Related Manuals for Xtreme XR1045 Alden TIER4
Summary of Contents for Xtreme XR1045 Alden TIER4
- Page 1 Operation and Safety Manual 24905-002-20 QRGOVSALES XR1045 Alden TIER4 CONTRACT # SP4510-17-A-0002 www.XMFG.com...
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Page 2: Table Of Contents
General Table of Contents Description Description Page Page Description Page Description Page Introduction Service Brake Pedal Operating the Engine General Steering Wheel Forklift Travel Replacement Manuals Horn Button Steering Modes Model/Serial Plate Fire Extinguisher (Optional) Wheel Alignment Orientation Emergency Stop (Optional) Starting Travel Safety Operator Seat... -
Page 3: Introduction
RIGHT Replacement Manuals Replacement manuals for the XR1045 Telehandler can be ob- tained by contacting our parts department by phone or visit- ing our website: Xtreme Manufacturing Phone: (800) 497-1704 QRGOVSALES www.XMFG.com LEFT Figure 2. Telehandler Direction Orientation www.XMFG.com... -
Page 4: Safety
WARNING (Orange) used with the safety alert symbol indicates a potentially hazardous situation which, if not Xtreme Manufacturing reserves the right to make technical avoided, could result in death or serious injury. changes for product improvement. This manual may contain... - Page 5 Safety Read Operator Read Maintenance General Safety Manual Before Manual Before Alert Symbol Operating This Working On Telehandler This Telehandler Read Material DO NOT OPERATE! Know First Aid Safety Data Instructions And/ Telehandler Down Sheets (MSDS) For Or Locations On For Service Or Chemicals And Work site...
- Page 6 Safety DO NOT DO NOT Fasten Jump While Allow Riders Seat Dismounting On Auxiliary Belt Attachments The Telehandler Set Parking DO NOT Allow DO NOT Allow Brake To OFF Riders On Telehandler Riders On Or In Disengage Frame Or Fenders The Operator Cab Parking Brake Set Parking Brake...
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Page 7: Employer Responsibility
Safety Employer Responsibility Operator Qualifications Under Occupational Safety and Health Administration (OSHA) Operators must be in good physical and mental condition, rules, employers are required to train workers about hazards with appropriate reflexes, reaction time, vision, depth related to operating and maintaining the telehandler. Suc- perception, and hearing. -
Page 8: Mounting/Dismounting
Safety Warning Mounting/Dismounting • Operate the telehandler only on firm, stable surfaces. Warning Holes, obstructions, debris, loose fill, and other work site hazards could result in death or serious injury. Failure to use proper safety procedures when mounting • DO NOT allow bystanders in the work area. and dismounting the telehandler could result in death or •... -
Page 9: Before Starting Forklift
Read and understand the entire manual to Keep the Operation and Safety Manual on prevent death, serious injury, or equipment damage. the telehandler at all times. Contact Xtreme Manufacturing for replacement manuals. Keep fingers and feet away from moving parts or pinch points to prevent pinching or crushing. -
Page 10: Operation Safety
• Work site operating directives and/or local or state approved by Xtreme. Falling off attachments codes might require a greater distance. or forks could result in death or serious injury. • Know the maximum height and reach of this telehan- NEVER allow passengers to dler. - Page 11 Safety Allow for adequate clearance between the DO NOT raise the boom while attachment and other objects when turning. operating on a slope. Raising The attachment extends beyond the front of the boom on a slope, even with- the telehandler. The operator must be aware out a load, will change the cen- of the maximum sweep of any attachment ter of gravity, could cause a tip...
