XR1045 Comprimido

Operation and
Safety Manual
Pre-delivery Inspection Report must be completed upon placing unit in

Cummins Tier 4F service. Please use QR link or visit
www.xmfg.com/warranty/pre-delivery-inspection-report
PN 24905-002 Rev C to register online.
February 2021
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.
Xtreme Manufacturing
8350 Eastgate Road
Henderson, NV 89015, USA
Contact Us:
Corporate Office
T: 1.800.497.1704
T: 1.702.636.2969
F: 1.702.636.4943
E: [email protected]
Service Hotline
T: 1.702.984.7249
Parts Hotline
T: 1.702.984.7250
Pre-delivery Inspection Report must be completed upon placing unit in service.

Please use QR link or visit
www.xmfg.com/warranty/pre-delivery-inspection-report to register online.
© 2021 XTREME MANUFACTURING. ALL RIGHTS RESERVED

Table of Contents
Table of Contents
Description Page Description Page

Introduction Accelerator Pedal 32
General 5 Service Brake Pedal 33
Replacement Manuals 5 Steering Wheel 33
Model/Serial Plate 5 Horn Button 33
Orientation 5 Operator Seat 33
Safety Operator Seat Controls 33
Safety Disclaimer 6 Weight Suspension Lever 34
Signal Words 6 Lumbar Support 34
Safety Symbols 6 Fore and Aft Adjustment Lever 34
Employer Responsibility 9 Backrest Angle Adjustment Lever 34
Operator Responsibility 9 Seat Belt 35
Operator Qualifications 9 Rear View Mirrors 35
Modifications 9 Controls and Indicators 36
Mounting/Dismounting 10 Travel Select Lever 36
Work Site Safety 10 Gear Select Switch 36
Before Starting Forklift 11 Parking Brake Switch 37
Operation Safety 12 Load Capacity Charts 37
Load Safety 14 Display Indicators 37
Attachments 15 Display Features 39
Shut Down Procedure 15 Steering Select Switch 42
Forklift Maintenance 15 Boom Control 42
Dead Engine Towing 17 Attachment Tilt Switch 43
Labels Frame Sway Control Handle 44
Labels 18 Auxiliary Attachment Control 44
Replacement Labels 21 Light Switch 44
Features Boom Angle Indicator 45
Standard Equipment 30 Boom Extend Letters 45
Optional Equipment 30 Frame Level Indicator 45
Specifications Forklift Lifting Points 46
Specifications 31 Boom Extend Letters 44
Operator Cab Frame Level Indicator 44
Ignition Switch 32 Forklift Lifting Points 45
Accessory Outlet 32
3 Operation Manual
Table of Contents
Table of Contents
Description Page Description Page
Operation Fork Ratings 59
Pre-Operation Inspection 47 Standard Carriage Operation 59
Pre-Operation Inspection Checklist 49 Fork Positioning Carriage Operation 59
Functional Tests 50 Quick Attach System 60
Operator Maintenance 51 Load Handling 63
Before Starting Forklift 52 Boom Lift Point 64
Starting Forklift 53 Suspended Loads 64
Normal Starting 53 Pick Up a Load 64
Jump Starting 54 Carry a Load 65
After Extended Shutdown Or Oil Change 54 Place a Load 65
Operating the Engine 55 Load Shift 65
Forklift Travel 55 Elevating Personnel 65
Steering Modes 55 Load Capacity Charts 67
Starting Travel 56 Frame Leveling 69
Shifting Gears 56 Preventive Maintenance
Warning Indicators 55 Establishing a Maintenance Program
Changing Travel Direction 57 Maintenance Schedule 70
Stopping Travel 57 Engine Diagnostic Fault Codes 71
Shut Down Procedure 57 Boom Emergency Lowering 72
Refueling 58 Lockout / Tagout
Fuel Types 58 Do Not Operate - Accident Prevention Tags 73
Engine Protection System 58 New or Additional Operators 73
Pintle Hook 58 Lockout/Tagout Procedure 73
Attachments 58 “Do Not Operate” Tags 74
Attachment Disclaimer 58
Operation Manual 4
Introduction
Introduction
General Model / Serial Plate
This Operation and Safety Manual provides the information When contacting our parts department, please have the
needed to safely operate the XR1045 Reach Forklift. forklift serial number available. The serial number plate is
located in the operator’s cab, at the base of the seat.
This manual should be considered a permanent part of the
forklift, and kept in the protective manual case located in the
For easy reference, you can record the serial number in the
operator’s cab.
space below.
Notice
Serial Number:
Before operating the forklift, read this manual complete-
ly and carefully to understand the safety instructions
and the operation of controls and safety equipment. You
must comply with all DANGER, WARNING, and CAUTION
notices. They are for your benefit.
Warning
Improper operation of this forklift could result in death or

