Xtreme XR3034 Operation And Safety Manual
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Xtreme XR3034 Operation And Safety Manual

Tier 4 final
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Operation and
Safety Manual
Tier 4 Final
PN 24941-001

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Summary of Contents for Xtreme XR3034

  • Page 1 Operation and Safety Manual Tier 4 Final PN 24941-001...
  • Page 2 Xtreme Manufacturing, LLC (w://www.xmfg.com/) is headquartered in Las Vegas, Nevada, and has fabrication facilities in Selma, California. In October 2013, Xtreme became the majority shareholder in Snorkel, a global aerial work platform manufacturer, which has manufacturing facilities in the US, UK & New Zealand, as well as a global sales distribution network. Find out more about Snorkel at www.snorkellifts.com.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Description Page Description Page Operator Seat Introduction Operator Seat Controls General Replacement Manuals Weight Suspension Lever Lumbar Support Model/Serial Number Plate Fore and Aft Adjustment Lever Forklift Direction Orientation Safety Backrest Angle Adjustment Lever Safety Disclaimer Seat Belt Rear View Mirrors...
  • Page 4 Table of Contents Table of Contents Description Page Description Page Starting Travel Suspended Loads Shifting Transmission Range Pick Up a Load Shifting Gears Carry a Load Warning Indicators and Fault Codes Place a Load Manual Regeneration Tow Pin & Pintle Hook (Optional) Stopping Travel Load Shift Changing Travel Direction...

  • Page 5: Introduction

    Right side, left side, front, and rear are directional references given from the operator’s seat when facing forward. Replacement Manuals RIGHT Replacement manuals for the XR3034 Reach Forklift can be obtained by contacting our parts department by phone or visiting our website: Xtreme Manufacturing Phone: (800) 497-1704 www.XMFG.com...

  • Page 6: Safety

    WARNING (Orange) used with the safety alert symbol indi- cates a potentially hazardous situation which, if not avoid- ed, could result in death or serious injury. Xtreme Manufacturing reserves the right to make technical Caution changes for product improvement. This manual may contain...
  • Page 7 Safety Read Operator Read Maintenance General Safety Manual Before Manual Before Alert Symbol Operating This Working On Forklift This Forklift Read Material DO NOT OPERATE! Know First Aid Safety Data Instructions And/ Forklift Down Sheets (MSDS) For Or Locations On For Service Or Chemicals And Work site...
  • Page 8 Safety DO NOT DO NOT Fasten Jump While Allow Riders Seat Dismounting On Auxiliary Belt The Forklift Attachments Set Parking DO NOT Allow DO NOT Allow Brake To OFF Riders On Forklift Riders On Or In Disengage Frame Or Fenders The Operator Cab Parking Brake Set Parking Brake...

  • Page 9: 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 forklift. Successful perception, and hearing.

  • Page 10: Mounting/Dismounting

    Safety Warning Mounting/Dismounting • The forklift is designed to handle rough terrain, however, Warning operating the forklift where large holes, obstructions, debris, loose fill, and other work site hazards exist could Failure to use proper safety procedures when mounting result in death or serious injury. and dismounting the forklift could result in death or serious •...

  • Page 11: Before Starting Forklift

    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.

  • Page 12: Operation Safety

    Safety the forklift cannot be leveled using the frame sway control, Warning do not attempt to raise or place load. Reposition forklift or have the surface leveled. Operators must be properly trained and qualified to operate this specific forklift. Warning Know the location, learn the specific purpose, and demonstrate safe and proper use of all To prevent death, serious injury, or prop-...
  • Page 13 Safety DO NOT shift through multiple gears with a Caution single turn of the gear select lever. Allow the engine speed to slow down before shifting to Never attempt to create Diesel Exhaust Fluid by mixing agri- the next lower gear. Improper use of the gear cultural grade urea with water.

  • Page 14: Load Safety

    Safety Check warning indicators and gauges on the Follow appropriate procedures to prevent dash panel frequently during operation. If a sudden changes in forklift speed that could warning indicator is illuminated or a gauge result in death or serious injury. shows abnormal readings, stop the forklift, follow proper shut down procedures, tag the forklift with “Do Not Operate”...

