Xtreme Manufacturing XR1147 Operation And Safety Manual
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Xtreme Manufacturing XR1147 Operation And Safety Manual

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Operation and
Safety Manual
PN 24969-000

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Summary of Contents for Xtreme Manufacturing XR1147

  • Page 1 Operation and Safety Manual PN 24969-000...
  • 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 Accelerator Pedal Introduction Service Brake Pedal General Steering Wheel Replacement Manuals Horn Button Model/Serial Plate Operator Seat Orientation Operator Seat Controls Safety Weight Suspension Lever Safety Disclaimer Lumbar Support Signal Words Fore and Aft Adjustment Lever Safety Symbols Backrest Angle Adjustment Lever ...
  • Page 4 Table of Contents Table of Contents Description Page Description Page Operation Attachment Disclaimer Pre-Operation Inspection Fork Ratings Pre-Operation Inspection Checklist Standard Carriage Operation Functional Tests Fork Positioning Carriage Operation Operator Maintenance Quick Attach System Before Starting Telehandler Load Handling Starting Telehandler Boom Lift Point Normal Starting Suspended Loads...

  • Page 5: Introduction

    Telehandler operation and maintenance. RIGHT Replacement Manuals Replacement manuals for the XR1147 Telehandler can be ob- tained by contacting our parts department by phone or visit- ing our website: Xtreme Manufacturing LEFT Phone: (800) 497-1704 www.XMFG.com...

  • Page 6: Safety

    Caution Xtreme Manufacturing reserves the right to make technical changes for product improvement. This manual may contain CAUTION (Yellow) with the safety alert symbol indicates a...
  • Page 7 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 8 Safety DO NOT DO NOT Fasten Allow Riders Jump While Seat Dismounting On Auxiliary Belt The Telehandler Attachments 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...

  • 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 Telehandler. Suc- perception, and hearing.

  • Page 10: 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 serious injury.

  • Page 11: Before Starting Telehandler

    Safety Perform the pre-operation inspection and Warning functional tests in an open area and away from any other obstacles or equipment. In- California Proposition 65 spections and functional tests may require assistance. Keep the assistant visible and a Engine exhaust from this product contains chemicals known safe distance from the Telehandler to prevent death or se- to the State of California to cause cancer, birth defects, and rious injury.

  • Page 12: Operation Safety

    Safety DO NOT adjust the seat or seat belt while the Operation Safety Telehandler is moving. Keep both hands on the wheel while the Telehandler is moving to prevent loss of Telehandler control which Danger could result in death or serious injury. Never try to escape the Telehandler if it be- Death or serious injury by electrocution will comes unstable.
  • Page 13 Safety NEVER allow passengers to • Load, unload, and turn the Telehandler on level ground, ride on the Telehandler. when possible. NOT allow riders on the frame • Slow down for turns. or operator cab. Allowing • Slow down for rough, slippery, or soft terrain. passengers to ride could result in serious injury.

  • Page 14: Load Safety

    Safety Contact with hot surfaces and the exhaust Load Safety pipe after the Telehandler has been operated could result in serious personal injury. Warning Failure to follow proper safety procedures Check warning indicators and gauges on when lifting, lowering, and traveling with a the dash panel frequently during operation.

  • Page 15: Attachments

    Safety Attachments Telehandler Maintenance Warning Warning Improper connection of an auxiliary attachment could Follow manufacturer’s instructions proper result in death or serious injury. Attachments not locked maintenance to make sure the Telehandler continues to meet into place can become unstable and fall on the operator or manufacturer’s specifications.
  • Page 16 Safety It is possible for the Telehandler to move ately. Flushing must begin immediately to avoid per- suddenly when the brakes are released, manent eye tissue damage. which could result in death, serious injury, • Internal contact - Drink large quantities of water or milk or property damage.

  • Page 17: Dead Engine Towing

    Safety and a collector bottle, as shown in Figure 4. Dead Engine Towing Apply hydraulic pressure using the manual hydraulic pump to release the brake. Parking Brake - Manual Release NOTE: For illustration purposes, we used an Enerpac P 142 manual HP pump.

  • Page 18: Labels

    Labels Labels igure 6. Label Legend (Left Side) Figure 7. Label Legend (Right Side) Operation Manual...
  • Page 19 Labels Front View Rear View Figure 8. Label Legend (Front) Figure 9. Label Legend (Rear) 21 20 Figure 10. Label Legend (Cab) Operation Manual...
  • Page 20 18331-000 CAUTION, ADJUSTABLE CARRIAGE 18041-001 LABEL WARNING PINCH POINT 18413-000 FILL DEF TANK 18042-000 DECAL XID XTREME SMALL GRN LOAD CHART, XR1147 STANDARD 17412-000 CARRIAGE 18043-000 DECAL XID XTREME MED GRN 18044-000 DECAL XID-X GRN 18046-000 DECAL LH SWOOSH-1 GRN...

