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Xtreme XR1045 Operation & Safety Manual

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(702) 636-2969
1415 W. Bonanza Rd. Las Vegas, NV 89106
(800) 497-1704
www.XtremeManufacturing.com
XR1045
Operation & Safety Manual

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Summary of Contents for Xtreme XR1045

  • Page 1 XR1045 Operation & Safety Manual (702) 636-2969 1415 W. Bonanza Rd. Las Vegas, NV 89106 (800) 497-1704 www.XtremeManufacturing.com...

  • Page 3: Table Of Contents

    XR1045 Table of Contents Introduction ......3 Seat Belt General Rear View Mirrors Replacement manuals...
  • Page 4 Lockout / Tagout ..... . . 74 Lockout/Tag out Procedure Removing Forklift From Service Returning Forklift To Service “Do Not Operate” Tags Page 2 Xtreme Manufacturing, LLC...

  • Page 5: Introduction

    Right side, left side, front, and rear are directional references given from the operator’s seat while facing in a Replacement manuals forward direction Replacement manuals for the XR1045 Reach Forklifts can be obtained by contacting: Xtreme Manufacturing Phone: (800) 497-1704 Figure 1-2.

  • Page 6: Safety

    Safety information provided in this manual is a basic CAUTION (Yellow) used without the safety alert symbol guide and an attempt to prevent accidents Xtreme indicates a potentially hazardous situation which, if Manufacturing cannot anticipate every circumstance that not avoided, may result in property damage.
  • Page 7 XR1045 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...
  • Page 8 DO NOT Allow Pinch Points Pinch Points Anyone Under Hands Body A Raised Load Have Adequate Warning! Ventilation If DO NOT Use Ether Explosion Operating This As A Starting Aid Hazard Forklift In An Enclosed Space Page 6 Xtreme Manufacturing, LLC...

  • Page 9: Employer Responsibility

    XR1045 Safety Employer Responsibility Operator Qualifications Under Occupational Safety and Health Administration Operators must be in good physical and mental condition, (OSHA) rules, employers are required to train workers with appropriate reflexes, reaction time, vision, depth about hazards related to operating and maintaining the...

  • Page 10: Mounting/Dismounting

    • Learn the location of all underground hazards at the defects, and other reproductive harm. work site, such as; gas and water pipes, electrical cables, and sewers. Underground objects could cause death or serious injury. Page 8 Xtreme Manufacturing, LLC...

  • Page 11: Before Starting Forklift

    Keep the Operation and Safety Manual on convenience for the operator. These the forklift at all times. Contact Xtreme descriptions DO NOT provide complete Manufacturing for replacement manuals. operation instructions. Read and understand the...

  • Page 12: Operation Safety

    • Stay on the forklift and ride out the roll over or power sources. tip over. • 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. Page 10 Xtreme Manufacturing, LLC...
  • Page 13 XR1045 Safety  Warning  Warning NEVER allow passengers to To prevent death, serious injury, or ride on the forklift. DO NOT property damage, make sure the forklift allow riders on the frame comes to a complete stop before moving or operator cab.
  • Page 14 DO NOT change steering modes until the forklift comes to a complete stop. Align all four (4) tires “straight-ahead,” or perpendicular to the axle, before changing steering mode. Page 12 Xtreme Manufacturing, LLC...

  • Page 15: Load Safety

    XR1045 Safety Load Safety Attachments  Warning  Warning Failure to follow proper safety procedures Improper connection of an auxiliary attachment could when lifting, lowering, and traveling with result in death or serious injury. Attachments not a load could result in death, serious injury, locked into place can become unstable and fall on the or property damage.

  • Page 16: Forklift Maintenance

    Follow the proper maintenance is completed. cold starting procedures and engine manufacturer’s specifications for using a starting aid. Page 14 Xtreme Manufacturing, LLC...
  • Page 17 XR1045 Safety  Warning  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. Lead-acid batteries produce flammable and •...

  • Page 18: Dead Engine Towing

    (Repeat steps 5-9 for each side of axle) 10. Crawl out from under the vehicle and clear the area of any unnecessary personnel 11. Carefully remove the blocking from each of the four tires and tow the vehicle to a secure location Page 16 Xtreme Manufacturing, LLC...

