Xtreme XR1570 Operating instructions

Xtreme XR1570 Operating instructions
Operation and
Safety Manual
Deutz Tier 4F
PN 24971-000 Rev C
February 2021
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.
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.
Xtreme Manufacturing
8350 Eastgate Road
Henderson, NV 89015, USA
Contact Us:
Corporate Office
T: 1.800.497.1704
T: 1.702.636.2969
F: 1.702.636.4943
E: [email protected]
Service Hotline
T: 1.702.984.7249
Parts Hotline
T: 1.702.984.7250
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.
© 2021 XTREME MANUFACTURING. ALL RIGHTS RESERVED
Table of Contents
Table of Contents
Description
Page
Description
Introduction
Page
Operator Seat Controls
33
General
5
Weight Suspension Lever
34
Replacement Manuals
5
Lumbar Support
34
Model/Serial Plate
5
Fore and Aft Adjustment Lever
34
Orientation
5
Backrest Angle Adjustment Lever
34
Seat Belt
35
Safety
Safety Disclaimer
6
Rear View Mirrors
35
Signal Words
6
Controls and Indicators
36
Safety Symbols
6
Travel Select Lever
36
Employer Responsibility
9
Gear Select Switch
36
Operator Responsibility
9
Parking Brake Switch
37
Operator Qualifications
9
Load Capacity Charts
37
Modifications
9
Display Indicators
37
Mounting/Dismounting
10
Status Lights
39
Work Site Safety
10
Display Features
40
Before Starting Forklift
11
Steering Select Switch
43
Operation Safety
12
Outrigger Control
43
Load Safety
14
Boom Control
44
Attachments
15
Attachment Tilt Switch
45
Shut Down Procedure
15
Frame Sway Control Handle
45
Forklift Maintenance
15
Auxiliary Attachment Control
45
Dead Engine Towing
17
Lights Switch
46
Labels
Boom Angle Indicator
46
Labels
18
Boom Extend Letters
46
Replacement Labels
21
Frame Level Indicator
46
Features
Boom Maintenance Stand (Optional)
47
Standard Equipment
30
Forklift Lifting Points
47
Optional Equipment
30
Operation
Specifications
Specifications
31
Operator Cab
Pre-Operation Inspection
48
Pre-Operation Inspection Checklist
50
Functional Tests
51
Ignition Switch
32
Diesel Exhaust Fluid (DEF)
51
Accessory Outlet
32
Operator Maintenance
52
Accelerator Pedal
32
Before Starting Forklift
53
Service Brake Pedal
33
Oil Change Request
53
Steering Wheel
33
Starting Forklift
54
Horn Button
33
Normal Starting
54
Operator Seat
33
Jump Starting
54
Forklift Travel
55
3
Operation Manual
Table of Contents
Table of Contents
Description
Page
Description
Page
Steering Modes
55
Fork Positioning Carriage Operation
61
Starting Travel
56
Quick Attach System
62
Shifting Gears
56
Load Handling
65
Stopping Travel
56
Boom Lift Point
66
Changing Travel Direction
57
Suspended Loads
66
Shut Down Procedure
57
Pick Up a Load
66
Refueling
57
Carry a Load
66
Pintle Hook
57
Place a Load
66
Warning and Fault Indicators
57
Load Shift
67
DEF Level Monitoring
58
Elevating Personnel
67
DEF Quality Monitoring
58
Load Capacity Charts
68
SCR Hardware Failure Errors
59
Frame Leveling
70
Crystallization Detection
59
Preventive Maintenance
DPF System
60
Establishing a Maintenance Program
71
Standstill Regeneration
60
Maintenance Schedule
71
Standstill Regeneration Conditions
60
Boom Emergency Lowering
73
Attachments
61
Lockout/Tagout
Attachment Disclaimer
61
Do Not Operate - Accident Prevention Tags
74
Fork Ratings
61
New or Additional Operators
74
Standard Carriage Operation
61
Lockout/Tagout Procedure
74
“Do Not Operate” Tags
75
Operation Manual
4
Introduction
12,
Introduction
General
Model / Serial Plate
This Operation and Safety Manual provides the information
needed to safely operate the XR1570 Reach Forklift.
When contacting our parts department, please have the
forklift serial number available. The serial number plate is
located in the operator’s cab, at the base of the seat.
This manual should be considered a permanent part of the
forklift, and kept in the protective manual case located in the
operator’s cab.
For easy reference, you can record the serial number in the
space below.
Notice
Serial Number:
Before operating the forklift, read this manual completely and carefully to understand the safety instructions
and the operation of controls and safety equipment. You
must comply with all DANGER, WARNING, and CAUTION
notices. They are for your benefit.
Warning
Improper operation of this forklift could result in death or
serious injury.
BEFORE starting the engine, do the following:
Read the Operation and Safety Manual
Read all the Safety Labels on the Forklift
Clear the area of all other persons
Figure 1. Serial Number Plate
Learn and practice safe use of forklift controls in a safe,
clear area, BEFORE you operate this forklift on a work site.
Orientation
It is your responsibility to observe applicable laws and
regulations, and to follow manufacturer’s instructions on
forklift operation and maintenance.
Right side, left side, front, and rear are directional references
given from the operator’s seat when facing forward.
RIGHT
FRONT
Replacement Manuals
Replacement manuals for the XR1570 Reach Forklift can be
obtained by contacting our parts department by phone or
visiting our website:
Xtreme Manufacturing
Phone: (800) 497-1704
www.XMFG.com
REAR
•
•
•
LEFT
Figure 2. Forklift Direction Orientation
5
Operation Manual
Safety
Safety
Safety Disclaimer
Signal Words
Signal words are the word or words that call attention to
the safety sign and designate a degree or level of hazard
seriousness. The signal words used in this manual are DANGER,
WARNING, and CAUTION.
Danger
DANGER (Red) used with the safety alert symbol indicates
an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
Warning
WARNING (Orange) used with the safety alert symbol
indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Xtreme Manufacturing reserves the right to make technical
changes for product improvement. This manual may contain
illustrations and photographs (for demonstration purposes),
which slightly deviate from the actual product.
Caution
CAUTION (Yellow) with the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
Safety information provided in this manual is a basic guide
and an attempt to prevent accidents. Xtreme Manufacturing
cannot anticipate every circumstance that might involve a
potential hazard. Warnings in this manual and on the forklift
are NOT all-inclusive.
Caution
CAUTION (Yellow) used without the safety alert symbol
indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
You are responsible for safe operation of the forklift and all
attachments. You must satisfy yourself that the techniques,
operating procedures, work methods, or mentioned by
Xtreme Manufacturing.
Safety Symbols
The safety of everyone around the forklift depends significantly
on your knowledge and understanding of all correct and safe
operating practices and procedures. You can help prevent
accidents by remaining alert and recognizing potentially
hazardous situations.
Warning
Safety symbols are provided to remind the operator of
hazardous situations. Xtreme Manufacturing provides these
symbols in an attempt to inform all operators, regardless of
reading and language skills, of as many potential hazards as
possible. These symbols cover many, but not all, potential
dangers and hazards associated with operating the forklift.
Follow State and Federal health and safety rules and/or local
regulations for operating and maintaining the forklift.
•
This manual does not replace any laws and regulations.
•
The operator is required to comply with all applicable
laws and regulations.
Operation Manual
Make safety a high priority while operating the forklift.
Learn and follow all safety messages in this manual and on
forklift labels to prevent death, serious injury, or equipment
damage. The following two pages include a list of some
of the safety symbols that may be used on this forklift.
6
Safety
Read Operator
Manual Before
Operating This
Forklift
Read Maintenance
Manual Before
Working On
This Forklift
Read Material
Safety Data
Sheets (MSDS) For
Chemicals And
Fluids
Know First Aid
Instructions And/
Or Locations On
Work site
Perform
Operator
Inspection
Before Starting
This Forklift
DO NOT
Operate If Using
Alcohol, Drugs,
Or Medications
Personal
Protective
Equipment
Personal
Protective
Equipment
Personal
Protective
Equipment
Personal
Protective
Equipment
Gloves
Safety Shoes
Safety Glasses
General Safety
Alert Symbol
DO NOT OPERATE!
Forklift Down
For Service Or
Maintenance
Personal
Protective
Equipment
Ear Protectors
Keep Flames
And Ignition
Sources Away
Lead Acid
Batteries Create
Explosive Gases
Warning!
Hydraulic Oil
Under Pressure
Hot Oil!
Hydraulic System
Under Pressure
Keep Hands
A Safe Distance
From Rotating
Fan Blades
Make Sure All
Safety Labels
Are Attached
And Legible
DO NOT Open
Unless Cap Is
Cool To Touch
Warning!
Rotating Belts
Can Cut Or
Entangle
Replace Worn And
Illegible Safety
Labels And Labels
7
Hardhat
No Smoking
Keep Lit
Cigarettes
Away
Use A Board Or
Cardboard To
Check Hydraulic
Leaks. DO NOT Use
Your Hand!
Warning!
Rotating
Fan Blades
Can Cut
Keep Hands A Safe
Distance From
Rotating Belts
Use Three Points
of Contact When
Entering and
Exiting Forklift
Operation Manual
Safety
DO NOT
Jump While
Dismounting
The Telehandler
Fasten
Seat
Belt
DO NOT Allow
Riders On Telehandler
Frame Or Fenders
DO NOT Allow
Riders On Or In
The Operator Cab
Engage Parking
Brake
Warning!
Warning!
Telehandler Roll Away
Can Cause Death
Or Serious Injury
Telehandler Tip Over
Can Cause Death
Or Serious Injury
Warning!
DO NOT Travel
With Boom Raised
DO NOT
Raise Boom While
Traveling On A
Slope
Warning!
Danger!
Electrocution Can
Cause Death Or
Serious Injury
Keep A Safe
Distance From
Electrical Lines
DO NOT Allow
Anyone Under
A Raised Load
Warning!
Explosion
Hazard
Warning! Establish
Radio Communication
Before Operating Solo
Operation Manual
Set Parking Brake
To ON
Attachment Can
Result In Death Or
Serious Injury
Pinch Points
Hands
DO NOT
Allow Riders
On Auxiliary
Attachments
Set Parking
Brake To OFF
Disengage
Parking Brake
DO NOT Jump!
If Telehandler Tips,
Keep Seat belt ON
And Brace Yourself
Tip Over Hazard,
Especially
Traveling Up A
Slope Without A
Load
Hot Surface!
Keep Hands Away
Pinch Points
Body
Have Adequate
Ventilation If
Operating This
Telehandler In An
Enclosed Space
Warning!
DO NOT Use Ether
As A Starting Aid
Operate With
Caution During
Storms Or High Wind
Warning!
HOT COOLANT.
DO NOT Use As A
Personnel Carrier
8
Safety
Employer Responsibility
Operator Qualifications
Under Occupational Safety and Health Administration (OSHA)
rules, employers are required to train workers about hazards
related to operating and maintaining the forklift. Successful
completion and certification of the Safety Training for Rough
Terrain Forklifts is required.
Operators must be in good physical and mental condition,
with appropriate reflexes, reaction time, vision, depth
perception, and hearing.
Operators must possess a valid, current driver’s license as
required for the work site; plus those required by applicable
State, Federal, and/or local laws:
Additional safety information and training resources can be
obtained through these publications, organizations, and/or
appropriate sources:
•
•
•
•
•
•
Successful completion and certification of Safety Training for
Rough Terrain Forklifts is required.
(29CFR) Code of Federal Regulations.
(OSHA) Occupational Safety and Health Administration.
(NIOSH) National Institute for Occupational Health and
Safety.
(ANSI) American National Standards Institute
(AEM) Association of Equipment Manufacturers
(ITSDF) Industrial Truck Standards Development
Foundation
•
•
•
Operators must be properly instructed on how to operate
the forklift and attachments.
Operators must operate the forklift according to ALL
appropriate safety regulations.
Operator trainees must remain under constant
observation and supervision of an experienced operator.
Modifications
Always consult Safety Data Sheets (SDS) for chemical hazards
and first aid instructions for any oil or lubricant being used.
SDS should be available from the manufacturer/supplier of
the fluid.
Warning
Modifications to the forklift or attachments
could affect forklift capacity and/or stability
which could result in death or serious injury.
DO NOT make modifications to the forklift or
attachments without prior written approval
from the manufacturer. Where such authorization is
granted, capacity, operation, and maintenance instruction
plates, tags, or labels shall be changed accordingly.
Operator Responsibility
Warning
Forklifts are potentially dangerous if proper safety
procedures are not followed. Workers who operate,
maintain, or work near the forklift can be at risk of roll over
and run over incidents or can be crushed or caught by the
forklift or its parts which could result in death or serious
injury if the forklift is not properly operated or maintained.
•
•
•
Read the Operation and Safety
Manual BEFORE operating the
forklift. Follow all safety instructions and labels. Only operate
the forklift if you understand
the safety instructions and warnings in all applicable manuals and technical publications. Always follow all State and
Federal health and safety laws and/or local regulations.
You must have the required training, skills, and tools to
perform installation, operation, maintenance, or repair
procedures properly and safely. Make sure the forklift and
attachments will not be damaged or made unsafe by any
procedures you choose.
Unauthorized modifications or alterations will void the
warranty.
DO NOT modify, disable, or bypass any safety devices.
DO NOT burn or drill holes in forks or other attachments.
Structural damage, modification, or alteration, including welding or drilling, can impair and weaken the protective capability
of the Rollover Protective Structure/Falling
Object Protective Structure (ROPS/FOPS) and
could result in death or serious injury.
•
9
Replace the ROPS/FOPS, if it is damaged, before
operating the forklift.
Operation Manual
Safety
Warning
Mounting/Dismounting
•
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 other hazards.
Face the forklift for mounting or dismounting. Use hand holds and steps to maintain
three (3) points of contact at all times, either
both hands and one foot or both feet and one
hand.
•
•
•
•
DO NOT use the controls, steering wheel, or foot pedals
as hand holds or steps. Avoid accidentally engaging or
disengaging a control.
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 on
the work site.
Follow work site signs and signals.
Check boom clearance before driving under a door
opening, bridge, etc.
Slow down when approaching obstructions. Use a
spotter, if necessary.
Stop for poor visibility conditions, such as dust, smoke,
fog, etc. Wait until visibility improves before continuing.
Operate the forklift in an enclosed area only
if there is a ventilation system capable of
routing hazardous fumes outside. Engine
exhaust contains products of combustion
that could cause death or serious injury.
DO NOT jump from the forklift. Clothing
can get caught on pedals, levers, or other
protruding parts. Landing on uneven surfaces
could result in death or serious personal
injury.
DO NOT operate the forklift if you are using
drugs, alcohol, or any medication that might
impair your judgment or ability.
Work Site Safety
•
Warning
•
Use proper safety procedures and avoid
hazardous situations while operating the
forklift to prevent death, serious injury, or
property damage.
•
•
•
•
You must be 18 years of age or older to operate the
forklift.
DO NOT operate the forklift on roads. The reach forklift
is not equipped for road travel.
Warning
Check the work site for any hazards before operating
the forklift.
Check the work surface for loose soil conditions and
overhead power lines.
Contact your local underground utility service or
digging hot line to mark all underground hazards.
Learn the location of all underground hazards at the
work site, such as; gas and water pipes, electrical cables,
and sewers. Underground objects could cause death or
serious injury.
California Proposition 65
Engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Caution
Use caution when operating the forklift
during storms or strong winds.
Operation Manual
10
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.
Contact with moving or heated parts could cause death or
serious injury.
Wear appropriate protective clothing. Personal protective
equipment can include, but is not limited to hardhat,
gloves, footwear, safety glasses or goggles, and hearing
protection. Make sure clothing is snug and properly belted.
DO NOT wear loose clothing, jewelry, watches, or anything
that can catch on forklift controls, moving parts, etc. Failure
to wear the proper protective clothing could result in death
or serious injury.
Perform the pre-operation inspection and
functional tests in an open area and away
from any other obstacles or equipment. Inspections 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.
Before Starting Forklift
Warning
A brief description of controls, indicators,
and instruments is provided as a convenience
for the operator. These descriptions DO NOT
provide complete operation instructions.
Read and understand the entire manual to
prevent death, serious injury, or equipment damage.
Keep the Operation and Safety Manual
on the forklift at all times. Contact Xtreme
Manufacturing for replacement manuals.
Clearly define responsibilities and procedures
for operating the forklift and all attachments.
DO NOT proceed until you seek expert
assistance from a qualified person if any
doubt or question arises about the correct or
safe methods for operating the forklift.
Keep fingers and feet away from
moving parts or pinch points to
prevent pinching or crushing.
DO NOT allow anyone between
the tires and the forklift frame
while operating the forklift. Doing so can result in death or
serious injury.
To avoid death or serious injury,
carefully read and understand
all instructions before operating
the forklift. DO NOT operate,
modify, repair, or maintain the
forklift unless you read and understand the instructions
and warnings in this and all other applicable manuals and
technical publications. Follow all State and Federal health
and safety laws and/or local regulations.
