Xtreme XR1045 Operation Manual

Partial Operation

& Safety Manual

Y

PRELIMINAR

Operation

PN 24905-002-NE

NOTICE:

This is a

PRELIMINARY AND PARTIAL

Operators Manual to cover the unit as supplied to

Traylor Brothers

by Xtreme Manufacturing

Las Vegas.

Please refer to Traylor Brothers supplement to the manual for complete instructions.

PN 24905-002-NE

REV 01

JAN 2016

AUTHOR:

OVY LUNGU

© 2016 XTREME MANUFACTURING. ALL RIGHTS RESERVED

Table of Contents


Description Page

Fore and Aft Adjustment Lever

Introduction

Backrest Angle Adjustment Lever

General 5

Seat Belt

Replacement Manuals 5

Rear View Mirrors

Model/Serial Plate 5

Controls and Indicators

Orientation 5

Travel Select Lever

Safety

Gear Select Knob

Safety Disclaimer 6

Parking Brake Knob

Signal Words 6

Load Capacity Charts

Safety Symbols 6

Coolant Gauge

Employer Responsibility 9

Fuel Gauge

Operator Responsibility 9

Steering Select Knob

Operator Qualifications 9

Boom Control

Modifications 9

Attachment Tilt Switch

Mounting/Dismounting 10

Attachment Tilt Lever

Work Site Safety 10

Frame Sway Control Handle

Before Starting Forklift 11

Auxiliary Attachment Control

Operation Safety 12

Boom Angle Indicator

Load Safety 14

Boom Extend Letters

Attachments 15

Frame Level Indicator

Shut Down Procedure 15

Forklift Lifting Points

Forklift Maintenance 16

Operation

Dead Engine Towing 17

Pre-Operation Inspection

Labels

Pre-Operation Inspection Checklist

Labels 18

Functional Tests

Replacement Labels 21

Operator Maintenance

Features

Before Starting Forklift

Standard Equipment 30

Starting Forklift

Optional Equipment 30

Forklift Travel

Specifications

Steering Modes

Specifications 31

Starting Travel

Operator Cab

Starting the Forklift

Accelerator Pedal

Service Brake Pedal

Steering Wheel

Operator Seat

Operator Seat Controls

32

32

32

PRELIMINAR

Weight Suspension Lever 33

Shifting Gears

Warning Indicators and Gauges

Stopping Travel

Changing Travel Direction

Shut Down Procedure

Refueling

Fuel Types

3

Lumbar Support

Y

Operation Manual

33

33

34

34

34

35

35

35

36

36

36

37

37

37

38

38

39

39

39

40

40

41

42

44

45

46

47

47

47

47

48

48

49

49

49

49

49

50


Description

Pintle Hook

Attachments

Attachment Disclaimer

Fork Ratings

Standard Carriage Operation

Fork Positioning Carriage Operation

Quick Attach System

Load Handling

Boom Lift Point

Suspended Loads

Pick Up a Load

Carry a Load

Place a Load

Page

56

57

57

52

55

56

56

50

50

50

50

51

51


Description

Load Shift

Elevating Personnel

Load Capacity Charts

Frame Leveling

Preventive Maintenance

Maintenance Schedule

Lockout / Tagout

Emergency Boom Lowering Valve

Do Not Operate - Accident Prevention Tags

New or Additional Operators

Lockout/Tagout Procedure

“Do Not Operate” Tags

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Page

57

57

59

61

62

64

65

65

65

66


PRELIMINAR

Introduction

General

This Operation and Safety Manual provides the information needed to safely operate the XR1045 Reach Forklift.

This manual should be considered a permanent part of the forklift, and kept in the protective manual case located in the operator’s cab.

Notice

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 included in this manual 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

Learn and practice safe use of forklift controls in a safe, clear area, BEFORE you operate this forklift on a work site.

It is your responsibility to observe applicable laws and regulations and to follow manufacturer’s instructions on forklift operation and maintenance.

Replacement Manuals

Replacement manuals for the XR1045 forklift can be obtained by contacting our parts department by phone or visiting our website:

Xtreme Manufacturing

Phone: (800) 497-1704 www.XMFG.com

Model / Serial Plate

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.

Serial Number:

Y

For easy reference, you can record the serial number in the space below.

Figure 1. Serial Number Plate

Orientation

Right side, left side, front, and rear are directional references given from the operator’s seat when facing forward.

RIGHT


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.

Y

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.

Safety

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 tools you use are safe; especially those not specifically 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.

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.

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.

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

General Safety

Alert Symbol

DO NOT OPERATE!

Telehandler Down

For Service Or

Maintenance

Perform

Operator

Inspection

Before Starting

This Telehandler

Personal

Protective

Equipment

Gloves

Personal

Protective

Equipment

Ear Protectors

Read Operator

Manual Before

Operating This

Telehandler

Read Material

Safety Data

Sheets (MSDS) For

Chemicals And

Fluids

DO NOT

Operate If Using

Alcohol, Drugs,

Or Medications

Personal

Protective

Equipment

Safety Shoes

Read Maintenance

Manual Before

Working On

This Telehandler

Know First Aid

Instructions And/

Or Locations On

Work site

Personal

Protective

Equipment

Hardhat

Personal

Protective

Equipment

Safety Glasses

Y

Keep Flames

And Ignition

Sources Away

Hydraulic System

Under Pressure

Warning! Establish

Radio Communication

Before Operating Solo

Warning!

Hydraulic Oil

Under Pressure

Hot Oil!

DO NOT Open

Unless Cap Is

Cool To Touch

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

Fan Blades

Make Sure All

Safety Labels

Are Attached

And Legible

Warning!

Rotating Belts

Can Cut Or

Entangle

Labels And Labels

Keep Hands At A Safe

Distance From

Rotating Belts

Use Three Points of Contact When

Entering and

Exiting Telehandler

7


DO NOT

Jump While

Dismounting

The Telehandler

DO NOT Allow

Riders On Telehandler

Frame Or Fenders

Attachment Can

Result In Death Or

Serious Injury

Warning!

Telehandler Roll Away

Can Cause Death

Or Serious Injury

Fasten

Seat

Belt

DO NOT Allow

Riders On Or In

The Operator Cab

Set Parking Brake

To ON

Engage Parking

Brake

Warning!

Telehandler Tip Over

Can Cause Death

Or Serious Injury

Hot Surface!

Keep Hands Away

Warning!

DO NOT Travel

With Boom Raised

DO NOT

Raise Boom While

Traveling On A

Slope

Warning!

Electrocution Can

Cause Death Or

Serious Injury

Pinch Points

Body

Danger!

Keep A Safe

Distance From

Electrical Lines

DO NOT Allow

Anyone Under

A Raised Load

Pinch Points

Hands

Have Adequate

Ventilation If

Operating This

Telehandler In An

Enclosed Space


Warning!

