Xtreme XR1045 Operation & Safety Manual Download Page 3

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For information call (800) 497-1704

Page 1

XR1045

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General 3

Replacement manuals 3

Model/Serial Number Plate 3

Orientation 3

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Disclaimer 4

Signal Words 4

Safety Symbols 4

Employer Responsibility 7

Operator Responsibility 7

Operator Qualifications 7

Modifications 7

Mounting/Dismounting 8

Work Site Safety 8

Before Starting Forklift 9

Operation Safety 10

Load Safety 13

Attachments 13

Shut Down Procedure 13

Forklift Maintenance 14

Dead Engine Towing . . . . . . . . . . . . . . . . . . . . . 16

Parking Brake Release (Front Axle) 16

Re-activating Parking Brakes (Front Axle) 17

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Label Legend 18

Left Side View 18

Right Side View 18

Front View 19

Rear View 19

Cab View 19

Replacement Labels 21

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Standard Equipment 32

Optional Equipment 32

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Ignition Switch 34

Accessory Outlet 34

Accelerator Pedal 34

Service Brake Pedal 35

Steering Wheel 35

Horn Button 35

Operator Seat 35

Operator Seat Controls 35

Weight Suspension Lever 35

Lumbar Support 36

Fore and Aft Adjustment Lever 36

Backrest Angle Adjustment Lever 36

Seat Belt 36

Rear View Mirrors 37

Controls and Indicators 37

Travel Select Lever 37

Gear Select Switch 38

Parking Brake Switch 38

Load Capacity Charts 38

Hydraulic Oil Temperature Indicator 38

Low Brake Pressure Indicator 39

Rear Axle Lock Indicator 39

Hourmeter 39

Voltage Gauge 39

Fuel Gauge 40

Oil Gauge 40

Coolant Gauge 40

Light Switches 40

Turn Signal and Hazard Switches 40

Rear Axle Centering Indicator 41

Steering Select and 2-Wheel Rear Switches 41

Declutch Indicator 41

Declutch Switch 41

Boom Control 42

Attachment Tilt Switch 43

Frame Sway Control Handle 44

Auxiliary Attachment Control 44

Optional Controls and Indicators 45

Two Wheel Rear (2WR) Steering Switch 45

Boom Angle Indicator 45

Boom Extend Letters 45

Frame Level Indicator 45

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Pre-Operation Inspection 46

Pre-Operation Inspection Checklist 48

Functional Tests 49

Functional Test Checklist 49

Operator Maintenance 50

Before Starting Forklift 51

Starting Forklift 51

Normal Starting 51

Cold Starting 52

Jump Starting 52

Forklift Travel 53

Steering Modes 53

Crab Steering 53

Two Wheel Steering (2W) 53

Four Wheel Steering (4W) 54

Two Wheel Rear Steering (2WR) (Optional) 54

Maximum Fork Sweep 54

Starting Travel 54

Shifting Gears 55

Warning Indicators and Gauges 55

Stopping Travel 56

Changing Travel Direction 56

Shut Down Procedure 56

Summary of Contents for XR1045

Page 1: ... 702 636 2969 800 497 1704 1415 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com XR1045 Operation Safety Manual ...

Page 2: ......

Page 3: ...irrors 37 Controls and Indicators 37 Travel Select Lever 37 Gear Select Switch 38 Parking Brake Switch 38 Load Capacity Charts 38 Hydraulic Oil Temperature Indicator 38 Low Brake Pressure Indicator 39 Rear Axle Lock Indicator 39 Hourmeter 39 Voltage Gauge 39 Fuel Gauge 40 Oil Gauge 40 Coolant Gauge 40 Light Switches 40 Turn Signal and Hazard Switches 40 Rear Axle Centering Indicator 41 Steering Se...

Page 4: ...4 Place A Load 64 Load Shift 65 Elevating Personnel 65 Frame Leveling 66 Load Capacity Charts 67 Using Load Capacity Charts 68 Reading Load Capacity Charts 68 Standard Carriage Load Capacity Chart 69 Preventive Maintenance 70 Establishing A Maintenance Program 70 Maintenance Schedules 70 Boom Emergency Lower Down Valve 72 Do Not Operate Accident Prevention Tags 72 New or Additional Operators 72 Lo...