Always check the condition of the seat belt
and mounting hardware before operating the
forklift. If the seat belt or mounting hardware
is defective, it may not properly restrain the
operator, resulting in death or serious injury.
•
•
Consult Safety Data Sheets (SDS)
for chemical hazards and first
aid instructions. SDS should be
available from the manufacturer
or supplier of the fluid.
11
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.
Operation Manual
Safety
the forklift cannot be leveled using the frame sway control,
do not attempt to raise or place load. Reposition forklift or
have the surface leveled.
Warning
Operators must be properly trained and
qualified to operate this specific forklift.
Know the location, learn the specific purpose,
and demonstrate safe and proper use of all
controls, instruments, indicator lights, and
safety and instruction labels. Safety is your responsibility.
Failure to follow these guidelines could result in death or
serious injury.
Warning
To prevent death, serious injury, or property damage, the operator must be seated
with seat belt fastened, arms, legs, and head
completely inside the Rollover Protection
Structure/Falling Object Protection Structure
(ROPS/FOPS), the travel select lever in NEUTRAL, the Parking Brake switch ON (engaged), and the service brakes applied BEFORE starting the forklift.
To prevent death or serious injury, the
operator must be seated with seat belt
fastened, the travel select lever set to
NEUTRAL, the Parking Brake switch ON
(engaged), the service brake applied, and the
area free of people and obstructions BEFORE starting the
forklift.
•
DO NOT adjust the seat or seat belt while the
forklift is moving. Keep both hands on the
wheel while the forklift is moving to prevent
loss of forklift control which could result in
death or serious injury.
Operation Safety
Danger
Never try to escape the forklift if it becomes
unstable. Learn and practice these safety procedures to protect yourself from a roll over or
tip over incident:
• Remain securely fastened in the seat belt.
Death or serious injury by electrocution will
result from contact with or inadequate clearance with energized power lines or apparatus.
• Never operate the forklift in an area where
active overhead power lines, overhead or
underground cables, or other power sources exist.
•
Contact the appropriate power or utility company
to de-energize power lines or take other suitable
precautions.
sources.
Keep the forklift, attachments, and loads a
safe distance from electrical power lines.
• Remain at least 10 feet, plus an additional 0.4 inches for each 1,000 volts over 50,000
volts, from active power lines and other power
•
Work site operating directives and/or local or state
codes might require a greater distance.
•
Know the maximum height and reach of this forklift.
•
Keep your head, body, and limbs within the ROPS/FOPS
structure.
•
Brace yourself and hold on firmly.
•
Lean away from the point of impact.
•
Stay on the forklift and ride out the roll over or tip over.
Warning
It is unlawful to tamper with or remove any component of
the aftertreatment system. It is also unlawful to use Diesel
Exhaust Fluid (DEF) that does not meet the specifications
provided or to operate the machine with no DEF.
Warning
Warning
Diesel Exhaust Fluid contains urea. DO NOT get the substance in your eyes. In case of contact, immediately flush
eyes with large amounts of water for a minimum of 15 minutes. DO NOT swallow internally. In the event the DEF is ingested, contact a physician immediately. Refer to the Safety
Data Sheet (SDS) for additional information.
Use of the frame sway control with the boom
raised above horizontal could cause tip over
resulting in death or injury. Always use the
frame sway control to level the forklift
BEFORE raising the boom above horizontal. If
Operation Manual
The seat belt MUST be worn while operating the
forklift. Failure to wear the seat belt could result in
death or serious injury.
12
Safety
•
•
NEVER allow passengers to ride
on the forklift. DO NOT allow
riders on the frame or operator
cab. Allowing passengers to ride
could result in serious injury. The
forklift is designated for the safety of the operator only.
NEVER use crab or four wheel (4W) steering for
traveling at high speeds. Use only two wheel
(2W) steering for higher speed travel and slow
the forklift before turning. Rapid turning
while using crab or four wheel-steering can
cause tip over which could result in death or serious injury.
•
•
•
•
Warning
Become completely familiar with the forklift
before operating on slopes. The forklift could
overturn due to sudden movement or while
operating on a slope resulting in death or
serious injury.
DO NOT raise the boom while
operating on a slope. Raising
the boom on a slope, even without a load, will change the center of gravity, could cause a tip
over, and result in death or serious injury.
DO NOT travel with an elevated boom. Retract
the boom fully. Lower the boom as low
as practical for proper visibility. Maintain
enough ground clearance for conditions.
Traveling with an elevated boom can cause tip
over, which could result in death or serious injury.
Allow for adequate clearance between the
attachment and other objects when turning.
The attachment extends beyond the front of
the forklift. The operator must be aware of
the maximum sweep of any attachment being used to avoid hitting personnel and other objects in the
area and to prevent death, serious injury, or property damage.
•
•
•
•
Warning
•
To prevent death, serious injury, or property damage, make sure the forklift comes to a
complete stop before moving the travel select
lever. A sudden change in direction of travel,
while carrying a load, could reduce stability
and/or cause the load to shift or fall.
DO NOT shift through multiple gears with a
single turn of the 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 injury.
•
•
Start, stop, travel, steer, and brake smoothly.
Load, unload, and turn the forklift on level ground,
when possible.
Slow down for turns.
Slow down for rough, slippery, or soft terrain.
Use caution around steep slopes, creeks, gullies, ridges,
ditches, and ravines.
Stay away from soft edges that could collapse under
the forklift.
•
•
DO NOT turn on a steep slope.
DO NOT drive the forklift across slopes.
Always drive the forklift straight up and down a slope
(never drive diagonally up or down a slope).
Drive the forklift forward up a slope (front of forklift facing uphill).
Back the forklift down a slope when loaded (front of
forklift facing uphill).
Follow appropriate procedures to prevent
sudden changes in forklift speed that could
result in death or serious injury.
• Turn the gear select lever to the lowest
speed before descending a slope and before
loading or unloading a trailer.
DO NOT adjust the travel select lever while the forklift
is moving.
DO NOT coast downhill. Keep the travel select lever in
the appropriate position.
DO NOT exit the forklift without following
proper shut down procedures.
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 these and
other appropriate guidelines:
Adjust speed for terrain and conditions.
Avoid obstacles by driving around them rather than
over them, when possible.
the forklift.
13
Engine fuel is flammable and can
cause a fire or explosion resulting
in death or serious injury. DO NOT
smoke while refueling and keep
sparks and open flames away from
Operation Manual
Safety
Load Safety
Caution
Never attempt to create Diesel Exhaust Fluid by mixing agricultural grade urea with water. Agricultural grade urea does
not met the specifications required and thye aftertreatment
system may be damaged.
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 15,000 pounds. The total
rated capacity of the forks being used must equal or exceed
forklift capacity. Forks can break causing loss of load and
possible death or serious injury.
Warning
The reach forklift includes a Frame Sway Override switch. Improper use of the Frame Sway
Override switch could result in death, serious
injury, or property damage.
DO NOT exceed the manufacturer’s rated
load for any auxiliary attachment. Any
attempt to lift or carry loads in excess of the
manufacturer’s rated load may cause forklift
tip over, loss of load, or structural damage
which could result in death or serious injury.
Make sure the forklift frame is level before
raising and extending the boom. Frame swaying left or right with the boom raised is extremely dangerous and can result in death or
serious injury.
•
•
•
•
•
Failure to keep personnel clear of the load
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 or over a forklift cab.
Use the frame sway control to level the forklift before
raising the boom.
Reposition the forklift if it cannot be leveled using the
frame sway control.
DO NOT enter or exit a tilted cab.
Remain seated with the seat belt securely fastened
while the cab is tilted.
Keep personnel at least 30 feet (9.14 meters) from a tilted forklift.
Contact with hot surfaces and the exhaust
pipe after the forklift has been operated
could result in serious personal injury.
•
•
•
•
•
Check warning indicators and gauges on the
dash panel frequently during operation. If a
warning indicator is illuminated or a gauge
shows abnormal readings, stop the forklift,
follow proper shut down tag the forklift
with “Do Not Operate” tags, and have a qualified mechanic
service or repair the forklift BEFORE placing it into service
again. Ignoring warning indicators can result in death,
serious injury, or property damage.
•
•
•
•
•
Caution
Release the key immediately after the engine starts. DO
NOT crank the engine for more than 15 seconds at a time.
Failure to do so can damage the starter motor.
Operation Manual
Review the rated load capacity of each auxiliary
attachment 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 load
distribution.
Adjust the load as necessary, especially for nonstandard
loads.
Use caution when handling loose material that can fall
into the cab.
Remove overhanging load materials, when possible,
and watch for sliding material.
DO NOT reach a load over posts or other objects that
can enter the cab, if tipped.
Avoid sudden stops, starts, or turns.
Avoid carrying a swinging 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.
DO NOT use the forklift as a work platform
or personnel carrier. Falling of attachments
could result in death or serious injury.
14
Safety
Attachments
Forklift Maintenance
Warning
Warning
Improper connection of an auxiliary attachment could
result in death or serious injury. Attachments not locked
into place can become unstable and fall on the operator or
other personnel near the forklift.
•
•
•
•
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.
Make sure attachment locking devices are always in
place.
DO NOT operate the forklift until you have positive
indication that the coupler pin and lever are fully
engaged.
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 268.8 bar (3,900 psi), which is
the maximum pressure of the forklift auxiliary hydraulic
system at the quick-disconnect couplers, could result in
death or serious injury.
Make sure all hydraulic connections are tight (if
equipped).
Attach “Do Not Operate” tags to the Ignition
switch and steering wheel before beginning
any service or maintenance.
•
•
•
•
Shut Down Procedure
•
Warning
To prevent death or serious injury, follow these procedures
before leaving the forklift cab:
•
•
•
•
Warning
Check hydraulic oil lines, tubes,
and hoses carefully. DO NOT
use your bare hand to check for
leaks. Always use a board or
cardboard when checking for
a hydraulic leak. Escaping hydraulic fluid under pressure,
even a pinhole size leak, can penetrate body tissue, which
could cause death or serious injury. If hydraulic oil is injected into your skin, a doctor familiar with this type of injury
must treat it immediately.
Park forklift on a firm, level surface.
Move travel select lever to NEUTRAL (N).
Set parking brake to ON (engaged).
Lower forks and attachments to the ground.
Always engage the parking
brake before leaving the
forklift. The forklift can roll if
the parking brake is not ON
(engaged), which could result in
death, serious injury, or property damage.
•
•
•
•
•
“Do Not Operate” tags indicate the forklift should
not be operated until all service or maintenance is
completed.
Keep two (2) legible “Do Not Operate” tags with the
forklift at all times. “Do Not Operate” tags are provided
at the end of this manual.
DO NOT operate the forklift and attachments if they
require repairs.
Make sure basic maintenance is completed and service
problems are corrected.
Death or serious injury can result from operating a
forklift before all repairs have been made and all proper maintenance is completed.
Serious injury could result from
hydraulic oil pressure or hot
oil. DO NOT remove a hydraulic tank filler cap unless it is
cool enough to touch with bare
hands. Remove the hydraulic tank filler cap slowly to relieve
pressure. Relieve all pressure in a hydraulic system before
any caps, lines, fittings, or related items are disconnected
or removed.
Turn Ignition switch to the OFF position.
Remove the key.
Unbuckle the seat belt.
Place “Do Not Operate” tags on the Starter switch
and steering wheel when maintenance or service is
required.
Block wheels when maintenance is required.
15
Operation Manual
Safety
It is possible for the forklift to move suddenly
when the brakes are released, which could
result in death, serious injury, or property
damage. To prevent sudden movement of
the forklift, place wheel chocks in front of and
behind wheels before the brakes are released.
If the forklift is to be towed, make sure the
released brake(s) can be reapplied or the tow
forklift has the braking capacity to stop the
forklift.
Warning
Tires must have proper ballast. DO NOT replace
foam-filled tires with pneumatic tires. Use of
pneumatic tires will severely affect vehicle load
capacity, which could result in death, serious
injury, or property damage.
Warning
California Proposition 65
DO NOT use ether as a starting
aid. Ether is flammable and
can cause an explosion when
starting the engine, which
could result in death or serious
injury. Follow the cold starting procedures and engine
manufacturer’s specifications for using a starting aid.
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm. Wash hands after
handling these items.
Warning
Warning
Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:
•
DO NOT use smoking materials near batteries.
•
Keep arcs, sparks, and open flames away from batteries.
•
Provide ventilation for flammable vapors.
•
Wear proper personal protective equipment, including
safety glasses.
•
•
•
•
Fluid in electric storage batteries contains sulfuric acid,
which is poison and could cause severe chemical burns.
Avoid all contact of fluid with eyes, skin, or clothing. Use
protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction. If contact does occur, follow these First Aid suggestions:
•
•
•
External contact - Flush with water.
•
•
Eyes - Flush with water (including under the eyelids) for
at least 15 minutes and get medical attention immediately. Flushing must begin immediately to avoid permanent eye tissue damage.
•
•
•
Internal contact - Drink large quantities of water or milk
to dilute stomach contents. Do not induce vomiting.
Get medical attention immediately.
Operation Manual
•
16
Wear eye protection when starting a forklift
with 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 jump start the forklift when travel select lever is
in gear, which can cause the forklift to lurch forward or
backward, and could result in death, serious injury, or
property damage.
To avoid injury or death when jump starting with
another forklift, make sure the two (2) forklifts are not
touching.
DO NOT allow jump start cable ends to contact each
other.
Connect charged battery positive (+) to stalled battery
positive (+).
Connect charged battery negative (–) to stalled forklift
ground. Make the connection to the stalled forklift
ground last.
Connect jump start cable to stalled forklift ground a
safe distance from the battery to prevent sparks near
the battery.
Jump start only with a power source with the same
voltage as the stalled forklift.
Turn off all lights and accessories on the stalled forklift
to prevent them from operating when the power source
is connected.
Electrolyte contains acid and could cause serious
personal injury if it contacts the skin or eyes.
Safety
Dead Engine Towing
Parking Brake Release (Front Axle)
Warning
Block all four (4) wheels. Failure to do so could result in
death or serious injury from forklift roll away.
1. Block all four wheels to prevent the forklift from moving
once the parking brake is disabled.
2. Position the towing vehicle in place. Attach any chain
needed to secure the disabled forklift.
A
c
B
D
Figure 3. Brake Release Locations (both sides)
3. Under the front of the
forklift, locate the four (4)
brake release bolts (A to D)
at the base of the front axle
[two (2) per side].
4. Loosen jam nuts. Loosen brake release bolts. Do not
completely remove bolts. Tighten one (1) full turn if bolts
completely back out (repeat for each side). Tighten jam nuts.
5. Crawl out from under the forklift and clear the area of any
unnecessary personnel.
6. Carefully remove the blocking from each of the four (4)
tires and tow the vehicle to a secure location.
Re-Activating Parking Brakes (Front Axle)
Figure 4. Brake Release Bolts (both sides of axle)
Warning
Block all four wheels. Failure to do so could result in death
or serious injury from forklift roll away.
1. After you have blocked all four (4) wheels, under the front
of the forklift, locate the four brake release bolts [two (2) per
side] at the base of the front axle.
2. Loosen jam nuts. Tighten brake release bolts until you
begin to feel resistance. Tighten jam nuts. Repeat for each side.
3. The parking brakes should now be re-activated and the
front wheels are locked. Remove the blocks from all four (4)
wheels.
4. Verify the parking brake works.
5. Remove any warning tags from the ignition or steering
wheel.
Figure 5. Brake Release Bolt
17
Operation Manual
Labels
Labels
Left Side View
9
36
40
35
38
48
25
41
45 46 47
INNER BOOM
44
51 34
26
10
52
10
17
12
3
37
Figure 6. Label Legend (Left Side)
Right Side View
9
39
36
35
42
38
25
43
44
7
26
4 27
10
33
51
31
12
37
8
19
6
34 56
30
10
26
53
53
34
52
Figure 7. Label Legend (Right Side)
Operation Manual
18
Labels
Front View
Rear View
39
26
51
52
53
10
32
10
57
12
53
10
25
37
37
Figure 8. Label Legend (Front)
12
Figure 9. Label Legend (Rear)
Cab View
2
49
23
28
22
10
55
1
17
21
20
11
5
16
15
57
3
Figure 10. Label Legend (Cab)
19
Operation Manual
Labels
Table 1. Labels
Item
Qty
Part No.
Description
Item
Qty
Part No.