  • Page 15: Attachments

    Safety Failure to keep personnel clear of the load Shut Down Procedure 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. Warning To prevent death or serious injury, follow these procedures •...
  • Page 16 Safety • DO NOT operate the forklift and attachments if they re- DO NOT use ether as a starting quire repairs. aid. Ether is flammable and can • Make sure basic maintenance is completed and service cause an explosion when start- problems are corrected.

  • Page 17: Jump Starting

    Dead Engine Towing Dead Engine Towing Parking Brake Release (Front Axle) Safety Parking Brake Release (Front Axle) Warning Warning Jump Starting Dead Engine Towing Block all four wheels. Failure to do so could result in Block all four wheels. Failure to do so could result in death or serious injury from vehicle roll away.
  • Page 18 R4030 Safety Re-Activating Parking Brakes (Front Axle) R4030 Warning Block all four wheels. Failure to do so could result in death or serious injury from vehicle roll away. 1. Block all four wheels to prevent the vehicle from moving once the parking brake is disabled. 2.

  • Page 19: Labels

    Labels Labels Left Side View 45 46 47 ON GLASS ON CHASSIS ON CHASSIS Fig 6. Label Legend (Cab Side) Operation Manual...
  • Page 20 Right Side View INSIDE COVER ON CHASSIS ON CHASSIS ON CHASSIS Fig 7. Label Legend (Tank Side) Operation Manual...
  • Page 21 Labels Front View Rear View Fig 8. Label Legend (Front) Fig 9. Label Legend (Rear) Cab View Fig 10. Label Legend (Cab) Operation Manual...
  • Page 22 18014-002 LABEL CHECK ENGINE OIL CJ-4 18015-001 LABEL CHECK COOLANT 18044-000 DECAL XTREME X 18016-001 LABEL CAUTION BURN 18351-000 LABEL XR3034 BOOM SWOOSH GREEN 18345-000 LABEL XR3034 BOOM STRIPE 18017-001 LABEL DANGER CRUSHING 18353-000 LABEL XR3034 BOOM SWOOSH GREEN 18018-001 LABEL DANGER ELECTROCUTION...

  • Page 23: Replacement Labels

    Labels Replacement Labels Replacement labels can be obtained by contacting Xtreme Manufacturing at (800) 497-1704. Please have the appropri- ate label number available when you call. Parking Brake Boom Boom Transmission Range Rear Rear Carriage Steering Tilt Front and Rear...
  • Page 24 Labels 7) 18015-001 8) 18016-001 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 Operation Manual...
  • Page 25 Labels 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 17) 18025-001 18) 18026-001 Operation Manual...
  • Page 26 Labels 19) 18027-001 20) 18031-001 WARNING AUXILIARY AUXILIARY 18033-000 21) 18032-001 22) 18033-000 23) 18039-000 24) 18041-001 Operation Manual...
  • Page 27 Labels CAUTION CRUSHING HAZARD VEHICLE DAMAGE may result from leaving hood open. CLOSE HOOD before lowering boom. 18066-001 25) 18042-000 26) 18066-001 FULL 18069-000 27) 18069-000 28) 18082-001 29) 18083-001 30) 18086-001 Operation Manual...
  • Page 28 Labels 31) 18090-001 32) 18300-001 18315-000 33) 18312-000 34) 18315-000 18044-000 35) 18043-000 36) 18044-000 Operation Manual...
  • Page 29 Labels 18345-000 18351-000 37) 18351-000 38) 18345-000 18346-000 18353-000 39) 18353-000 40) 18346-000 DIESEL EXHAUST FLUID (DEF) ONLY 18409-000 41) 18339-000 42) 18409-000 CARRIAGE DAMAGE DAMAGE may result from adjusting forks 24,000 lbs. when carriage is loaded. ONLY ADJUST FORKS WHEN CARRIAGE IS UNLOADED.
  • Page 30 Labels 18343-000 45) 18343-000 DEATH or SERIOUS INJURY could result from improper operation when using tow connection. DO NOT ELEVATE BOOM ABOVE 30 WHEN TOWING. DO NOT EXCEED RATED TOW CAPACITY. Max vertical load 500 LBS. Max tow capacity 5000 LBS. 18332-000 48) 18332-000 18344-000...
  • Page 31 Labels XR3034 LOAD CHART - FORK POSITIONING CARRIAGE (5FT LOAD CENTER) LOAD RATINGS SHOWN ARE FOR VEHICLES EQUIPPED WITH FOAM FILLED TIRES ONLY. 7,750 LBS AT 60 IN MIN CAPACITY FORK (15,500 LBS PAIR). FORKS MUST BE 8FT LONG WHEN USING 5FT LOAD CENTER.