serious injury.
BEFORE starting the engine, do the following:
• Read the Operation and Safety Manual
• Read all the Safety Labels on the Forklift
• Clear the area of all other persons Figure 1. Serial Number Plate
Learn and practice safe use of forklift controls in a safe,

clear area, BEFORE you operate this forklift on a work site. Orientation
It is your responsibility to observe applicable laws and
regulations and to follow manufacturer’s instructions on Right side, left side, front, and rear are directional references
forklift operation and maintenance. given from the operator’s seat when facing forward.
Replacement Manuals
RIGHT
FRONT
Replacement manuals for the XR1045 Reach Forklift can be

REAR
obtained by contacting our parts department by phone or

visiting our website:
Xtreme Manufacturing
Phone: (800) 497-1704
www.XMFG.com LEFT
Figure 2. Forklift Direction Orientation
5 Operation Manual
Safety
Safety
Safety Disclaimer Signal Words
Signal words are the word or words that call attention to

the safety sign and designate a degree or level of hazard
seriousness. The signal words used in this manual are DANGER,
WARNING, and CAUTION.
Danger
DANGER (Red) used with the safety alert symbol indicates
an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
Warning
WARNING (Orange) used with the safety alert symbol

indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Xtreme Manufacturing reserves the right to make technical Caution

changes for product improvement. This manual may contain
illustrations and photographs (for demonstration purposes),
CAUTION (Yellow) with the safety alert symbol indicates a
which slightly deviate from the actual product.
potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
Safety information provided in this manual is a basic guide
and an attempt to prevent accidents. Xtreme Manufacturing
cannot anticipate every circumstance that might involve a Caution
potential hazard. Warnings in this manual and on the forklift
are NOT all-inclusive. CAUTION (Yellow) used without the safety alert symbol
indicates a potentially hazardous situation which, if not
You are responsible for safe operation of the forklift and all avoided, may result in property damage.
attachments. You must satisfy yourself that the techniques,
operating procedures, work methods, or mentioned by
Xtreme Manufacturing. Safety Symbols
The safety of everyone around the forklift depends significantly
on your knowledge and understanding of all correct and safe Warning
operating practices and procedures. You can help prevent
accidents by remaining alert and recognizing potentially Safety symbols are provided to remind the operator of
hazardous situations. hazardous situations. Xtreme Manufacturing provides these
symbols in an attempt to inform all operators, regardless of
Follow State and Federal health and safety rules and/or local reading and language skills, of as many potential hazards as
regulations for operating and maintaining the forklift. possible. These symbols cover many, but not all, potential
dangers and hazards associated with operating the forklift.
• This manual does not replace any laws and regulations.
Make safety a high priority while operating the forklift.
• The operator is required to comply with all applicable Learn and follow all safety messages in this manual and on
laws and regulations. forklift labels to prevent death, serious injury, or equipment
damage. The following two pages include a list of some
of the safety symbols that may be used on this forklift.
Operation Manual 6
Safety
Read Operator Read Maintenance

General Safety Manual Before Manual Before
Alert Symbol Operating This Working On
Telehandler This Telehandler
DO NOT OPERATE! Read Material

Know First Aid
Safety Data
Telehandler Down Instructions And/
Sheets (MSDS) For
For Service Or Or Locations On
Chemicals And
Maintenance Work site
Fluids
Perform DO NOT
Personal
Operator Operate If Using
Protective
Inspection Alcohol, Drugs,
Equipment
Before Starting Or Medications
This Telehandler Hardhat
Personal Personal Personal

Protective Protective Protective
Equipment Equipment Equipment
Gloves Safety Shoes Safety Glasses
Personal
Protective No Smoking
Lead Acid
Equipment Batteries Create Keep Lit
Ear Protectors Explosive Gases Cigarettes
Away
Warning! Use A Board Or

Keep Flames Hydraulic Oil Cardboard To
And Ignition Under Pressure Check Hydraulic
Sources Away Leaks. DO NOT Use
Your Hand!
Hot Oil!
Warning!
DO NOT Open
Hydraulic System Rotating
Unless Cap Is
Under Pressure Fan Blades
Cool To Touch
Can Cut
Keep Hands Warning!

