XTREME XR Series (XR620/621/842/1045/1245/1254/1267/1534/2050/3034) Forward Reach Forklifts Service & Repair Manual
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Service Manual
Forward Reach Forklifts
XR620/621/842/1045/1245
1254/1267/1534/2050/3034
Xtreme Manufacturing, LLC
1415 West Bonanza Road
Las Vegas, NV 89106
(702) 858-2404
(702) 646-2196 (fax)
www.xtrememanufacturing.com
IMPORTANT
Read and understand this manual before
operating or performing maintenance on these forklifts.
Copyright © 2010 – Xtreme Manufacturing, LLC
P/N 24933-000 Rev 01 – 05/10
Ask your supervisor to explain any operation, maintenance, or safety information
that you do not fully understand.
Untrained personnel can cause death or severe injury. Do not operate or perform
maintenance on a forklift until you have read and understand:
• The Operation and Safety Manual for the forklift.
• Chapter 2 of this Service Manual.
• The safety decals affixed to the forklift.
• Your employer's applicable work rules regarding the safety,
operation, and maintenance of the forklift.
• Applicable federal, state, or local government regulations.
Untrained personnel can cause death or severe injury. Do not operate or work on a
forklift until you have been trained in the safe operation and maintenance of the
forklift.
– REPLACEMENT OF MANUALS –
Contact Xtreme Manufacturing, LLC, to obtain replacement Operation and Safety
Manuals, Owner’s Service Manuals, Service Manuals, or Illustrated Parts Catalogs.
Xtreme Manufacturing, LLC
1415 West Bonanza Road
Las Vegas, NV 89106
(702) 851-3750
xtrememanufacturing.com
List of Effective Pages XR620/621/842/1045/1245/1254/1267/1534/2050/3034
List of Effective Pages
This manual consists of 277 pages as listed below:
Front cover page
Inside front cover page
Title page
Pages A through B
Pages i through x
Pages 1-1 through 1-32
Pages 2-1 through 2-22
Pages 3-1 through 3-6
Pages 4-1 through 4-6
Pages 5-1 through 5-34
Pages 6-1 through 6-14
Pages 7-1 through 7-8
Pages 8-1 through 8-48
Pages 9-1 through 9-22
Pages 10-1 through 10-32
Pages 11-1 through 11-6
Pages 12-1 through 12-6
Pages Index 1 through Index 6
Pages A-1 through A-20
Inside back cover page
Back cover page
Copyright © 2010 – Xtreme Manufacturing Co.
Service Manual Rev 01 – 05/10 A
P/N 24933-000
Service Bulletins XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Service Bulletins
The following Service Bulletins have been incorporated in this manual:
Number Title Comments
Service Manual Rev 01 – 05/10 B
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Table of Contents
PARA. TITLE PAGE
List of Effective Pages ................................................................................................... A
Service Bulletins ............................................................................................................ B
Table of Contents ........................................................................................................... i
List of Illustrations ........................................................................................................ vi
List of Tables ................................................................................................................. ix
SECTION 1 – GENERAL INFORMATION & SPECIFICATIONS ....................................... 1-1
1-1 Scope of Manual ......................................................................................................... 1-1
1-2 Applicability ................................................................................................................. 1-1
1-3 Service Bulletins.......................................................................................................... 1-1
1-4 Related Technical Documentation .............................................................................. 1-2
1-5 Forklift Nomenclature .................................................................................................. 1-2
1-6 Component Data Plates .............................................................................................. 1-10
1-7 Lubricants and Fluids .................................................................................................. 1-14
1-8 Filters and Strainers .................................................................................................... 1-15
1-9 Forklift and Engine Specifications ............................................................................... 1-16
1-10 Torque Wrench Use .................................................................................................... 1-26
1-11 Cap Screw Torque Values .......................................................................................... 1-27
SECTION 2 – MAINTENANCE & OPERATION SAFETY ................................................. 2-1
2-1 General ....................................................................................................................... 2-1
2-2 Safety Signal Words.................................................................................................... 2-1
2-3 Notes ........................................................................................................................... 2-1
2-4 Safety Symbols ........................................................................................................... 2-2
2-5 Lockout/Tagout Procedure.......................................................................................... 2-6
2-6 General Maintenance Precautions.............................................................................. 2-7
2-7 Viton Seals .................................................................................................................. 2-7
2-8 Using Compressed Air Safely ..................................................................................... 2-8
2-9 Battery Handling and Maintenance............................................................................. 2-8
2-10 Engine Operation and Maintenance ........................................................................... 2-10
2-11 Fuel Handling and Maintenance ................................................................................. 2-10
2-12 California Proposition 65 Warnings............................................................................. 2-11
2-13 Functional Tests .......................................................................................................... 2-11
2-14 Safe Operation Checklist ............................................................................................ 2-12
2-15 Functional Test Checklist ............................................................................................ 2-13
2-16 Load Handling ............................................................................................................. 2-14
Service Manual Rev 01 – 05/10 i
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Table of Contents – Cont.