1
1
18008-000
Data Plate
38
1
18043-000
Xtreme logo
2
1
18004-060
Dash Overlay
39
1
18044-000
Xtreme X
3
1
18010-001
Caution, Slip/Trip Hazard
40
1
18046-000
Boom Swoosh Left Front
4
1
18011-001
Caution, Engine Damage Hazard
41
1
18047-000
Boom Swoosh Left Rear
5
1
18013-001
Diesel Only (Tier 4)
42
1
18048-000
Boom Swoosh Right Front
6
1
18014-001
Check Engine Oil (Tier 4)
43
1
18049-000
Boom Swoosh Right Rear
7
1
18015-001
Check/Fill Coolant
44
2
18472-000
XR1570
8
1
18016-001
Caution, Burn Hazard
45
1
18056-000
Boom Lettering A-B-C-D
9
2
18017-001
Danger, Crushing Hazard
46
1
18057-000
Boom Lettering E-F
10
8
18018-001
Danger, Electrocution Hazard
47
1
18058-000
Boom Lettering G-H
11
1
18018-002
Danger, Electrocution Hazard
48
1
18311-003
Boom Hook 15k
12
3
18019-001
Danger, Crushing Hazard
49
1
18331-000
Caution, Adjustable Carriage
13
1
18020-001
Warning, Tip-Over Hazard
50
1
18332-000
Warning, Tow Capacity
14
1
18021-001
Danger, Crushing Hazard
51
1
18307-001
Warning, Falling Hazard
15
1
18022-001
Warning, Tip Over Hazard
52
1
18306-001
Danger, Crushing Hazard
16
1
18023-001
Warning, Welding and Modification
Hazard
53
1
18306-000
Danger, Crushing Hazard
17
1
18025-001
Warning, Falling Hazard
54
1
18241-015
Label, XR1570 CG Lifting Points
1
18026-001
Warning, Unrestrained Operator
Hazard
55
1
18413-000
Fill DEF Tank
56
1
18409-000
“DEF ONLY” Label
1
18027-001
Danger, Rotating Equipment
Hazard
57
1
18412-000
Caution, Equipment Damage
58
2
18241-016
Decal, CG & Lift Points, XR1570
~
1
17423-000
Load Chart,1570 Std. Carr. OR up
~
1
17424-000
Load Chart,1570 Std. Carr OR down
~
1
17423-001
Load Chart 1570 Swing Carr OR up
~
1
17424-001
Load Chart 1570 Swing Carr OR dn.
18
19
20
1
18031-001
Warning, Safe Operation Checklist
21
1
18032-001
Warning, Improper Use Hazard
22
1
18033-000
Auxiliary Handle Control
23
1
18034-000
Boom Handle Control
24
1
18039-000
Boom Angle Indicator
25
6
18041-001
Warning, Pinch Point Hazard
26
3
18042-000
Xtreme logo (chassis)
27
2
18066-001
Caution, Crushing Hazard
28
1
18067-100
Frame Sway Handle
29
1
18334-001
Handle Auxiliary Controls
30
1
18069-000
Hydraulic Tank Fluid Level
31
1
18082-001
Warning, Injection Hazard
32
2
18083-001
Warning, Explosion Hazard
33
1
18086-001
Hydraulic Fluid, Use Dexron III
34
4
18090-001
Warning, Tip Over Hazard
35
2
18300-001
Warning, Falling Hazard
36
2
18312-000
Warning, Falling Hazard
37
4
18315-000
Tie Down Point
Operation Manual
20
Description
Labels
From outside Las Vegas, Nev., call Xtreme Manufacturing toll
free at (800) 497-1704.
Replacement Labels
Replacement labels can be obtained by contacting Xtreme
Manufacturing directly at (702) 636-2969.
Please have the correct label number available when you call.
Parking Brake
OFF
ON
Boom
Wiper
Rear
Wash
Front
Left
Steering
Front and Rear
Wheels Must Be
Centered Before
Engaging.
On
Turn
702-636-2969
www.XMFG.com
2) 18004-060
3) 18010-001
4) 18011-001
5) 18013-002
6) 18014-002
21
Off
Hazard
1) 18008-000
On
Up
Right
Crab
2W
800-497-1704
18004-060
Off
Lights
Down
Outriggers
4W
Operation Manual
Labels
Operation Manual
7) 18015-001
8) 18016-001
9) 18017-001
10) 18018-001
11) 18018-002
12) 18019-001
22
Labels
13) 18020-001
14) 18021-001
15) 18022-001
16) 18023-001
17) 18025-001
18) 18026-001
23
Operation Manual
Labels
19) 18027-001
20) 18031-001
WARNING
Operation Manual
21) 18032-001
22) 18033-000
23) 18034-000
24) 18039-000
24
Labels
25) 18041-001
26) 18042-000
27) 18066-001
28) 18067-100
FULL
18334-001
18069-000
29) 18334-001
30) 18069-000
25
Operation Manual
Labels
Operation Manual
31) 18082-001
32) 18083-001
33) 18086-001
34) 18090-001
35) 18300-001
36) 18312-000
26
Labels
37) 18315-000
38) 18043-000
39) 18044-000
40) 18046-000
41) 18047-000
42) 18048-000
27
Operation Manual
Labels
18472-000
43) 18049-000
44) 18472-000
A
C
B
D
18056-000
45) 18056-000
E
F
18057-000
G
46) 18057-000
H
18058-000
47) 18058-000
CARRIAGE DAMAGE
DAMAGE may result from adjusting forks
when carriage is loaded.
ONLY ADJUST FORKS WHEN CARRIAGE
IS UNLOADED.
18331-000
49) 18331-000
48) 18311-003
DEATH or SERIOUS INJURY could result from
improper operation when using tow connection.
DO NOT ELEVATE BOOM ABOVE 30 WHEN
TOWING.
DO NOT EXCEED RATED TOW CAPACITY.
Max vertical load 500 LBS.
Max tow capacity 5000 LBS.
50) 18332-000
51) 18307-001
Operation Manual
28
18332-000
Labels
53) 18306-000
52) 18306-001
MODEL: XR1570
UNLADEN VEHICLE WEIGHT: 48,180 lbs
UNLADEN CENTER OF GRAVITY
FORWARD LIFT POINT
AFT LIFT POINT
78.50"
APPROX
147.0"
WHEEL BASE
18241-016
54) 18241-016
55) 18413-000
CAUTION
DIESEL EXHAUST
FLUID (DEF)
ONLY
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.
18409-000
18412-000R01
56) 18409-000
57) 18412-000
29
Operation Manual
Features
Features
Standard Equipment
Feature
Boom
Chassis
Optional Equipment
Description
Feature
Universal quick attach head
Tires
Three (3) section boom
Hydraulics Auxiliary hydraulic circuit with quick attach
Foam-filled
Boom equipped with heavy duty boom rollers
Attachment tilt switch
Rear axle stabilization
Frame sway control handle
1-1/4 inch main frame plate
Frame sway override switch
Sealed pivot pins for extended service periods
Cab
Description
Options
Enclosed cab with A/C
High boom mount design
Heater/defroster/windshield wiper
Sliding engine transmission cowling
Work light package
Low mounted central engine & drive train
Turn signals/hazard lights
Lights (front and rear)
12 Volt electrical system
Hydraulic side-swing carriage (with quick attach
couplers)
Fuel level, engine coolant temperature, voltage,
and oil pressure gauges
Full line of attachments
Limited slip differential
Easy access drop down electrical panel
12 Volt accessory power outlet
Brake oil pressure, parking brake, axle lock,
rear wheel alignment, declutch indicator,
transmission range, tilt interlock, engine
warning lights
Electric horn and backup alarm
Declutch switch
Rear view mirror
Adjustable seat with seat belt
Deluxe suspension seat
Boom angle and frame level indicator
3600 visibility
Boom angle and frame level indicator
Operation Manual
30
Specifications
Specifications
Standard Equipment
Performance
Capacity . . . . . . .
Lift Height . . . . . .
Forward Reach . . .
Frame Leveling L/R
Operating Weight .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
15,000 lbs
69’ 10”
53’8”
11°/11°
48,180 lbs
Engine . . . . .
Fuel Capacity .
Transmission .
Brakes . . . . . .
Parking Brake .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Deutz 3.6, 134hp
72 gal
3-Speed
Inboard Wet Disc
SAHR
Heavy-duty Frame/Chassis
Heavy-duty Roller Boom
Robust Wiring
Full-time Planetary 4-Wheel Drive
Steering - 4-Wheel Circle, Crab, 2-Wheel Front
Back-Up Alarm
Open ROPS/FOPS
Xtreme Service Accessibility
Suspension Seat
Rear Axle Stabilization (RAS)
Rear View Mirrors
Power Train
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Attachments
Standard Carriage - 72 “ or 96”
Fork Positioning Carriage - 72”
+ 10° Side Tilt Carriage - 48” or 72”
+ 45° Swing Carriage - 52” or 72”
Block Forks - 2” X 2” X 48”
Pallet Forks - 2.25” X 5” X 48”
Lumber Forks - 2” X 7” X 60”
Utility Bucket - 1.25 cu. yd.
Concrete Bucket - 0.5 cu. yd., or 1.00 cu. yd.
Truss Boom - 12’ or 15’
Grapple - Pipe Grapples
Wallboard/Sheet Material Handler
Tires
Tires (Standard Eq)
Foam Filled
15.5 x 25 E3
Hydraulics
GPM . . . . . . . . . . . . . . 49
PSI . . . . . . . . . . . . . . . . 4,000
Hydraulic Oil Capacity . . . 58 gal
Dimensions
Length to fork face .
Width . . . . . . . . .
Height . . . . . . . .
Wheel Base . . . . .
Ground Clearance .
Turning Radius . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
26’6” ( 318”)
8’6” (102”)
9’2” (110”)
12’3” (147”)
1’3” (15”)
15’10” (190”)
Accessories and Options
Enclosed Cab
Limited Slip Differential
Air Conditioning
Boom Work Lights
Rotating Beacon
31
Operation Manual
Operator Cab
Operator Cab
Warning
Accessory Outlet
A brief description of controls, indicators, and
instruments is provided as a convenience for
the operator. These descriptions DO NOT provide complete operation instructions. Read
and understand the entire manual to prevent
death, serious injury, or equipment damage.
A 12 Volt accessory outlet is provided as a power source for
personal items, such as a radio or cell phone.
Ignition Switch
A key is required to operate the ignition switch.
Figure 12. Accessory Outlet
Accelerator Pedal
Press the accelerator pedal to increase engine speed. The accelerator pedal is spring-loaded to return to idle speed.
Figure 11. Key and Ignition Switch
The ignition switch has three (3) positions: OFF, RUN, and
START. To start the engine, turn the key to the RUN position,
wait until the Wait to Start Indicator “E” (Figure 27) goes off
and then turn the key to the START position to crank the engine. After the engine starts, release the key.
Ignition Switch
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.
Operation Manual
Figure 13. Accelerator Pedal
32
Operator Cab
Service Brake Pedal
Operator Seat
Press the service brake pedal to slow or stop the forklift. The
service brake pedal activates the service brakes on all four (4)
wheels.
Operator Seat Controls
The operator seat can be adjusted four (4) ways: weight
suspension, lumbar support, fore and aft, and backrest angle.
Figure 14. Service Brake Pedal
Figure 16. Operator Seat
Steering Wheel
Turn the steering wheel left or right to steer the forklift in the
corresponding direction.
Horn Button
Press the horn button to sound the horn.
B
A
Figure 15. Steering Wheel (A) And Horn Button (B)
33
Operation Manual
Operator Cab
Weight Suspension Lever
Fore and Aft Adjustment Lever
Rotate the weight suspension lever to increase or decrease the
seat cushion suspension based on the weight of the operator
and comfort level desired.
Pull the fore and aft adjustment lever outward from the seat
to release the seat lock. Slide the seat forward or backward to
a comfortable location and release the lever to lock the seat in
the desired position.
Figure 17. Weight Suspension Lever
Figure 19. Fore and Aft Adjustment Lever
Lumbar Support
Backrest Angle Adjustment Lever
The seat controls include a four (4) position lumbar support
knob. Rotate the lumbar support knob to raise, lower, increase,
or decrease the lumbar support.
Pull the backrest angle adjustment lever up to release the seat
backrest lock. Adjust the angle of the backrest and release the
lever to lock the backrest to the desired angle.
Figure 18. Lumbar Support
Operation Manual
Figure 20. Backrest Angle Adjustment Lever
34
Operator Cab
Before starting the engine, adjust the seat for position and
comfort (refer to the Operator Seat section of this manual) and
then adjust the seat belt as follows:
Seat Belt
Warning
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.
Always check the condition of the seat belt
and mounting hardware before operating
the forklift. If the seat belt or mounting
hardware is defective, 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.
2. Pull the retractable seat belt across your lap. Position the
seat belt as low on your body as possible.
3. Insert the latch plate into the buckle (on the right side of
the seat) until a “click” is heard.
4. Make sure seat belt retracts snugly across your lap.
Rear View Mirrors
The forklift is equipped with a standard 2” wide retractable
seat belt. A 3” wide retractable seat belt is available where
required by local laws and regulations.
Two (2) adjustable rear view mirrors are provided to aid the
operator’s rear vision.
Figure 21. Retractable Seat Belt
Figure 22. Cab-Mounted Mirror
One (1) rear-view mirror is mounted on the upper left of the
operator’s cab.
Warning
DO NOT adjust the seat or seat belt while the
forklift is moving. Keep both hands on the
wheel while the forklift is moving to prevent
loss of forklift control which could result in
death or serious injury.
35
Operation Manual
Operator Cab
One (1) rear-view mirror is mounted on the right side of the
chassis.
F
N
R
Figure 24. Travel Select Lever
Figure 23. Chassis-Mounted Mirror
Gear Select Switch
Controls and Indicators
The Gear Select switch has a twist grip handle with three (3)
positions: 1 - FIRST, 2 - SECOND, and 3 - THIRD.
Travel Select Lever
NOTE: The forklift can be operated in three (3) forward and
three (3) reverse gears.
The travel select lever change the direction of travel; it has
three (3) positions: FORWARD, NEUTRAL, and REVERSE.
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
travel select lever when changing to the FORWARD or REVERSE
position.
NOTE: The travel select lever must be in the NEUTRAL
position to start the forklift.
Figure 25. Gear Select Switch
NOTE: The back-up alarm automatically sounds when the
travel select lever is in the REVERSE position.
Operation Manual
36
Operator Cab
To engage the parking brake, flip the red Parking Brake
Switch Guard (A) up and set the Parking Brake Switch (B) to
ON (DOWN). To disengage the parking brake, turn the Parking
Brake Switch (A) to OFF (UP) position. The parking brake
indicator (C) illuminates when the parking brake is set to ON
(engaged).
Parking Brake Switch
The Parking Brake Switch (A) has two (2) positions: ON and
OFF.
A
Load Capacity Charts
C
B
Load Capacity Charts are located on the left side of the front
control panel. Load Capacity Charts are provided to assist the
operator in determining how to safely handle loads with the
forklift, including boom angle, height, and reach.
D
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 indicators.
Figure 26. Parking Brake and Load Capacity Chart
(A) Parking Brake Switch Guard
(B) Parking Brake Switch
(C) Parking Brake Indicator
(D) Load Capacity Chart
A
B
W
G
E
C
D
I
H
N
F
J
K
L
M
P
O
Q
S
T
X
R
U
V
Figure 27. Main Screen - Gauge Display Mode
37
Operation Manual
Operator Cab
A. HYDRAULIC OIL TEMPERATURE
I. SCR WARNING
The Hydraulic Oil Temperature Indicator illuminates when the
oil temperature is above 1800 F. If this 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 proper shut down
procedures, tag the forklift with “Do Not Operate” tags, and
have a qualified mechanic service or repair the forklift BEFORE
placing it into service again.
The amber SCR Warning Indicator (Selective Catalytic
Reduction) comes on in case of any error in the SCR system
(DEF quality, system tampering and system malfunction) or if
the DEF level in the storage tank is low (see below). A flashing
SCR warning Indicator is used for tank level monitoring.
J. DEF LEVEL GAUGE
The DEF (Diesel Exhaust Fluid) level gauge indicates on a
graph and as a percentage the DEF level. DEF reagent should
be added when the SCR Warning indicator comes on.
B. WATER IN FUEL
The Water In Fuel Indicator will be displayed when there is
water present in the Diesel fuel.
A solid light indicates that the DEF level is low (between 10%
and 15%).
C. LOW BRAKE PRESSURE INDICATOR AND WARNING
Two flashes per second indicate very low DEF level (under
10%).
The Low Brake Pressure Indicator illuminates if the hydraulic
oil pressure gets too low. If the Low Brake Pressure Indicator
is illuminated, do not release the parking brake or engage
transmission until the indicator is out. If the indicator does not
go out, stop the forklift, follow proper shut down procedures,
tag forklift with “Do Not Operate” tags, and have a qualified
mechanic service or repair the forklift BEFORE placing it into
service again.
One flash per second indicates that the DEF is critically low
(under 5%). Add DEF reagent immediately.
NOTE: The DEF tank capacity is five (5) gallons.
K. ENGINE STOP
The Engine Stop Indicator is displayed with a flashing Engine
Warning Indicator when the engine is either shut down or an
engine shutdown is imminent.
D. OIL PRESSURE INDICATOR / LOW PRESSURE WARNING
The Oil Pressure Indicator monitors the engine oil pressure. At
normal operating pressure (above 20 psi) it stays green. When
the oil pressure drops below 20 psi this indicator becomes Low
Oil Pressure Warning and it turns yellow (between 12-20 psi).