  • Page 19: Re-Activating Parking Brakes (Front Axle)

    XR1045 Safety Re-activating Parking Brakes (Front Axle)  Warning Block all four wheels. Failure to do so could result in death or serious injury from vehicle roll away. 1. After you have blocked all four wheels, crawl under the front axle The following procedure is to be performed per side 2.

  • Page 20: Labels

    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 18 Xtreme Manufacturing, LLC...

  • Page 21: Front View

    XR1045 Labels Front View Rear View Figure 3-3. Label Legend Front View. Figure 3-4. Label Legend Rear View. Cab View Figure 3-5. Label Legend Cab View. Page 19 For information call (800) 497-1704...
  • Page 22 Hydraulic Fluid, Use Dexron III 18090-001 Warning, Tip Over Hazard 18300-001 Warning, Falling Hazard 18312-000 Warning, Falling Hazard 18315-000 Tie Down Point 18043-000 Xtreme Logo 18044-000 Xtreme X 18046-000 Boom Swoosh Left Front 18047-000 Boom Swoosh Left Rear Page 20 Xtreme Manufacturing, LLC...

  • Page 23: Replacement Labels

    XR1045 Labels Replacement Labels Replacement labels can be obtained by contacting Xtreme Manufacturing at (800) 497-1704 Please have the appropriate label number available when you call Parking Brake Volts Fuel Coolant 702-636-2969 Lights Hourmeter 800-497-1704 Front Hazard Turn Rear Axle...
  • Page 24 Labels XR1045 7) 18015-001 8) 18016-001 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 Page 22 Xtreme Manufacturing, LLC...
  • Page 25 XR1045 Labels 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 17) 18025-001 18) 18026-001 Page 23 For information call (800) 497-1704...
  • Page 26 Labels XR1045 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 22) 18033-000 23) 18034-000 24) 18039-000 Page 24 Xtreme Manufacturing, LLC...
  • Page 27 XR1045 Labels 25) 18041-001 26) 18042-000 27) 18066-001 28) 18067-000 29) 18334-000 30) 18069-000 Page 25 For information call (800) 497-1704...
  • Page 28 Labels XR1045 31) 18082-001 32) 18083-001 33) 18086-001 34) 18090-001 35) 18300-001 36) 18312-000 Page 26 Xtreme Manufacturing, LLC...
  • Page 29 XR1045 Labels 37) 18315-000 38) 18043-000 39) 18044-000 40) 18046-000 41) 18047-000 42) 18048-000 Page 27 For information call (800) 497-1704...
  • Page 30 Labels XR1045 43) 18049-000 44) 18070-000 45) 18053-000 46) 18054-000 18311-000 47) 18055-000 48) 18311-000 Page 28 Xtreme Manufacturing, LLC...
  • Page 31 50 hours, then every Slide 250 hours. Pads 18360-000 51) 18360-000 XR1045 LOAD CHART - STANDARD CARRIAGE XR1045 LOAD CHART - SWING CARRIAGE 'S' RATING FOR FORKS LOAD RATINGS STRAIGHT. 'T' RATING SHOWN ARE FOR FOR FORKS ROTATED VEHICLES EQUIPPED FROM STRAIGHT.
  • Page 32 702-636-2969 • 800-497-1704 REACH FT REACH FT 17022-000 17023-000 54) 17022-000 55) 17023-000 XR1045 LOAD CHART - 3FT TRUSS BOOM WITH WINCH XR1045 LOAD CHART - 12FT TRUSS BOOM WITH WINCH LOAD RATINGS TRUSS WEIGHT LOAD RATINGS TRUSS WEIGHT SHOWN ARE FOR...
  • Page 33 XR1045 Labels XR1045 LOAD CHART - STANDARD CARRIAGE WITH TELESCOPIC JIB XR1045 LOAD CHART - FORK POSITIONING CARRIAGE (STAR MODEL 1360 OR EQUIVALENT) 10 9 8 7 6 5 4 3 2 7" 11" TELESCOPIC 2' 8" SET FORK SPACING...