Keep Hands At A Safe
A Safe Distance Rotating Belts Distance From
From Rotating Can Cut Or Rotating Belts
Fan Blades Entangle
Make Sure All Use Three Points

Replace Worn And
Safety Labels of Contact When
Illegible Safety
Are Attached Entering and
Labels And Labels
And Legible Exiting Telehandler
7 Operation Manual
Safety
DO NOT DO NOT
Fasten
Jump While Allow Riders
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
Frame Or Fenders The Operator Cab Disengage
Parking Brake
Set Parking Brake DO NOT Jump!

Attachment Can To ON
If Telehandler Tips,
Result In Death Or Engage Parking Keep Seat belt ON
Serious Injury Brake And Brace Yourself
Warning! Warning! Tip Over Hazard,

Especially
Telehandler Roll Away Telehandler Tip Over Traveling Up A
Can Cause Death Can Cause Death Slope Without A
Or Serious Injury Or Serious Injury Load
Warning! DO NOT
Raise Boom While Hot Surface!
DO NOT Travel Traveling On A Keep Hands Away
With Boom Raised Slope
Warning! Danger!
Electrocution Can Keep A Safe Pinch Points
Cause Death Or Distance From Body
Serious Injury Electrical Lines
Have Adequate
DO NOT Allow Ventilation If
Pinch Points
Anyone Under Operating This
Hands
A Raised Load Telehandler In An
Enclosed Space
Warning! Warning!
DO NOT Use Ether Operate With
Explosion
As A Starting Aid Caution During
Hazard
Storms Or High Wind
Warning! Establish Warning! DO NOT Use As A

Radio Communication HOT COOLANT. Personnel Carrier
Before Operating Solo
Operation Manual 8
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.
completion and certification of the Safety Training for Rough
Terrain Forklifts is required. Operators must possess a valid, current driver’s license as
required for the work site; plus those required by applicable
Additional safety information and training resources can be State, Federal, and/or local laws:
obtained through these publications, organizations, and/or
appropriate sources: Successful completion and certification of Safety Training for
Rough Terrain Forklifts is required.
• (29CFR) Code of Federal Regulations.
• (OSHA) Occupational Safety and Health Administration. • Operators must be properly instructed on how to operate
• (NIOSH) National Institute for Occupational Health and the forklift and attachments.
Safety. • Operators must operate the forklift according to ALL
• (ANSI) American National Standards Institute appropriate safety regulations.
• (AEM) Association of Equipment Manufacturers • Operator trainees must remain under constant
• (ITSDF) Industrial Truck Standards Development observation and supervision of an experienced operator.
Foundation
Always consult Safety Data Sheets (SDS) for chemical hazards Modifications
and first aid instructions for any oil or lubricant being used.
SDS should be available from the manufacturer/supplier of
the fluid. Warning
Modifications to the forklift or attachments

Operator Responsibility could affect forklift capacity and/or stability
which could result in death or serious injury.
DO NOT make modifications to the forklift or
Warning attachments without prior written approval
from the manufacturer. Where such authorization is
Forklifts are potentially dangerous if proper safety granted, capacity, operation, and maintenance instruction
procedures are not followed. Workers who operate, plates, tags, or labels shall be changed accordingly.
maintain, or work near the forklift can be at risk of roll over
and run over incidents or can be crushed or caught by the • Unauthorized modifications or alterations will void the
forklift or its parts which could result in death or serious warranty.
injury if the forklift is not properly operated or maintained. • DO NOT modify, disable, or bypass any safety devices.
• DO NOT burn or drill holes in forks or other attachments.
Read the Operation and Safety
Manual BEFORE operating the
forklift. Follow all safety in-
structions and labels. Only op- Structural damage, modification, or alter-
erate the forklift if you under- ation, including welding or drilling, can im-
stand the safety instructions and warnings in all applicable pair and weaken the protective capability
manuals and technical publications. Always follow all State of the Rollover Protective Structure/Falling
and Federal health and safety laws and/or local regulations. Object Protective Structure (ROPS/FOPS) and
You must have the required training, skills, and tools to
could result in death or serious injury.
perform installation, operation, maintenance, or repair
procedures properly and safely. Make sure the forklift and
• Replace the ROPS/FOPS, if it is damaged, before
attachments will not be damaged or made unsafe by any
operating the forklift.
procedures you choose.
9 Operation Manual
Safety
Mounting/Dismounting Warning
• Operate the forklift only on firm, stable surfaces. Holes,