When the engine oil pressure is DANGEROUSLY low, below 10
psi, it becomes red. If the Low Oil Pressure Warning comes on
during normal operation, stop the forklift, follow proper shut
down procedures, tag forklift with “Do Not Operate” tags, and
have a qualified mechanic service or repair the forklift BEFORE
placing it into service again.
An Engine Stop Indicator displayed with both the Oil Pressure
Indicator and a flashing Engine Warning Indicator shows the
oil pressure is low. The engine should be shutdown, following
proper shut down procedures.
L. FUEL GAUGE
The fuel gauge indicates the percentage of fuel left in the tank.
The total capacity of the fuel tank is 48 gallons. Above 20%
of fuel left in the tank, the indicator is green, turning yellow
between 10 and 20%. It turns red when the fuel level is very
low, 10% and under.
E. WAIT TO START
M. GENERAL WARNING
The Wait To Start Indicator is displayed when the key switch is
moved to the RUN position. Wait until the indicator goes out
before starting the engine.
In case of any engine errors the General Warning Indicator will
be activated. Whenever this warning indicator is active, a fault
code is stored in the error memory. No system reactions like
power reduction can become active without error indicator.
F. SERVICE REMINDER
The Service Reminder Indicator flashes for 30 seconds at key
ON to indicate that Service is required.
Two different states are possible:
G. REAR AXLE LOCKED
Indicates that the rear axle is locked.
H. TACHOMETER
The Tachometer indicates engine RPM using an analog display
and below it a digital display.
Operation Manual
•
Solid on - Errors that allow continuing engine operation
with minor restrictions.
•
Blinking - Errors that cause an engine shut down or shut
down request.
Emission related errors of the EAT system will also be displayed
38
Operator Cab
below the tachometer in the hour meter box (T), which now
becomes the Status Display. The General Warning Indicator
will also come on.
tag forklift with “Do Not Operate” tags, and have a qualified
mechanic service or repair the forklift BEFORE placing it into
service again.
N. REAR AXLE CENTERED
R. HIGH EXHAUST TEMPERATURE
Indicates that the rear axle is centered.
This symbol is activated if the engine exhaust temperature exceeds 1,1660 F in normal operation mode.
O. ENGINE COOLANT TEMPERATURE
S. MAIN MENU INDICATOR
The Engine Coolant Temp Indicator monitors the engine
cooling system. After starting the forklift, allow time for the
indicator to display a temperature close to the normal range
before operating the forklift. After the engine has sufficiently
been warmed up, normal engine coolant temperature
should read between 180 to 2050F. The Engine Coolant Temp
Indicator turns yellow at coolant temperatures between 205
and 2150F to warn that the engine operates at higher than
normal temperature. The Engine Coolant Temp Indicator
becomes red when the temperature reaches 2160F, indicating
an engine overheating situation.
Pres the select button corresponding to this indicator to open
the Main Menu.
T. HOUR METER
The Hour meter indicates and records engine operating
hours. Use the Hour meter to establish a forklift maintenance
schedule.
U. DIGITAL CLOCK
Displays the current time, selectable in 12 hr or 24 hr format.
P. REGENERATION (REGEN) INDICATOR
V. REGENERATION (REGEN) MENU
This is a multi-functional indicator for standstill request and
active standstill. The following states of the standstill indicator
are possible:
Pres the select button corresponding to this indicator to
access the Regen Menu.
W. LEFT SIDE OUTRIGGER DOWN
•
Off - no standstill active, no standstill request active
•
Solid On - standstill active (on-going)
•
Slow blinking (every 2 sec.) - standstill required. Operator can start standstill if the machine is in safe conditions
(the forklift is stationary, engine is warmed and no DEF
errors are active). See Standstill Regeneration Conditions
for more information.
X. RIGHT SIDE OUTRIGGER DOWN
Fast blinking (3/sec.) - standstill required.
See the illustration below. Press the select button
corresponding to this indicator to operate the backup camera.
•
Indicates that the outrigger on the left side of the forklift is
locked in the DOWN position.
Indicates that the outrigger on the right side of the forklift is
locked in the DOWN position.
Y. BACKUP CAMERA (OPTIONAL)
If the operator tries to release a standstill with the push button, but the standstill is inhibited for any reason, the indicator
will be switched off for 2 seconds before starting the blinking
mode again. This provides a confirmation to the operator that
the push button was accepted.
Y
NOTE: During an active standstill, some of the machine
functions are deactivated. The engine runs with the desired
standstill speed. NO MACHINE OPERATION IS ALLOWED
DURING THIS PERIOD.
Q. BATTERY VOLTAGE
The Battery Voltage Indicator monitors the amount of charge
in Volts (V). The normal system voltage is between 12.5 and
14 V. The indicator turns yellow if the charge is between 11.5
and 12.5 V, and becomes red if the charge drops below 11.5V.
If the voltage indicator shows abnormal readings (below
11.5V), stop the forklift, follow proper shut down procedures,
Figure 28. Backup Camera (Optional)
39
Operation Manual
Operator Cab
Display Features
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 lights.
POWER UP
When the ignition is turned on, the display powers up and
defaults to GAUGE DISPLAY mode. The display should remain
in this mode for normal operation.
Select Buttons
Figure 31. Hidden Utilities
Select Buttons
SYSTEM SETTINGS
Menu Button
Pressing the SYSTEM SETTINGS select button will display
engine information. The top left button restores the factory
defaults. The up/down buttons are used to navigate this
menu. Pressing the MENU select button will return to the
previous menu.
Enter Button
Figure 29. Gauge Display
MAIN MENU
Pressing the MENU select button will bring up the MAIN
MENU. Pressing the GAUGE DISPLAY select button, will return
to the GAUGE DISPLAY mode.
Figure 32. Engine Diagnostics
When making changes to the system settings, you will be
prompted to confirm or cancel the new entries.
Figure 30. Main Menu
UTILITIES
Pressing the UTILITIES select button will bring up the Hidden
Utilities Menu.
Figure 33. Engine Diagnostics
Operation Manual
40
Operator Cab
CLOCK SETUP
DIAGNOSTICS
Pressing the CLOCK SETUP soft button will enter a menu
where the clock can be setup or adjusted.
Pressing the ENGINE DIAGNOSTICS soft button will display
engine information. Use the up/down buttons to navigate
Pressing the MENU button will return to the GAUGE DISPLAY.
Figure 34. Clock Setup Menu
Figure 37. Diagnostics Menu
SERVICE REMINDERS
END OF LINE (EOL) TEST
Pressing the SERVICE REMINDERS soft button will display data
pertaining to maintenance schedules.
Pressing the EOL Test select button will enter a test menu
that runs the aftertreatment/regen system and makes sure it
works properly. Follow the EOL Test on-screen instructions.
Figure 35. Service Reminders Menu
If a scheduled service is due, the GAUGE DISPLAY indicates below the tachometer in the hour meter box, the service needed.
Figure 38. EOL Test Instructions
The EOL test results will be displayed on the screen.
Figure 36. Service Requested
Figure 39. EOL Test
41
Operation Manual
Operator Cab
REGEN RELEASE
Pressing the top left-hand select button will start the regen
process.
FAULT BUTTON POP-UPS
A fault condition may trigger a pop-up dialog box describing
the nature of the fault. It is displayed below the tachometer
in the hour meter box (T), which now becomes the Status
Display. The General Warning Indicator will also come on.
A soft button may need to be pressed to acknowledge the
fault.
B
C
CLEAR ALL FAULTS
Figure 42. Restore Defaults Confirmation. Enter Key “B”, Menu Key “C”
Pressing the CLEAR FAULTS select button (A) will remove all
the faults displayed.
REGEN MENU
The Regen Menu is accessed by pressing the select button “D”
at the bottom right corner of the Murphy display.
A
D
Figure 40. Clear Faults
USER SETTINGS
Figure 43. Main Screen; Regen Indicator At Bottom Right Screen Corner
Pressing the USER SETTINGS soft button will enter a mode
where some display settings may be adjusted using the Up/
Down buttons.
Pressing the Regen Stop/Inhibit select button will stop or inhibit the regen process.
E
F
G
H
Figure 41. User Settings
Figure 44. Regen Screen With No Alerts
The default settings can be restored using the top left button.
Each Restore Defaults needs to be confirmed or canceled on
the next screen. Pressing the MENU button will return to the
previous menu.
Operation Manual
The message area in the middle of the screen will display a
message regarding the conditions that need to be met for the
regen process to start.
42
Operator Cab
ment for emergency reasons. It temporarily deactivates engine inducements caused by the Engine Aftertreatment System (EAT).
The restore time and the handling of repeated activation of
the EAT override button are treated dependent on the type of
active errors.
INDUCEMENT
To meet the EPA requirements for tier four final diesel emissions, a two stage inducement system is used. As soon as a relevant error is detected, the operator is informed with an EAT
related warning message.
Figure 45. Regen Conditions
•
Derating Step 1: For DEF-Level, DEF-Quality and
DEF-Tampering there will be no derating. For Standstill
and DPF-Ash the available engine torque is reduced by 25
% in the whole operating range of the engine. The torque
reduction becomes active with minimum ramp of 10 %
per minute.
•
Derating Step 2: If the error remains active, a final inducement becomes active. The final inducement is a
forced low idle operation and will be announced by warning messages 10 minutes prior to activation. The torque
reduction occurs at a rate of 10 % per minute. The engine
speed is reduced by 360 rotations every minute.
THE REGEN PROCESS
The Regen Release select button “E” (Figure 44) is used to start
the re-gen process. If a regen is requested and all the conditions of the machine to be able to regen are met, (park brake
set, shifter in neutral, engine is idling and warm, inhibit button
is not active), then the regen process starts. If any of these
conditions is not met, the regen process doesn’t start; the
Regen Indicator shuts off for 2 seconds then it starts blinking
again.
Warning
INDUCEMENT OVERRIDE - During final inducement (derating step 2) an override or restore functionality is not
allowed. Due to previous warnings the operator must be
aware of the impending circumstance.
Once the regeneration starts, no machine functions should
be operated.
•
Repeated Occurrence: If DEF quality or tampering is
detected again within a period of 40 operating hours, a
warning is created immediately. The maximum time left
before final inducement (derating step 2) will become active is 30 minutes. The inducement level 30 minutes before final inducement becomes active.
GAUGE DISPLAY
Press the GAUGE DISPLAY select button “H” (Figure 44) to
return to the GAUGE DISPLAY mode.
To enter the MAIN MENU, press the bottom left-hand button
“B” (Figure 37).
Figure 46. Regen Screen With All Alerts Active
DEF-LEVEL MONITORING
The engine ECU takes over control of the engine speed and
adjusts it as required. This process takes approximately 30
minutes. The regen process status is displayed on the screen.
If no DEF reagent is available in the storage tank, the emission
requirements cannot be fulfilled and the machine will derate
eventually to idle only.
REGEN STOP / INHIBIT
There are three error messages available, representing the
monitoring steps with active engine limitations.
For emergency reasons, a standstill regeneration in process
can be stopped by pressing the bottom left-hand button “F”.
Besides stopping a standstill in progress, this button also toggles the inhibit switch if a standstill is not in progress.
The machine is fully restored to normal functionality and operation when a tank fill is performed and indicated. A tank fill is
assumed when the level exceeds the Reduction level 1 trigger
level. If the filled DEF level does not exceed the initial warning
level (<10%), the operator warning system remains activated.
INDUCEMENT OVERRIDE
The select button “G” (Figure 44) overrides engine induce43
Operation Manual
Operator Cab
Outrigger Control
Boom Control
The boom control handle has variable motions from the
center position that control boom and tilt functions.
The outrigger toggle switches are used to lower and raise the
outriggers. The outrigger indicators “W” and “X” (Figure 27)
illuminate when the outriggers are fully extended and on the
ground.
The boom control handle is used to raise, lower, extend,
retract the boom, tilt the carriage (or attachment), and
control auxiliary functions (when equipped with a carriage or
attachment with additional functions).
NOTE: The boom control handle is a variable speed control.
Function speed is proportional to handle movement. The
more the handle is moved in the appropriate direction, the
faster the corresponding function will occur.
NOTE: Increasing engine speed can increase boom lift and
extend speed.
NOTE: Two (2) boom functions can be performed at the
same time by moving the handle into the corner between (2)
functions
Figure 47. Outrigger Left and right Toggle Switches
Boom Control Handle Functions
Function
Purpose
Aux Select Button
Control auxiliary functions
Enable Trigger
Trigger must be enabled for other
functions of the control handle to
operate
Tilt Switch
Control carriage tilt (up/down)
A
B
Figure 48. Outriggers Down
C
Once outriggers are fully extended, the transmission is disengaged, and the frame sway is locked. Frame sway lock can be
overridden with the frame sway override switch.
D
E
F
G
H
Figure 49. Outriggers Up
Operation Manual
Figure 50. Boom Control Handle Functions
44
Operator Cab
Frame Sway Control Handle
Attachment Tilt Switch
Function
The Attachment Tilt Switch located on the top of the boom
control handle controls attachment tilt functions.
1
Move handle right
Frame sway left
Move handle left
NOTE: Lock the frame sway by placing the travel select lever
in NEUTRAL or applying the service or parking brake.
FRONT OF
VEHICLE
NOTE: Maximum frame sway is 220 overall or 110 each
direction, left and right.
Warning
2
The forklift includes a Frame Sway Override
switch. Improper use of the Frame Sway
Override switch could cause death, serious
injury, or property damage.
The frame sway feature
becomes locked and
will not operate when
the boom is raised 40°
or more. Pressing the
Frame Sway Override
switch (the trigger) on
the control handle will
override the lockout
feature and allow slow
frame sway.
Figure 51. Attachment Tilt Switch - (A) Tilt Down (B) Tilt Up
The Attachment Tilt Switch:
•
Purpose
Frame sway right
Controls the attachment tilt functions by rolling the
switch upward and downward. For the attachment to
tilt up, roll switch downward. For the attachment to tilt
down, roll switch upward.
•
Is a variable speed switch. Function speed is proportional
to how far the switch is rolled. The more the switch is rolled
in the appropriate direction, the faster the corresponding
function will occur.
NOTE: The attachment carriage will retain any set angle
throughout boom raising, lowering, retracting, or extending
operations.
Auxiliary Attachment Control
The Auxiliary Attachment Control lever controls the functions
of approved optional attachments that can be mounted to
the forklift and require hydraulic supply for operation.
Figure 52. Frame Sway Control Handle
Figure 53. Auxiliary Attachment Control Lever
45
Operation Manual
Operator Cab
Lights Switch
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.
Flip the toggle switch to ON to turn the front lights on.
Figure 56. Boom Extend Letters
Figure 54. Lights Switch
Frame Level Indicator
Boom Angle 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 forklift has been positioned in a
level condition.
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.
NOTE: The boom angle indicator is a plumb arrow with angular
graduations from -50 to +700
Figure 55. Boom Angle Indicator
Operation Manual
Figure 57. Frame Level Indicator
46
Operator Cab
Boom Maintenance Stand (If Equipped)
Forklift Lifting Points
The XR1570 lifting points are shown below (Figure 58). The
forklift should only be lifted if lifting points are installed.
The Boom Maintenance Stand is an optional safety equipment
used to support the boom during any and maintenance
activities where the boom is raised.
Warning
When preparing to set boom stand, make sure machine is on a
flat level ground and machine has no load on the forks.
•
Raise machine boom to 40 degrees for clearance and
remove latch and pin from boom stand weldment.
•
Position the boom stand in the upright position and reapply the pin to secure stand.
•
Proceed by slowly lowering machine boom to lay on
stand. Verify that hoses and wiring do not contact the pad.
If this occurs, raise the boom and adjust stand as needed.
Ensure that no one is in the work radius before
lifting forklift to avoid crushing hazard.
DO NOT
try to lift or handle heavy
components without the use of appropriate
lifting equipment.
DO NOT use attachments that are corroded
excessively.
When not in use, fold the support down and latch it in
place. When preparing to remove boom stand, make sure all
maintenance has been performed and area is clean.
•
Inspect the forklift and the attachments periodically for
corrosion.
•
Raise machine boom to 40 degrees for clearance and
remove pin from stand weldment
•
Inspect the forklift and the attachments periodically for
corrosion.
•
Lay boom stand in the down position and re-latch stand
to secure.
MODEL: XR1570
UNLADEN VEHICLE WEIGHT: 48,180 lbs
UNLADEN CENTER OF GRAVITY
FORWARD LIFT POINT
AFT LIFT POINT
78.50"
APPROX
147.0"
WHEEL BASE
18241-016
Figure 58. XR1570 Lifting Points
47
Operation Manual
Operation
Operation
Caution
Pre-Operation Inspection
Contact with hot surfaces and the exhaust
pipe after the forklift has been operated
could result in serious personal injury.
To perform the pre-operation inspection make sure the
forklift is NOT running, the engine is cool, the forklift is parked
on level ground, the boom is completely retracted, and the
frame is level.
NOTE: Copy and use the Pre-Operation Inspection Checklist
in this section.
Warning
Always check the condition of the seat belt
and mounting hardware before operating the
forklift. If the seat belt or mounting hardware
is defective, it may not properly restrain the
operator, resulting in death or serious injury.
