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Hydraulic SystemXR620/621/842/1045/1245/1254/1267/1534/2050/3034Figure 8-4. Hydraulic Reservoir Fill Cap8-7 CHANGE HYDRAULIC FLUIDEVERY 2,000 HOURS OFOPERATIONPerform the following procedure to change the hydraulic fluid:PersonnelSpecial tools and equipment– TASK REQUIREMENTS –One mechanicSafety glassesContainers (2)FunnelParts and consumable materials Danger tags (2)Hydraulic fluid, Dexron III(AW46 for older units with clear fluid)Safety solventBrushLint-free wiping cloths or clean clothNOTE: The strainer should be replaced or cleaned when the hydraulic fluid is changed.Refer to para. 8-8 for replacement procedure and para. 8-9 for cleaning procedure.Service Manual Rev 01 – 05/10 8-8P/N 24933-000
Hydraulic SystemXR620/621/842/1045/1245/1254/1267/1534/2050/3034INITIAL SET-UP1. Park forklift on level surface.2. Set Travel Select lever to NEUTRAL (N).3. Set Parking Brake switch to ON.4. Retract boom and lower carriage. Allow sufficient space to open forklift covers.5. Set Ignition switch to OFF.6. Attach danger tags to steering wheel and ignition key. Refer to para. 2-5, for lockout-tagoutprocedure.7. Relieve hydraulic system pressure as follows:a. Remove air breather from reservoir. Be careful to prevent contamination of air breather orreservoir fittings.b. Depress pressure relief valve in center of reservoir air breather fitting.DRAIN AND FILL RESERVOIR1. Place container under each drain plug (Figure 8-5).2. Clean area around fill plug (Figure 8-4) on filler/breather plate.3. Remove fill plug.4. Clean area around each drain plug.5. Remove both drain plugs from reservoir and allow hydraulic fluid to fill containers. When containersare full almost full, reinstall drain plugs.6. Dispose of hydraulic fluid in accordance with state and/or local laws.7. Repeat Steps 5 and 6 until reservoir and hydraulic system are fully drained.8. Install both reservoir drain plugs and tighten.9. Use clean funnel to add new hydraulic fluid to reservoir through fill port on filler/breather plate. Addfluid until fluid level reaches mid point on reservoir sight gauge (Figure 8-3).10. Install fill cap on filler/breather plate and tighten.11. Install air breather on filler/breather plate and tighten hand tight.12. Start engine and check for leaks at both drain plugs, fill plug, and air breather.NOTE: It is necessary to operate all hydraulic subsystems to expel any air bubblesentrained in the hydraulic fluid.13. Use boom control to raise and extend boom. Then retract and lower boom.14. Use sway control to tilt forklift to left, right, and back to level orientation.15. Recheck reservoir fluid level sight gauge. Add more fluid as required using above procedure.Service Manual Rev 01 – 05/10 8-9P/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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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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