Page 5: ... 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 Reach Forklifts can be obtained by contacting Xtreme Manufacturing Phone 800 ...

Page 6: ...nd regulations Signal Words Signal words are the word or words that call attention to the safety sign and designate a degree or level of hazard seriousness The signal words used in this manual are DANGER WARNING and CAUTION Danger DANGER Red used with the safety alert symbol indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING Oran...

Page 7: ...DO NOT Operate If Using Alcohol Drugs Or Medications Personal Protective Equipment Safety Shoes Lead Acid Batteries Create Explosive Gases Warning Hydraulic Oil Under Pressure Hot Oil DO NOT Open Unless Cap Is Cool To Touch Warning Rotating Belts Can Cut Or Entangle Replace Worn And Illegible Safety Labels And Labels Read Maintenance Manual Before Working On This Forklift Know First Aid Instructio...

Page 8: ...s On Or In The Operator Cab Set Parking Brake To ON Engage Parking Brake Warning Forklift Tip Over Can Cause Death Or Serious Injury DO NOT Raise Boom While Traveling On A Slope Danger Keep A Safe Distance From Electrical Lines Pinch Points Hands DO NOT Use Ether As A Starting Aid DO NOT Use As A Personnel Carrier DO NOT Allow Riders On Auxiliary Attachments Set Parking Brake To OFF Disengage Park...

Page 9: ...afety 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 v...

Page 10: ... the work site such as gas and water pipes electrical cables and sewers Underground objects could cause death or serious injury 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 Avoid personnel machinery and vehicles in the work area Know the rul...

Page 11: ...g Perform a pre operation inspection and functional tests at the beginning of each work shift Perform the pre operation inspection first DO NOT perform the pre operation inspection with the engine running or hot Contact with moving or heated parts could cause death or serious injury Perform the pre operation inspection and functional tests in an open area Inspections and functional tests may requi...

Page 12: ...al or state codes might require a greater distance Know the maximum height and reach of this reach forklift Warning Use of the frame sway control with the boom raised above horizontal could cause tip over resulting in death or injury Always use the frame sway control to level the forklift BEFORE raising the boom above horizontal If the forklift cannot be leveled using the frame sway control do not...

Page 13: ...nel and other objects in the area and to prevent death serious injury or property damage Warning To prevent death serious injury or property damage make sure the forklift comes to a complete stop before moving the travel select lever A sudden change in direction of travel while carrying a load could reduce stability and or cause the load to shift or fall DO NOT shift through multiple gears with a ...

Page 14: ...me Sway Override switch Improper use of the Frame Sway Override switch could result in death serious injury or property damage 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 Use the frame sway control to level the forklift before raising the boom Reposition...

Page 15: ...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 Attachments Warning Improper connection of an auxiliary attachment could result in death or serious injury Attachments not locked into place can become unstable and fall on the operator or ot...

Page 16: ...age 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 i...

Page 17: ... and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling these items Warning Wear eye protection when starting a forklift with jump start cables Improper jump start procedures could cause the battery to explode which could result in death or serious injury Never jump start ...

Page 18: ...of axle The following procedure is to be performed per side 5 Remove hex screws from brake release bolts Alternate loosening hex screws 1 2 turn until fully loosened Set aside lock screws 6 Alternately tighten brake release bolts A B C until you first begin to feel resistance This will take approximately two to three turns 7 Using a torque wrench alternately tighten bolts A B C one half turn until...

Page 19: ...urn until the torque drops to 25 ft lbs 34 Nm 4 Again alternately loosen brake release bolts A B C one half turn until the torque drops off sharply 5 Alternately loosen brake release bolts A B C until you feel the bolt flange begin to press against the snap ring Tighten the bolt one quarter turn 6 Insert hex screws into brake release bolts A B C Alternately tighten each hex screw 1 2 turn until se...

Page 20: ...Page 18 Xtreme Manufacturing LLC Labels XR1045 Labels Label Legend Left Side View Figure 3 1 Label Legend Left Side View Right Side View Figure 3 2 Label Legend Right Side View ...