Warning
Wear appropriate protective clothing. Personal protective
equipment can include, but is not limited to hardhat,
gloves, footwear, safety glasses or goggles, and hearing
protection. Make sure clothing is snug and properly belted.
DO NOT wear loose clothing, jewelry, watches, or anything
that can catch on forklift controls, moving parts, etc. Failure
to wear the proper protective clothing 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.
Check hydraulic oil lines, tubes,
and hoses carefully. DO NOT
use your bare hand to check for
leaks. Always use a board or
cardboard when checking for
a hydraulic leak. Escaping hydraulic fluid under pressure,
even a pinhole size leak, can penetrate body tissue, which
could cause death or serious injury. If hydraulic oil is injected into your skin, a doctor familiar with this type of injury
must treat it immediately.
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.
Contact with moving or heated parts could cause death or
serious injury.
Perform a pre-operation inspection and functional tests in an open area.
Become familiar with all safety and hazard labels, regulations, and procedures. Make sure
all proper labels are attached to the forklift
and remain legible.
Serious injury could result from
hydraulic oil pressure or hot
oil. DO NOT remove a hydraulic tank filler cap unless it is
cool enough to touch with bare
hands. Remove the hydraulic tank filler cap slowly to relieve
pressure. Relieve all pressure in a hydraulic system before
any caps, lines, fittings, or related items are disconnected
or removed.
Remove forklift from service and place “Do
Not Operate” tags on the Starter switch and
steering wheel if anything is found to be in
need of repair or maintenance, defective, or
unsafe in any way.
Never remove the radiator cap while the
engine is hot. The cooling system is under
pressure. Hot coolant could cause severe
burns or eye injury. Wear protective clothing
and safety glasses.
Operation Manual
48
Operation
Warning
Warning
Wear eye protection when starting a forklift with jump start cables. Improper jump
start procedures could cause the battery to
explode, which could result in death or serious injury.
Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:
•
Never jump start a frozen battery, as it can explode. Let
the battery thaw out before charging.
•
NEVER jump start the forklift when travel select lever is
in gear, which can cause the forklift to lurch forward or
backward, and could result in death, serious injury, or
property damage.
•
To avoid injury or death when jump starting with
another forklift, make sure the two (2) forklifts are not
touching.
•
DO NOT allow jump start cable ends to contact each
other.
•
Connect charged battery positive (+) to stalled battery
positive (+).
•
Connect charged battery negative (–) to stalled forklift
ground. Make the connection to the stalled forklift
ground last.
•
Connect jump start cable to stalled forklift ground a
safe distance from the battery to prevent sparks near
the battery.
•
Internal contact - Drink large quantities of water or milk
to dilute stomach contents. Do not induce vomiting.
Get medical attention immediately.
Jump start only with a power source with the same
voltage as the stalled forklift.
•
Turn off all lights and accessories on the stalled forklift
to prevent them from operating when the power source
is connected.
IMPORTANT - In case of internal contact, DO NOT give fluids
that induce vomiting.
•
Electrolyte contains acid and could cause serious
personal injury if it contacts the skin or eyes.
•
DO NOT use smoking materials near batteries.
•
Keep arcs, sparks, and open flames away from batteries.
•
Provide ventilation for flammable vapors.
•
Wear proper personal protective equipment, including
safety glasses.
Fluid in electric storage batteries contains sulfuric acid,
which is poison and could cause severe chemical burns.
Avoid all contact of fluid with eyes, skin, or clothing. Use
protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction. If contact does
occur, follow these First Aid suggestions:
•
External contact - Flush with water.
•
Eyes - Flush with water (including under the eyelids)
for at least 15 minutes and get medical attention
immediately. Flushing must begin immediately to
avoid permanent eye tissue damage.
•
Tires must have proper ballast. DO NOT
replace foam-filled tires with pneumatic tires.
Use of pneumatic tires will severely affect
forklift load capacity, which could result in
death, serious injury, or property damage.
Warning
California Proposition 65
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm. Wash hands after
handling these items.
To avoid engine damages, any machine operation is strictly forbidden during an active
standstill/regen.
49
Operation Manual
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 match the carriage installed and are legible.
Check that frame level indicator is working properly.
Check condition and operation of the seat belt and mounting hardware.
Check that Operation and Safety Manual is in the protective case and legible.
Check forks for welds, cracks, misalignment, or any other damage.
Check that carriage fork pins are straight and in place to prevent forks from changing position or coming off the carriage.
Check all hydraulic hoses and hose connections for wear or leaks.
Check tilt cylinders for leaks or any other damage
Check boom for straightness or any other damage.
Check all four (4) tires and wheels for:
Punctures, cracks, cuts, gouges, bulges, foreign objects, or any other damage to tires.
Loose or missing lug nuts.
Bent flanges or any other damage to rims.
Check front and rear sway cylinders and hoses for leaks or any other damage.
Check electrical connections on rear sway cylinder.
Check mirrors for cracks, cleanliness, and proper adjustment.
Check hydraulic reservoir sight gauge for proper fluid level. Add hydraulic fluid, if necessary.
Check engine compartment with engine off for:
Loose or damaged belts, hoses, and radiator fan blades.
Check air filter minder (on air filter housing).
Coolant reservoir level. Add radiator coolant, if necessary.
Engine oil level. Add engine oil, if necessary.
Electrical wires and connectors.
Check transmission fluid level while engine is running.
Check front and rear axles for leaks or any other damage.
Check main boom lift cylinder, carriage master tilt cylinders, and hydraulic lines for leaks or any other damage.
Check battery terminals for corrosion.
Check battery for cracked, melted, or damaged case.
. any damaged or illegible labels.
Check that all labels are present and legible. Replace
Check that operator’s cab is empty of all trash, debris, or any loose items.
Check that personal belongings are secured in the personal storage box.
Check that pedals, and non-skid surfaces are clean and free of grease, oil, dirt, snow, or ice.
Date: __________________________
Operation Manual
Initials: __________________________
50
Operation
Test the service and parking brakes.
• Apply the service brake pedal after the forklift
begins to move and the forklift should stop
immediately.
• Apply the parking brake. Make sure brakes hold on
the steepest incline at the job site. The forklift should
not move unless the parking brake is released.
Functional Tests
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.
Contact with moving or heated parts could cause death or
serious injury.
Test each steering function. Operate the forklift in
forward and reverse at low idle speed and turn the
steering wheel approximately 1/4 turn in each direction
for each of the following modes:
Perform the pre-operation inspection and
functional tests in an open area and away
from any other obstacles or equipment.
Inspections and functional tests may require
assistance. Keep the assistant visible and a
safe distance from the forklift to prevent death or serious
injury.
•
Align the wheel and set the Steering Select switch
to crab steering.
•
Align the wheel and set the Steering Select switch
to 2 wheel (2W) steering.
•
Align the wheel and set the Steering Select switch
to 4 wheel (4W) steering.
Check the gauges after the engine warms to the proper
operating range.
Remove forklift from service and place “Do
Not Operate” tags on the starter switch and
steering wheel if anything is found to be in
need of repair or maintenance, defective, or
unsafe in any way.
The safety, efficiency, and service life of your forklift will be
increased by performing functional tests at the beginning
of each shift. If any of the items in the functional tests are
not operating properly or within set tolerances, stop the
forklift, follow proper shut down procedures, tag the forklift
with “Do Not Operate” tags, and have a qualified mechanic
service or repair the forklift before placing it into service
again.
•
Check the voltage gauge. The voltage gauge
should read between 11 to 15 Volts.
•
Check the engine coolant temperature gauge. The
engine coolant temperature gauge should read
between 1800 to 2000 F.
•
Check the engine oil pressure gauge. The engine
oil pressure gauge should read between 40 to 80
PSI.
Diesel Exhaust Fluid (DEF)
Operate the boom control handle forward and
backward to lower and raise boom.
The DEF tank should be filled after every fuel refill. DEF should
be added when the Low DEF Level indicator is displayed. Refer
to the Operation section on Warning Indicators and Fault
Codes and the Engine Indicator Chart. The total capacity of
the DEF tank is 5 gallons.
Operate the boom control handle left and right to
retract and extend boom.
Operate the attachment tilt thumb stick up and down
to tilt the attachment.
Warning
Operate the sway control handle left and right to frame
sway left or right.
If no DEF reagent is available in the DEF tank, the emission
requirements cannot be fulfilled and the machine derates
eventually to idle only, following a predetermined schedule.
Operate the auxiliary attachment control (if an auxiliary
attachment is being used).
Turn work lights on and off.
Press the horn button to sound the horn.
Caution
Place the travel select lever in reverse to sound the
backup alarm.
Release the parking brake.
Using anything other than DEF fluid may result in permanent
aftertreatment damage.
Operate the forklift in forward and reverse.
51
Operation Manual
Operation
Operator Maintenance
B
A
A
B
Figure 59. Check Hydraulic Oil Sight Gauge (A); Add Hydraulic Oil, if Necessary (B).
WARNING! HOT CAP! DO NOT Remove Hydraulic
Tank Filler Cap Unless It Is Cool Enough To Touch
With Bare Hands.
INSET
Figure 62. Check Engine Oil Level
Use the yellow dipstick “A” . Add engine oil (API CJ-4 ), If Necessary (“B”, See Inset).
Figure 60. Add DEF (Diesel Exhaust Fluid) when the Low DEF Level
indicator is displayed.
Figure 63. Check Battery Case and Terminals
Figure 61. Check Coolant Reservoir Level. Add Coolant,
if Necessary.
WARNING! Hot Coolant. DO NOT Open Radiator Cap When Hot To Touch.
Operation Manual
Figure 64. Store Operation Manual in Protective Case
52
Operation
NOTE: The engine will only start when the travel select lever is
in NEUTRAL (N) and the Parking Brake switch is ON (engaged).
Before Starting Forklift
Warning
B
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 other hazards.
Face the forklift for mounting or dismounting. Use hand holds and steps to maintain
three (3) points of contact at all times, either
both hands and one foot or both feet and one
hand.
DO NOT use the controls, steering wheel, or foot pedals
as hand holds or steps. Avoid accidentally engaging or
disengaging a control.
A
Figure 66. Parking Brake Switch (A) Must Be ON (Engaged) to Start the
Forklift. Parking Brake Indicator Light (B) and Switch Guard (C)
DO NOT jump from the forklift. Clothing
can get caught on pedals, levers, or other
protruding parts. Landing on uneven surfaces
could result in death or serious personal
injury.
1.
Master battery disconnect on.
2.
Use safe mounting/dismounting procedures to enter the
operator cab.
3.
Adjust the operator seat for position and comfort. (Refer
to Seat Adjustment section in this manual)
4.
Adjust mirrors (this may require assistance).
5.
Adjust the side console control panel.
6.
Fasten seat belt.
7.
Make sure the travel select lever is set to NEUTRAL (N) and
the Parking Brake is ON (engaged).
C
Oil Change Request
Running the engine in standstill operation mode for longer
periods may lead to oil dilution. Under normal operating conditions of the engine the number of standstill regenerations
and the total time in standstill operation mode do not cause
critical oil dilution.
If, due to system errors, extreme operating conditions or
misuse of the service regeneration function, the standstill regeneration time is critically high, an additional engine oil exchange becomes necessary.
The ECU monitors the time in standstill operation mode and
activates a system error if a threshold is exceeded. The error
code requires an additional oil exchange service and can only
be reset via Service Tool.
Two different error codes are possible:
F
N
R
•
The first error indicates an unusual high regeneration
time in a short term monitoring interval (50 hours).
•
The second error informs about unusual high regeneration time in a long term monitoring interval (corresponding to the standard oil exchange interval).
For the XR1570 forklift, the Oil Change Request triggers from
the ECU are:
•
Five (5) standstill regenerations within 50 hours, or
•
Twenty (20) standstill regenerations within 500 hours
Caution
Do not idle for extended periods of time. Excessive idle time
can cause poor engine performance.
Figure 65. Travel Select Lever Must Be in NEUTRAL (N) Position to Start
the Forklift
53
Operation Manual
Operation
NOTE: If the engine fails to start on the first try, wait until the
engine and starter come to a complete stop before cranking
the engine again.
Starting Forklift
Normal Starting
Caution
Release the key immediately after the engine starts. DO
NOT crank the engine for more than 15 seconds at a time.
Failure to do so can damage the starter motor.
Warning
To prevent death, serious injury, or property damage, the operator must be seated
with seat belt fastened, arms, legs, and head
completely inside the Rollover Protection
Structure/Falling Object Protection Structure
(ROPS/FOPS), the travel select lever in NEUTRAL, and the
Parking Brake switch ON (engaged) BEFORE starting the
forklift.
Jump Starting
Jump Start or replace the battery of the forklift when the
battery is discharged to the point that it will not crank the
starter.
Warning
Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:
Figure 67. Key and Ignition Switch
•
DO NOT use smoking materials near batteries.
•
Keep arcs, sparks, and open flames away from batteries.
•
Provide ventilation for flammable vapors.
Wear proper personal protective equipment, including
safety glasses.
1.
Place Key in Ignition Switch. Place the parking brake in
the ON position and the transmission in NEUTRAL.
2.
To start the engine, turn key in ignition switch clockwise
to the RUN position.
•
3.
Wait until the Wait to Start
Indicator goes off and then turn
the key to the START position to
crank the engine.
4.
Release key immediately after the
engine starts. The Ignition Switch
will automatically return to RUN.
Fluid in electric storage batteries contains sulfuric acid,
which is poison and could cause severe chemical burns.
Avoid all contact of fluid with eyes, skin, or clothing. Use
protective gear when handling batteries. DO NOT tip a battery beyond a 45° angle in any direction.
If contact does occur, follow these First Aid suggestions:
NOTE: The Start position is springloaded. When the key is released, the
ignition switch will automatically return to the RUN position.
NOTE: If the engine fails to start on the first try, wait until the
engine and starter come to a complete stop before cranking
the engine again.
5.
6.
After the engine starts, allow the engine to idle for
approximately 60 seconds.
External contact - Flush with water.
•
Eyes - Flush with water (including under the eyelids) for
at least 15 minutes and get medical attention immediately. Flushing must begin immediately to avoid permanent eye tissue damage.
•
Internal contact - Drink large quantities of water or milk
to dilute stomach contents. Do not induce vomiting.
Get medical attention immediately.
IMPORTANT - In case of internal contact, DO NOT give fluids
that induce vomiting.
Apply the service brake pedal and disengage the Parking
Brake switch.
Operation Manual
•
54
Operation
Warning
•
•
•
•
•
•
•
•
•
•
1.
Forklift Travel
Wear eye protection when starting a forklift
with 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 jump start the forklift when travel select lever is
in gear, which can cause the forklift to lurch forward or
backward, and could result in death, serious injury, or
property damage.
To avoid injury or death when jump starting with another forklift, make sure the two (2) forklifts are not
touching.
DO NOT allow jump start cable ends to contact each
other.
Connect charged battery positive (+) to stalled battery
positive (+).
Connect charged battery negative (–) to stalled forklift ground. Make the connection to the stalled forklift
ground last.
Connect jump start cable to stalled forklift ground a
safe distance from the battery to prevent sparks near
the battery.
Jump start only with a power source with the same voltage as the stalled forklift.
Turn off all lights and accessories on the stalled forklift
to prevent them from operating when the power source
is connected.
Electrolyte contains acid and could cause serious
personal injury if it contacts the skin or eyes.
Connect one end of the positive (+) jumper cable to the
positive (+) post of the discharged battery.
2.
Connect the other end of the positive (+) jumper cable to
the positive (+) post of the charged battery.
3.
Connect one end of the negative (-) jumper cable to the
negative (-) post of the charged battery.
4.
Make the final jumper cable connection to the stalled
forklift ground at the furthest point from the battery.
5.
Start the forklift. Refer to the Starting Forklift section in
this manual.
6.
After the engine starts, allow the engine to idle for
approximately 60 seconds.
7.
Remove the jumper cables in reverse order of their
connection (i.e. negative cable ground connection first,
etc)
Steering Modes
Warning
Never use crab or four wheel (4W) steering for
traveling at high speeds. Use only two wheel
(2W) steering for higher speed travel and slow
the forklift before turning. Rapid turning using crab, four wheel (4W), or the optional two
wheel rear (2WR) steering could cause tip over, which could
result in death, serious injury, or property damage.
Check the turning radius around the forklift before making
a turn, especially if using four wheel (4W) steering or two
wheel rear (2WR) steering, which provide a tighter turning
radius. Look over your shoulder in the direction of the turn
when backing. Failure to remain aware of your turning radius area could result in death, serious injury, or equipment
damage.
Caution
DO NOT change steering modes until the forklift slows or
comes to a complete stop. Align all four (4) wheels “straightahead”, or perpendicular to the axle, before changing
steering mode. Changing steering modes without aligning
all four (4) wheels may result in equipment damage.
The forklift includes three STANDARD modes of steering;
Crab, Two Wheel (2W), and Four Wheel (4W) Steering. Use the
Steering Select switch located on the dash panel to change
steering modes.