Warning 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 forklift could result in death or serious • Avoid personnel, machinery, and forklifts in the work
injury. area.
• Know the rules for movement of people and forklifts on
• Keep steps clear of dirt, mud, snow, ice, debris, and oth- the work site.
er hazards. • Follow work site signs and signals.
Face the forklift for mounting or dismount- • Check boom clearance before driving under a door
ing. Use hand holds and steps to maintain opening, bridge, etc.
three (3) points of contact at all times, either • Slow down when approaching obstructions. Use a
both hands and one foot or both feet and one spotter, if necessary.
hand. • Stop for poor visibility conditions, such as dust, smoke,
fog, etc. Wait until visibility improves before continuing.
• DO NOT use the controls, steering wheel, or foot pedals
as hand holds or steps. Avoid accidentally engaging or
DO NOT operate the forklift if you are using
disengaging a control.
drugs, alcohol, or any medication that might
DO NOT jump from the forklift. Clothing impair your judgment or ability.
can get caught on pedals, levers, or other You must be 18 years of age or older to
protruding parts. Landing on uneven surfaces operate the forklift.
could result in death or serious personal
injury. DO NOT operate the forklift on roads. The forklift is not
equipped for road travel.
Work Site Safety Warning

Operate the forklift in an enclosed area only
Warning if there is a ventilation system capable of
routing hazardous fumes outside. Engine
Use proper safety procedures and avoid exhaust contains products of combustion
hazardous situations while operating the that could cause death or serious injury.
forklift to prevent death, serious injury, or
property damage.
Warning
• Check the work site for any hazards before operating
the forklift. California Proposition 65
• Check the work surface for loose soil conditions and
overhead power lines. Engine exhaust from this product contains chemicals known
• Contact your local underground utility service or to the State of California to cause cancer, birth defects, and
digging hot line to mark all underground hazards. other reproductive harm.
• Learn the location of all underground hazards at the
work site, such as: Caution
1. Gas and water pipes
2. Electrical cables
3. Sewers
Use caution when operating the forklift
Underground objects could cause death or serious in-
during storms or strong winds.
jury.
Operation Manual 10
Safety
Warning Warning
Perform a pre-operation inspection and