Page 21: ...For information call 800 497 1704 Page 19 XR1045 Labels Front View Figure 3 4 Label Legend Rear View Rear View Figure 3 5 Label Legend Cab View Cab View Figure 3 3 Label Legend Front View ...

Page 22: ...e Auxiliary Controls Optional 30 1 18069 000 Hydraulic Tank Fluid Level 31 1 18082 001 Warning Injection Hazard 32 2 18083 001 Warning Explosion Hazard 33 1 18086 001 Hydraulic Fluid Use Dexron III 34 4 18090 001 Warning Tip Over Hazard 35 2 18300 001 Warning Falling Hazard 36 2 18312 000 Warning Falling Hazard 37 4 18315 000 Tie Down Point 38 2 18043 000 Xtreme Logo 39 3 18044 000 Xtreme X 40 1 1...

Page 23: ...008 000 On Off Lights Rear Axle Centered Parking Brake OFF ON 18001 003 702 636 2969 800 497 1704 Coolant Fuel Oil Volts Hourmeter On Off Declutch 4W 2W Crab R e a r A x le L o c k e d H y d ra u li c O il T e m p e ra tu re L o w B ra k e P re s s u re On Off Rear Boom On Off Front On Off 2 Wheel Rear Steer Front Rear Wheels Must Be Centered Before Engaging Turn Hazard 2 18001 003 3 18010 001 4 1...

Page 24: ...Page 22 Xtreme Manufacturing LLC Labels XR1045 7 18015 001 8 18016 001 9 18017 001 10 18018 001 11 18018 002 12 18019 001 ...

Page 25: ...For information call 800 497 1704 Page 23 XR1045 Labels 13 18020 001 14 18021 001 15 18022 001 16 18023 001 17 18025 001 18 18026 001 ...

Page 26: ...Page 24 Xtreme Manufacturing LLC Labels XR1045 19 18027 001 20 18031 001 WARNING 21 18032 001 22 18033 000 23 18034 000 24 18039 000 ...

Page 27: ...For information call 800 497 1704 Page 25 XR1045 Labels 25 18041 001 26 18042 000 27 18066 001 28 18067 000 29 18334 000 30 18069 000 ...

Page 28: ...Page 26 Xtreme Manufacturing LLC Labels XR1045 31 18082 001 32 18083 001 33 18086 001 34 18090 001 35 18300 001 36 18312 000 ...

Page 29: ...For information call 800 497 1704 Page 27 XR1045 Labels 37 18315 000 38 18043 000 39 18044 000 40 18046 000 41 18047 000 42 18048 000 ...

Page 30: ...Page 28 Xtreme Manufacturing LLC Labels XR1045 43 18049 000 44 18070 000 45 18053 000 46 18054 000 47 18055 000 18311 000 48 18311 000 ...

Page 31: ... ONLY 5 000 LBS AT 24 IN MIN CAPACITY FORK 10 000 LBS PAIR 52 17020 000 0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35 40 45 REACH FT LOAD HEIGHT FT 702 636 2969 800 497 1704 P N 17021 000 XR1045 LOAD CHART SWING CARRIAGE 2 0 FT LOAD CENTER 2 0 FT LOAD CENTER S T S T S RATING FOR FORKS STRAIGHT T RATING FOR FORKS ROTATED FROM STRAIGHT FORKS MUST BE STRAIGHT WHEN THE BOOM IS ABOVE 55 DEGREES 50 60 0 5...

Page 32: ...B NOMINAL PLATFORM CAPACITY 2FT 3 5FT NOMINAL RAILING 8 FT PLATFORM MAX 475 LB P8 10 FT PLATFORM MAX 550 LB P10 5 000 LBS AT 24 IN MIN CAPACITY FORK 10 000 LBS PAIR 58 17072 000 XR1045 LOAD CHART SLING MOUNT 35 30 25 20 15 10 5 0 35 30 25 20 15 10 5 40 45 50 P N 17129 000 0 30 25 15 10 5 40 45 35 50 0 55 60 20 65 68 BO O M A N G LE H G F E D B A C H F B E D C A G 5 9 00 0 LBS 8 00 0 LBS 6 00 0 LBS...