  • Page 32: Features

    Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Two (2) section boom Options Enclosed cab with A/C Boom equipped with heavy duty rollers for lon- Heater/defroster/windshield wiper ger life and less maintenance Work light package Chassis Rear axle stabilization Backup camera 2”...

  • Page 33: Specifications

    Brakes ....Inboard Wet Disc Suspension Seat Parking Brake ..SAHR Quick Attach (Common Fit) Tires Xtreme Service Accessibility Tires (Standard Eq) Foam Filled Attachments 16 x 25 E3 Standard Carriage - 72”...

  • Page 34: 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 prevent death, serious injury, or equipment damage. Ignition Switch Fig 12.

  • Page 35: Service Brake Pedal

    Operator Cab Air Conditioning Controls If the Cab is equipped with air conditioning, the controls are next to the operator seat. Use the top rotary knob (A) to con- trol the fan speed. Use the bottom rotary knob to control the air temperarure.

  • Page 36: 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 37: Seat Belt

    Operator Cab 1. Grasp the free end of the seat belt (located on the left side Seat Belt of the seat) and make sure the belt webbing is not twisted or entangled in any portion of the seat assembly. Warning 2.

  • Page 38: Controls And Indicators

    Operator Cab Controls and Indicators Travel Select Lever The travel select lever has three (3) positions: FORWARD, NEUTRAL, and REVERSE, which change the direction of travel. Travel Select Lever Position Purpose F (Forward) UP Position (away from the operator) N (Neutral) CENTER Position R (Reverse) DOWN Position (toward the operator)

  • Page 39: Light Switches

    Operator Cab Steering Select Switch 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. Changing steering modes at higher travel speeds can make the forklift unstable, and cause a loss of control, which could result in death, serious injury, or property damage.

  • Page 40: Display Indicators

    Operator Cab H. REGENERATION MENU Display Indicators Pushing the soft button adjacent to the Regen Menu indica- tor displays the exhaust system regeneration mode with the The display allows the operator to view vital engine information available options (Fig. 43). and other critical functions, including gauge display, engine I.
  • Page 41 Operator Cab π Fig 34. Display Indicators Operate” tags, and have a qualified mechanic service or repair fault code is stored in the error memory. the forklift BEFORE placing it into service again. Two different states are possible: Q. FUEL GAUGE AND LOW FUEL INDICATOR •...

  • Page 42: Display Features

    Operator Cab V. HIGH EXHAUST TEMPERATURE (HEST) The High Exhaust Temperature (HEST) indicator will be displayed when the exhaust temperature is higher than normal. Refer to the Operation section on Warning Indicators and the Engine Indicator Chart (Fig. 67). W. ESC REGEN DISABLED The ESC Regen Disabled indicator will be displayed if the ESC Regen has been manually disabled by the user.
  • Page 43 Operator Cab UTILITIES Pressing the UTILITIES soft button will bring up another menu. SERVICE REMINDERS Pressing the SERVICE REMINDERS soft button will display data pertaining to maintenance schedules. Pressing the MENU button will return to the UTILITIES mode. Fig 38. User Settings Fig 41.

  • Page 44: Boom Control

    Operator Cab REGENERATION MENU Boom Control Pressing the ENTER button while in GAUGE DISPLAY mode or pressing the REGEN MENU soft button will bring up a menu The boom control handle (Fig. 45) has variable motions from that displays the exhaust system regeneration mode with the the center position that control boom and tilt functions.

  • Page 45: Attachment Tilt Switch

    Operator Cab Fig 48. Attachment Tilt Control Switch. (A) Attachment Tilt Down. (B) Attachment Tilt Up Frame Sway Control Handle The Frame Sway Control Handle installed on the side console panel, controls frame sway functions. Fig 46. Boom Control Handle Functions Attachment Tilt Switch The Attachment Tilt Switch located on the top of the boom control handle controls attachment tilt functions.

  • Page 46: Override Operation

    Operator Cab Frame Sway Control Handle Function Handle Action FRAME SWAY RIGHT Move Control Handle RIGHT FRAME SWAY LEFT Move Control Handle LEFT NOTE: Maximum frame sway is 16° overall or 8° each direc- tion, left and right. Override Operation Fig 51.