  • Page 34: Features

    Features XR1045 Features Optional Equipment Table 3. XR1045 Optional Equipment Standard Equipment Description Feature Table 2. XR1045 Standard Equipment Options Hydraulic side-swing carriage (with quick attach couplers) Description Feature Heater/Defroster/Windshield wiper Boom Universal quick attach head Limited Slip Differential Three (3) section boom...

  • Page 35: Specifications

    XR1045 Specifications Standard Equipment Specifications Heavy-duty Frame/Chassis Heavy-duty Roller Boom XR1045 Specifications Melonite Pins and Rollers Direct Dual Control Hydraulic Valve Actuation Performance Robust Wiring, No Spades, No Pins Capacity 10,000 lbs Rear Axle Stabilization (RAS) Lift Height 44’8” Center Inline Engine Drive Train Forward Reach 30’4”...

  • Page 36: Operator Cab

    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 6-4. Accelerator Pedal. Page 34 Xtreme Manufacturing, LLC...

  • Page 37: Service Brake Pedal

    XR1045 Operator Cab Service Brake Pedal Operator Seat Press the service brake pedal to slow or stop the forklift Operator Seat Controls The service brake pedal activates the service brakes on all four (4) wheels The operator seat can be adjusted four (4) ways: weight suspension, height, fore and aft, and backrest angle Figure 6-5.

  • Page 38: Lumbar Support

    Figure 6-11. Fore and Aft Adjustment Lever. (2”) wide retractable seat belt A three inch (3”) wide retractable seat belt is available where required by state and local laws and regulations Figure 6-13. Retractable Seat Belt. Page 36 Xtreme Manufacturing, LLC...

  • Page 39: Rear View Mirrors

    XR1045 Operator Cab  Warning DO NOT adjust the seat or seat belt while the forklift is moving. Keep both hands on the wheel while the forklift is moving to prevent loss of forklift control which could result in death or serious injury.

  • Page 40: Gear Select Switch

    Set Parking Brake switch (A) to ON (DOWN) to engage the parking brake and to OFF (UP) to disengage the parking brake The parking brake indicator (B) illuminates when the parking brake is set to ON (engaged) Figure 6-20. Hydraulic Oil Temperature Indicator Page 38 Xtreme Manufacturing, LLC...

  • Page 41: Low Brake Pressure Indicator

    XR1045 Operator Cab Low Brake Pressure Indicator Hourmeter The low brake pressure indicator illuminates if the The hourmeter indicates and records engine operating hydraulic brake oil pressure gets low hours and has a total readout of 9,999 9 hours Use the...

  • Page 42: Fuel Gauge

    After the engine has sufficiently warmed up, normal engine coolant temperature should read between 180 to 200°F Figure 6-29. Turn Signal and Hazard Light Switches. Page 40 Xtreme Manufacturing, LLC...

  • Page 43: Rear Axle Centering Indicator

    XR1045 Operator Cab Rear Axle Centering Indicator Declutch Indicator The rear axle centering indicator illuminates when the rear The declutch indicator illuminates when the Declutch wheels are aligned perpendicular to the rear axle The rear switch is set to the ON position...

  • Page 44: Boom Control

    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, moving the handle to the forward, left corner will lower and retract the boom at the same time Page 42 Xtreme Manufacturing, LLC...

  • Page 45: Attachment Tilt Switch

    XR1045 Operator Cab Attachment Tilt Switch Table 7. Boom Control Handle Functions The Attachment Tilt Switch located on the top of the boom control handle controls attachment tilt functions Figure 6-36. Attachment Tilt Switch. (A) Attachment Tilt Down. (B) Attachment Tilt Up.

  • Page 46: Frame Sway Control Handle

    Figure 6-39. Auxiliary Attachment Control Lever.  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. Page 44 Xtreme Manufacturing, LLC...

  • Page 47: Optional Controls And Indicators

    XR1045 Operator Cab Optional Controls and Indicators Boom Extend Letters As the boom is extended, boom extend letters appear on Two Wheel Rear (2WR) Steering Switch the left side of the boom visible to the operator These letters indicate boom extension as it corresponds to the...

  • Page 48: Operation

    Remove forklift from service and place “Do protective clothing and safety glasses. Not Operate” tags on the Starter switch and steering wheel if anything is found to be in need of repair or maintenance, defective, or unsafe in any way. Page 46 Xtreme Manufacturing, LLC...
  • Page 49 XR1045 Operation  Warning  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 Lead-acid batteries produce flammable and serious injury.