PARA. TITLE PAGE
2-17 Picking Up a Load ....................................................................................................... 2-16
2-18 Carrying a Load........................................................................................................... 2-16
2-19 Placing a Load ............................................................................................................ 2-16
2-20 Load Shift .................................................................................................................... 2-17
2-21 Proper Use of Forks .................................................................................................... 2-17
2-22 Prohibited Practices .................................................................................................... 2-17
2-23 Operator Hand Signals ............................................................................................... 2-17
2-24 Safety Decals .............................................................................................................. 2-24
SECTION 3 – MAINTENANCE SCHEDULE .................................................................... 3-1
3-1 Establishing a Preventive Maintenance Program ....................................................... 3-1
3-2 Long-Interval Maintenance Requirements .................................................................. 3-5
SECTION 4 – AXLE CYLINDER AND OUTRIGGER LUBRICATION ................................ 4-1
4-1 General Maintenance Safety ...................................................................................... 4-1
4-2 Using a Grease Gun ................................................................................................... 4-2
4-3 Lubricate Axle Cylinders and Outriggers .................................................................... 4-3
SECTION 5 – ENGINE ................................................................................................... 5-1
5-1 General Maintenance Safety ...................................................................................... 5-1
5-2 Check Engine Oil Level ............................................................................................... 5-1
5-3 Check Engine Coolant Level ....................................................................................... 5-3
5-4 Check for Oil and Coolant Leaks ................................................................................ 5-6
5-5 Check for Water in Fuel-Water Separator................................................................... 5-7
5-6 Empty Air Filter Dust Cup ........................................................................................... 5-9
5-7 Check Condition and Tension of Drive Belts .............................................................. 5-11
5-8 Change Engine Oil ...................................................................................................... 5-11
5-9 Replace Oil Filters ....................................................................................................... 5-14
5-10 Replace Fuel Filter ...................................................................................................... 5-17
5-11 Check Specific Gravity of Coolant .............................................................................. 5-19
5-12 Drain and Flush Cooling System ................................................................................ 5-22
5-13 Replace Air Filter......................................................................................................... 5-24
5-14 Check Air Filter............................................................................................................ 5-25
5-15 Check Condition and Tension of Drive Belts .............................................................. 5-26
5-16 Check and Adjust Valve Tip Clearances..................................................................... 5-28
5-17 Check Engine Hoses and Connections ...................................................................... 5-30
Service Manual Rev 01 – 05/10 ii
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Table of Contents – Cont.
PARA. TITLE PAGE
5-18 Check Radiator Hoses and Connections .................................................................... 5-31
5-19 Check Engine Wiring and Connections ...................................................................... 5-32
5-20 Check for Oil, Coolant, and Fuel Leaks ...................................................................... 5-33
SECTION 6 – TRANSMISSION, AXLES, & DRIVE SHAFTS ........................................... 6-1
6-1 General Maintenance Safety ...................................................................................... 6-1
6-2 Using a Grease Gun ................................................................................................... 6-1
6-3 Lubricate Axle Grease Fittings .................................................................................... 6-2
6-4 Lubricate Drive Shafts ................................................................................................. 6-4
6-5 Replace Transmission Filters and Fluids .................................................................... 6-6
6-6 Check Axle Oil Level ................................................................................................... 6-8
6-7 Check Wheel End Oil Level ........................................................................................ 6-11
6-8 Drain and Fill Axle Wheel End .................................................................................... 6-13
SECTION 7 – WHEELS & TIRES ................................................................................... 7-1
7-1 General Maintenance Safety ...................................................................................... 7-1
7-2 Check Wheel Lug Nut Torque..................................................................................... 7-1
7-3 Inspect Wheel/Tire Assembly ..................................................................................... 7-3
7-4 Replace Wheel/Tire Assembly .................................................................................... 7-4
7-5 Replace Tire ................................................................................................................ 7-7
SECTION 8 – HYDRAULIC SYSTEM.............................................................................. 8-1
8-1 General Maintenance Safety ...................................................................................... 8-1
8-2 Hydraulics Maintenance Safety and Precautions ....................................................... 8-1
8-3 Handling Hydraulic Fluid ............................................................................................. 8-2
8-4 Making Leak-Free Connections .................................................................................. 8-2
8-4-1 Hose and Tubing Installation Practices....................................................................... 8-2
8-4-2 Operating Conditions .................................................................................................. 8-2
8-4-3 Maintenance Practices................................................................................................ 8-3
8-5 Keeping the Hydraulic System Clean ......................................................................... 8-4
8-6 Check Hydraulic Fluid Level ....................................................................................... 8-6
8-7 Change Hydraulic Fluid............................................................................................... 8-8
8-8 Replace Suction Strainer ............................................................................................ 8-10
8-9 Clean Hydraulic Reservoir Strainer............................................................................. 8-12
8-10 Replace Air Breather ................................................................................................... 8-14
8-11 Replace High-Pressure Filter ...................................................................................... 8-16
8-12 Replace Return Line Filter .......................................................................................... 8-19
Service Manual Rev 01 – 05/10 iii
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Table of Contents – Cont.