  • Page 21: Replacement Labels

    Labels From outside the Las Vegas, Nevada area please call Xtreme Replacement Labels Manufacturing toll 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 Boom Wiper...
  • Page 22 Labels 7) 18015-001 8) 18016-001 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 Operation Manual...
  • Page 23 Labels 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 17) 18025-001 18) 18026-001 Operation Manual...
  • Page 24 Labels 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 23) 18039-000 CONTROL BOOM BOOM FORK TILT RETRACT EXTEND DOWN SWAY SWAY LEFT RIGHT FORK TILT CONTROL JOYSTICK ENABLE 18408-001 24) 18408-001 Operation Manual...
  • Page 25 Labels 25) 18041-001 26) 18042-000 27) 18043-000 28) 18044-000 29) 18046-000 30) 18047-000 Operation Manual...
  • Page 26 Labels 31) 18048-000 32) 18049-000 18054-000 18053-000 33) 18053-000 34) 18054-000 18055-000 35) 18055-000 36) 18066-001 FULL 18069-000 37) 18307-001 39) 18069-000 Operation Manual...
  • Page 27 Labels 40) 18471-000 41) 18081-000 42) 18082-001 43) 18083-001 44) 18086-001 45) 18090-001 Operation Manual...
  • Page 28 Labels 46) 18300-001 47) 18312-000 18311-008 49) 18311-000 48) 18315-000 CAUTION DEATH or SERIOUS INJURY could result from EQUIPMENT DAMAGE improper operation when using tow connection. Wait at least two (2) minutes after shutting DO NOT ELEVATE BOOM ABOVE 30 WHEN engine off before setting the battery disconnect TOWING.
  • Page 29 DAMAGE may result from adjusting forks when carriage is loaded. 18409-000 ONLY ADJUST FORKS WHEN CARRIAGE IS UNLOADED. 18331-000 52) 18409-000 53) 18331-000 54) 18413-000 XR1147 LOAD CHART STANDARD CARRIAGE 2.0 FT NO OPERATION ABOVE LOAD 40 DEGREES BOOM 70° CENTER 65°...

  • Page 30: Features

    Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Universal quick attach head Options Enclosed cab with air conditioning Three (3) section boom Heater/defroster/windshield wiper Boom equipped with heavy duty boom rollers Work light package Chassis Rear axle stabilization Hydraulic side-swing carriage (with quick attach couplers) 1-1/4 inch main frame plate...

  • Page 31: Specifications

    Specifications Specifications Performance Standard Equipment Capacity ... . 11,000 lbs Heavy-duty Frame/Chassis Lift Height ... 54’ 8” Heavy-duty Roller Boom Forward Reach .

  • Page 32: Operator Cab

    Operator Cab Operator Cab Warning Accessory Outlet A brief description of controls, indicators, and A 12 volt accessory outlet is provided as a power source for instruments is provided as a convenience for personal items, such as a radio or cell phone. the operator.

  • Page 33: Service Brake Pedal

    Operator Cab Service Brake Pedal Horn Button Press the service brake pedal to slow or stop the Telehandler. Press the horn button to sound the horn. The service brake pedal activates the service brakes on all four (4) wheels. Figure 16. Horn Button Operator Seat Figure 14.

  • Page 34: 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 35: Seat Belt

    Operator Cab or entangled in any portion of the seat assembly. Seat Belt Pull the retractable seat belt across your lap. Position the seat belt as low on your body as possible. Warning Insert the latch plate into the buckle (on the right side of the seat) until a “click”...

  • Page 36: Controls And Indicators

    Operator Cab Parking Brake Switch Controls and Indicators The Parking Brake toggle switch (A) has two (2) positions: ON Travel Select Lever and OFF. The travel select lever has three (3) positions: FORWARD, NEUTRAL, and REVERSE, and is used to change the direction of travel.

  • Page 37: Display Indicators

    Operator Cab oil pressure gets too low. If the Low Brake Pressure indicator Display Indicators is illuminated, do not release the parking brake or engage transmission until the indicator is out. If the indicator does not go out, stop the Telehandler, follow proper shut down The display allows the operator to view vital engine procedures, tag Telehandler with “Do Not Operate”...
  • Page 38 Operator Cab F. WAIT TO START Q. DEF GAUGE / LOW DEF LEVEL INDICATOR The Wait to Start Indicator is displayed when the key switch is The DEF Gauge indicates the quantity of fluid in the Diesel Ex- moved to the RUN position. Wait until the indicator goes out haust Fluid (DEF) tank.