  • Page 50: Pre-Operation Inspection Checklist

    Check that operator’s cab is empty of all trash, debris, or any loose items Check that personal belongings are secured in the personal storage box Check that pedals, and non-skid surfaces are clean and free of grease, oil, dirt, snow, or ice Date: __________________________ Initials: __________________________ Page 48 Xtreme Manufacturing, LLC...

  • Page 51: Functional Tests

    XR1045 Operation Functional Tests Functional Test Checklist Operate the boom control handle forward and  Warning backward to raise and lower boom Perform a pre-operation inspection and Operate the boom control handle left and right to functional tests at the beginning of each extend and retract boom work shift.

  • Page 52: Operator Maintenance

    Figure 7-4. Check Engine Oil Level. Add Engine Oil, If Necessary. Figure 7-2. Add Hydraulic Oil, If Necessary. Figure 7-5. Check Battery Case and Terminals. Figure 7-3. Check Coolant Reservoir Level. Add Coolant, If Figure 7-6. Store Operation and Safety Manual In Protective Case. Necessary. Page 50 Xtreme Manufacturing, LLC...

  • Page 53: Before Starting Forklift

    XR1045 Operation Before Starting Forklift  Warning Failure to use proper safety procedures when mounting and dismounting the forklift could result in death or serious injury. • Keep steps clear of dirt, mud, snow, ice, debris, and other hazards. Figure 7-8. Parking Brake Switch (A) Must Be ON (Engaged) To Start The Reach Forklift.

  • Page 54: Cold Starting

    Do not induce Figure 7-12. Ignition Switch Automatically Returns To RUN. vomiting. Get medical attention immediately. Important - In case of internal contact, do not give fluids that induce vomiting. Page 52 Xtreme Manufacturing, LLC...

  • Page 55: Forklift Travel

    XR1045 Operation  Warning Forklift Travel Steering Modes Wear eye protection when starting a forklift with jump start cables. Improper jump  Warning start procedures could cause the battery to explode, which could result in death or serious injury. NEVER use crab or four wheel (4W) •...

  • Page 56: Four Wheel Steering (4W)

    5. Move the travel select lever to FORWARD or REVERSE for the appropriate direction of travel 6. Release the service brake pedal 7. Slowly press the accelerator pedal to start travel Figure 7-13. Maximum Fork Sweep. Page 54 Xtreme Manufacturing, LLC...

  • Page 57: Shifting Gears

    XR1045 Operation The hydraulic oil temperature indicator illuminates when Shifting Gears the oil temperature is above 180°F (82°C) Stop and idle the engine, allowing time for cooling If the indicator does  Warning not go out after five (5) minutes, shut the engine down DO NOT shift through multiple gears with a single turn of the gear select lever.

  • Page 58: Stopping Travel

    NEUTRAL (N), set the Parking Brake switch to ON (engaged), lower and retract the boom, and shut off the engine before exiting the forklift. Page 56 Xtreme Manufacturing, LLC...

  • Page 59: Refueling

    Fuel Types forklift Xtreme Manufacturing assumes no liability for any third party attachment that would alter the center Use ASTM #2 diesel fuel with a minimum Cetane rating of...

  • Page 60: Standard Carriage Operation

    The standard carriage uses manually adjustable forks and can be tilted up or down by using the thumb switch on the control handle Figure 7-18. Attachment Tilt Control Switch. (A) Attachment Tilt Down. (B) Attachment Tilt Up. Page 58 Xtreme Manufacturing, LLC...

  • Page 61: Quick Attach System

    XR1045 Operation  Warning Quick Attach System Hydraulic attachments have a This forklift includes a quick attach system that allows maximum hydraulic pressure for easy attachment changes Perform attachment rating. Failure to make sure the connection and removal procedures on level ground...
  • Page 62 Adapter and Attachment. (A) Not Aligned. (B) Aligned. 6. Raise the quick attach lock lever Figure 7-25. Raise Quick Attach Lock Lever. Figure 7-23. Raise Boom To Seat Pivot Pins (A) In Attachment Hooks (B). Page 60 Xtreme Manufacturing, LLC...
  • Page 63 XR1045 Operation 7. With lock lever raised, insert quick attach pin  Warning completely through the attachment and quick attach adapter 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...