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Page 12: Load Safety
Safety distribution. Warning • Adjust the load as necessary, especially for nonstandard loads. The telehandler includes a Frame Sway • Use caution when handling loose material that can fall Override switch. Improper use of the Frame into the cab. Sway Override switch could result in death, •... -
Page 13: Forklift Maintenance
Safety NOTE: The parking brake MUST be actuated (engaged) only a hydraulic leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, which when telehandler is at standstill. could cause death or serious injury. If hydraulic oil is inject- Always engage the parking ed into your skin, a doctor familiar with this type of injury brake... -
Page 14: Jump Starting
Safety • Wear proper personal protective equipment, including • Connect charged battery positive (+) to stalled battery safety glasses. positive (+). • Connect charged battery negative (–) to stalled Fluid in electric storage batteries contains sulfuric acid, telehandler ground. Make the connection to the stalled which is poison and could cause severe chemical burns. -
Page 15: Dead Engine Towing
Safety Remove the hydraulic hose connected to one port Dead Engine Towing Connect a manual HP hydraulic pump to the parking brake ports using a threaded coupling (9/16” - 18 UNF) and a collector bottle, as shown in Figure 5. Parking Brake - Manual Release Apply hydraulic pressure using the manual hydraulic pump to release the brake. -
Page 16: Labels
Labels Labels Front View Left Side View Figure 8. Label Legend (Front) Figure 6. Label Legend, Left (Cab) Side Right Side View Rear View Figure 9. Label Legend (Rear) Figure 7. Label Legend, Right (Hydraulic Tank) Side Cab View Figure 10. Label Legend (Cab) Operation Manual www.XMFG.com... - Page 17 LABEL DISCONNECT DELAY 18039-000 DECAL XRM-ANGLE INDICATOR 17179-000 LOAD CHART, FORK POS. CARRIAGE 18041-001 LABEL WARNING PINCH POINT 18314-000 LABEL, BOOM HOOK 18042-000 DECAL XID XTREME SMALL GRN 18334-005 LABEL, JOYSTICK HORN 18043-000 DECAL XID XTREME MED GRN www.XMFG.com Operation Manual...
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Page 18: Replacement Labels
Labels From outside Las Vegas, Nev., call Xtreme Manufacturing toll Replacement Labels free at (800) 497-1704. Replacement labels may be obtained by contacting Xtreme Please have the correct label number available when you call. Manufacturing at (702) 636-2969. Parking Brake... - Page 19 Labels 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 www.XMFG.com Operation Manual...
- Page 20 Labels 17) 18025-001 18) 18026-001 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 22) 18033-000 FRONT HANDLE OPERATION AUX A AUX B 18347-000R01 23) 18347-000 24) 18039-000 Operation Manual www.XMFG.com...
- Page 21 Labels 25) 18041-001 26) 18042-000 27) 18043-000 28) 18044-000 29) 18046-000 30) 18047-000 31) 18048-000 32) 18049-000 www.XMFG.com Operation Manual...
- Page 22 Labels 18054-000 18053-000 33) 18053-000 34) 18054-000 18055-000 35) 18055-000 36) 18066-001 FULL 18069-000 37) 18067-100 38) 18069-000 39) 18070-001 40) 18081-000 Operation Manual www.XMFG.com...
- Page 23 Labels 41) 18082-001 42) 18083-001 43) 18086-001 44) 18090-001 18311-000 45) 18300-001 46) 18311-000 47) 18312-000 48) 18315-000 www.XMFG.com Operation Manual...
- Page 24 Labels DEATH or SERIOUS INJURY could result from CARRIAGE DAMAGE improper operation when using tow connection. DO NOT ELEVATE BOOM ABOVE 30 WHEN DAMAGE may result from adjusting forks TOWING. when carriage is loaded. DO NOT EXCEED RATED TOW CAPACITY. ONLY ADJUST FORKS WHEN CARRIAGE Max vertical load 500 LBS.
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Page 25: Features
Features Features Standard Equipment Standard Equipment Feature Description Feature Description Boom Universal quick attach head Electrical Back-up alarm with manual shut-off switch Three (3) section boom Horn button on the operator handle (joystick) Boom equipped with heavy duty boom rollers Strobe light with manual On/Off switch Arrow Fork Positioning &... -
Page 26: Specifications
Brakes ....Inboard Wet Disc Suspension Seat Parking Brake ..SAHR Quick Attach (Common Fit) Rear View Mirrors Xtreme Service Accessibility Tires Attachments Tires (Standard Eq) Foam Filled 13.00 x 24 E3... -
Page 27: Major Components