  • Page 47: Boom Angle Indicator

    • Lay boom stand in the down position and re-latch stand to secure. Forklift Lifting Points The XR3034 lifting points are shown below. The forklift should Fig 53. Boom Extend Letters only be lifted if lifting points are installed. Warning...

  • Page 48: Operation

    Operation Operation Caution Pre-Operation Inspection Contact with hot surfaces and the exhaust To perform the pre-operation inspection make sure the pipe after the forklift has been operated forklift is NOT running, the engine is cool, the forklift is parked could result in serious personal injury. on level ground, the boom is completely retracted, and the frame is level.
  • Page 49 Operation Warning Warning Wear eye protection when connecting jump start cables. Improper jump start procedures could cause the battery to explode, which could result in death or serious injury. Lead-acid batteries produce flammable and potentially ex- • Never jump start a frozen battery, as it can explode. Let plosive gases.

  • Page 50: 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 51: Functional Tests

    Operation Place the travel select lever in reverse to sound the Functional Tests backup alarm and check function of back up camera. Release the parking brake. Warning Operate the forklift in forward and reverse. Test the gear select lever (and/or thumb switch) while Perform a pre-operation inspection and func- operating the forklift in forward and reverse.

  • Page 52: Operator Maintenance

    Operation Operator Maintenance INSET Fig 55. Check Hydraulic Oil. Check Hydraulic Oil Sight Gauge (A); Add Hy- Fig 58. Check Engine Oil Level. draulic Oil, if Necessary (B). WARNING! DO NOT Check Engine Oil Level Using Yellow Dipstick “A” . Add Engine Remove Hydraulic Tank Filler Cap Unless It Is Oil (API CJ-4 ), If Necessary (“B”, See Inset).

  • Page 53: Before Starting Forklift

    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 oth- er hazards. Face the forklift for mounting or dismount- ing.

  • Page 54: Starting Forklift

    Operation 4. Release key immediately after the engine starts. The Starting Forklift Ignition Switch will automatically return to RUN. Normal Starting Caution Release the key immediately once the motor starts. If the Warning motor does not start, DO NOT crank the starter motor con- tinuously for more than 15 seconds.

  • Page 55: Forklift Travel

    Operation Two Wheel Front Steering (2W) Forklift Travel Two wheel (2W) steering allows the front wheels to turn in the same direction as the Steering Modes steering wheel. The rear wheels remain in a fixed forward position. Two wheel (2W) steering is useful for traveling at higher Warning speeds.

  • Page 56: Starting Travel

    Operation Starting Travel Shifting Gears Warning Warning Use proper safety procedures and avoid Allow the engine speed to slow down before hazardous situations while operating the shifting to the next lower gear. Improper forklift to prevent death, serious injury, or use of the gear select lever could cause property damage.
  • Page 57 Operation TIER IV FINAL ENGINE with the Check Engine Indicator and a flashing Low DEF Level Indicator shows the DEF tank CHECK ENGINE INDICATOR LIGHT is empty and the engine power is operating The Check Engine Indicator displayed by itself at reduced power or limited to idle;...
  • Page 58 Operation is no concern for operating with high exhaust during a manual regeneration. temperature. EXHAUST SYSTEM CLEANING (ESC) INDICATOR The HEST Indicator will be displayed with a flashing ESC Indicator when the exhaust The ESC Indicator will be displayed by itself when a manual regeneration is recommended.

  • Page 59: Manual Regeneration

    Operation Manual Regeneration Changing Travel Direction Caution Warning DO NOT leave the reach forklift unattended during manual Make sure the forklift comes to a complete regeneration. stop before moving the travel select lever. A sudden change in direction of travel, while The manual regeneration should be performed by qualified carrying a load, can reduce stability and/ personnel.

  • Page 60: Refueling

    Low DEFLevel indicator is displayed. stability of this forklift. Xtreme Manufacturing assumes no Refer to the Operation section on Warning Indicators and liability for any third party attachment that would alter the Fault Codes and the Engine Indicator Chart (Fig.

  • Page 61: Fork Ratings

    Operation Standard Carriage Operation Fork Ratings The standard carriage uses manually adjustable forks and can Warning be tilted up or down by using the thumb switch on the control handle. DO NOT exceed forklift capacity of 30,000 pounds (13,608 Kilograms) with a 72 inch fixed carriage or 28,000 lbs (12,700 kilo- grams) with a 72 inch adjustable carriage.