Explosion

Hazard

Warning!

HOT COOLANT.

DO NOT Use Ether

As A Starting Aid

DO NOT Use As A

Personnel Carrier

Warning!

Operate With

Caution During

Storms Or High Wind

PRELIMINAR

8

DO NOT

Allow Riders

On Auxiliary

Attachments

Set Parking

Brake To OFF

Disengage

Parking Brake

Y

Safety

DO NOT Jump!

If Telehandler Tips,

Keep Seat belt ON

And Brace Yourself

Tip Over Hazard,

Especially

Traveling Up A

Slope Without A

Load

Safety

Employer Responsibility

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.

Additional safety information and training resources can be obtained through these publications, organizations, and/or appropriate sources:

• (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

Always consult Material Safety Data Sheets (MSDS) for chemical hazards and first aid instructions for any oil or lubricant being used. MSDS should be available from the manufacturer/ supplier of the fluid.

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.

Operator Qualifications

Operators must be in good physical and mental condition, with appropriate reflexes, reaction time, vision, depth perception, and hearing.

Y

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:

Successful completion and certification of Safety Training for

Rough Terrain Forklifts is required.

• 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

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.

• 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

9


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.

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.

Work Site Safety

Warning

• Operate the forklift only on firm, stable surfaces. Holes, obstructions, debris, loose fill, and other work site hazards could result in death or serious injury.

• DO NOT allow bystanders in the work area.

Y

• 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.

Safety

DO NOT operate the forklift if you are using drugs, alcohol, or any medication that might impair your judgment or ability.

You must be 18 years of age or older to operate the forklift.

DO NOT operate the forklift on roads. The forklift is not equipped for road travel.

Warning

Warning

Use proper safety procedures and avoid hazardous situations while operating the forklift to prevent death, serious injury, or property damage. Check the work site for any hazards before operating the forklift.

• Check the work surface for loose soil conditions and overhead power lines.

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.

• 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:

1. Gas and water pipes

2. Electrical cables

3. Sewers

Caution

Use caution when operating the forklift during storms or strong winds.

Underground objects could cause death or serious injury.


10

Safety

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.

Before Starting Forklift

Warning

Y inspection with the engine running or hot.

Contact with moving or heated parts could cause 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.

Warning

Keep the Operation and Safety Manual on the forklift at all times. Contact Xtreme

Manufacturing for replacement manuals.

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.

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

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.

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.

or supplier of the fluid.

Consult Material Safety

Data Sheets (MSDS) for chemical hazards and first aid instructions. MSDS should be available from the manufacturer

• 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.

PRELIMINAR

11


Warning

Y 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.

Safety

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.

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.

Operation Safety

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 de-energize power lines or take other suitable precautions.

Keep the forklift, attachments, and loads a safe distance from electrical power lines.

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.

• The seat belt MUST be worn while operating the forklift. Failure to wear the seat belt could result in death or serious injury.

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.

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.

• Keep your head, body, and limbs within the ROPS/FOPS structure.

• 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.

• Stay on the forklift and ride out the roll over or tip over

12


Safety

Warning

DO NOT use the forklift as a work platform or personnel carrier. Falling of attachments could result in death or serious injury.

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 designed 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.

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.

Y

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.

• 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 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.

Caution

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.

It is advised that if operators should operate the machine solo then they shall establish radio communications with appropriate personnel in case of an emergency.

Warning

Warning

Tampering with safety devices is prohibited.

To prevent death, serious injury, or property damage, make sure the forklift comes to a complete stop before moving the travel select

PRELIMINAR

13


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 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).

could result in serious personal injury.

Y

Safety

Contact with hot surfaces and the exhaust pipe after the forklift has been operated 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 once the motor starts. If the motor does not start, DO NOT crank the starter motor continuously for more than 15 seconds. Failure to release the key after the motor has started or continuous cranking can damage the starter motor.

Warning

Follow appropriate procedures to prevent sudden changes in forklift speed that could result in death or serious injury

The forklift includes a Frame Sway Override switch. Improper use of the Frame Sway Override switch could result in death, serious injury, or property damage.

• 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.

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.

• DO NOT coast downhill. Keep the travel select lever in the appropriate position.

• Use the frame sway control to level the forklift before raising the boom.

• DO NOT exit the forklift without following proper shutdown procedures.


• Reposition the forklift if it cannot be leveled using the frame sway control.

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.

• Remain seated with the seat belt securely fastened while the cab is tilted.

• DO NOT enter or exit a tilted cab.

PRELIMINAR

14

Safety

Load Safety

Warning

Failure to follow proper safety procedures when lifting, lowering, and traveling with a load could result in death, serious injury, or property damage.

DO NOT exceed forklift capacity of 10,000 lbs.

The total rated capacity of the forks being used must equal or exceed forklift capacity. Forks can break causing loss of load and possible death or serious injury.

Attachments

Warning

Y into place can become unstable and fall on the operator or other personnel near the forklift.

• 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.

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.

• 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 3,500 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).

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.

Shut Down Procedure

Warning

• 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.

To prevent death or serious injury, follow these procedures before leaving the forklift cab:

• DO NOT exceed the manufacturer’s recommended load capacity.

• Park forklift on a firm, level surface.

• Move travel select lever to NEUTRAL (N).

• DO NOT operate the forklift with an unsafe load distribution.

• Set parking brake to ON (engaged).

• Lower forks and attachments to the ground.

• Adjust the load as necessary, especially for nonstandard loads.

• Use caution when handling loose material that can fall into the cab.

Always engage the parking brake before leaving the forklift.

The forklift can roll if the parking brake knob is not in the ON

(engaged) position, which could result in death, serious injury, or

• 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 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.

property damage.

• Unbuckle the seat belt.

PRELIMINAR

15


Forklift Maintenance

Warning

Follow the manufacturer’s instructions for proper maintenance to make sure the forklift continues to meet manufacturer’s specifications. Failure to properly maintain the forklift can result in improper performance, which could cause death, serious injury, or property damage.

Attach “Do Not Operate” tags to the steering wheel before beginning any service or maintenance.

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.

Y

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.

Safety

• “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 in 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.

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.

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

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.

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.


16

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.

5. Tighten one (1) full turn if bolts completely back out

(repeat for each side). Tighten jam nuts.

Y

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.

3. Under the front of the forklift, locate the four (4) brake release bolts [two (2) per side] at the base of the front axle.

A

C

Figure 5. Brake Release Bolt

6. Crawl out from under the forklift and clear the area of any unnecessary personnel.

7. Carefully remove the blocking from each of the four (4) tires and tow the vehicle to a secure location.

B

Figure 3. Brake Release Locations (both sides)

D

4. Loosen jam nuts. Loosen brake release bolts. Do not completely remove bolts.

Re-Activating Parking Brakes (Front 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.