Page 33: ...E PER LOAD POSITION ZONE TELESCOPIC SECTION LOAD POSITION 7 8 9 10 1 2 3 4 5 9 10 10 5 11 0 11 7 2 410 2 280 1 250 1 275 1 300 1 325 1 800 1 840 1 880 1 920 2 025 2 150 2 280 2 410 2 025 2 150 1 005 985 950 970 LOAD RATING VS LOAD ZONE PER LOAD POSITION ZO NE 2 ZO NE 3 ZO NE 4 ZONE 1 ZO NE 5 0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50 68 H G F E D B C H F B E D C A G A 61 17139 0...

Page 34: ...uges Easy access drop down electrical panel 12 Volt accessory power outlet Brake oil pressure parking brake axle lock rear wheel alignment and declutch indicator lights Electric horn and backup alarm Declutch switch Rear view mirrors Adjustable suspension seat with seat belt 360 panoramic visibility Boom angle and frame level indicator Deluxe suspension seat Tires Foam filled Hydraulics Auxiliary ...

Page 35: ...y duty Roller Boom Melonite Pins and Rollers Direct Dual Control Hydraulic Valve Actuation Robust Wiring No Spades No Pins Rear Axle Stabilization RAS Center Inline Engine Drive Train Full time Planetary 4 Wheel Drive Steering 4 Wheel Circle Crab 2 Wheel Front Back Up Alarm Open ROPS FOPS Adjustable Hydraulic Operator Controls Suspension Seat Quick Attach Common Fit Xtreme Service Accessibility At...

Page 36: ...n Switch Position Purpose OFF Shuts down entire electrical system except the horn and accessory outlet RUN All controls and indicators are operable PREHEAT Use for cold starting conditions START Engages starter motor to crank engine NOTE The PREHEAT and START positions are spring loaded When the key is released the Ignition switch will automatically return to the RUN position Figure 6 2 Ignition S...

Page 37: ...forklift in the corresponding direction Figure 6 6 Steering Wheel Horn Button Press the horn button to sound the horn Figure 6 7 Horn Button Operator Seat Operator Seat Controls The operator seat can be adjusted four 4 ways weight suspension height fore and aft and backrest angle Figure 6 8 Operator Seat Weight Suspension Lever Rotate the weight suspension lever to increase or decrease the seat cu...

Page 38: ...he angle of the backrest and release the lever to lock the backrest to the desired angle Figure 6 12 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 DO NOT operate...

Page 39: ...ts 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 Figure 6 14 Cab Mounted Mirror One 1 rear view mirror is mounted on the frame Figure 6 15 Frame Mounted Mirror Controls and Indicators Travel Select Lever The travel select lever has three 3 positions...

Page 40: ... 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 reach forklift including boom angle height and reach Figure 6 19 Typical Load Capacity Chart Hydraulic Oil Temperature Indicator The hydraulic oil temperature indicator illuminates when the oil temp...

Page 41: ...smission is in NEUTRAL or the service brake is applied and when the boom is above 40 If the rear axle lock indicator does not illuminate 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 Figure 6 22 Rear Axle Lock Indicator Hourmeter The hourmeter indicates...

Page 42: ...ter 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 200 F 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 ...

Page 43: ...of control which could result in death serious injury or property damage The Steering Select switch has three 3 steering positions Crab Two Wheel Steering 2W and Four Wheel Steering 4W The 2 Wheel Rear switch has two 2 positions On and Off Figure 6 31 Steering Select and 2 Wheel Rear Switches Declutch Indicator The declutch indicator illuminates when the Declutch switch is set to the ON position I...

Page 44: ...ol 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 two 2 functions For example mov...

Page 45: ...attachment tilt functions by rolling the switch forward and backward Is a variable speed switch Function speed is proportional to how far the switch is rolled The more the switch is rolled in the appropriate direction the faster the corresponding function will occur Table 8 Attachment Tilt Switch Function Handle Action ATTACHMENT TILT DOWN Roll switch forward away from the operator ATTACHMENT TILT...

Page 46: ...FT NOTE Lock the frame sway by placing the travel select lever in NEUTRAL or applying the service or parking brake NOTE Maximum frame sway is 22 overall or 11 each direction left and right Warning 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 Figure 6 38 Frame Sway Override Switch The fram...

Page 47: ...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 5 to 70 Figure 6 41 Boom Angle Indicator Boom Extend Letters As the boom is extended boom extend letters...