PARA. TITLE PAGE
8-13 Taking Hydraulic Fluid Sample ................................................................................... 8-21
8-14 Replacing a Hose ........................................................................................................ 8-24
8-15 Tightening Loose Fittings ............................................................................................ 8-27
8-16 Replace Cartridge Valve ............................................................................................. 8-27
8-17 Replace Cartridge Valve Solenoid .............................................................................. 8-30
8-18 Location of Hydraulic Components ............................................................................. 8-32
8-19 Distribution Manifold Hose Connections ..................................................................... 8-32
8-20 Maintenance Requirements for Failed Pump ............................................................. 8-47
SECTION 9 – ELECTRICAL SYSTEM ........................................................................... 9-1
9-1 General Maintenance Safety ...................................................................................... 9-1
9-2 Battery Safety.............................................................................................................. 9-1
9-3 Battery Description ...................................................................................................... 9-3
9-4 Battery Cable Description ........................................................................................... 9-3
9-5 Check Condition of Battery and Cables ...................................................................... 9-3
9-6 Replace Battery........................................................................................................... 9-4
9-7 Inspect and Clean Battery........................................................................................... 9-8
9-8 Install Auxiliary Battery................................................................................................ 9-10
9-9 Electrical Center Assembly ......................................................................................... 9-13
9-10 Engine Relay Assembly .............................................................................................. 9-18
9-11 Replace a Relay .......................................................................................................... 9-20
9-12 Replace a Fuse ........................................................................................................... 9-21
SECTION 10 – BOOM & ATTACHMENTS ...................................................................... 10-1
10-1 General Maintenance Safety ...................................................................................... 10-1
10-2 Using a Grease Gun ................................................................................................... 10-1
10-3 Boom and Attachment Lubrication .............................................................................. 10-2
10-4 Lubricate Boom Extend Chain .................................................................................... 10-8
10-5 Inspect Boom Chains .................................................................................................. 10-9
10-5-1 Chain Nomenclature ................................................................................................... 10-10
10-5-2 Visually Inspect Chain................................................................................................. 10-10
10-5-3 Measure Chain Edge Wear......................................................................................... 10-13
10-5-4 Measure Chain Elongation.......................................................................................... 10-15
10-6 Check and Adjust Boom Chain Tension ..................................................................... 10-17
10-7 Slide Blocks................................................................................................................. 10-18
10-8 Slide Block Inspection ................................................................................................. 10-18
10-9 Replace Slide Blocks .................................................................................................. 10-22
Service Manual Rev 01 – 05/10 iv
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
Table of Contents – Cont.