Crab Steering
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.
Two Wheel Front Steering (2W)
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)
steering is useful for traveling at higher speeds.
55
Operation Manual
Operation
Four Wheel Steering (4W)
1.
Four wheel (4W) steering allows the front
wheels to turn in the same direction and the
rear wheels to turn in the opposite direction
of the steering wheel. The rear wheels follow
the front wheel path. Four wheel (4W) steering
is useful for a short turning radius and in muddy or sandy
conditions.
2.
3.
4.
5.
6.
7.
Two Wheel Rear Steering (2WR) - OPTIONAL
OPTIONAL two wheel rear (2WR) steering allows
the rear wheels to turn in the same direction as
the steering wheel. The front wheels remain in a
fixed forward position.
Shifting Gears
NOTE: A separate switch is located on the right side of the
dash panel to engage and disengage the optional two wheel
rear (2WR) steering mode.
Warning
DO NOT shift through multiple gears with a
single turn of the 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 could result in death or
serious injury.
Warning
Allow for adequate clearance between the
attachment and other objects when turning.
The attachment extends beyond the front
of the forklift. The
operator must be
aware of the maximum sweep of
any attachment being used, when
turning, to avoid hitting personnel and other objects in the area
to prevent death, serious injury,
or property damage.
The transmission has three (3) gears that can be used for
traveling in forward or reverse.
To shift gears rotate the gear select lever to the next gear
while the forklift is traveling.
Starting Travel
Use proper safety procedures and avoid
hazardous situations while operating the
forklift to prevent death, serious injury, or
property damage.
•
Use first gear (1) for highest torque and pulling power.
•
Use higher gears for higher ground speed.
•
Never travel in top gear (3) when carrying a load.
•
Allow the engine speed to slow down before shifting to
a lower gear.
Stop the forklift by applying the service brake pedal. Slow the
forklift down until it comes to a complete stop.
Move the travel select lever to NEUTRAL (N) and set the
parking brake to ON (engaged).
Check the work site for any hazards before operating
the forklift.
Check the work surface for loose soil conditions and
overhead power lines.
Warning
To prevent death, serious injury, or property
damage, apply service brakes until the forklift
comes to a complete stop, move travel select
lever to NEUTRAL (N), set the Parking Brake
switch to ON (engaged), lower and retract the
boom, and shut off the engine before exiting the forklift.
To avoid death or serious injury, the operator must have the
seat belt fastened, the travel select lever set to NEUTRAL,
the Parking Brake ON (engaged), and the area free of people
and obstructions BEFORE starting the forklift.
Operation Manual
•
Stopping Travel
Warning
•
Start the forklift. Refer to the Starting Forklift section in
this manual.
Apply service brake.
Release parking brake.
Rotate the gear select switch to the gear desired.
Move the travel select lever to FORWARD or REVERSE for
the appropriate direction of travel.
Release the service brake pedal.
Slowly press the accelerator pedal to start travel.
56
Operation
under most operating conditions.
Changing Travel Direction
•
Stop the forklift by applying the service brake pedal. Move the
travel select lever to FORWARD or REVERSE.
Use standard #2 diesel fuel for operating at temperatures
above 320 F.
•
Release the service brake pedal. Slowly press the accelerator
pedal to start travel.
Use a blend of #1 and #2 diesel fuel (“winterized” #2
diesel) for operating at temperatures below 320 F.
•
Fuels with Cetane ratings higher than 40 may be needed
in higher altitude or an extremely low temperature
climate to prevent misfiring and excessive smoke.
Warning
Make sure the forklift comes to a complete
stop before moving the travel select lever. A
sudden change in direction of travel, while
carrying a load, can reduce stability and/
or cause the load to shift or fall, which could
result in death, serious injury, or property damage.
Pintle Hook
Warning
Death or serious injury could result from improper operation when using tow connection.
Do not elevate boom above 30 degrees when
towing. Do not exceed rated tow capacity
(500 lbs vertical load, 5000 lbs tow capacity).
Shut Down Procedure
1.
Park forklift on level ground, if possible.
2.
Stop the forklift by applying the service brake pedal.
3.
Place the travel select lever in NEUTRAL (N) and set the
parking brake to ON (engaged).
4.
Lower the boom and rest carriage on ground.
5.
Turn the ignition key to OFF and remove the key.
6.
If the forklift is parked on an incline, block the wheels.
Shut off the engine.
7.
Ground fuel nozzle against the filler neck to avoid sparks.
The Pintle Hook is used for towing trailers and equipment, rated at or below 5,000 lbs maximum capacity. Failure to comply
with this capacity limitation, or elevating the boom above 30
degrees when towing could result in death or serious injury.
Warning and Fault Indicators
Fault condition dialog boxes will pop up and warning lights
on the display will illuminate during critical circumstances.
Some of these conditions demand immediate attention and
forklift servicing. If an Engine Shutdown fault condition is
present, the forklift should be shut down as soon as practical
to prevent serious mechanical failure.
Refueling
Warning
Warning
A fault condition may trigger a pop-up 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
Not Operate” tags, and have a qualified mechanic service
or repair the forklift BEFORE placing it into service again.
Report all warning indicators and fault codes to a qualified
mechanic. Ignoring warning indicators or fault codes can
cause improper performance, which could result in death,
serious injury, or property damage.
Engine fuel is flammable and
can cause a fire or explosion resulting in death or serious injury. DO NOT smoke while refueling and keep sparks and open
flames away from the forklift.
•
Make sure the forklift is level to obtain an accurate fuel
level reading.
•
Shut off the engine.
•
Ground the fuel nozzle against the filler neck to avoid
sparks. Use ASTM #2 diesel fuel with a minimum Cetane
rating of 40 for better fuel economy and performance
57
Operation Manual
Operation
ENGINE WARNING INDICATOR
DEF Level Monitoring
A steady Engine Warning Indicator by itself
shows the engine is operating normally but
there are one or more minor faults with the
engine electronic management system.
A flashing Engine Warning Indicator by itself shows there
are one or more serious faults and the engine is operating
in at reduced 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. See Engine Indicator Chart for more info.
If no DEF reagent is available in the storage tank, the emission
requirements cannot be fulfilled and the machine will derate
eventually to idle only.
Three error messages are available representing the monitoring steps with active engine limitations.
When a DEF tank fill is performed and indicated, the machine
is fully restored to normal functionality and operation. A tank
fill is assumed when the level exceeds the initial warning level
(>10%).
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.
If the tank fill condition is not met (DEF level is below 10%),
after 10 minutes the available torque is dropped by 25%. Ten
minutes after that, the RPM is slowly lowered to low idle at a
rate of 6rpm/s.
ENGINE STOP INDICATOR
The Engine Stop Indicator is displayed with
a flashing Engine Warning Indicator when
the engine is either shut down or an engine
shutdown is imminent.
DEF Quality Monitoring
If the reagent quality requirements are not met, the emission performance of the engine cannot be guaranteed. The
SCR-system could be damaged if the DEF used in the engine
is out of specification. Dilution of the reagent with water will
lead to deteriorated NOX reduction and clogging of the catalyst with resulting damage to the SCR-system.
An Engine Stop Indicator displayed with both the Oil Pressure
Indicator and flashing Engine Warning Indicator shows the oil
pressure is low The engine should be shutdown. Automatic
engine shutdown is imminent.
OIL PRESSURE INDICATOR
An Oil Pressure Indicator displayed with both
the Engine Stop Indicator and flashing Engine
Warning Indicator shows the oil pressure is
low The engine should be shutdown. Automatic engine
shutdown is imminent.
High Exhaust
Engine
Temperature
FLASH
Warning
(HEST)
Diesel
Engine
Particulate
ON
Stop
Filter
DPF
Engine Oil
Disabled
ON
ON
ON
ON
NOTE: The DEF reagent used must comply with ISO 22241.
Mis-fueling with diesel leads to injection of diesel and DEF
reagent into the catalyst and the very high combustion temperatures will damage the catalyst.
High Exhaust
Diesel
Temperature
Particulate
Shutdown
(HEST)
Filter
Engine should be shutdown by
DPF
Shutdown
operator. Automatic shutdown
will
Disabled
occur after a short period of time.
Engine should be shutdown by
Engine is either shutdown or automatic
operator. Automatic shutdown will
shut down is imminent
occur after a short period of time.
Lamp State
ONExhaust
High
Temperature
Engine operating with no power deDescription
Lamp State
Engine
State
Description
High
Exhaust
Temperature
Active or
manual
regeneration
Active or manual
regeneration
rate or during forced regeneration
No Faults
ON
Excessive
Soot Loading
No Faults
Normal
operation
Normal operation
Engineoperating
operating
withno
no
faults
Excessive
Soot LoadingEngine
Manual
regeneration
recommended
Manual regeneration
recommended
with
de-rate
Active Diagnostic
Regeneration
Disabled
normally
withby
one
Regeneration
disabled
operator or
Regeneration disabled by operator or Engine is operating
present
Active Diagnostic
fault
present
ON Minor fault Regeneration
DisabledEngine operatingMinor
with no
de-rate
or more faults present
machine
machine
FLASH
ON
ON
SeriousDe-rate
Soot Loading
Serious
fault present
Engine
De-rate
Serious
fault present
Serious
Soot Loading
Manual
regeneration
required
Manual
regeneration
required
Engine operating
operating
with
reduced
power
FLASH
ON
Shutdown
ON
Dangerous
Soot Loading
Engine should be shutdown by
Engine should be shutdown by
Engine
is either
shutdown
ordown.
automatic
Soot
loading
not
recoverable with
Soot loading not recoverable with
Engine
should
be shut
operator. Automatic
shutdown
willLoading
Shutdown
operator. Automatic shutdown will
Dangerous
Soot
shut down
is imminent
regeneration
regeneration
Automatic
shutdown
is imminent
occur after a short period of time.
occur after a short period of time.
ON
FLASH
ON
High
ONLow
Exhaust
Temperature
Oil Pressure
Engine should be shutdown by
Engine should be shutdown by
Engineisoperating
with noorpower
deEngine
either shutdown
automatic
Active orAutomatic
manualHigh
regeneration
Exhaust
Temperature
Active orAutomatic
manual regeneration
operator.
shutdown will
Low
Oil Pressure
operator.
shutdown
will
rate orshut
during
forced
regeneration
down
is imminent
occur after a short period of time.
occur after a short period of time.
ON
Figure 68. Engine Indicator Chart
Operation Manual
58
Operation
Out of specification reagent is detected within maximum
30 minutes and a warning will be activated. If low efficiency
DEF is detected after refilling the DEF tank, (i. e. the reducing
agent not according to ISO 22241-1), a low Efficiency Rate of
the SCR system warning message is displayed.
Crystallization Detection
The SCR system is monitored for crystallization. If crystallization is detected, the system can request special engine operation modes as countermeasure.
If the operator ignores the standstill request, a specific error
message will be created and optional system reactions like
power reduction may become active. See also escalation management standstill.
Figure 69. DEF Quality Escalation Steps
SCR Hardware Failure Errors
Figure 71. Crystallization Escalation Steps
Hardware failure errors such as defects of the urea pump are
indicated below. If the Urea Injection can still be guaranteed,
no restriction is set. In other cases a restriction is set and derating will be active after a delay time.
DPF System
The DPF system is a closed soot filter system that accumulates
soot during machine operation. The filter regeneration is a
continuous process (CRT) starting as soon as the necessary
conditions at the inlet of the system are reached. These conditions are mainly exhaust temperatures and NOx/Soot-ratio.
In case of a Hardware failure, the Urea Warning Lamp and the
Engine Error Indicator are permanently active.
The filter load is permanently monitored and controlled. If the
regeneration process is not possible for any reason, the system triggers additional actions to start the regeneration. Operator input is required only if these actions are not successful.
Under average operating conditions, the filter soot load is
within an expected range and no further action is needed.
Standstill lamp is off.
If the operating conditions of the machine do not allow a successful continuous regeneration process, the filter load can exceed the expected range. This could happen in extremely low
load applications, or if the machine is always operated only
Figure 70. Hardware Failure Escalation Steps
59
Operation Manual
Operation
Main: If all preconditions are fulfilled, the main process starts.
The exhaust temperature is increased. The duration of the
standstill is approximately 30 minutes.
for short intervals. In this case the engine enters HEAT MODE
1 and certain engine internal actions (i.e. using intake throttle
flap or exhaust flap) are performed in order to improve the regeneration conditions (Level 1). Operator input is not needed
at this point. The standstill lamp is off.
Afterrun: When the main process is finished, the engine and
the EAT-system cool down to protect the hardware. The duration of the afterrun is approximately 5 minutes.
Standstill Regeneration
If the engine heat mode described above is not sufficient to allow a reduction of the soot load, the filter load continues rising
and finally a standstill-regeneration is requested. The standstill is the last option to regenerate a filter if all other attempts
to clean the filter failed. The machine should not be operated
during an active standstill regeneration!
During an active standstill, high exhaust gas temperatures
may occur. The engine speed changes to a predefined value
and cannot be influenced by the operator. Due to extreme engine settings, the engine oil quality is influenced by standstill.
After a certain number of standstill an oil change may be necessary. Standstill lamp blinks twice a second (Level 3).
A standstill has to be released by the operator. If the operator ignores the standstill request, engine protections are activated (Level 4). Once a standstill was requested, the request
remains active until a standstill regen is successfully finished.
If the standstill request is further ignored and the soot load
gets extremely high, a service-regeneration via Service Tool
(SERDIA, VCADS) has to be performed by a qualified service
technician, and the regeneration cannot be performed by the
operator. The standstill lamp blinks 3 times/sec. (Level 5).
Figure 72. DPF Regeneration Strategy
When the soot load has reached a critical level (Level 6) where
safe regeneration no longer can be possible, the DPF has to
be replaced before operation is allowed to continue. The
standstill lamp blinks rapidly, 3 times/sec.
If HEAT MODE 1 is not sufficient to allow a reduction of the
soot load, the filter load continues rising and stronger engine
internal actions become necessary to improve the regeneration conditions and the engine enters HEAT MODE 2. Fuel
consumption and engine dynamic response is higher than in
HEAT MODE 1. The standstill lamp is off (Level 2).
Standstill Regeneration Conditions
The forklift needs to meet the following conditions to be able
to perform a successful standstill regeneration:
Standstill Process
The complete standstill process consists of three phases:
Launch: The standstill requires a warmed up engine to start
the process. This also includes the SCR system, especially the
DEF tank must not be frozen. An optional launch phase can
be activated that allows the operator to release the standstill
before the engine is actually warmed up. In this launch phase,
the engine speed is increased and the engine operation accelerates the warm up.
Operation Manual
60
•
Park brake must be ON and shifter in neutral (N) position
•
The inhibit button is not active
•
Engine is at idle with the coolant temperature > 1580 F
and exhaust gas temperature after DOC < 4820 F
•
DEF level above 15% with no quality errors (i.e. DEF tank
not frozen, DEF quality conforms to ISO 22241-1, etc.)
•
The operator needs to acknowledge the coming regeneration process via input through the release button
Operation
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 load center (B). This
rating specifies the maximum load capacity that the individual
fork can safely carry at a maximum load center of 24 inches.
Attachments
Attachment Disclaimer
Because forks are always used in multiples, the total rating
of any combination of forks will be the sum of their rated
capacity. Other than block forks, all forks should be used in
matched pairs. Block forks should be used in matched sets.
Warning
DO NOT exceed the manufacturer’s rated
load for any auxiliary attachment. Any
attempt to lift or carry loads in excess of the
manufacturer’s rated load may cause forklift
tip over, loss of load, or structural damage
which could result in death, serious injury, or property
damage.
The maximum load capacity for this forklift is 15,000 lbs. The
matched pair or set of forks used on this forklift should have
total load ratings which equal or exceed 15,000 lbs. When the
load rating of the forklift differs from the load capacity of the
forks, the lower value becomes the overall load capacity.
Xtreme Manufacturing makes no representations or warranties,
expressed or implied, as to the design, manufacture, or fitness
for use with this forklift of any third party attachment. This
forklift 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 forklift. Xtreme Manufacturing assumes no
liability for any third party attachment that would alter the
center of gravity or stability.
Standard Carriage Operation
The standard carriage uses manually adjustable forks and can
be tilted up or down by using the thumb stick on the control
handle.
A
Fork Ratings
Warning
B
DO NOT exceed forklift capacity of 15,000
pounds. The total rated capacity of the forks
being used must equal or exceed forklift
capacity. Forks can break causing loss of load
and could result in death or serious injury.
Figure 74. Attachment Tilt Control Switch.
(A) Attachment Tilt Down (B) Attachment Tilt Up
Fork Positioning Carriage Operation
Caution
Do not adjust forks when Fork Positioning Carriage is loaded. Adjusting forks when carriage is loaded may result
in loss of load or carriage damage. Always use the Fork
Positioning control handle to adjust the forks BEFORE
loading the carriage.
To move the forks outward, press the top button on the front
control handle, or move the auxiliary handle to the left. To
move the forks inward, press the lower button on the front
control handle, or move the auxiliary handle to the right.