Major Components Major Components Side View Figure 11. Right (Hydraulic Tank) Side View With Optional Mil Std 209 Lifting Lugs Figure 12. Left (Cab) Side View With Optional Mil Std 209 Lifting Lugs www.XMFG.com Operation Manual... -
Page 28: Rear View
Major Components Rear View, Left Figure 13. Rear Left Quarter View Rear View, Right Figure 14. Rear Right Quarter View Operation Manual www.XMFG.com... -
Page 29: Front View
Major Components Front View Figure 15. Front View Major Standard Components Major Standard Components Major Standard Components Item Description Item Description Chassis Enclosed Cabin ROPS/FOPS Boom Fuel Tank (Diesel) Master Cylinder MIL Std 209 Tie Downs & Lifting Lugs (Optional) Lift Cylinder Boom Angle Indicator Tires, Foam Filled... -
Page 30: Operator Cab
Operator Cab Operator Cab Warning A brief description of controls, indicators, and instruments is provided as a convenience for the operator. These descriptions DO NOT pro- vide complete operation instructions. Read and understand the entire manual to pre- vent death, serious injury, or equipment damage. Ignition Switch The ignition switch has three (3) positions: OFF, RUN, and START. -
Page 31: Steering Wheel
Operator Cab Emergency Stop (Optional) The optional Emergency Stop cuts the power from the bat- tery, turning the forklift OFF completely. Use this button in emergency situations only. To restart the machine, pull/twist the Emergency Stop and follow machine start-up procedure. Figure 19. -
Page 32: Weight Suspension Lever
Operator Cab Weight Suspension Lever Fore and Aft Adjustment Lever Rotate the weight suspension lever to increase or decrease the Pull the fore and aft adjustment lever outward from the seat seat cushion suspension based on the weight of the operator to release the seat lock. -
Page 33: Seat Belt
Operator Cab Pull the retractable seat belt across your lap. Position the Seat Belt seat belt as low on your body as possible. Insert the latch plate into the buckle (on the right side of Warning the seat) until a “click” is heard. Make sure seat belt retracts snugly across your lap. -
Page 34: Controls And Indicators
Operator Cab Controls and Indicators Gear Select Switch The Gear Select switch has a twist grip handle with the Travel Select Lever following positions: 1 - FIRST, 2 - SECOND, 3 - THIRD, and Automatic. The travel select lever has three (3) positions: FORWARD, NEUTRAL, and REVERSE, which change the direction of travel. -
Page 35: Parking Brake Switch
Operator Cab Parking Brake Switch Load Capacity Charts The Parking Brake switch (A) has two (2) positions: ON and The Load Capacity Charts are located on the left side of the OFF. front control panel. The Load Capacity Charts are provided to assist the operator in determining how to safely handle loads with the telehandler, including boom angle, height, and reach. - Page 36 Operator Cab A. HIGH HYDRAULIC OIL TEMP below 10psi) and the Oil Pressure Warning (red) is displayed, stop the telehandler, follow proper shut down procedures, tag The hydraulic oil temperature indicator illuminates when the telehandler with “Do Not Operate” tags, and have a qualified oil temperature is above 1800 F.
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Page 37: Display Features
Operator Cab UTILITIES S. TRANSMISSION TEMP INDICATOR AND WARNING Pressing the UTILITIES soft button will bring up the Hidden The Transmission Temperature Indicator monitors and displays Utilities Menu. the oil temperature within the transmission. At normal operating temperature it stays green. Between 215 and 224 0F it turns yellow to warn that the transmission operates above the recommended temperature range. - Page 38 Operator Cab CLOCK SETUP TRANSMISSION CALIBRATION Pressing the CLOCK SETUP soft button will enter a menu After each transmission oil change the transmission needs where the clock can be setup or adjusted. to be re-calibrated to accommodate for clutch wear. When the TRANSMISSION CALIBRATION button is pressed, the TCU (Transmission Control Unit) enters transmission calibration mode and it checks first for all the machine conditions...
- Page 39 Operator Cab USER SETTINGS Pressing the USER SETTINGS soft button will enter a mode where some display settings may be adjusted using the Up/ Down buttons. Figure 47. First Clutch Calibration Successful DIAGNOSTICS Pressing the ENGINE DIAGNOSTICS soft button will display engine information.