  • Page 39: Display Features

    Operator Cab Two different states are possible: • Solid on - Errors that allow continuing engine operation with minor restrictions. • Blinking - Errors that cause an engine shut down or shut down request. Emission related errors of the EAT system will also be dis- played on the Status Display and the malfunction indicator will come on.
  • Page 40 Operator Cab Figure 34. Engine Diagnostics Figure 37. Service Requested 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.
  • Page 41 Operator Cab It calibrates the first clutch, and upon successful calibration it Each Restore Defaults needs to be confirmed or canceled on moves to the second and so forth. The Telehandler must be the next screen. Pressing the MENU button will return to the OFF after calibration is complete.

  • Page 42: Steering Select Switch

    Operator Cab Steering Select Switch 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 43: Attachment Tilt Switch

    Operator Cab The boom control joystick has variable motions from the center position that control boom and tilt functions. It is used CONTROL to raise, lower, extend, retract the boom, tilt the carriage (or BOOM BOOM FORK TILT RETRACT EXTEND DOWN attachment), and control auxiliary functions (when equipped SWAY...

  • Page 44: Frame Sway Control

    Operator Cab FRONT 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 220 overall or 110 each direction, left and right. VEHICLE Warning The Telehandler includes a Frame Sway Override switch.

  • Page 45: Boom Angle Indicator

    -50 to +700 Figure 57. Frame Level Indicator Telehandler Lifting Points Figure 55. Boom Angle Indicator The XR1147 lifting points are shown below. The Telehandler should only be lifted if lifting points are installed. Boom Extend Letters Warning As the boom is extended, the boom extend letters on the left side of the boom are visible to the operator.

  • Page 46: Operation

    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.

  • 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 sway control handle left and right to frame Functional Test Checklist sway left or right. Operate the auxiliary attachment control (if an auxiliary Warning attachment is being used). Turn work lights on and off. Perform a pre-operation inspection and func- tional tests at the beginning of each work Press the horn button to sound the horn.

  • Page 50: Operator Maintenance

    Operation Operator Maintenance Figure 62. Check Engine Oil Level. Add Engine Oil (API CJ-4), If Neces- Figure 59. Check Hydraulic Oil Sight Gauge sary. Figure 60. Add Hydraulic Oil, If Necessary Figure 63. Check Battery Case and Terminals Figure 61. Check Coolant Reservoir Level. Add Coolant, if Necessary. Figure 64.

  • Page 51: Before Starting Telehandler

    Operation The Parking Brake switch (A) has two (2) positions: ON and Before Starting Telehandler OFF. Warning Failure to use proper safety procedures when mounting and dismounting the Telehandler could result in death or serious injury. • Keep steps clear of dirt, mud, snow, ice, debris, and oth- er hazards.

  • Page 52: Jump Starting

    Operation 2. Disengage the driving unit, or if equipped, put the trans- NOTE: If the engine fails to start on the first try, wait until the mission in NEUTRAL. engine and starter come to a complete stop before cranking the engine again. 3.

  • Page 53: After Extended Shutdown Or Oil Change

    Operation • External contact - Flush with water. • Remove the jumper cables in reverse order of their connection (i.e. negative cable ground first, etc.) • Eyes - Flush with water (including under the eyelids) for • Electrolyte contains acid and could cause serious at least 15 minutes and get medical attention immedi- personal injury if it contacts the skin or eyes.
  • Page 54 Operation service or repair the Telehandler BEFORE placing it into The Check Engine Indicator displayed by itself shows service again. Report all warning indicators and fault codes the engine is operating normally but there are one to a qualified mechanic. Ignoring warning indicators or or more minor faults with the engine electronic fault codes can cause improper performance, which could management system.
  • Page 55 Operation near combustibles, the automatic regeneration may be The HEST indicator will be displayed by itself when temporarily disabled by pressing the Enter button or Regen the exhaust temperature is elevated due to an soft button to bring up the After Treatment Control menu automatic regeneration.

  • Page 56: Manual Regeneration

    Operation turning radius area could result in death, serious injury, or Manual Regeneration equipment damage. Caution Caution DO NOT change steering modes until Telehandler slows or DO NOT leave Telehandler unattended during manual comes to a complete stop. Align all four (4) wheels “straight- regeneration.