3. The parking brakes should now be re-activated and the

PRELIMINAR

Figure 4. Brake Release Bolts (both sides of axle)

2. Loosen jam nuts. Tighten brake release bolts until you begin to feel resistance. Tighten jam nuts. Repeat for each side.

4. Verify the parking brake works.

5. Remove any warning tags from the steering wheel.

17


Labels

Left Side View

Figure 6. Label Legend (Left Side)

Right Side View

PRELIMINAR

Figure 7. Label Legend (Right Side)

18


Y

Labels

Labels

Front View Rear View

Y

Figure 9. Label Legend (Rear) Figure 8. Label Legend (Front)

Cab View

51

52

53

54

23

PRELIMINAR

Figure 10. Label Legend (Cab)

29

19


Table 1. Labels

Item Qty Part No. Description

1

1 18008-000 Data Plate

1 18148-000 (A) Permissible - Dash Overlay, LH

2

3

4

1 18148-002 (B) Permissible - Dash Overlay, RH

1 18010-001 Caution, Slip/Trip Hazard

5

6

1 18011-001 Caution, Engine Damage Hazard

1 18013-001 Diesel Only (Tier 4)

7

8

1 18014-001 Check Engine Oil (Tier 4)

1 18015-001 Check/Fill Coolant

9

1 18016-001 Caution, Burn Hazard

2 18017-001 Danger, Crushing Hazard

10

8 18018-001 Danger, Electrocution Hazard

11

1 18018-002 Danger, Electrocution Hazard

12


13

1 18020-001 Warning, Tip-Over Hazard

14


15

1 18022-001 Warning, Tip Over Hazard

16

1 18023-001

Warning, Welding and Modification

Hazard

17

1 18025-001 Warning, Falling Hazard

Item Qty

46

1

47

1

48

1

49

1

50

1

51

1

52

1

53

1

54 1

38

1

39

1

40

1

41

1

42

1

43

1

44

2

45

1

Part No. Description

18043-000 Xtreme logo

18044-000 Xtreme X

18046-000 Boom Swoosh Left Front

Y

18047-000 Boom Swoosh Left Rear

18048-000 Boom Swoosh Right Front

18049-000 Boom Swoosh Right Rear

18372-000 XR1045

18056-000 Boom Lettering A-B-C-D

18057-000 Boom Lettering E-F

18058-000 Boom Lettering G-H

18311-002 Boom Hook 10k (Optional)

18331-000 Caution, Adjustable Carriage

18332-000 Warning, Tow Capacity

17020-100 Load Chart, Standard Carriage

17364-100 Load Chart, Lift Point

18148-004 Permissible - Pull To Start

18148-001 Permissible - Label, Parking Brake

18

19

1

1

18026-001

18027-001

Warning, Unrestrained Operator

Hazard

Danger, Rotating Equipment

Hazard

20

1 18031-001 Warning, Safe Operation Checklist

21

1 18032-001 Warning, Improper Use Hazard

22

1 18033-100 Auxiliary Handle Control

23

1 18358-000 Manual Tilt

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 18148-003 Permissible - Frame Sway Override

30

1 18069-000 Hydraulic Tank Fluid Level

31

1 18082-001 Warning, Injection Hazard

32

33

34

35

2

1

4

2

18083-001

18086-001

18090-001

18300-001

PRELIMINAR

36

2 18312-000 Warning, Falling Hazard

37

4 18315-000 Tie Down Point

20


Labels

Labels

Replacement Labels

Replacement labels can be obtained by contacting Xtreme

Manufacturing at (800) 497-1704. Please have the correct label number available when you call.

1) 18008-000

900 PSI

702-636-2969

800-497-1704

N

R

LOW BRAKE

PRESSURE

F

1 2 3

18148-000

Y

2(A) 18148-000

CRAB

FRONT & REAR WHEELS

MUST BE CENTERED

BEFORE ENGAGING.

18148-002

2W

4W

STEERING

2(B) 18148-002

3) 18010-001

4) 18011-001

DIESEL

CHECK

PRELIMINAR

5) 18013-001 6) 18014-001

18014-001

21


7) 18015-001

9) 18017-001

8) 18016-001

Y

Labels

10) 18018-001


22

Labels

13) 18020-001

15) 18022-001

14) 18021-001

Y

16) 18023-001

23


19) 18027-001

WARNING

21) 18032-001

20) 18031-001

Y

Labels

22) 18033-100


24

Labels

25) 18041-001 26) 18042-000

Y

27) 18066-001 28) 18067-100

FULL

29) 18148-003

18148-003

PRELIMINAR

25


31) 18082-001

33) 18086-001

32) 18083-001

Y

Labels

34) 18090-001


26

Labels

37) 18315-000

39) 18044-000

38) 18043-000

Y

40) 18046-000

27


43) 18049-000

A B C D

45) 18056-000

18056-000

E

44) 18070-001

Y

Labels

F

46) 18057-000

18057-000

G H

47) 18058-000

18058-000

48) 18311-000

18311-000

CARRIAGE DAMAGE

DAMAGE may result from adjusting forks when carriage is loaded.

ONLY ADJUST FORKS WHEN CARRIAGE

IS UNLOADED.

18331-000

49) 18331-000

DEATH or SERIOUS INJURY could result from improper operation when using tow connection.

DO NOT ELEVATE BOOM ABOVE 30 WHEN

TOWING.

PRELIMINAR

50) 18332-000

18332-000

28


Labels

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

5,000 LBS AT 24 IN

MIN CAPACITY FORK

(10,000 LBS PAIR).

P/N 17020-000

50

XR1045 LOAD CHART - STANDARD CARRIAGE

45

40

35

30

25

20

15

10

5

0

10

5

0

5

1,800 LBS

H

15

20

25

30

BO

OM

A

NG

45

LE

50

55

40

35

60

65

68

H

G

F

E

D

C

B

A

2,200 LBS

G

3,000 LBS

F

4,500 LBS

E

6,000 LBS 8,000 LBS

9,000 LBS

10,000 LBS

D

C

B A

2.0 FT

LOAD

CENTER

2.0 FT

LOAD

CENTER

35 30 25 20 15 10 5 0

51) 17020-000

P/N 17181-000

LOAD RATINGS

SHOWN ARE FOR



TIRES ONLY.

STANDARD CARRIAGE

MUST BE ATTACHED

AND UNLADEN WHEN

BOOM LIFT POINT IS

IN USE.

G

20

0

-5

30

-5

-8

H

25

0

5

10

10

5

2,200 LBS

1,800 LBS

15 15

XR1045 LOAD CHART - BOOM LIFT POINT

45

40

35

30

25

20

BO

OM

A

NG

LE

40

45

20

25

30

35

50

55

60

65

68

H

G

F

E

D

C

B

A

Y

3,000 LBS

4,500 LBS

6,000 LBS

8,000 LBS

9,000 LBS

10,000 LBS

F

15

E

10

D

C

B A

5 0

52) 17181-000

UNINTENDED MOTION HAZARD

DEATH or SERIOUS INJURY could result from unintended motion. Do not start engine unless the parking brake is on.