  • Page 64: Attachment Removal

    8. Pull out the quick attach pin at the bottom of the system) quick attach adapter Figure 7-29. Disconnect Quick Attach Couplers. (A) Female Coupler. (B) Male Coupler. Figure 7-31. Pull Quick Attach Pin from Attachment and Quick Attach Adapter. Page 62 Xtreme Manufacturing, LLC...

  • Page 65: Load Handling

    XR1045 Operation 9. Lower the attachment to the ground in a Load Handling level position  Danger Death or serious injury by electrocution will result from contact with or inadequate clearance with energized power lines or apparatus. • Never operate the forklift in an area where active overhead power lines, overhead or underground cables, or other power sources exist.

  • Page 66: Suspended Loads

    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 Page 64 Xtreme Manufacturing, LLC...

  • Page 67: Load Shift

    XR1045 Operation 4. Use the frame sway control to level the forklift For 7) Protection must be provided for the personnel in their additional information, refer to the Frame Leveling normal working position on the platform from moving section in this manual parts of the rough terrain forklift that represent a hazard 5.

  • Page 68: Frame Leveling

    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 Figure 7-34. Frame Sway Control Handle. Page 66 Xtreme Manufacturing, LLC...

  • Page 69: Load Capacity Charts

    XR1045 Operation The frame sway control handle controls the frame sway Load Capacity Charts (right and left) functions To lock the frame sway, place the travel select lever in  Warning NEUTRAL or apply the service or parking brake DO NOT exceed rated capacities. Any NOTE: Maximum frame sway is 22°...

  • Page 70: Using Load Capacity Charts

    5. Operator reads load capacity chart for attachment carriage to learn it will be safe to place the load at any boom angle with the boom extend letter “F” showing Figure 7-39. Boom Angle Indicator. Page 68 Xtreme Manufacturing, LLC...

  • Page 71: Standard Carriage Load Capacity Chart

    XR1045 Operation Standard Carriage Load Capacity Chart XR1045 LOAD CHART - STANDARD CARRIAGE LOAD RATINGS SHOWN ARE FOR VEHICLES EQUIPPED WITH FOAM FILLED TIRES ONLY. 2.0 FT 5,000 LBS AT 24 IN LOAD MIN CAPACITY FORK CENTER (10,000 LBS PAIR).

  • Page 72: Preventive Maintenance

    Check condition and tension of drive belts (use tension meter to check belt tension) Lubricate front and rear drive shaft grease fittings Lubricate front and rear axle grease fittings Change differential oil Change wheel-end oil Check wheel lug nuts torqued to 380-420 ft-lbs Page 70 Xtreme Manufacturing, LLC...
  • Page 73 XR1045 Preventive Maintenance After Every 500 Hours of Operation After Every 1,000 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...

  • Page 74: Boom Emergency Lower Down Valve

    In addition, make sure that the new operator has completed a walk-around inspection of the vehicle, Figure 8-2. Boom Access Cover. is familiar with all Labels on the vehicle, and has demonstrated the correct use of all controls Page 72 Xtreme Manufacturing, LLC...
  • Page 75 XR1045 Preventive Maintenance THIS PAGE INTENTIONALLY LEFT BLANK Page 73 For information call (800) 497-1704...

  • Page 76: Lockout / Tagout

    1. Remove lock and “Do Not Operate” tag from battery disconnect switch 2. Raise and secure battery cover 3. Remove “Do Not Operate” tags from steering wheel and ignition key Page 74 Xtreme Manufacturing, LLC...

  • Page 77: Do Not Operate Tags

    XR1045 Lockout / Tagout Do Not Operate Tags Page 75 For information call (800) 497-1704...
  • Page 78 Lockout / Tagout XR1045 Page 76 Xtreme Manufacturing, LLC...
  • Page 79 XR1045 Lockout / Tagout Page 77 For information call (800) 497-1704...
  • Page 80 24905-000-01 4/10 (702) 636-2969 1415 W. Bonanza Rd. Las Vegas, NV 89106 (800) 497-1704 www.XtremeManufacturing.com...

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