result in deat...

Page 67: ...pscrew 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 Be aware of lowering the boom to avoid pinch points and crushing hazards 11 When boom is fully lowered tighten valve with hex wrench then tighten nut to secure valve ...

Page 68: ...ed by an employee or is loaned or rented to someone other than the purchaser make certain that the new operator is trained in accordance with OSHA regulations and reads and understands this Operation Safety Manual before operating the vehicle In addition make sure that the new operator has completed a walk around inspection of the vehicle is familiar with all the labels on the vehicle and has demo...

Page 69: ...Operation Manual 69 Lockout Tagout Do Not Operate Tags ...

Page 70: ...Operation Manual 70 Lockout Tagout ...

Page 71: ...Operation Manual 71 Lockout Tagout ...

Page 72: ...1415 W BONANZA RD LAS VEGAS NV 89106 702 636 2969 800 497 1704 www XMFG com PN 24927 001 DZ XR5959 TIER 4 FINAL OPERATION AND SAFETY MANUAL ...

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