PULL TO START

18148-004

53) 18148-004

18148-001

ON

OFF

UNINTENDED MOTION HAZARD

DEATH or SERIOUS INJURY could result from unintended motion.

Do not start engine unless the parking brake is on.

PARKING BRAKE

54) 18148-001

PRELIMINAR

29


Features

Feature

Boom

Chassis

Cab

Standard Equipment

Description

Universal quick attach head

Three (3) section boom

Boom equipped with heavy duty boom rollers

Rear axle stabilization

1-1/4 inch main frame plate

Sealed pivot pins for extended service periods

High boom mount design

Low mounted central engine & drive train

Fuel level and engine coolant temperature gauges

Brake oil pressure gauge

Rear view mirror

Adjustable seat with seat belt

Deluxe suspension seat

Boom angle and frame level indicator

3600 visibility

Tires Foam-filled

Hydraulics Auxiliary hydraulic circuit with quick attach

Attachment tilt control handle

Frame sway control handle

Frame sway override knob

Feature

Options

Optional Equipment

Description

Hydraulic side-swing carriage (with quick attach couplers)

Y

Limited slip differential

Various carriage sizes

Full line of attachments

Solid Tires

Features


PRELIMINAR

30

Specifications

Specifications

Performance

Capacity . . . . . . . . . . . . 10,000 lbs

Lift Height . . . . . . . . . . . 44’8”

Forward Reach . . . . . . . . 30’4”

Frame Leveling L/R . . . . . 11°/11°

Operating Weight . . . . . . 27,130 lbs

Power Train

Engine . . . . . . . . . . . . . Deutz BF4M1013E, 128 hp

Fuel Capacity . . . . . . . . . 48 gal

Transmission . . . . . . . . . 3-Speed

Brakes . . . . . . . . . . . . . . Inboard Wet Disc

Parking Brake . . . . . . . . . SAHR

Standard Equipment

Heavy-duty Frame/Chassis

Heavy-duty Roller Boom

Melonite Pins and Rollers

Direct Dual Control Hydraulic Valve Actuation

Rear Axle Stabilization (RAS)

Center Inline Engine Drive Train

Full-time Planetary 4-Wheel Drive

Y

Steering - 4-Wheel Circle, Crab, 2-Wheel Front

Open ROPS/FOPS

Adjustable Hydraulic Operator Controls

Suspension Seat

Quick Attach (Common Fit)

Rear View Mirrors

Xtreme Service Accessibility

Tires

Tires (Standard Eq) Foam Filled

13.00 x 24 E3

Hydraulics

GPM . . . . . . . . . . . . . . 185.4

PSI . . . . . . . . . . . . . . . . 3,500

Hydraulic Oil Capacity . . . 45 gal

Attachments

Standard Carriage - 48” or 72”

+45° Swing Carriage - 48” or 72”

+10° Side Tilt Carriage - 52” or 72”

Pallet Forks - 2.25” X 4” X 48”

Lumber Forks - 1.75” X 7” X 60”

Block Forks - 2” X 2” X 48”

Utility Bucket - 1.25 cu. yd.

Concrete Bucket - 0.5 cu. yd., or 1.00 cu. yd.

Truss Boom - 12’

Wallboard/Sheet Material Handler

Dimensions

Length to fork face . . . . . . 21’9”

Width . . . . . . . . . . . . . . 101”

Height . . . . . . . . . . . . . 7’11”

Wheel Base . . . . . . . . . . 120”

Ground Clearance . . . . . . 16.5”

Turning Radius . . . . . . . . 12’

Accessories and Options

Enclosed Cab

Limited Slip Diferential

PRELIMINAR

31


Operator Cab

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.

Operator Cab

Accelerator Pedal

Press the accelerator pedal (A) to increase engine speed (Figure 13). The accelerator pedal is spring-loaded to return to idle speed.

Y

A

Starting the Forklift

To start the forklift, pull out (to the right) the knob on the right side of the dashboard, as shown in Figure 11.

B

Figure 13. Accelerator Pedal (A) and Service Brake Pedal (B)

Service Brake Pedal

Press the service brake pedal (B) to slow or stop the forklift

(Figure 13 above). The service brake pedal activates the service brakes on all four (4) wheels.

Steering Wheel

Turn the steering wheel left or right to steer the forklift in the corresponding direction.

Figure 11. Pull To Start Knob

NOTE:

The Travel Select lever

(A)

must be in NEUTRAL (N) position and the Parking Brake knob

(B)

must be in the ON position to start the forklift (Figure 12).

B

PRELIMINAR

Figure 14. Steering Wheel Figure 12. Travel Select Lever

A

32


Operator Cab

Operator Seat

Operator Seat Controls

The operator seat can be adjusted four (4) ways: weight suspension, lumbar support, fore and aft, and backrest angle.

Lumbar Support

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.

Y

Figure 17. Lumbar Support

Figure 15. Operator Seat

Weight Suspension 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.

Fore and Aft Adjustment Lever

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.

PRELIMINAR

Figure 16. Weight Suspension Lever Figure 18. Fore and Aft Adjustment Lever

33


Backrest Angle Adjustment Lever

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 19. Backrest Angle Adjustment Lever

Seat Belt

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, which could result in death or serious injury.


• The seat belt MUST be worn while operating the forklift.

Failure to wear the seat belt could result in death or serious injury.

The forklift is equipped with a standard two inch (2”) wide retractable seat belt.

Operator Cab

A three inch (3”) wide retractable seat belt is available where required by local laws and regulations.

Warning

Y


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:

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.

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

Two (2) adjustable rear view mirrors are provided to aid the operator’s rear vision. One (1) rear-view mirror is mounted on the upper left of the operator’s cab.

PRELIMINAR

Figure 20. Retractable Seat Belt

Figure 21. Cab-Mounted Mirror

34


Operator Cab

One (1) rear-view mirror is mounted on the right side of the chassis.

F

N

R

Y

Figure 22. Chassis-Mounted Mirror

Controls and Indicators

Travel Select Lever

The travel select lever has three (3) positions: FORWARD,

NEUTRAL, and REVERSE, which change the direction of travel.

Purpose

Travel Select Lever

Position

F (Forward) UP Position

N (Neutral) CENTER Position

R (Reverse) DOWN Position

Figure 23. Travel Select Lever

Gear Select Knob

The Gear Select switch has a twist grip handle with three (3) positions: 1 - FIRST, 2 - SECOND, and 3 - THIRD.