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Page 40: Steering Select Switch
Operator Cab Steering Select Warning DO NOT change steering modes until the telehandler slows or comes to a complete stop. Align all four (4) wheels perpendicular to the axle, before changing steering mode. Changing steering modes at higher travel speeds can make the telehandler unstable, and cause a loss of control, which could result in death, serious injury, or property damage. -
Page 41: Attachment Tilt Switch
Operator Cab Attachment Tilt The Attachment Tilt switch is located on the top of the Boom Control Joystick and is used to control attachment tilt functions. The Attachment Tilt Switch: • Controls the attachment tilt functions by rolling the switch upward (A) and downward (B). •... -
Page 42: Frame Sway Control
Operator Cab Auxiliary Attachment Control Frame Sway Control The Frame Sway Control Handle: • Controls the frame sway functions by moving the control handle left and right. • Is a variable speed control. Function speed is proportional to control handle movement. The more the control han- dle is moved in the appropriate direction, the faster the corresponding function will occur. -
Page 43: Fork Positioning Carriage Operation
Operator Cab Fork Positioning Carriage Operation Caution Do not adjust forks when the Fork Positioning Carriage is loaded. Adjusting forks when carriage is loaded may result in loss of load or carriage damage. Always use the Fork Po- sitioning control handle to adjust the forks BEFORE loading the carriage. -
Page 44: Wiper
Operator Cab Boom Extend Letters Wiper As the boom is extended, the boom extend letters on the left Flip the Wiper toggle switch to ON to activate the windshield side of the boom are visible to the operator. These letters wiper. -
Page 45: Telehandler Lifting Points
Figure 69. XR1045 24V Optional - MIL Std. 209 Front Lifting Points Figure 67. XR1045 24V Standard Tie-Downs, Rear Figure 70. XR1045 24V Optional - MIL Std. 209 Rear Lifting Points MODEL: XR1045 ALDEN TIER4 UNLADEN VEHICLE WEIGHT: 30,300 lbs 91.0"... -
Page 46: Pre-Operation Inspection
Operation Operation Pre-Operation Inspection Caution Contact with hot surfaces and the exhaust To perform the pre-operation inspection make sure the pipe after the telehandler has been operated telehandler is NOT running, the engine is cool, the telehandler could result in serious personal injury. is parked on level ground, the boom is completely retracted, and the frame is level. - Page 47 Operation • Never jump start a frozen battery, as it can explode. Let Warning the battery thaw out before charging. • NEVER jump start the telehandler when travel select lever is in gear, which can cause the telehandler to lurch forward or backward, and could result in death, serious injury, or property damage.
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Page 48: Pre-Operation Inspection Checklist
Operation Pre-Operation Inspection Checklist 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. Check condition and operation of the seat belt and mounting hardware. -
Page 49: Functional Tests
Operation Operate the auxiliary attachment control (if an auxiliary Functional Test Checklist attachment is being used). Turn the work lights and the strobe light on and off. Warning Press the horn button to sound the horn. Perform a pre-operation inspection and func- Place the travel select lever in reverse to sound the tional tests at the beginning of each work backup alarm. -
Page 50: Operator Maintenance
Operation Operator Maintenance Figure 75. Check Engine Oil Level. Add Engine Oil (API CJ-4), If Neces- Figure 72. Check Hydraulic Oil Sight Gauge sary. Figure 73. Add Hydraulic Oil, If Necessary Figure 76. Check Battery Case and Terminals Figure 74. Check Coolant Reservoir Level. Add Coolant, if Necessary. Figure 77. -
Page 51: Before Starting Forklift
Operation Adjust mirrors (this may require assistance). Before Starting Telehandler Adjust the side console control panel. Fasten seat belt. Warning Make sure the travel select lever is set to NEUTRAL (N) and the Parking Brake is ON (engaged). Failure to use proper safety procedures when mounting and dismounting the telehandler could result in death or NOTE: The engine will only start when the travel select lever is serious injury. -
Page 52: Starting Forklift
Operation With the Ignition Switch in the ON position, the engine Starting Telehandler indicator lamps come on momentarily and then go out. Under cold conditions, the Wait-to-Start lamp will illumi- nate at Ignition Switch ON position, and will stay on for a Normal Starting period of up to 30 seconds. -
Page 53: Jump Starting
Operation other telehandler, make sure the two (2) telehandlers Jump Starting are not touching. • DO NOT allow jump start cable ends to contact each Jump Start or replace the battery of the telehandler when other. the battery is discharged to the point that it will not crank the •... -
Page 54: Operating The Engine
Operation Check the turning radius around the telehandler before Caution making a turn, especially if using four wheel (4W) steering or two wheel rear (2WR) steering, which provide a tighter Release the key immediately once the motor starts. If the turning radius. -
Page 55: Wheel Alignment
Operation Start the telehandler. Refer to the Starting Telehandler Warning section in this manual. Operate the boom to lift the forks and the carriage off the Allow for adequate clearance between the ground to a safe travel position. attachment and other objects when turning. Apply service brake. -
Page 56: Changing Travel Direction
Operation Shutdown fault condition is present, stop the telehandler, Rear Axle Locked follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler BEFORE placing it into Service Reminder service again. -
Page 57: Shut Down Procedure
Operation Fuel Types Shut Down Procedure Use ASTM #2 diesel fuel with a minimum Cetane rating of Caution 40 for better fuel economy and performance under most operating conditions. Failure to follow the correct shutdown procedure may • Use standard #2 diesel fuel for operating at temperatures result in damage to the turbocharger and shorten the above 32°F (0°C). -
Page 58: Attachments
Figure 86. Fork Ratings Xtreme Manufacturing makes no representations or warranties, (A) Maximum Load Capacity Rating (B) 24 inch Load Center expressed or implied, as to the design, manufacture, or fitness for use with this telehandler of any third party attachment. -
Page 59: Quick Attach System
Operation Extend the boom and/or drive the telehandler forward Quick Attach System until the pivot pins (A) are below and between the two (2) attachment hooks (B). This telehandler includes a quick attach system that allows for easy attachment changes. Perform attachment connection and removal procedures on level ground. - Page 60 Operation Figure 92. 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 90. Tilt Attachment To Align Holes Between Quick Attach Adapter (C) and Attachment (B).