Page 48: ...e in need of repair or maintenance defective or unsafe in any way Caution Contact with hot surfaces or the exhaust pipe after the forklift has been operated could result in minor or moderate personal injury 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 opera...

Page 49: ... to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling these items Warning Wear eye protection when starting a forklift with jump start cables Improper jump start procedures could cause the battery to explode which could result in death or serious injury Never jump start a frozen battery as it can explode Let the battery thaw out before charg...

Page 50: ...ng lug nuts Bent flanges or any other damage to rims Check front and rear sway cylinders and hoses for leaks or any other damage Check mirrors for cracks cleanliness and proper adjustment Check hydraulic reservoir sight gauge for proper fluid level Add hydraulic fluid if necessary Check engine compartment for Loose or damaged belts hoses and radiator blades Coolant reservoir level Add radiator coo...

Page 51: ...l handle left and right to extend and retract boom Operate the attachment tilt thumb switch up and down to tilt the attachment Operate the sway control handle left and right to sway frame left and right Operate the auxiliary attachment control lever if a hydraulic attachment is being used Turn work lights on and off Press the horn button to sound horn Place the travel select lever in reverse to so...

Page 52: ...ic Oil Sight Gauge Figure 7 2 Add Hydraulic Oil If Necessary Figure 7 3 Check Coolant Reservoir Level Add Coolant If Necessary Figure 7 4 Check Engine Oil Level Add Engine Oil If Necessary Figure 7 5 Check Battery Case and Terminals Figure 7 6 Store Operation and Safety Manual In Protective Case ...

Page 53: ...is may require assistance 5 Adjust the side console control panel 6 Fasten seat belt 7 Make sure the travel select lever is set to NEUTRAL N and the Parking Brake is ON engaged NOTE The engine will only start when the travel select lever is in NEUTRAL N and the Parking Brake switch is ON engaged Figure 7 7 Travel Select Lever Must Be In NEUTRAL N To Start The Reach Forklift Figure 7 8 Parking Brak...

Page 54: ...lift when the battery is discharged to the point that it will not crank the starter Warning Lead acid batteries produce flammable and potentially explosive gases To avoid death or serious injury when checking testing or charging batteries DO NOT use smoking materials near batteries Keep arcs sparks and open flames away from batteries Provide ventilation for flammable vapors Wear proper personal pr...

Page 55: ...ine again 6 After the engine starts let idle for 30 to 60 seconds 7 Remove the jumper cables in the reverse order of their connection i e negative cable ground connection first etc 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 usin...

Page 56: ...e of the maximum sweep of any attachment being used when turning to avoid hitting personnel and other objects in the area to prevent death serious injury or property damage Figure 7 13 Maximum Fork Sweep Starting Travel 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 haza...

Page 57: ... 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 Ignoring warning indicators can cause improper performance which could result in death serious injury or property damage There are three 3 warning indicator lights on the dash panel that illuminate during critical circumstances All three 3 warning ...

Page 58: ...e forklift comes to a complete stop move travel select lever to NEUTRAL N set the Parking Brake switch to ON engaged lower and retract the boom and shut off the engine before exiting the forklift 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 an...

Page 59: ...r carry loads in excess of the manufacturer s rated load could 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 use...

Page 60: ...r set of forks used on this forklift should have total load ratings which equal or exceed 10 000 pounds 4 536 kilograms 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 thumb switch on the contro...

Page 61: ...pler 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 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 t...

Page 62: ...se the boom until pivot pins A have seated fully in attachment hooks B Figure 7 23 Raise Boom To Seat Pivot Pins A In Attachment Hooks B 5 Tilt the attachment up slightly The quick attach adapter should be tight against the rear of the attachment Align the holes between the quick attach adapter and attachment Figure 7 24 Tilt Attachment To Align Holes Between Quick Attach Adapter and Attachment A ...

Page 63: ...Groove A of Quick Attach Pin Warning Hydraulic attachments have a maximum hydraulic pressure rating Failure to make sure the attachment is equipped with a pressure reducing valve or is rated to be equal or slightly greater than 3 500 psi 241 bar which is the maximum pressure of the forklift auxiliary hydraulic system at the quick disconnect couplers could result in death or serious injury Make sur...