functional tests at the beginning of each work
shift. Perform the pre-operation inspection
first. DO NOT perform the pre-operation
inspection with the engine running or hot.
Wear appropriate protective clothing. Personal protective Contact with moving or heated parts could cause death or
equipment can include, but is not limited to hardhat, serious injury.
gloves, footwear, safety glasses or goggles, and hearing
Perform the pre-operation inspection and
protection. Make sure clothing is snug and properly belted.
functional tests in an open area and away
DO NOT wear loose clothing, jewelry, watches, or anything
from any other obstacles or equipment. In-
that can catch on forklift controls, moving parts, etc. Failure
spections and functional tests may require
to wear the proper protective clothing could result in death
assistance. Keep the assistant visible and a
or serious injury.
safe distance from the forklift to prevent death or serious
injury.
Become familiar with all safety and hazard
Before Starting Forklift labels, regulations, and procedures. Make
sure all proper safety and hazard labels are
attached to the forklift and remain legible.
Warning
Keep the Operation and Safety Manual A brief description of controls, indicators,
on the forklift at all times. Contact Xtreme and instruments is provided as a convenience
Manufacturing for replacement manuals. for the operator. These descriptions DO NOT
provide complete operation instructions.
Read and understand the entire manual to
prevent death, serious injury, or equipment damage.
Clearly define responsibilities and procedures
for operating the forklift and all attachments.
DO NOT proceed until you seek expert Keep fingers and feet away from
assistance from a qualified person if any moving parts or pinch points to
doubt or question arises about the correct or prevent pinching or crushing.
safe methods for operating the forklift. DO NOT allow anyone between
the tires and the forklift frame
To avoid death or serious injury, while operating the forklift. Doing so can result in death or
carefully read and understand serious injury.
all instructions before operating
the forklift. DO NOT operate, Always check the condition of the seat belt
modify, repair, or maintain the and mounting hardware before operating the
forklift unless you read and understand the instructions forklift. If the seat belt or mounting hardware
and warnings in this and all other applicable manuals and is defective, it may not properly restrain the
technical publications. Follow all State and Federal health operator, resulting in death or serious injury.
and safety laws and/or local regulations.
• DO NOT operate the forklift until the seat belt or mount-
ing hardware is replaced, if worn or damaged.
Consult Safety Data Sheets • The seat belt MUST be worn while operating the forklift.
(SDS) for chemical hazards and Failure to wear the seat belt could result in death or
first aid instructions. MSDS serious injury.
should be available from the
manufacturer or supplier of the
fluid.
11 Operation Manual
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.
Know the location, learn the specific purpose, Warning
and demonstrate safe and proper use of all
controls, instruments, indicator lights, and To prevent death, serious injury, or prop-
safety and instruction labels. Safety is your responsibility. erty damage, the operator must be seated
Failure to follow these guidelines could result in death or with seat belt fastened, arms, legs, and head
serious injury. completely inside the Rollover Protection
Structure/Falling Object Protection Structure
To prevent death or serious injury, the
(ROPS/FOPS), the travel select lever in NEUTRAL, the Park-
operator must be seated with seat belt
ing Brake switch ON (engaged), and the service brakes ap-
fastened, the travel select lever set to
plied BEFORE starting the forklift.
NEUTRAL, the Parking Brake switch ON
(engaged), the service brake applied, and the
• The seat belt MUST be worn while operating the
area free of people and obstructions BEFORE starting the forklift. Failure to wear the seat belt could result in
forklift. death or serious injury.
DO NOT adjust the seat or seat belt while the
Operation Safety forklift is moving. Keep both hands on the
wheel while the forklift is moving to prevent
loss of forklift control which could result in
Danger death or serious injury.
Never try to escape the forklift if it becomes
Death or serious injury by electrocution will unstable. Learn and practice these safety pro-
result from contact with or inadequate clear- cedures to protect yourself from a roll over or
ance with energized power lines or apparatus. tip over incident:
• Never operate the forklift in an area where • Remain securely fastened in the seat belt.
active overhead power lines, overhead or
underground cables, or other power sources exist. • Keep your head, body, and limbs within the ROPS/FOPS
structure.
• Contact the appropriate power or utility company
to de-energize power lines or take other suitable • Brace yourself and hold on firmly.
precautions. • Lean away from the point of impact.
Keep the forklift, attachments, and loads a • Stay on the forklift and ride out the roll over or tip over.
safe distance from electrical power lines.
• Remain at least 10 feet, plus an addition- Warning
al 0.4 inches for each 1,000 volts over 50,000
volts, from active power lines and other power It is unlawful to tamper with or remove any component of
sources. the aftertreatment system. It is also unlawful to use Diesel
• Work site operating directives and/or local or state Exhaust Fluid (DEF) that does not meet the specifications
codes might require a greater distance. provided or to operate the machine with no DEF.
• Know the maximum height and reach of this forklift.