- Page 61 Operation 9. Connect the quick attach couplers (this only applies to at- tachments with a quick attach hydraulic system). Caution The hydraulic auxiliary hoses need to be threaded manually through the horse head when connecting or removing the attachment. Figure 95. Quick Attach Couplers 7.
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Page 62: Load Handling
Operation 9. Lower the attachment to the ground in a level position. • Never operate the telehandler 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. -
Page 63: Boom Lift Point
Operation and watch for sliding material. There is a dedicated boom lift point load chart • DO NOT reach a load over posts or other objects that (available order separately), which should can enter the cab, if tipped. referenced when using the boom lift point. Refer to the •... -
Page 64: Carry A Load
Operation Carry A Load Load Shift If the load shifts, stop the telehandler immediately. Carry the load as low as possible while maintaining good Lower and adjust the load to center its weight. ground clearance and visibility. If the load shift is too great for adjustment, rearrange the Back away slowly. - Page 65 Operation laterally on the telehandler and retained against the before any operation is begun. Use the frame sway to vertical face of the forks, carriage, or lifting mechanism. level the telehandler. If the telehandler cannot be leveled, 10. Provide a means to securely attach the platform to the reposition the telehandler.
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Page 66: Load Capacity Charts
Operation work platform from pinch points or moving parts while in their normal working position on the platform. 23. Provide overhead protection device as required by work site conditions or if requested by the user of the platform. Load Capacity Charts Warning DO NOT exceed rated capacity. -
Page 67: Frame Leveling
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 telehandler BEFORE raising the boom above horizontal. If the telehandler cannot be leveled using the frame sway control, do not attempt to raise or place load. -
Page 68: Boom Maintenance Stand
Operation The frame sway feature becomes locked and will not operate when the boom is raised 40° or more. Applying service brake, parking brake, and placing travel select lever in NEUTRAL, then pressing the Frame Sway Override switch (the yellow button on the front of the control joystick) will override the lockout feature and allow frame sway. -
Page 69: Preventive Maintenance
Preventive Maintenance After First 50 Hours of Operation Preventive Maintenance Change engine oil and filters Establishing a Maintenance Program Check air filter (replace if necessary) Replace fuel filter and pre-filter The hour meter displays elapsed engine operating hours Check engine hoses and connections for leaks, and has a total readout of 9,999.9 hours. -
Page 70: Engine Diagnostic Fault Codes
Preventive Maintenance After Every 500 Hours of Operation or 6 Months Engine Diagnostic Fault Codes Replace air filters The electronic engine control system displays and records cer- tain detectable fault codes. The fault codes are retained in the Replace fuel filters ECM until cleared by the user. -
Page 71: Boom Emergency Lower Down Valve
Preventive Maintenance Boom Emergency Lower Down 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. -
Page 72: Lubrication Diagram
Preventive Maintenance Lubrication Diagram Figure 111. Lubrication Diagram Operation Manual www.XMFG.com... - Page 73 Preventive Maintenance www.XMFG.com Operation Manual...
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Page 74: Lockout / Tagout
Lockout / Tagout Lockout / Tagout 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 telehandler should not be operated. Do Not Operate Tags, which can be cut out and used, are included at the end of this manual. -
Page 75: Do Not Operate Tags
Lockout / Tagout Do Not Operate Tags www.XMFG.com Operation Manual... - Page 76 Henderson, NV 89015, USA Contact Us: T: 1.800.497.1704 T: 1.702.636.2969 F: 1.702.636.4943 E: info@xmfg.com ALDEN EQUIPMENT, INC. 66 1/2 BRIDGE ST. AMSTERDAM, NY 12010 T: 1.888.468.9715 F: 1.518.842.9977 E: www.aldenequipment.com PN 24905-002-20 REV 01 Feb 2018 XR1045 Alden TIER4 QRGOVSALES CONTRACT # SP4510-17-A-0002...