Figure 73. Fork Ratings
(A) Maximum Load Capacity Rating (B) 24 inch Load Center
61
Operation Manual
Operation
Quick Attach System
1
This forklift includes a quick attach system that allows for easy
attachment changes. Perform attachment connection and
removal procedures on level ground.
2
Attachment Connection
Warning
Improper connection of an auxiliary
attachment can result in death or serious
injury. 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.
3
Figure 75. Fork Positioning Control Handle
•
Warning
•
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 3,900 psi, which is the
maximum pressure of the forklift auxiliary hydraulic system
at the quick-disconnect couplers, 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
indication that the carriage attachment is fully engaged.
1.
Position the forklift directly behind the attachment.
NOTE: Allow enough distance to extend the boom approximately 18 to 20 inches.
2.
Tilt the quick attach adapter forward.
3.
Extend the boom and/or drive the forklift forward until
the pivot pins (A) are below and between the two (2)
attachment hooks (B).
When the auxiliary attachment control lever is moved right
or left it activates hydraulic pressure through the quick attach
couplers to move the carriage.
B
A
B
A
Figure 77. Drive Forklift Forward to Align Pivot Pins (A) with Attachment
Hooks (B)
4.
Figure 76. Quick Attach Couplers For Hydraulic Systems.
(A) Female Coupler. (B) Male Coupler.
Operation Manual
62
Raise the boom until pivot pins (A) have seated fully in
attachment hooks (B).
Operation
7.
With lock lever raised, insert quick attach pin completely
through the attachment and quick attach adapter.
Figure 78. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment
Hooks (B)
5.
Tilt the attachment up slightly. The quick attach adapter
should be tight against the rear of the attachment. Align
the holes between the quick attach adapter and attachment.
Figure 81. Insert Quick Attach Pin Through Attachment and Quick
Attach Adapter.
C
8.
Release the quick attach lock lever and make sure it has
lowered and seated itself in groove (A) of the quick attach
pin
B
Figure 79. Tilt Attachment To Align Holes (B) and (C) Between Attachment and Quick Attach Adapter.
6.
Raise the quick attach lock lever.
Figure 82. Quick Attach Lock Lever and Quick Attach Pin.
Warning
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 3,900 psi, which is the
maximum pressure of the forklift auxiliary hydraulic system
at the quick-disconnect couplers, could result in death or
serious injury.
Figure 80. Quick Attach Lock Lever.
63
Operation Manual
Operation
9. Connect the quick attach couplers (this only applies to
attachments with a quick attach hydraulic system).
Figure 84. Quick Attach Lock Lever
attach adapter.
B
A
Figure 83. Quick Attach Couplers For Hydraulic Systems.
(A) Female Coupler. (B) Male Coupler.
Figure 85. Pull Quick Attach Pin from Attachment and Quick Attach
Adapter.
Attachment Removal
9.
NOTE: To remove a standard carriage with forks, spread the
forks apart on the carriage shaft. This provides adequate support for the carriage to stand alone.
1.
Bring the forklift to a complete stop.
2.
Move the travel select lever to NEUTRAL (N).
3.
Set the parking brake switch to ON (engaged).
4.
Extend the boom approximately 18 to 20 inches .
5.
With attachment 10 to 12 inches off of the ground, tilt the
attachment backward.
6.
Disconnect the quick attach couplers. This only applies to
attachments with a quick attach hydraulic system.
7.
Raise the quick attach lock lever.
8.
Pull out the quick attach pin at the bottom of the quick
Operation Manual
Lower the attachment to the ground in a level position.
Figure 86. Lower Attachment to Ground in Level Position
64
Operation
10. Tilt and lower boom until pivot pins (A) have disconnected
from attachment hooks (B).
Warning
Failure to follow proper safety procedures
when lifting, lowering, and traveling with
a load could cause death, serious injury, or
property damage.
B
DO NOT exceed forklift capacity of 15,000 lbs. The total
rated capacity of the forks being used must equal or exceed
forklift capacity. Forks can break causing loss of load and
could result in death or serious injury.
A
Warning
DO NOT exceed the manufacturer’s rated
load for any auxiliary attachment. Any
attempt to lift or carry loads in excess of the
manufacturer’s rated load may cause forklift
tip over, loss of load, or structural damage
which could result in death, serious injury, or property
damage.
Figure 87. Tilt and Lower Boom to Release Pivot Pins (A) from Attachment Hooks (B).
11. Retract the boom to fully disconnect the attachment from
the quick attach link.
Failure to keep personnel clear of the load
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
or over a forklift cab.
Load Handling
Danger
Death or serious injury by electrocution
will result from contact with or inadequate
clearance with energized power lines or
apparatus.
•
Never operate the forklift in an area where active
overhead power lines, overhead or underground
cables, or other power sources exist.
•
Contact the appropriate power or utility company to deenergize power lines or take other suitable precautions.
Keep the forklift, attachments, and loads a
safe distance from electrical power lines.
•
Remain at least 10 feet, plus an additional 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.
65
•
Review the rated load capacity of each auxiliary
attachment 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 load
distribution.
•
Adjust the load as necessary, especially for nonstandard
loads.
•
Use caution when handling loose material that can fall
into the cab.
•
Remove overhanging load materials, when possible,
and watch for sliding material.
•
DO NOT reach a load over posts or other objects that
can enter the cab, if tipped.
•
Avoid sudden stops, starts, or turns.
•
Avoid carrying a swinging 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.
Operation Manual
Operation
3.
Boom Lift Point
4.
There may be a lift point on the underside of the boom that
may be used to lift and carry loads.
5.
Warning
Tip Over Hazard. Death or serious injury
could result from improper operation. DO
NOT exceed rated lift capacity. Refer to the
“Standard Fork Carriage Load Chart” for
vehicle’s load handling capacity. Refer to
ANSI/ITSDF B56.6 for information regarding the handling of
suspended loads.
Any attempt to lift or carry loads in excess of those shown on
the load capacity charts could cause forklift tip over, loss of
load, or structural damage which could result in death, serious
injury, or property damage.
Transport the load with the bottom of the load and the
boom as low as possible.
With the load elevated, move the forklift slowly and
cautiously. Only move the forklift to the extent needed to
raise, transport, and place the load.
Use guy lines to restrain load swing if possible.
Pick Up A Load
1.
2.
3.
4.
5.
6.
Use correct load chart to review the rated load capacity of
the auxiliary attachment being used. NEVER exceed specified weights and load centers.
Approach the load slowly and squarely with the fork tips
straight and level.
Adjust the spacing of the forks so they engage the pallet
or load at its maximum width. NEVER use just one fork to
lift a load.
Tilt the attachment forward so the forks hang freely on
the fork shaft.
Insert forks under the load until the load is against the
fork frame.
Tilt the forks back, and raise the boom slightly to secure
the load.
Carry A Load
1.
2.
3.
Figure 88. Boom Lift Point
All load ratings shown on load capacity charts are based on
the forklift being on firm, level ground, the forks being evenly
positioned on the carriage, the load being centered on the
forks, properly sized tires properly inflated, and the forklift
being in good operating condition.
Place A Load
Suspended Loads
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 loads can become unstable, and could cause
death, serious injury, or property damage.
1. Do not exceed the load capacity of the forklift (as noted
on the load chart).
2. Only lift the load vertically, and never drag it horizontally.
Operation Manual
Carry the load as low as possible while maintaining good
ground clearance and visibility.
Back away slowly.
To travel with a load, use first gear (1) for highest torque
and pulling power. NEVER travel in higher gears when
carrying a load.
1.
Before placing the load, refer to the appropriate load
capacity chart to determine safe boom extension range.
2.
Set the Parking Brake switch to ON (engaged).
3.
Set the Declutch switch to ON.
4.
Use the frame sway control to level the forklift.
Warning
Use of the frame sway control with the boom
raised above horizontal could cause tip over
resulting in death or injury. Always use the
frame sway control to level the forklift
BEFORE raising the boom above horizontal.
If the forklift cannot be leveled using the frame sway control, do not attempt to raise or place load. Reposition forklift or have the surface leveled.
66
Operation
normal working position on the platform from moving
parts of the rough terrain forklift that represent a hazard.
For additional information, refer to the Frame Leveling
section in this manual.
5.
Align the forks at the level the load is to be placed.
8.
Information prominently indicated on the platform;
6.
Extend the boom slowly until the load is just above the
area where it is to be placed.
9.
Maximum work load including personnel and equipment.
7.
Lower the boom until the pallet rests in position and the
forks are free to retract.
8.
Retract the forks slowly from under the load.
10. Weight of empty platform.
11. Provide a means so that the platform can only be centered
laterally on the forklift and retained against the vertical
face of the forks, carriage, or lifting mechanism.
12. Provide a means to securely attach the platform to the
lifting mechanism, and to prevent the platform from
inadvertent pivoting.
Load Shift
1.
2.
3.
13. Provide restraining means for securing personnel such as
an anchorage for attaching the lanyard of a body belt or
harness.
If the load shifts, stop the forklift immediately.
Lower and adjust the load to center its weight.
If the load shift is too great for adjustment, rearrange the
load before attempting to move the forklift.
14. Provide a guardrail or similar structure with a nominal
height to the platform of 42 inches around its upper
periphery and include a mid rail. It may be hinged,
removable, or of chains, and used if proper positioning
is easily discernible. Such restraining means shall be
capable of withstanding a concentrated horizontal force
of 200 lbs applied at the point of least resistance without
permanent deformation. A body belt and lanyard is
to have an attachment point provided for freedom of
movement, and its length is limited to a free-fall of 5’
measured from the point of attachment to the operator.
The complete system shall be capable of withstanding
three consecutive drop tests to simulate a 250 lbs person
free falling 6’ without allowing the test weight to fall free
to the ground. A deceleration device may be included.
Elevating Personnel
Warning
Use only a compliant work platform to lift or lower
personnel. Never drive the forklift with the work platform
in a raised position or with personnel on board, even for
a short distance. Doing so could result in death, serious
injury, or property damage.
Please refer to ANSI/ITSDF B56.6 for additional design and
operating information regarding elevating personnel.
15. Lanyards shall be arranged so as not to cause a tripping
hazard.
Design Requirements For A Personnel Platform:
1.
Platform floor must have a slip resistant surface located
not more than 8 inches above the normal load supporting
surface of the fork.
2.
Platform floor dimensions shall not exceed two times the
load center distance. This floor dimension is measured
parallel to the longitudinal center pane of the forklift.
3.
Platform floor width shall not be greater than the overall
width of the forklift, measured across the load bearing
tires, plus 10 inches on each side.
4.
Minimum space requirements for each person on the
platform shall not be less than 18 inches in either direction.
5.
Minimum 4 inches height toe plate around the perimeter
of the platform which may be omitted at the access
opening.
6.
On the overhead protection device, when requested by
the user.
7.
Protection must be provided for the personnel in their
16. Body belts should have a width of at least 1.75 inches.
17. Structural safety factor - all load supporting structural
elements of the work platform shall have a structural
safety factor of not less than 2-to-1 based on the minimum
yield strength of the material used.
Capacity Limitations:
The combined weight in pounds of the platform, load, and
personnel shall not exceed 33% of the capacity of the related
load center position indicated on the machine load chart.
Preparation and Set-Up:
67
1.
DO NOT alter or modify the work platform in any manner
that is detrimental to its safe use.
2.
Make sure that the work platform is securely attached
to the quick attach or forks. Follow the platform
manufacturer’s instructions.
Operation Manual
Operation
3.
Make sure the platform, carriage, and forks are secured to
prevent them from pivoting from side to side.
the work platform should be marked to warn anyone on
the ground that overhead work is being done.
4.
On side tilt or swing carriage, the carriage must be centered
and/or leveled horizontally and vertically. The hydraulic
system quick disconnects must also be disconnected and
the carriage securely fastened to prevent any tilting or
side to side swinging motion.
22. The platform shall be lowered to ground level for
personnel to enter and exit. Personnel shall not climb
on any part of the rough terrain forklift in attempting to
enter and exit.
5.
Ensure the forklift has a firm footing and is level.
6.
Be sure the forklift is in a level position (side to side) before
any operation is begun. Use the frame sway to level the
forklift. If the forklift cannot be leveled, reposition the
forklift.
7.
Place the travel select lever in the NEUTRAL position.
8.
Engage the parking brake switch. Blocking the wheels is
also recommended.
9.
Level the platform in both the side-to-side and front-toback directions before use.
23. Protection must be provided for the personnel on the
work platform from pinch points or moving parts while in
their normal working position on the platform.
24. Provide overhead protection device as required by work
site conditions or if requested by the user of the platform.
Load Capacity Charts
Warning
10. Before lifting or lowering personnel, be sure the forklift
lifting mechanism operates smoothly through the entire
lifting and lowering of the platform and maintains its selfleveling function. The forklift must operate smoothly
both empty and loaded.
DO NOT exceed rated capacity. Any attempt
to lift or carry loads in excess of those shown
on the load capacity charts could cause forklift tip over, loss of load, or structural damage
which could result in death, serious injury, or
property damage.
11. Lift and lower personnel smoothly, with caution, and only
at their request.
All load ratings shown on load capacity charts are based
on the forklift being on firm, level ground, the forks being
evenly positioned on the carriage, the load being centered
on the forks, properly sized tires properly inflated and/
or foam filled, and the forklift being in good operating
condition.
12. Keep hands and feet clear of controls other than those in
use.
13. Be certain that the path of platform travel is clear
of hazards, e.g., storage racks, scaffolds, overhead
obstructions, and electrical wires.
14. Be sure any lift limiting devices and latches are functioning
properly.
Load capacity charts, located on the left side 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 forklift, including what angle, how high, and
how far to extend the boom.
15. A trained operator shall be in position to control the
forklift. When the operator is not in the operating
position, block the wheels and apply the parking brake
with all controls in neutral.
16. Alert elevated personnel before moving the platform.
Then move the platform smoothly and with caution.
17. Always lower the platform if you must move the forklift
for adjustment in positioning.
18. Be certain that personnel and equipment on the platform
do not exceed the available space.
19. Any body belt, lanyard, or deceleration devices which
has sustained permanent deformation or is otherwise
damaged shall be replaced.
20. Use of railings, planks, ladder, etc. on the platform for
purpose of achieving additional reach or height is
prohibited.
21. Before elevating personnel, the area around and under
Operation Manual
Figure 89. Load Capacity Chart
68
Operation
Using Load Capacity Charts
Reading Load Capacity Charts
The forklift includes two (2) indicators to assist the operator
for accurately using the load capacity charts. These indicators
are the Boom Extend Letters and the Boom Angle Indicator.
To accurately read the load capacity charts, you must
determine three (3) things:
•
Weight of the load being lifted
•
Height of structure where load is to be placed
•
Distance from front tires where load will be placed
Boom extend letters are located on the left 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.
For example:
1. The operator determines load weight and makes sure load
does not exceed fork, attachment, or boom capacity.
NOTE: For example, when letter “A” first appears, the boom
extension corresponds to the arc of line “A” throughout all the
load capacity charts.
The load is 4,000 pounds.
2. The operator safely moves the load to a loading position:
• places forks under load
• tilts and raises load safely
• fully retracts boom
• drives forklift to position perpendicular to structure
• levels the forklift
3. The operator determines height of structure where load is
to be placed.
The structure height is 40 feet from ground level.
4. The operator determines distance from front tires where
load will be placed.
The distance in front of forklift where the load will be placed
is 43 feet.
Figure 90. Boom Extend Letters
5. 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 “G” showing.
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.
NOTE: The boom angle indicator is a plumb arrow with
angular graduations from -5 to +700.
17424-000
Figure 92. Load Capacity Chart
Figure 91. Boom Angle Indicator
69
Operation Manual
Operation
Frame Leveling
Warning
Use of the frame sway control with the boom
raised above horizontal could cause tip over
resulting in death or injury. Always use the
frame sway control to level the forklift
BEFORE raising the boom above horizontal.
If the forklift cannot be leveled using the frame sway control, do not attempt to raise or place load. Reposition forklift or have the surface leveled.
Figure 94. Frame Level Indicator.
The frame sway control handle has variable motions from the
center that control frame sway (right and left).
Warning
Frame Sway Functions
Function
The reach forklift includes a Frame Sway
Override switch. Improper use of the Frame
Sway Override switch could cause death, serious injury, or property damage.
Control Handle Action
FRAME SWAY RIGHT
Move control handle RIGHT.
FRAME SWAY LEFT
Move control handle LEFT.
The frame sway feature becomes locked and will not operate
when the boom is raised 40° or more. Applying service brake,
parking brake, and placing travel select lever in NEUTRAL,
then pressing the Frame Sway Override switch (the trigger on
the Front Control handle) will override the lockout feature and
allow frame sway.
Figure 93. Frame Sway Control Handle.
The frame sway control handle controls the frame sway (right
and left) functions.
To lock the frame sway, place the travel select lever in
NEUTRAL or apply the service or parking brake.
NOTE: Maximum frame sway is 22° overall or 11° each direction, left and right.