NOTE:

The forklift can be operated in three (3) forward and three (3) reverse gears.

NOTE:

The travel select lever must be in the NEUTRAL position to start the forklift.

NOTE:

The parking brake knob must be in the ON position to start the forklift.

NOTE:

PRELIMINAR

Figure 24. Gear Select Knob

35


Parking Brake Knob

The Parking Brake Knob has two (2) positions: (A) ON and (B)

OFF.

Operator Cab

Low Brake Pressure Gauge

Y

have a qualified mechanic service or repair the forklift BEFORE placing it into service again.

A

B

Figure 25. Parking Brake Knob

(A) Parking Brake ON (B) Parking Brake OFF

Set Parking Brake knob to ON (FORWARD, position A) to engage the parking brake and to OFF (AFT, position B) to disengage the parking brake.

Figure 27. Low Brake Pressure Gauge

Load Capacity Charts

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.

Warning

Do not release the parking brake or engage transmission until the Low Brake Pressure gauge displays a pressure greater than 900 psi.

Coolant Gauge

The coolant gauge indicates the temperature of the coolant in the engine cooling system. After starting the forklift, allow time for the coolant temp gauge pointer to begin to move before operating the forklift. After the engine has sufficiently warmed up, normal engine coolant temperature should read between 180 to 2000F. If the coolant gauge shows abnormal readings, 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.


36

Operator Cab

Figure 28. Coolant Gauge

Fuel Gauge

The fuel gauge, located behind the operator seat and visible through the rear cabin safety glass panel, indicates the fuel level in the fuel tank.

Y

Figure 30. Steering Select and 2-Wheel Rear Knob

Boom Control

The boom control handle has variable motions from the center position that control boom and tilt functions.

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 29. Fuel Gauge

Steering Select Knob

Warning

DO NOT change steering modes until the forklift slows or comes to a complete stop. Align all four (4) wheels perpendicular to the axle, before changing steering mode.

PRELIMINAR

Crab, Two Wheel Steering (2W), and Four Wheel Steering (4W).

NOTE:

None of the switches on the Boom Control Handle are functional on this unit.

37


C

D

A

B

E

F

G

H

•

Attachment Tilt Lever

The Attachment Tilt Lever:

Operator Cab

Controls the attachment tilt functions by moving the handle side to side.

Y

• It is variable speed. Function speed is proportional to how far the handle is moved. The more the handle is moved in the appropriate direction, the faster the corresponding function will occur.

1

2

Figure 33. Attachment Tilt Lever

(1) Attachment Tilt Down (2) Attachment Tilt Up

Function

PRELIMINAR

Figure 32. Boom Control Handle Functions

Purpose

Attachment tilt down Move handle right

Attachment tilt up Move handle left

NOTE:

The attachment carriage will retain any set angle throughout boom raising, lowering, retracting, or extending operations.

38

Attachment Tilt Lever


Operator Cab

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.

Y

Figure 34. Frame Sway Control Handle

Function

Frame Sway Control Handle

Purpose

Frame sway right

Frame sway left

Move handle right

Move handle left

NOTE:

Lock the frame sway by applying the service or parking brake.

NOTE:

Maximum frame sway is 220 overall or 110 each direction, left and right.

Warning

The forklift includes a Frame Sway Override knob. Improper use of the Frame Sway

Override switch could cause death, serious injury, or property damage.

Figure 36. Auxiliary Attachment Control Lever

Boom Angle Indicator

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

The frame sway feature becomes locked and will not operate when the boom is raised 40° or more. Pulling the Frame Sway

Override knob will override the lockout feature and allow slow frame sway.

39


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.

Operator Cab

Warning

DO NOT try to lift or handle heavy components without the use of appropriate lifting equipment.

Y

Warning

Do not use attachments that are corroded excessively.

Figure 38. Boom Extend Letters

Frame Level Indicator

The frame level indicator is mounted on the upper right corner of the operator’s cab. The frame level indicator allows the operator to view if the forklift has been positioned in a level condition.

• All the attachments should be stored in an appropriate enclosure as to prevent corrosion and deterioration due to environmental conditions.

• Inspect the forklift and the attachments periodically for corrosion.

Figure 39. Frame Level Indicator

PRELIMINAR

40


Operator Cab

Forklift Lifting Points

The XR1045 lifting points are shown below. The forklift should only be lifted if lifting points are installed.

Warning

MODEL: XR1045

UNLADEN VEHICLE WEIGHT: 27,130 lbs

UNLADEN CENTER OF GRAVITY

AFT LIFT POINT

FORWARD LIFT POINT

75.0"

APPROX

120.0"

WHEELBASE

Figure 40. XR1045 Lifting Points

PRELIMINAR

41


18241-003

Operation

Pre-Operation Inspection

Caution

Contact with hot surfaces and the exhaust pipe after the forklift has been operated could result in serious personal injury.

Warning

Operation

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.





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.


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 in an open area.

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

Become familiar with all safety and hazard labels, regulations, and procedures. Make sure all proper labels are attached to the forklift and remain legible.

need of repair or maintenance, defective, or unsafe in any way. 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.

Never remove the radiator cap while the engine is hot. The cooling system is under

PRELIMINAR

Operation

Warning

Use proper safety procedures and avoid hazardous situations while operating the forklift to prevent death, serious injury, or property damage. Check the work site for any hazards before operating the forklift.


• 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:

1. Gas and water pipes

2. Electrical cables

3. Sewers

Underground objects could cause death or serious injury.

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.

DO NOT operate the forklift if you are using drugs, alcohol, or any medication that might impair your judgment or ability.

You must be 18 years of age or older to operate the forklift.

DO NOT operate the forklift on roads. The forklift is not equipped for road travel.

Warning

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.

Warning

Y 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.

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.



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.

• Keep your head, body, and limbs within the ROPS/FOPS structure.

• Stay on the forklift and ride out the roll over or tip over

43


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.

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 are legible.

Check that frame level indicator is working properly.

the carriage.

Check condition and operation of the seat belt and mounting hardware.

Check all hydraulic hoses and hose connections for wear or leaks.

Check that Operation and Safety Manual is in the protective case and legible.

Check forks for welds, cracks, misalignment, or any other damage.

the carriage.

Check all hydraulic hoses and hose connections for wear or leaks.

Check tilt cylinder for leaks or any other damage.

Check all four (4) tires and wheels for:

Check all four (4) tires and wheels for:

Punctures, cracks, cuts, gouges, bulges, foreign objects, or any other damage to tires.

.

.

. Add

Check front and rear sway cylinders and hoses for leaks or any other damage.

Check mirrors for cracks, cleanliness, and proper adjustment.

Check hydraulic reservoir sight

Check engine compartment for:

Loose or damaged belts, hoses, and radiator blades.

. Add

Coolant reservoir level. Add radiator coolant, if necessary.