  • Page 62: Fork Positioning Carriage Operation

    Operation Quick Attach System Fork Positioning Carriage Operation This forklift includes a quick attach system, located in the center of the horsehead below the tilt cylinder; it allows for Caution easy attachment changes. Perform attachment connection and removal procedures on level ground. Do not adjust forks when the Fork Positioning Carriage is loaded.
  • Page 63 Operation Install the retaining pin to lock in attachment. Fig 77. Retaining Pin Connect the quick attach couplers (Fig. 73). This only ap- Fig 74. Drive Vehicle Forward To Align Pivot Pins with Attachment Hooks plies to attachments with a quick attach hydraulic system. Tilt and raise the boom until pivot pins have seated fully in attachment hooks.

  • Page 64: Load Handling

    Operation Attachment Removal Load Handling NOTE: To remove a standard carriage with forks, spread the forks apart on the carriage shaft. This provides better support Danger for the carriage to stand alone. Bring the forklift to a complete stop. Death or serious injury by electrocution Move the travel select lever to NEUTRAL (N).

  • Page 65: Boom Lift Point

    Operation There is a boom lift point on the underside of the boom that • Review the rated load capacity of each auxiliary attach- may be used to lift and carry loads. ment before performing any operation. • Use the correct load chart and NEVER exceed specified weights and load centers.

  • Page 66: Carry A Load

    Operation Tow Pin & Pintle Hook (Optional) Carry A Load Carry the load as low as possible while maintaining good ground clearance and visibility. Warning Back away slowly. Death or serious injury could result from To travel with a load, use first gear (1) for highest torque improper operation when using the tow and pulling power.

  • Page 67: Elevating Personnel

    Operation height to the platform of 42” around its upper periphery Elevating Personnel 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 Warning a concentrated horizontal force of 200 lbs applied at the point of least resistance without permanent deformation.

  • Page 68: Frame Leveling

    Operation Place the travel select lever in the NEUTRAL position. Frame Leveling Engage the parking brake switch. Blocking the wheels is also recommended. Warning Level the platform in both the side-to-side and front-to- back directions before use. Use of the frame sway control with the boom 10.

  • Page 69: Load Capacity Charts

    Operation 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 fork- lift tip over, loss of load, or structural damage which could result in death, serious injury, or property damage.
  • Page 70 -5 to +570. at any boom angle with the boom extend letter “C” showing. XR3034 LOAD CHART - FORK POSITIONING CARRIAGE LOAD RATINGS SHOWN ARE FOR...

  • Page 71: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance Establishing a Maintenance Program Lubricate front and rear axle grease fittings The hourmeter displays elapsed engine operating hours. Use Lubricate front and rear axle cylinder pivot point the hour meter and the schedules contained in this section to grease fittings establish a comprehensive preventive maintenance program.
  • Page 72 Preventive Maintenance After Every 500 Hours of Operation After Every 2,000 Hours of Operation Comply with 50-Hour Maintenance Requirements Comply with 50-Hour Maintenance Requirements Comply with 250-Hour Maintenance Requirements Comply with 250-Hour Maintenance Requirements Replace air filter Comply with 500-Hour Maintenance Requirements Replace fuel filters Comply with 1000-Hour Maintenance Requirements Check engine hoses and connections for leaks,...

  • Page 73: Boom Emergency Lower Down Valve

    Preventive Maintenance Warning Boom Emergency Lower Down Valve Keep fingers and feet away from moving Both of the lift and extend cylinders are equipped with a parts or pinch points to prevent pinching or needle valve which allows the cylinder to retract without the crushing.

  • Page 74: Lockout / Tagout

    Lockout / Tagout Lockout / Tagout Lower battery cover. Do Not Operate - Accident Prevention Tags Set battery disconnect switch to OFF. Lock battery disconnect switch. Before beginning any maintenance or service, place a Do Not Operate Tag on both the starter key switch and the steering Attach “DO NOT OPERATE”...

  • Page 75: Do Not Operate Tags

    Lockout / Tagout Do Not Operate Tags Operation Manual...
  • Page 76 1415 W. BONANZA RD LAS VEGAS, NV 89106 (702) 636-2969 (800) 497-1704 www.XMFG.com XR 3034 PN 24941-001 Tier 4 Final...

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