Page 64: ...d 4 Extend the boom approximately 18 to 20 inches 0 46 to 0 5 meters 5 With 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 7 29 Disconnect Quick Attach Couplers A Female Coupler B Male Coupler 7 Raise the quick attach lock lever Figure 7 30 Raise Quick Attach Lock Le...

Page 65: ...e forklift attachments and loads a safe distance from electrical power lines Remain at least 10 feet 3 meters plus an additional 0 4 inches 10 millimeters 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 reach forklift Warning F...

Page 66: ...ontally 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 Pick Up A Load 1 Use the correct load chart to review the rated load capacity of the auxiliary attachment being u...

Page 67: ...vided for the personnel in their normal working position on the platform from moving parts of the rough terrain forklift that represent a hazard 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 rough terrain forklift truck and retained aga...

Page 68: ...ft truck When the operator is not in the operating position block the truck wheels and apply the parking brake with all controls in neutral 16 Alert elevated personnel before moving the platform Then move the platform smoothly and with caution 17 Always lower the platform if you must move the rough terrain forklift truck for adjustment in positioning 18 Be certain that personnel and equipment on t...

Page 69: ...e brake parking brake and placing travel select lever in NEUTRAL then pressing the Frame Sway Override switch the trigger on the Front Control handle will override the lockout feature and allow frame sway Figure 7 36 Frame Sway Override Switch Load Capacity Charts Warning DO NOT exceed rated capacities Any attempt to lift or carry loads in excess of those shown on the load capacity charts could ca...

Page 70: ...duations from 5 to 70 Figure 7 39 Boom Angle Indicator Reading Load Capacity Charts To accurately read the load capacity charts you must determine three 3 things Weight of load being lifted Height of structure where load is to be placed Distance from front tires where load will be placed For example 1 The operator determines load weight and makes sure load does not exceed fork attachment or boom c...

Page 71: ...35 50 0 55 60 20 65 68 BO O M A N G LE H G F E D B A C H F B E D C A G 5 9 0 00 LB S 8 0 00 LB S 6 0 00 LB S 4 5 00 LB S 3 0 00 LB S 1 8 00 LB S 2 2 00 LB S 2 0 FT LOAD CENTER 2 0 FT LOAD CENTER 10 00 0 LB S 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 Figure 7 40 Standard Carriage Load Capacity Chart ...

Page 72: ...tension Lubricate front and rear drive shaft grease fittings Lubricate front and rear axle grease fittings Change differential oil Change wheel end oil Check wheel lug nuts torqued to 380 420 ft lbs Lubricate boom pivot point grease fittings Lubricate front and rear axle cylinder pivot point grease fittings Lubricate boom roller grease fittings and chains Replace hydraulic return line filter Repla...

Page 73: ...d filters Replace hydraulic reservoir air breather Replace hydraulic return line filter Replace hydraulic high pressure filter After Every 1 000 Hours of Operation Comply with 50 Hour Maintenance Requirements Comply with 250 Hour Maintenance Requirements Comply with 500 Hour Maintenance Requirements Change wheel end oil Change differential oil Inspect boom chains After Every 2 000 Hours of Operati...

Page 74: ...ve 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 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 Figure 8 2 Boom Access Cover Figure 8 3 Extend Cylinder Lower Down Va...

Page 75: ...For information call 800 497 1704 Page 73 XR1045 PreventiveMaintenance THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 76: ...Do Not Operate tag to battery disconnect switch Figure 8 5 Battery Disconnect Switch Warning If forklift is unsafe for operation or maintenance the defect or defects must be clearly documented and posted in a conspicuous place on the forklift Failure to comply could result in death serious injury or property damage Returning Forklift To Service When the forklift has been repaired and made safe for...

Page 77: ...For information call 800 497 1704 Page 75 XR1045 Lockout Tagout Do Not Operate Tags ...

Page 78: ...Page 76 Xtreme Manufacturing LLC Lockout Tagout XR1045 ...

Page 79: ...For information call 800 497 1704 Page 77 XR1045 Lockout Tagout ...

Page 80: ...1415 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com 702 636 2969 800 497 1704 24905 000 01 4 10 ...

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