Engine oil level. Add engine oil, if necessary.

Check battery terminals for corrosion.

.

Check front and rear axles for leaks or any other damage.

Check main boom cylinders and hydraulic lines for leaks or any other damage.

Check battery terminals for corrosion.

.

.

.

Check battery for cracked, melted, or damaged case.

Check electrical connections on rear sway cylinder.

PRELIMINAR

Date: __________________________ Initials: __________________________

Date: __________________________ Initials: __________________________

44


Y

Operation

Operation

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.


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.

If anything is found to be in need of repair or maintenance, defective, or unsafe in any way, remove forklift from service and place “Do

Not Operate” tags on the starter switch and steering wheel.

Operate the boom control handle forward and backward to lower and raise boom.

Operate the boom control handle left and right to retract and extend boom.

Operate the attachment lever side to side to tilt the attachment.

Operate the sway control handle left and right to frame sway left or right.

Operate the auxiliary attachment control (if an auxiliary attachment is being used).

Place the travel select lever in reverse to sound the backup alarm.

Release the parking brake.

Operate the forklift in forward and reverse.

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. The forklift should not move unless the parking brake is released.

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.

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:

• 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.

• Check the engine coolant temperature gauge. The engine coolant temperature gauge should read between180 to 2000F.

PRELIMINAR

45


Operator Maintenance

Figure 41. Check Hydraulic Oil Sight Gauge

Y

Operation

Figure 44. Check Engine Oil Level (White Arrow Above).

Figure 42. Add Hydraulic Oil, if Necessary

Figure 45. Add Engine Oil (API CJ-4), If Necessary.

Warning

A

B

Figure 43. Check Coolant Reservoir Level (A). Add Coolant if Necessary (B).




46

Operation

Before Starting Forklift

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.

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. Use safe mounting/dismounting procedures to enter the operator cab.

2. Adjust the operator seat for position and comfort. (Refer to Seat Adjustment section in this manual)

3. Adjust mirrors (this may require assistance).

4. Adjust the side console control panel.

5. Fasten seat belt.

6. Make sure the travel select lever is set to NEUTRAL (N) and the Parking Brake is ON (engaged).

A

Figure 46. Parking Brake (A) Must Be ON (Engaged) and the

Travel Select Lever (B) Must Be In NEUTRAL (N) to Start the

Forklift.

Starting the Forklift

To start the forklift, pull out (to the right) the knob on the right side of the dashboard (Figure 47).

Y

Figure 47. Pull To Start Knob

Forklift Travel

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 Crab, Two Wheel (2W), and Four Wheel

(4W) Steering. Use the Steering Select knob located on the right side of the dash panel to change steering modes.

47


Operation

Starting Travel

Warning

Y hazardous situations while operating the forklift to prevent death, serious injury, or property damage.

• Check the work site for any hazards before operating the forklift.


Figure 48. Steering Select Knob

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.

Four Wheel Steering (4W)

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.

Warning

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 ON (engaged), and the area free of people and obstructions

BEFORE starting the forklift.

1. Start the forklift. Refer to the Starting the Forklift section in this manual. The Travel Select lever must be in NEU-

TRAL (N) and the Parking Brake knob must be in the ON position to start the forklift (Figure 50).

2. Apply service brake.

3. Release parking brake.

4. Move the travel select lever to FORWARD or REVERSE for the appropriate direction of travel.

5. Release the service brake pedal.

6. Slowly press the accelerator pedal to start travel.

Warning

Allow for adequate clearance between the

PRELIMINAR objects in the area to prevent death, serious injury, or property damage.

Figure 49. Maximum Fork Sweep

48


Operation

Shifting Gears

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.

The transmission has three (3) gears that can be used for traveling in forward or reverse. To shift gears rotate the gear select knob to the next gear while the forklift is traveling.

• 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.

Warning Indicators and Gauges

If the brake pressure gauge displays less than 900 psi, 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.

Warning

Y switch to ON (engaged), lower and retract the boom, and shut off the engine before exiting the forklift.

Changing Travel Direction

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.

1. Stop the forklift by applying the service brake pedal.

2. Move travel select lever to FORWARD (F) or REVERSE (R).

3. Release the service brake pedal.

4. Slowly press the accelerator pedal to start travel.

Figure 51. Travel Select Lever

Figure 50. Low Brake Pressure gauge

Stopping Travel

PRELIMINAR

3. Move the travel select lever to NEUTRAL (N).

4. Set the parking brake to ON (engaged).

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 knob to ON (engaged).

4. Lower the boom and rest carriage on ground.

5. If the forklift is parked on an incline, block the wheels.

49


Refueling

Warning

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.

1. Make sure the forklift is level to obtain an accurate fuel level reading.

2. Shut off the engine.

3. Ground the fuel nozzle against the filler neck to avoid sparks.

NOTE:

The fuel gauge is located behind the operator seat

(Figure 29).

Operation

Attachments

Attachment Disclaimer

Warning

Y

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.

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.

Fuel Types

Fork Ratings

Warning

Use ASTM #2 diesel fuel with a minimum Cetane rating of

40 for better fuel economy and performance under most operating conditions.

• Use standard #2 diesel fuel for operating at temperatures above 32°F.

• Use a blend of #1 and #2 diesel fuel (“winterized” #2 diesel) for operating at temperatures below 32°F.

• Fuels with Cetane ratings higher than 40 may be needed in higher altitude or in an extremely low temperature climate to prevent hard starts and excessive smoke.

Pintle Hook

DO NOT exceed forklift capacity of 10,000 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.

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 pounds and is based upon a 24 inches 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.

Death or serious injury could result from improper operation when using tow connection.

Do not elevate boom above 30 degrees when

PRELIMINAR

degrees when towing could result in death or serious injury.

Figure 52. Pintle Hook

Operation

Fork Positioning Carriage Operation

Caution

Y 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, move the auxiliary handle (A) to the left. To move the forks inward, move the auxiliary handle

(A) to the right.

Figure 53. Fork Ratings

(A) Maximum Load Capacity Rating (B) 24 in. Load Center

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.

The maximum load capacity for this forklift is 10,000 lbs. The matched pair or set of forks used on this forklift should have total load ratings which equal or exceed 10,000 lbs. When the load rating of the forklift differs from the load capacity of the forks, the lower value becomes the overall load capacity.

Standard Carriage Operation

The standard carriage uses manually adjustable forks and can be tilted up or down by using the manual tilt lever.

A

Figure 55. 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 3,500 psi, which is the maximum pressure of the forklift auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

When the auxiliary attachment control lever is moved right or left it activates hydraulic pressure through the quick attach couplers to move the carriage.

Operation

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).

Y

A

B

B

A

Figure 56. Quick Attach Couplers For Hydraulic Systems.

(A) Female Coupler. (B) Male Coupler.