A frame level indicator is mounted on the inside upper right
corner of the operator’s cab. The frame level indicator allows
the operator to view if the forklift has been positioned in a
level condition. Always frame sway the forklift right or left until the indicator shows 0° (level).
Operation Manual
Figure 95. Frame Sway Override Switch.
70
Preventive Maintenance
Preventive Maintenance
Check condition and tension of drive belts (use
tension meter to check belt tension)
Establishing a Maintenance Program
The hour meter displays elapsed engine operating hours
and has a total readout of 9,999.9 hours. Use the hour meter
and the schedules contained in this section to establish a
comprehensive preventive maintenance program.
Lubricate front and rear drive shaft grease fittings
Lubricate outrigger pivot point grease fittings
Lubricate front and rear axle grease fittings
Change differential oil
Change wheel-end oil
Check wheel lug nuts torqued to 380-420 ft lbs
Lubricate boom pivot point grease fittings
Lubricate front and rear axle cylinder pivot point
grease fittings
Lubricate boom roller grease fittings and chains
Replace hydraulic return line filter
Figure 96. Hour Meter
Replace transmission filter and top off fluid, as
required
Maintenance Schedule
After Every 50 Hours of Operation
Every Day or 8 Hours of Operation
See Pre-Operation Inspection Checklist
Lubricate boom pivot point grease fittings
After First 50 Hours of Operation
Lubricate front and rear axle cylinder pivot point
grease fittings
Lubricate outrigger pivot point grease fittings
Change engine oil and filters
Check air filter (replace if necessary)
Replace fuel filter and prefilter
Check engine hoses and connections for leaks,
damage, and tightness
Check radiator hoses for leaks, damage, and tightness
Check electrical cables, leads, and connections for
damage and tightness
Check for oil and coolant leaks
71
Operation Manual
Preventive Maintenance
After Every 250 Hours of Operation
Check specific gravity of engine coolant
Comply with 50-Hour Maintenance Requirements
Replace transmission fluid and filters
Check structures for damage and cracked welds
Replace hydraulic reservoir air breather
Check pins for wear and damage
Replace hydraulic return line filter
Verify that all fasteners are in place and are tight
Replace hydraulic high-pressure filter
Change engine oil and filter
Check air filter (replace if necessary)
After Every 1,000 Hours of Operation
Check tension and condition of drive belts (use
tension meter to check belt tension)
Comply with 50-Hour Maintenance Requirements
Lubricate front and rear drive shaft grease fittings
Comply with 250-Hour Maintenance Requirements
Lubricate front and rear axle grease fittings
Comply with 500-Hour Maintenance Requirements
Check differential oil level
Change wheel-end oil
Check wheel-end oil level
Change differential oil
Check boom chain tension (adjust if necessary)
Inspect boom chains
Inspect boom rollers and slide blocks for condition
and tightness
After Every 2,000 Hours of Operation
Lubricate boom roller grease fittings and chains
Comply with 50-Hour Maintenance Requirements
Comply with 250-Hour Maintenance Requirements
After Every 500 Hours of Operation
Comply with 500-Hour Maintenance Requirements
Comply with 50-Hour Maintenance Requirements
Comply with 1000-Hour Maintenance Requirements
Comply with 250-Hour Maintenance Requirements
Change hydraulic fluid
Replace air filters
Clean or replace hydraulic reservoir strainer
Replace fuel filters
Empty air filter dust cup
After Every 4,000 Hours of Operation
Check engine hoses and connections for leaks,
damage, and tightness
Drain and flush cooling system
Check radiator hoses for leaks, damage, and tightness
Check electrical cables, leads, and connections for
damage and tightness
Operation Manual
72
Preventive Maintenance
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.
Secure the Telehandler and area by following the procedure
below until the situation has been properly evaluated.
1.
Clear the area around the Telehandler of all personnel.
2.
Engage the parking brake switch to the ON position and
Place the sift lever in NEUTRAL.
3.
Block all four wheels.
4.
Section off a large area under the boom with tape to
restrict any personnel from entering this potentially
dangerous area.
73
Operation Manual
Lockout / Tagout
Lockout / Tagout
Do Not Operate - Accident Prevention Tags
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 forklift should not be operated. Do Not
Operate Tags, which can be cut out and used, are included at
the end of this manual. Retain these Tags for use at a later
date.
New or Additional Operators
Figure 97. Battery Disconnect Switch
At the time of original purchase, the purchaser of this forklift
was instructed by the seller on its proper use. If this forklift is
to be used 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 forklift.
Warning
If forklift is unsafe for operation or maintenance, the defect
or defects must be clearly documented and posted in a
conspicuous place on the forklift. Failure to comply could
result in death, serious injury, or property damage.
In addition, make sure that the new operator has completed
a walk-around inspection of the forklift, is familiar with all the
labels on the forklift, and has demonstrated the correct use of
all controls.
Return Forklift to Service
When the forklift has been repaired and made safe for
operation and maintenance, perform the following procedure
to return forklift to service.
Lockout/Tagout Procedure
Perform the following procedure to lockout and tag out the
forklift. This procedure, requiring a lock, and danger tags are
to be used whenever the forklift is unsafe for operation or
maintenance.
1.
Remove lock and “DO NOT OPERATE” tag from battery
disconnect switch.
2.
Close battery access cover.
3.
Remove “DO NOT OPERATE” tags from steering wheel and
ignition key.
Removing Forklift From Service
1. Attach “DO NOT OPERATE” tags to steering wheel and
ignition key.
2. Open battery access cover.
3. Set battery disconnect switch to OFF.
4. Lock battery disconnect switch.
5. Attach “DO NOT OPERATE” tag to battery disconnect switch.
Figure 98. DO NOT OPERATE Tag
Operation Manual
74
Lockout / Tagout
Do Not Operate Tags
75
Operation Manual
Warranty
Xtreme Manufacturing Product Warranty Policy
1) Xtreme Manufacturing warrants, its authorized sales and service centers (herein referred to as “SSC”), new
product(s) the mainframe and chassis weldments shall be free from defect in material and workmanship for
the period of 10 years or 10,000 hours whichever comes first. The boom weldment and boom rollers shall be
free from defects in material and workmanship for the period of 5 years or 5,000 hours whichever comes first.
The powertrain assemblies consistingof engine, transmission and drive axles and all other componentsnot
listed above shall be free from defects in material and workmanship for the period of 2 year or 2,000 hours
after date of delivery. This warranty is made to the original owner of the new product(s) and is transferable for
the duration of the coverage period, to the subsequent owner with prior written approval from Xtreme
Manufacturing (see limitations).
2) Machines may be held in an authorized Distributor/ SSC’s stock for a maximum period of six (6) months
from the date of shipment from Xtreme, before the warranty period is automatically initiated on each
machine.
3) It is the responsibility of the Distributor/SSC to complete and return to Xtreme Manufacturing a Pre‐delivery
Inspection Record, Warranty Registration Form, before the act of rental / loan / demonstration of the machine
or delivery to an end user. In the case of direct sale to end customers the same responsibility lies with the end
customer.
4) Any end customer, SSC, distributor or dealer shall not be entitled to the benefits of this warranty and
Xtreme Manufacturing shall have no obligationshere under unless the “Pre‐Delivery and Inspection Record”
has been properly completed and returned to the Xtreme Manufacturing Warranty department within fifteen
(15) days after delivery of the Xtreme Manufacturing product to the Customer or Dealer’s demonstration /
rental fleet. Xtreme Manufacturing must be notified, in writing, within ten (10) days, of any machine sold to a
Customer from a Dealer/SSC’s rental fleet during the warranty period.
5) Any part or parts which upon examination by the Xtreme Product Support Department are found to be
defective within the specified warranty period, will be replaced or repaired at the sole discretion of Xtreme
Manufacturing, through its local Authorized Distributor/SSC, at no charge. Any parts replaced under warranty
must be original Xtreme parts obtained through an authorized Xtreme Manufacturing Distributor/SSC unless
expressly agreed otherwise in writing and in advance by Xtreme Manufacturing’s warranty department.
Xtreme Warranty Statement
Operation Manual
Effective: 1/1/2017
76
Xtreme Manufacturing Product Warranty Policy
6) All parts claimed under warranty must be held available for return and inspection upon request for a period
of 90 days from date of claim submission, it is necessary that all parts are individuallytaggedor marked with
their part number and the warranty claim number. All parts returning should be still in a factory state, free of
any alteration to the original design. If the parts are subject to repair it will need to be pre authorized by the
Xtreme Product Support Group and or Warranty Department prior to the repair being completed. After 90
days all parts replaced under warranty which have not been returned, to Xtreme Manufacturing should be
destroyed. Failure to produce parts requested by the Warranty Administrator for inspection within a period of
14 days will result in the claim being automatically rejected in full. Materials returned for warranty inspection
must have the following procedure:
Carefully packaged to prevent additional damage during shipping
Drained of all contents and all open ports capped or plugged
Shipped in a container taggedor marked with the RMA number
Shipped PREPAID (ground service only). Any item(s) returned for warranty by any other means may
be refused and returned, unless prior approval is agreed with Xtreme.
7) At the direction of the Xtreme Manufacturing Warranty department, any componentpart(s) of Xtreme
Manufacturing products to be replaced or repaired under this warranty program must be returned freight
prepaid for inspection. An RMA (Returns material authorization) must be requested from Xtreme
Manufacturing Warranty department, a copy to be placed with the returning componentpart(s).
8) All warranty replacement parts will be shipped freight prepaid (standard charges, ground shippingonly)
from the Xtreme Manufacturing Parts department, Service Department or from the Vendor to Dealer/SSC or
Customer. Any other shippingmethod is the customer responsibility.
9) All warranty claims are subject to approval by Xtreme Manufacturing Service department. Xtreme
Manufacturing reserves the right to limit or adjust claims with regard to defective parts, labor or travel time
based on usual and customary guidelines.
10) Reimbursement policy, labor will be paid at 75% of posted hourly shop rate. Travel time will be paid at $50
per hour up to a maximum of 3 hours. Xtreme Manufacturing will pay 1 hour of troubleshootingtime per
warranty claim, unless expressly agreed otherwise in writing and in advance by Xtreme’s Warranty
Department. An annual rate declaration must to be supplied to the Xtreme Warranty administrator by January
31st and will be used as the reimbursable rate for that calendar year.
Xtreme Warranty Statement
Effective: 1/1/2017
77
Operation Manual
Xtreme Manufacturing Product Warranty Policy
REPLACEMENT PARTS WARRANTY
1. Any part replaced under this limited warranty is not subject to further warranty cover beyond the normal
warranty period of the machine upon which the part was installed.
2. Any replacement parts sold (not delivered under a warranty claim) will be subject to a warranty period of
(6) six months from the date of invoice.
3. Parts held by an authorized Distributor/SSC are covered under warranty for a period of (12) twelve months
from the date of invoice, provided that those parts have been subject to appropriate storage to prevent
damage and deterioration (conditional on Xtreme Manufacturing review).
CLAIM PROCEDURE
The Xtreme Manufacturing Warranty department must be notified within forty‐eight hours (48) of any
possible warranty situation during the applicable warranty period. Personnel performing major warranty
repair or parts replacement must obtain specific approval by the Xtreme Manufacturing Warranty department
prior to performing the warranty repair or replacement.
When a Distributor/SSC / Customer perceive a warranty issue to exist the following steps must be adhered to:
•
•
•
•
•
•
Customer/SSC / Distributor to place a purchase order for genuine Xtreme Manufacturing replacement
parts.
Xtreme Manufacturing to dispatch parts via the requested method (in line with the required response
time).
Confirmation that a qualified technician is available to replace the part and that this person has been
accepted by Xtreme Manufacturing to carry out such work under the warranty of the machine. Failure
to do this may nullify the warranty.
Customer /SSC / Distributor to allocate a warranty claim number to the repair.
All correspondencein respect of the claim to be on an official Xtreme Manufacturing warranty claim
form as supplied by Xtreme Manufacturing’s warranty department.
All warranty claims must be submitted within 30 days of the date of the machine repair.
FREIGHT DAMAGE
•
•
If a machine is received in a damagedcondition, then the damage must be noted on the bill of lading
and /or delivery documents and photographsmust be taken at the point of delivery, prior to signing
acceptance of the consignment.
The freight company and Xtreme Manufacturing must be contacted by the Distributor and a damage
claim registered by either party immediately.
Operation Manual
78
Xtreme Manufacturing Product Warranty Policy
The above requirements apply only to freight damage associated with equipment supplied by Xtreme
Manufacturing transport. Customer freight issues are excluded from this warranty policy.
THIS PRODUCT WARRANTY POLICY SPECIFICALLYEXCLUDES:
•
1. Engines, motors, tires and batteries are manufactured by specialist suppliers to Xtreme Manufacturing, who
furnish their own warranty policies. Xtreme Manufacturing will, however, to the extent permitted pass
through any such warranty protection to the Distributor/SSC / Customer.
2. Xtreme Manufacturing products which has been modified or altered outside Xtreme Manufacturing
factories without written approval, if such modification or alteration, in the sole judgmentof Xtreme
Manufacturing Engineeringand/or Service Departments, adversely affects the stability, reliability or service
life of the Xtreme Manufacturing product or any componentthereof.
3. Any Xtreme Manufacturing product which has been subject to misuse and abuse, improper maintenance or
accident. “Misuse” includes but is not limited to operation beyond the factory‐rated load capacity and speeds.
“Improper maintenance” includes but is not limited to failure to follow the recommendationscontained in the
Xtreme Manufacturing Operation, Maintenance, and repair Parts Manuals.
4. Normal wear of any Xtreme Manufacturing componentpart(s). Normal wear of componentparts may vary
with the type, application or type of environment in which the machine may be used; such as, but not limited
to sandblastingapplications.
5. Routine maintenance, routine maintenance items and minor adjustments are not covered by this warranty,
includingbut not limited to hydraulic fluid, filters and lubrication, paint and decals engine tune‐up, brake
adjustments etc. Xtreme Manufacturing will not cover leaks from fittings, hoses and any other connection
points after the unit has been in service for 90 days or 150 hours of operation which ever comes first.
6. Any Xtreme Manufacturing product that has come into direct contact with any chemical or abrasive
material.
7. Incidental or consequential expenses, losses, or damages related to any part or equipment failure, including
but not limited to freight cost to transport the machine to a repair facility, downtime of the machine, lost time
for workers, lost orders, lost rental revenue, lost profits, expenses or increased cost. This warranty is expressly
in lieu of all other warranties, representations or liabilities of Xtreme Manufacturing, either expressed or
implied, unless otherwise amended in writing by Xtreme Manufacturing.
8. Xtreme Manufacturing warranty policy does not cover any duties, taxes, environmental fees including
without limitation, disposal or handlingof tires, batteries and petrochemical items.
9. Items specifically excluded are: fuel injectors, motor brushes, glow plugs, contactor tips and springs, filters,
lamp bulbs, lamp lenses, coolants, lubricants, brake pads and cleaning materials.
10. Failure of replacement parts due to fault misdiagnosisor incorrect fitting by the
Xtreme Warranty Statement
Effective: 1/1/2017
79
Operation Manual
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.
Wherever possible the end customer shall obtain all warranty support & make all warranty claims through the
local Xtreme Manufacturing authorized Distributor /SSC / Dealer. Warranty support should be from the
Distributor /SSC / Dealer from whom the Xtreme Manufacturing product was purchased. Where Xtreme
Manufacturing equipment is supplied directly from the factory, the end customer, if unable to contact a
Distributor/SSC / Dealer, may contact the Xtreme Manufacturing Warranty Department for further assistance.
APPEAL
The buyer may appeal in writing against a rejected or adjusted claim to Xtreme Manufacturing warranty
department within a period of 21 days of receiving the rejection or adjustment notice. The appeal should be
groundedon express reasons and supported by relevant evidence. Appeals received outside of this time limit
will not be considered.
Xtreme Warranty Statement
Operation Manual
Effective: 1/1/2017
80
Xtreme Manufacturing Product Warranty Policy
XTREME MANUFACTURING WARRANTY SCHEDULE
Limited Warranty Periods
Item
Warranty Period
Main Frame and Chassis
Boom weldment and rollers
Powertrain and all other components not listed above
Parts held in a Distributor’s stock
10 years or 10,000 hours, parts
replacement or repair
5 years or 5,000 hours, parts replacement
or repair
2 years or 2,000 hours, parts replacement
or repair
12 months from date of invoice, subject
to adequate storage / protection.
Parts sold (non warranty)
6 months from date of invoice
Batteries supplied on new machines
6 months from warranty registration date
Other specifically excluded parts:
Fuel injectors
Brake pads
Glow plugs
Springs
Oils
Filters
Lamp bulbs
Lamp lenses
Coolants
Lubricants
Cleaning materials
All consumable / wear parts.
Not covered by Warranty
Xtreme Warranty Statement
Effective: 1/1/2017
81
Operation Manual
8350 Eastgate Road Henderson, NV 89015
(702) 636-2969 (800) 497-1704
www.XMFG.com
PN 24971-000 Rev C
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.
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