Warning
Warning
Diesel Exhaust Fluid contains urea. DO NOT get the sub-
stance in your eyes. In case of contact, immediately flush
Use of the frame sway control with the boom
eyes with large amounts of water for a minimum of 15 min-
raised above horizontal could cause tip over
utes. DO NOT swallow internally. In the event the DEF is in-
resulting in death or injury. Always use the
gested, contact a physician immediately. Refer to the Safety
frame sway control to level the forklift
Data Sheet (SDS) for additional information.
BEFORE raising the boom above horizontal. If
Operation Manual 12
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. Agricultural grade urea does select lever could cause transmission damage
not met the specifications required and thye aftertreatment or forklift tip over/roll over and result in death or serious in-
system may be damaged. jury.
Operate the forklift for maximum stability.
Warning Unstable forklifts can tip over, resulting in
death, serious injury, or property damage.
DO NOT use the forklift as a work platform Keep the forklift stable by following these
or personnel carrier. Falling of attachments and other appropriate guidelines:
• Adjust speed for terrain and conditions.
• Avoid obstacles by driving around them rather than
NEVER allow passengers to ride over them, when possible.
on the forklift. DO NOT allow • Start, stop, travel, steer, and brake smoothly.
riders on the frame or operator
cab. Allowing passengers to ride • Load, unload, and turn the forklift on level ground,
could result in serious injury. when possible.
The forklift is designed for the safety of the operator only. • Slow down for turns.
NEVER use crab or four wheel (4W) steering for • Slow down for rough, slippery, or soft terrain.
traveling at high speeds. Use only two wheel • Use caution around steep slopes, creeks, gullies, ridges,
(2W) steering for higher speed travel and slow ditches, and ravines.
the forklift before turning. Rapid turning
• Stay away from soft edges that could collapse under
while using crab or four wheel steering can
the forklift.
cause tip over which could result in death or serious injury.
DO NOT travel with an elevated boom.