Quick Attach System

This forklift includes a quick attach system that allows for easy attachment changes. Perform attachment connection and removal procedures on level ground.

Attachment Connection

Figure 57. Drive Forklift Forward to Align Pivot Pins (A) with

Attachment Hooks (B)

4.

Raise the boom until pivot pins (A) have seated fully in attachment hooks (B).

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.

• 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.

NOTE:

Allow enough distance to extend the boom approximately 18 to 20 inches.

2.

Tilt the quick attach adapter forward.

Figure 58. 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.

52


Operation

C

Y

B

Figure 59. Tilt Attachment To Align Holes Between Quick Attach Adapter (C) and Attachment (B).

6.

Raise the quick attach lock lever.

Figure 61. Insert Quick Attach Pin Through Attachment and

Quick Attach Adapter.

8.

Release the quick attach lock lever and make sure it has lowered and seated itself in groove (A) of the quick attach pin.

Figure 62. Quick Attach Lock Lever and Quick Attach Pin.

Figure 60. Quick Attach Lock Lever.

Warning

7.

With lock lever raised, insert quick attach pin completely through the attachment and quick attach adapter.

maximum pressure of the forklift auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

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

PRELIMINAR

53


9.

Connect the quick attach couplers (this only applies to attachments with a quick attach hydraulic system).

7.

Raise the quick attach lock lever.

Y

Operation

Figure 63. Quick Attach Couplers For Hydraulic Systems.


Attachment Removal

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 the attachment 10”-12” 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).

Figure 65. Quick Attach Lock Lever

8.

Pull out the quick attach pin at the bottom of the quick attach adapter.

Figure 66. Pull Quick Attach Pin from Attachment and Quick

Attach Adapter.

9.

Lower the attachment to the ground in a level position.

A

PRELIMINAR


Figure 67. Lower Attachment to Ground in Level Position

54


Operation

10.

Tilt and lower boom until pivot pins (A) have disconnected from attachment hooks (B).

•

Keep the forklift, attachments, and loads a safe distance from electrical power lines.

Y 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.

B

A

Warning

Failure to follow proper safety procedures when lifting, lowering, and traveling with a load could cause death, serious injury, or property damage.

Figure 68. Tilt and Lower Boom to Release Pivot Pins (A) from Attachment Hooks (B).

DO NOT exceed forklift capacity of 10,000 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.

11.

Retract the boom to fully disconnect the attachment from the quick attach link.

Warning

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 de-energize power lines or take other suitable precautions.

•

•

•

Use the correct load chart and NEVER exceed specified weights and load centers.

DO NOT exceed the manufacturer’s recommended load capacity.

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.

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.

• Review the rated load capacity of each auxiliary attachment before performing any operation.

PRELIMINAR distribution.

55


• 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

Suspended Loads

Y 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.

Boom Lift Point

Warning

DO NOT exceed rated capacities. 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.

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.

3.

Transport the load with the bottom of the load and the boom as low as possible.

4.

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.

5.

Use guy lines to restrain load swing if possible.

There is boom lift point on the underside of the boom that may be used to lift and carry loads.

Pick Up A Load

There is a dedicated boom lift point load chart on the forklift, which should be referenced when using the boom lift point. Refer to the suspended loads section of this manual when handling suspended loads for specific warnings and instructions unique to this type of operation.

1.

Use correct load chart to review the rated load capacity of the auxiliary attachment being used. NEVER exceed specified weights and load centers.

2.

Approach the load slowly and squarely with the fork tips straight and level.

3.

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.

4.

Tilt the attachment forward so the forks hang freely on the fork shaft.

Figure 69. Boom Lift Point

5.

Insert forks under the load until the load is against the fork frame.

PRELIMINAR

56


Operation

Carry A Load

1.

Carry the load as low as possible while maintaining good ground clearance and visibility.

2.

Back away slowly.

3.

To travel with a load, use first gear (1) for highest torque and pulling power. NEVER travel in higher gears when carrying a load.

Place 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.

3.

Load Shift

1.

If the load shifts, stop the forklift immediately.

2.

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.

Y

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.

Warning

Please refer to ANSI/ITSDF B56.6 for additional design and operating information regarding elevating personnel.

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 BE-

FORE 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.

Design Requirements For A Personnel Platform:

1.

Platform floor must have a slip resistant surface located not more than 8” 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.

4.

Use the frame sway control to level the forklift. For additional information, refer to the Frame Leveling section in this manual.

3.

Platform floor width shall not be greater than the overall width of the forklift, measured across the load bearing tires, plus 10” on each side.

5.

Align the forks at the level the load is to be placed.

4.

Minimum space requirements for each person on the platform shall not be less than 18” in either direction.

6.

Extend the boom slowly until the load is just above the area where it is to be placed.

7.

Lower the boom until the pallet rests in position and the forks are free to retract.

5.

Minimum 4” height toe plate around the perimeter of the platform which may be omitted at the access opening.

8.

Retract the forks slowly from under the load.

Exercise caution when moving objects containing liquids, as the load may shift during lifting and handling.

6.

On the overhead protection device, when requested by the user.

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57


Operation

8.

Information prominently indicated on the platform;

A)

Maximum work load including personnel and equipment.

B)

Weight of empty platform.

9.

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.

10.

Provide a means to securely attach the platform to the lifting mechanism, and to prevent the platform from inadvertent pivoting.

2.

Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturer’s instructions.

3.

Make sure the platform, carriage, and forks are secured to prevent them from pivoting from side to side.

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.

5.

Ensure the forklift has a firm footing and is level.

11.

Provide restraining means for securing personnel such as an anchorage for attaching the lanyard of a body belt or harness.

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.

12.

Provide a guardrail or similar structure with a nominal height to the platform of 42” 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 feet, measured from the point of attachment to the operator.

The complete system shall be capable of withstanding three consecutive drop test to simulate a 250 lbs person free falling

6 ft. without allowing the test weight to fall free to the ground.

A deceleration device may be included.

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.

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.

13.

Lanyards shall be arranged so as not to cause a tripping hazard.

14.

Body belts should have a width of at least 1.75”.

11.

Lift and lower personnel smoothly, with caution, and only at their request.

12.

Keep hands and feet clear of controls other than those in use.

15.

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:

13.

Be certain that the path of platform travel is clear of hazards, e.g., storage racks, scaffolds, overhead obstructions, and electrical wires.

The combined weight in lbs 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:

1.

DO NOT

14.

Be sure any lift limiting devices and latches are functioning properly.

15.

A trained operator shall be in position to control the forklift. When the operator is not in the operating position,

PRELIMINAR

58


Operation

how far to extend the boom.

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 the work platform should be marked to warn anyone on the ground that overhead work is being done.

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.

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

Figure 70. Load Capacity Chart

Y

Using 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.

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.