  • Page 57: Starting Travel

    Operation Warning Shifting Gears Allow for adequate clearance between the attachment and other objects when turning. Warning The attachment extends beyond the front of the Telehandler. The operator must be aware DO NOT shift through multiple gears with a of the maxi- single turn of the gear select lever.

  • Page 58: Shut Down Procedure

    Operation • Make sure the Telehandler is level to obtain an accurate Warning fuel level reading. • Shut off the engine. To prevent death, serious injury, or property • Ground the fuel nozzle against the filler neck to avoid damage, apply service brakes until the sparks.

  • Page 59: Attachments

    Telehandler 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, Figure 72. Fork Ratings expressed or implied, as to the design, manufacture, or fitness (A) Maximum Load Capacity Rating (B) 24 inch Load Center for use with this Telehandler of any third party attachment.

  • Page 60: Fork Positioning Carriage Operation

    Operation Fork Positioning Carriage Operation Quick Attach System This Telehandler includes a quick attach system that allows for Caution easy attachment changes. Perform attachment connection and removal procedures on level ground. Do not adjust forks when the carriage is loaded. Adjusting forks when carriage is loaded may result in loss of load or Attachment Connection carriage damage.
  • Page 61 Operation Figure 77. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment Hooks (B) Figure 79. Quick Attach Lock Lever. 5. Tilt the attachment up slightly. The quick attach adapter should be tight against the rear of the attachment. Align the 6.
  • Page 62 Operation 7. Raise the quick attach lock lever. Figure 83. Quick Attach Lock Lever 8. Pull out the quick attach pin at the bottom of the quick Figure 81. Quick Attach Lock Lever and Quick Attach Pin. attach adapter. Warning Hydraulic attachments have a maximum hydraulic pressure rating.

  • Page 63: Load Handling

    Operation 10. Tilt and lower boom until pivot pins (A) have disconnected Keep the Telehandler, attachments, and loads from attachment hooks (B). a safe distance from electrical power lines. • 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.

  • Page 64: Boom Lift Point

    Operation • Adjust the load as necessary, especially for nonstandard Suspended Loads loads. • Use caution when handling loose material that can fall into the cab. Avoid carrying a suspended load. If necessary, • Remove overhanging load materials, when possible, secure the load by attaching it to the and watch for sliding material.

  • Page 65: 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 66 Operation 8. Information prominently indicated on the platform; 3. Make sure the platform, carriage, and forks are secured to A) Maximum work load including personnel and equipment. prevent them from pivoting from side to side. B) Weight of empty platform. 4.

  • Page 67: Load Capacity Charts

    Operation 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.
  • Page 68 • Height of structure where load is to be placed the boom extend letter “E” showing. • Distance from front tires where load will be placed XR1147 LOAD CHART STANDARD CARRIAGE 2.0 FT NO OPERATION ABOVE LOAD 40 DEGREES BOOM 70°...

  • Page 69: Frame Leveling

    Operation NOTE: Maximum frame sway is 22° overall or 11° each direc- Frame Leveling tion, left and right. Warning Warning The Telehandler includes a Frame Sway Over- Use of the frame sway control with the boom ride switch. Improper use of the Frame Sway raised above horizontal could cause tip over Override switch could cause death, serious resulting in death or injury.

  • Page 70: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance Check for oil and coolant leaks Establishing a Maintenance Program Check condition and tension of drive belts (use tension meter to check belt tension) The hour meter displays elapsed engine operating hours Lubricate front and rear drive shaft grease fittings and has a total readout of 9,999.9 hours.

  • Page 71: Engine Diagnostic Fault Codes

    Preventive Maintenance Check cooling fan belt tensioner All fault codes recorded will either be active (fault code is pres- ently active on the engine) or inactive (fault code was active at Check electrical cables, leads, and connections for some time, but is not presently active). damage and tightness The STOP ENGINE lamp is red and indicates the need to stop Check specific gravity of engine coolant...

  • Page 72: Boom Emergency Lower Down Valve

    Preventive Maintenance The diagnostic on/off switch circuit signals the system that the Locate needle valve on extend cylinder. Loosen nut on operator is requesting to read any active fault code recorded valve, then loosen valve with hex wrench. in the ECM. When the ECM receives the signal from the diagnostic ON/OFF switch, the yellow and red warning lights come on and start flashing if any active fault code is recorded in the...

  • Page 73: 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 74: Do Not Operate Tags

    Lockout / Tagout Do Not Operate Tags Operation Manual...
  • Page 75 Operation Manual...
  • Page 76 8350 EASTGATE ROAD HENDERSON, NV 89015 (702) 636-2969 (800) 497-1704 www.XMFG.com XR1147 Tier 4 Final PN 24969-000...

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