Retract the boom fully. Lower the boom as
Warning
low as practical for proper visibility. Maintain
Become completely familiar with the forklift
enough ground clearance for conditions.
before operating on slopes. The forklift could
Traveling with an elevated boom can cause
overturn due to sudden movement or while
tip over, which could result in death or serious injury.
operating on a slope resulting in death or
Allow for adequate clearance between the serious injury.
attachment and other objects when turning. DO NOT raise the boom while
The attachment extends beyond the front of operating on a slope. Raising
the forklift. The operator must be aware of the the boom on a slope, even with-
maximum sweep of any attachment being used to avoid hit- out a load, will change the cen-
ting personnel and other objects in the area and to prevent ter of gravity, could cause a tip
death, serious injury, or property damage.
over, and result in death or serious injury.
• DO NOT turn on a steep slope.
Warning • DO NOT drive the forklift across slopes.
• Always drive the forklift straight up and down a slope
To prevent death, serious injury, or property (never drive diagonally up or down a slope).
damage, make sure the forklift comes to a
• Drive the forklift forward up a slope (front of forklift fac-
complete stop before moving the travel se-
ing uphill).
lect lever. A sudden change in direction of
travel, while carrying a load, could reduce • Back the forklift down a slope when loaded (front of
stability and/or cause the load to shift or fall. forklift facing uphill).
13 Operation Manual
Safety
Follow appropriate procedures to prevent • Reposition the forklift if it cannot be leveled using the
sudden changes in forklift speed that could frame sway control.
result in death or serious injury. • DO NOT enter or exit a tilted cab.
• Turn the gear select lever to the lowest • Remain seated with the seat belt securely fastened
speed before descending a slope and before while the cab is tilted.
loading or unloading a trailer. • Keep personnel at least 30 feet from a tilted forklift.
• DO NOT adjust the travel select lever while the forklift
is moving.
• DO NOT coast downhill. Keep the travel select lever in Load Safety
the appropriate position.
• DO NOT exit the forklift without following proper shut-
Warning
down procedures.
Engine fuel is flammable and
Failure to follow proper safety procedures
can cause a fire or explosion
when lifting, lowering, and traveling with a
resulting in death or serious in-
load could result in death, serious injury, or
jury. DO NOT smoke while refu-
property damage.
eling and keep sparks and open
flames away from the forklift. DO NOT exceed forklift capacity of 10,000 lbs.
The total rated capacity of the forks being used must equal
Contact with hot surfaces and the exhaust or exceed forklift capacity. Forks can break causing loss of
pipe after the forklift has been operated load and possible death or serious injury.
could result in serious personal injury.
DO NOT exceed the manufacturer’s rated
load for any auxiliary attachment. Any
Check warning indicators and gauges on the attempt to lift or carry loads in excess of the
dash panel frequently during operation. If a manufacturer’s rated load may cause forklift
warning indicator is illuminated or a gauge tip over, loss of load, or structural damage
shows abnormal readings, stop the forklift, which could result in death or serious injury.
follow proper shut down tag the forklift
with “Do Not Operate” tags, and have a qualified mechanic Failure to keep personnel clear of the load
service or repair the forklift BEFORE placing it into service area while the load is being raised or lowered
again. Ignoring warning indicators can result in death, could result in death or serious injury. DO
serious injury, or property damage. NOT lift, swing, or move a load over anyone
or over a forklift cab.
• Review the rated load capacity of each auxiliary
Caution attachment before performing any operation.
• Use the correct load chart and NEVER exceed specified
Release the key immediately after the engine starts. DO weights and load centers.
NOT crank the engine for more than 15 seconds at a time. • DO NOT exceed the manufacturer’s recommended load
Failure to do so can damage the starter motor. capacity.
• DO NOT operate the forklift with an unsafe load
distribution.
Warning • Adjust the load as necessary, especially for nonstandard
loads.
The forklift includes a Frame Sway Override • Use caution when handling loose material that can fall
switch. Improper use of the Frame Sway into the cab.
Override switch could result in death, serious • Remove overhanging load materials, when possible,
injury, or property damage. and watch for sliding material.
Make sure the forklift frame is level before raising and • DO NOT reach a load over posts or other objects that
extending the boom. Frame swaying left or right with the can enter the cab, if tipped.
boom raised is extremely dangerous and can result in death • Avoid sudden stops, starts, or turns.
or serious injury. • Avoid carrying a swinging load. If necessary, secure
• Use the frame sway control to level the forklift before the load by attaching it to the forklift tie-downs and/
raising the boom. or have another person assist with safely steadying the
load.
Operation Manual 14
Safety
Attachments Forklift Maintenance
Warning Warning
Improper connection of an auxiliary attachment could Follow the manufacturer’s instructions for proper
result in death or serious injury. Attachments not locked maintenance to make sure the forklift continues to meet
into place can become unstable and fall on the operator or manufacturer’s specifications. Failure to properly maintain
other personnel near the forklift. the forklift can result in improper performance, which could
cause death, serious injury, or property damage.
• Make sure attachment locking devices are always in
place. Attach “Do Not Operate” tags to the Ignition
• DO NOT operate the forklift until you have positive switch and steering wheel before beginning
indication that the coupler pin and lever are fully any service or maintenance.
engaged.
• Hydraulic attachments have a maximum hydraulic
pressure rating. Failure to make sure the attachment
• “Do Not Operate” tags indicate the forklift should not be
is equipped with a pressure reducing valve, or is rated
operated until all service or maintenance is completed.
to be equal or greater than 3,500 psi, which is the
• Keep two (2) legible “Do Not Operate” tags with the
maximum pressure of the forklift auxiliary hydraulic
forklift at all times. “Do Not Operate” tags are provided
system at the quick-disconnect couplers, could result in
in this manual.
death or serious injury.
• DO NOT operate the forklift and attachments if they re-
• Make sure all hydraulic connections are tight (if
quire repairs.
equipped).
• Make sure basic maintenance is completed and service
problems are corrected.
• Death or serious injury can result from operating a fork-
Shut Down Procedure lift before all repairs have been made and all proper
maintenance is completed.
Warning
To prevent death or serious injury, follow these procedures

