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Hydraulic SystemXR620/621/842/1045/1245/1254/1267/1534/2050/3034• Spilled hydraulic fluid is a combustible and slip hazard material that requiresimmediate containment and cleaning. Failure to identify the spill, alert nearbypersonnel, and clean the spilled fluid may result in death or serious personalinjury, and damage to equipment and facilities.Very minute foreign particles, as small as 10 microns, can adversely affectoperation of the hydraulic systems. (One micron equals one millionth of a meter.)Use extreme caution to prevent dirt, debris, and other contaminants from enteringthe hydraulic system.8-3 HANDLING HYDRAULIC FLUIDThe following general precautions must be observed when handling hydraulic fluid:• NEVER allow different categories of hydraulic fluids to become mixed. Chemical reactionsmay occur; fire resistant fluids may lose their fire resistance; and seals may be damaged.• NEVER, under any circumstances, service the forklift with a fluid other than Dexron III (AW46for older units with clear fluid).• ENSURE that hydraulic fluid and fluid containers are protected from contamination of any kind.Dirt particles may cause hydraulic components to become inoperative, cause seal damage,etc. If there is any question regarding the cleanliness of the fluid, DO NOT use it. Containersfor hydraulic fluid must never be left open to air longer than necessary.• DO NOT expose hydraulic fluid to high temperature or open flames. Mineral-based fluids, suchas Dexron III, are highly flammable.8-4 MAKING LEAK-FREE CONNECTIONSSome leakage in a hydraulic system is unavoidable. An example of this type of leakage would be theslight amount of fluid found on cylinder rods. However, any leakage reduces efficiency and causes powerloss. Factors that contribute to leakage are:• Hose and tubing installation practices.• Operating conditions.• Maintenance practices.8-4-1 HOSE AND TUBING INSTALLATION PRACTICESInstalling hoses and tubing according to Xtreme Manufacturing maintenance instructions (Figure 8-1) willpromote long life of external seals. Vibration or stresses that result from improper installation can shakeloose connections. Avoid pinching, cocking, or incorrectly installing seals during hydraulic componentinstallation.8-4-2 OPERATING CONDITIONSTo ensure correct seal life, the operating conditions of the forklift must be controlled. A shaft seal orpiston-rod seal exposed to moisture, salt, dirt, or any other abrasive contaminant will adversely affect aseal. Also, operators should always try to keep their loads within the recommended limits to preventleakage caused by excessive pressures.Service Manual Rev 01 – 05/10 8-2P/N 24933-000
Hydraulic SystemXR620/621/842/1045/1245/1254/1267/1534/2050/30348-4-3 MAINTENANCE PRACTICESRegular filter and hydraulic fluid changes, using high-quality Dexron III hydraulic fluid, adds to seal life.Using an inferior fluid will cause wear on seals and interfere with desirable hydraulic fluid properties.Proper maintenance prevents introduction of contaminants that can damage seals. Never use additiveswithout approval from Xtreme Manufacturing. Manufacturers recommend soaking seals overnight inhydraulic fluid before installation. Do not install seals dry. Before installation, always coat seals with cleanhydraulic fluid.Figure 8-1. Making Leak-Free ConnectionsService Manual Rev 01 – 05/10 8-3P/N 24933-000
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Service ManualForward Reach Forklif
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List of Effective PagesXR620/621/84
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Table of ContentsXR620/621/842/1045
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General Information & Specification
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Maintenance & Operation SafetyXR620
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Maintenance ScheduleXR620/621/842/1
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Axle Cylinder & Outrigger Lubricati
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EngineXR620/621/842/1045/1245/1254/
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EngineXR620/621/842/1045/1245/1254/
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EngineXR620/621/842/1045/1245/1254/
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Page 129 and 130: Wheels & TiresXR620/621/842/1045/12
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Electrical SystemXR620/621/842/1045
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Boom & AttachmentsXR620/621/842/104
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Checkout ProceduresXR620/621/842/10
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Storage & TransportationXR620/621/8
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IndexXR620/621/842/1045/1245/1254/1
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IndexXR620/621/842/1045/1245/1254/1
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IndexXR620/621/842/1045/1245/1254/1
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Maintenance Forms & Safety TagsXR62
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AFTER FIRST 50 HOURS OF OPERATIONRE
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AFTER EVERY 500 HOURS OF OPERATIONR
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AFTER EVERY 2,000 HOURS OF OPERATIO
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Maintenance History LogFORKLIFT MOD
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Fork Inspection LogFORKLIFT MODEL:
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Pre-Operation Checklist Operate the
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Grease Fittings ListComponent No. o
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A-17
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NotesA-19
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ContactXtreme Manufacturing, LLC141
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