NOTE:

For example, when letter “A” first appears, the boom extension corresponds to the arc of line “A” throughout all the load capacity charts.

Warning

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.

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.

PRELIMINAR

a load with the forklift, including what angle, how high, and

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.

59


NOTE:

The boom angle indicator is a plumb arrow with angular graduations from -50 to +700.

Figure 72. Boom Angle Indicator

Reading Load Capacity Charts

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

Operation

For example:

1.

The operator determines load weight and makes sure load does not exceed fork, attachment, or boom capacity.

The load is 3,000 lbs.

2.

The operator safely moves the load to a loading position.

• Places forks under load

• Tilts and raises load safely

• Fully retracts boom

Y

• 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 30 feet from ground level.

4.

The operator determines distance from front tires where load will be placed.

The distance in front of forklift where load will be placed is 20 feet.

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 “E” showing.

Figure 73. Load Capacity

Chart

LOAD RATINGS

SHOWN ARE FOR



TIRES ONLY.

5,000 LBS AT 24 IN

MIN CAPACITY FORK

(10,000 LBS PAIR).

50

XR1045 LOAD CHART - STANDARD CARRIAGE

45

40

35

30

25

20

15

5

0

20

25

30

BO

OM

A

NG

LE

50

45

55

40

35

60

65

68

H

G

F

E

D

C

B

A

5

0

15

10

1,800 LBS

5

H

G

2,200 LBS

F

3,000 LBS

4,500 LBS

E

6,000 LBS

8,000 LBS

9,000 LBS

10,000 LBS

D

C

B A

2.0 FT

LOAD

CENTER

2.0 FT

LOAD

CENTER

P/N 17020-000

60


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.

The frame sway control handle has variable motions from the center that control frame sway (right and left).

Figure 75. Frame Level Indicator.

Function

Frame Sway Functions

Control Handle Action

FRAME SWAY RIGHT Move control handle RIGHT.

FRAME SWAY LEFT Move control handle LEFT.

Warning

Y

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.

The frame sway feature becomes locked and will not operate when the boom is raised 40° or more. Applying service brake, parking brake, then pulling the Frame Sway Override knob will override the lockout feature and allow frame sway.

Figure 74. Frame Sway Control Handle.

The frame sway control handle controls the frame sway (right and left) functions.

To lock the frame sway, apply the service or parking brake.

NOTE:

Maximum frame sway is 22° overall or 11° each direction, left and right.

PRELIMINAR

til the indicator shows 0° (level).

61



Maintenance Schedule

Every Day or 8 Hours of Operation

See

Pre-Operation Inspection Checklist


After Every 50 Hours of Operation

Lubricate boom pivot point grease fittings

Lubricate front and rear axle cylinder pivot point grease fittings

Lubricate outrigger pivot point grease fittings


Y

After First 50 Hours of Operation

Change engine oil and filters

Check air filter (replace if necessary)

Replace fuel filter and pre-filter

Check engine hoses and connections for leaks, damage, and tightness

Check radiator hoses for leaks, damage, and tightness

Check for oil and coolant leaks

Check condition and tension of drive belts (use tension meter to check belt tension)

Lubricate front and rear drive shaft grease fittings

Lubricate outrigger pivot point grease fittings

Lubricate front and rear axle grease fittings

Comply with 50-Hour Maintenance Requirements

Change engine oil and filter

Check air filter (replace if necessary)

Check tension and condition of drive belts (use tension meter to check belt tension)

Lubricate front and rear drive shaft grease fittings

Lubricate front and rear axle grease fittings

Check differential oil level

Check wheel-end oil level

Check boom chain tension (adjust if necessary)

Inspect boom rollers and slide blocks for condition and tightness

Lubricate boom roller grease fittings and chains

Change differential oil


Change wheel-end oil


Check wheel lug nuts torqued to 380-420 ft-lbs


Lubricate boom pivot point grease fittings

Replace air filters

Lubricate front and rear axle cylinder pivot point grease fittings

Replace fuel filters

Lubricate boom roller grease fittings and chains

Replace hydraulic return line filter

Replace transmission filter and top off fluid, as required

Empty air filter dust cup

PRELIMINAR

62





Replace air filters

Replace fuel filters

Empty air filter dust cup

Check engine hoses and connections for leaks, damage, and tightness

Check radiator hoses for leaks, damage, and tightness

Check specific gravity of engine coolant

Replace transmission fluid and filters

Replace hydraulic reservoir air breather

Replace hydraulic return line filter

Replace hydraulic high-pressure filter

After Every 1,000 Hours of Operation




Change wheel-end oil

Change differential oil

Inspect boom chains


Y


Change hydraulic fluid

Clean or replace hydraulic reservoir strainer


Drain and flush cooling system

PRELIMINAR

63



Emergency Boom Lowering Valve

Both of the lift and extend cylinders are equipped with a needle valve which allows the cylinder to retract without the direct assist of the machine’s hydraulic power. This feature is intended to be used only in the event of total loss of engine or hydraulic pump failure with an elevated boom.

In any event, the forklift should be secured until the situation has been properly evaluated. Secure the forklift and area by following the procedures below:

Figure 77. Boom Access Cover

1.

Clear the area around the forklift of all personnel.

2.

Place the sift lever in NEUTRAL and engage the parking brake switch to the ON position.

3.

Section off a large area under the boom with tape to restrict any personnel from entering this potentially dangerous area.

4.

If the load is in a position where it can be removed safely, completely remove the load from the carriage and/or attachment. Otherwise leave the load in place.

5.

Remove boom access cover on back of boom.

6.

Locate needle valve on extend cylinder. Loosen nut on valve, then loosen valve with hex wrench.

7.

Fully retract boom with control handle in cab.

8.

When boom is fully retracted, tighten valve with hex wrench, then tighten nut to secure valve.

9.

Locate needle valves on lift cylinders. Loosen nut on valve, then loosen valve with hex wrench (repeat for both sides).

Figure 78. Extend Cylinder Lower Down Valve

10.

Fully lower boom with control handle in cab.

11.

When boom is fully lowered, tighten valve with hex wrench, then tighten nut to secure valve (repeat for both sides).

PRELIMINAR


Y


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.

Return Forklift to Service

When the forklift has been repaired and made safe for operation and maintenance, remove “DO NOT OPERATE” tags from steering wheel.

Y

New or Additional Operators

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.

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.

Figure 80. DO NOT OPERATE Tag

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.

Removing Forklift From Service

Attach “DO NOT OPERATE” tags to steering wheel.

Warning

If forklift is unsafe for operation or maintenance, the defect

PRELIMINAR

Do Not Operate Tags


Y

PRELIMINAR


Y

PRELIMINAR

1415 W. BONANZA RD LAS VEGAS, NV 89106

(702) 636-2969 (800) 497-1704 www.XMFG.com

PN 24905-002-NE

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