PARA. TITLE PAGE
10-10 Inspect Boom Rollers .................................................................................................. 10-23
10-11 Fork Nomenclature...................................................................................................... 10-27
10-12 Measure Fork Flank Wear .......................................................................................... 10-29
10-13 Fork Inspection............................................................................................................ 10-31
10-14 Manually Retracting and Lowering Boom ................................................................... 10-33
SECTION 11 – CHECK-OUT PROCEDURES .................................................................. 11-1
11-1 Check Operation of Rear Axle Stabilization System................................................... 12-1
SECTION 12 – STORAGE & TRANSPORTATION .......................................................... 12-1
12-1 General Maintenance Safety ...................................................................................... 12-1
12-2 Preparing Engine for Long-Term Storage................................................................... 12-1
12-3 Preparing Forklift for Long-Term Storage ................................................................... 12-4
12-4 Transporting Forklift .................................................................................................... 12-5
APPENDIX – MAINTENANCE FORMS AND SAFETY TAGS .......................................... A-1
A-1 Preventive Maintenance and History Logs ................................................................. A-1
A-2 Pre-Operation Checklist .............................................................................................. A-1
A-3 Safety Tags ................................................................................................................. A-1
Maintenance Schedule...................................................................................................................... A-2
Maintenance History Log .................................................................................................................. A-8
Fork Inspection Log........................................................................................................................... A-11
Pre-Operation Checklist .................................................................................................................... A-13
Grease Fittings List ........................................................................................................................... A-15
Danger Tags ..................................................................................................................................... A-16
Condition Tags .................................................................................................................................. A-17
Notes ................................................................................................................................................. A-18
Service Manual Rev 01 – 05/10 v
P/N 24933-000
Table of Contents XR620/621/842/1045/1245/1254/1267/1534/2050/3034
List of Figures
FIGURE TITLE PAGE
1-1 Forklift Nomenclature .................................................................................................. 1-3
1-2 Forklift Covers ............................................................................................................. 1-7
1-3 Forklift Cab .................................................................................................................. 1-8
1-4 Front Control Panel ..................................................................................................... 1-9
1-5 Side Control Console .................................................................................................. 1-10
1-6 Location of Chassis and Engine Data Plates.............................................................. 1-11
1-7 Location of Transmission Data Plates ........................................................................ 1-12
1-8 Location of Axle Data Plates ....................................................................................... 1-13
1-9 SAE Grade 8 Bolt Markings ........................................................................................ 1-28
2-1 Danger and Condition Tags ........................................................................................ 2-6
2-2 Battery Disconnect Switch .......................................................................................... 2-7
2-3 Operator Hand Signals ............................................................................................... 2-18
2-4 Safety Decals .............................................................................................................. 2-19
3-1 Forklift Hour Meter ...................................................................................................... 3-1
4-1 Front and Rear Axle Cylinder Grease Fittings ............................................................ 4-3
4-2 Outrigger Grease Fittings – XR1245/1254/1267/2050 ............................................... 4-4
5-1 Engine Oil Fill Cap and Dipstick.................................................................................. 5-3
5-2 Coolant Level Indicator ............................................................................................... 5-5
5-3 Radiator....................................................................................................................... 5-5
5-4 Fuel-Water Separator ................................................................................................. 5-8
5-5 Engine Air Filter Assembly .......................................................................................... 5-10
5-6 Oil Drain Plug and Dipstick ......................................................................................... 5-13
5-7 Recommended Engine Oil Viscosity Grades .............................................................. 5-13
5-8 Element-Type Oil Filter ............................................................................................... 5-15
5-9 Canister-Type Oil Filter ............................................................................................... 5-16
5-10 Fuel Filter Element ...................................................................................................... 5-18
5-11 Coolant Recovery Tank and Radiator Drain ............................................................... 5-20
5-12 Specific Gravity Chart ................................................................................................. 5-21
5-13 Cylinder Block Drain Plug ........................................................................................... 5-23
5-14 Checking Drive Belt Tension....................................................................................... 5-27
5-15 Checking and Adjusting Engine Valve Clearances..................................................... 5-29
5-16 Radiator Hoses and Connections ............................................................................... 5-32
Service Manual Rev 01 – 05/10 vi
P/N 24933-000
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$42.99
Models covered:
- XR620
- XR621
- XR842
- XR1045
- XR1245
- XR1254
- XR1267
- XR1534
- XR2050
- XR3034
This manual provides comprehensive support for the maintenance and repair needs of the XTREME XR Series Forward Reach Forklifts, including models XR620, XR621, XR842, XR1045, XR1245, XR1254, XR1267, XR1534, XR2050, and XR3034. It is an essential resource for professionals and enthusiasts seeking to ensure the longevity and optimal performance of their equipment.
The content covers a broad spectrum of topics including engine specifications, hydraulic systems, electrical schematics, and safety protocols. Each section provides clear and precise instructions accompanied by detailed illustrations and diagrams, enabling users to navigate complex repairs and adjustments with confidence.
Whether you're a seasoned mechanic or a diligent owner keen on DIY maintenance, this guide equips you with the knowledge to tackle tasks ranging from routine servicing to intricate repairs. Its thorough approach ensures that users can approach maintenance tasks with the same level of precision and care as professional technicians, promoting a safer working environment and enhancing the machinery's reliability.
For those who prefer a more traditional format, the manual is available as a comprehensive document, ensuring that vital information is always accessible, regardless of one's familiarity with digital tools. This format is ideal for keeping a physical copy in the workshop or vehicle, allowing for quick reference during repairs or maintenance checks.
In summary, this manual serves as an invaluable tool for anyone involved in the upkeep of the XTREME XR Series Forward Reach Forklifts, offering detailed insights into the mechanics of these complex machines. With its detailed coverage and accessible presentation, it stands as a crucial resource for ensuring the efficient and safe operation of your equipment.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