before leaving the forklift cab: Warning
• Park forklift on a firm, level surface. Check hydraulic oil lines, tubes,
• Move travel select lever to NEUTRAL (N). and hoses carefully. DO NOT
• Actuate (engage) the parking brake. use your bare hand to check for
• Lower forks and attachments to the ground. leaks. Always use a board or
NOTE: The parking brake MUST be actuated (engaged) only cardboard when checking for
when forklift is at standstill. a hydraulic leak. Escaping hydraulic fluid under pressure,
even a pinhole size leak, can penetrate body tissue, which
Always engage the parking could cause death or serious injury. If hydraulic oil is inject-
brake before leaving the forklift. ed into your skin, a doctor familiar with this type of injury
The forklift can roll if the parking must treat it immediately.
brake is not ON (engaged), Serious injury could result from
which could result in death, hydraulic oil pressure or hot
serious injury, or property damage. oil. DO NOT remove a hydrau-
• Turn Ignition switch to the OFF position. lic tank filler cap unless it is
• Remove the key. cool enough to touch with bare
• Unbuckle the seat belt. hands. Remove the hydraulic tank filler cap slowly to relieve
• Place “Do Not Operate” tags on the Starter switch and pressure. Relieve all pressure in a hydraulic system before
steering wheel when maintenance or service is required. any caps, lines, fittings, or related items are disconnected
• Block wheels when maintenance is required. or removed.
15 Operation Manual
Safety
It is possible for the forklift to move suddenly ately. Flushing must begin immediately to avoid per-
when the brakes are released, which could manent eye tissue damage.
result in death, serious injury, or property • Internal contact - Drink large quantities of water or milk
damage. To prevent sudden movement of to dilute stomach contents. Do not induce vomiting.
the forklift, place wheel chocks in front of and Get medical attention immediately.
behind wheels before the brakes are released. IMPORTANT - In case of internal contact, DO NOT give fluids
that induce vomiting.
If the forklift is to be towed, make sure the
released brake(s) can be reapplied or the tow Warning
forklift has the braking capacity to stop the
forklift. California Proposition 65
DO NOT use ether as a starting Battery posts, terminals, and related

aid. Ether is flammable and accessories contain lead and lead
can cause an explosion when compounds, chemicals known to the State
starting the engine, which of California to cause cancer, birth defects, or
could result in death or serious other reproductive harm. Wash hands after
injury. Follow the cold starting procedures and engine handling these items.
manufacturer’s specifications for using a starting aid.
Tires must have proper ballast. DO NOT Warning

replace foam-filled tires with pneumatic tires.
Use of pneumatic tires will severely affect Wear eye protection when starting a forklift
forklift load capacity, which could result in with jump start cables. Improper jump
death, serious injury, or property damage. start procedures could cause the battery
to explode, which could result in death or
serious injury.
Warning • Never jump start a frozen battery, as it can explode. Let
the battery thaw out before charging.
• NEVER jump start the forklift when travel select lever is
in gear, which can cause the forklift to lurch forward or
backward, and could result in death, serious injury, or
property damage.
• To avoid injury or death when jump starting with
another forklift, make sure the two (2) forklifts are not
Lead-acid batteries produce flammable and potentially ex-
touching.
plosive gases. To avoid death or serious injury when check-
• DO NOT allow jump start cable ends to contact each
ing, testing, or charging batteries:
other.
• DO NOT use smoking materials near batteries. • Connect charged battery positive (+) to stalled battery
• Keep arcs, sparks, and open flames away from batteries. positive (+).
• Provide ventilation for flammable vapors. • Connect charged battery negative (–) to stalled forklift
• Wear proper personal protective equipment, including ground. Make the connection to the stalled forklift
safety glasses. ground last.
• Connect jump start cable to stalled forklift ground a
Fluid in electric storage batteries contains sulfuric acid,
safe distance from the battery to prevent sparks near
which is poison and could cause severe chemical burns.
the battery.
Avoid all contact of fluid with eyes, skin, or clothing. Use
• Jump start only with a power source with the same
protective gear when handling batteries. DO NOT tip a bat-
voltage as the stalled forklift.
tery beyond a 45° angle in any direction.
• Turn off all lights and accessories on the stalled forklift
If contact does occur, follow these First Aid suggestions:
to prevent them from operating when the power source
• External contact - Flush with water. is connected.
• 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.
Operation Manual 16
Safety
and a collector bottle, as shown in Figure 4.

Dead Engine Towing
6. 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.
The parking brake is a SAHR - Spring Applied Hydraulic Re-
leased brake. In case of a breakdown or a malfunction of the
hydraulic system, the parking brake can be released by using a
manual high pressure hydraulic pump that must be connect-
ed to the axle parking brake ports ( Figure 3).
NOTE: The minimum release pressure is 435 psi. The maxi-
mum release pressure is 653 psi.
Warning
NEVER perform this procedure with the engine running. The

Ignition Switch should be in OFF position, the Parking Brake
ON (engaged) and the red cover over the parking brake
switch CLOSED.
Warning Figure 4. Connect HP Pump to HP Parking Brake Ports (both sides of

axle). See Figure 3 For Ports Location.
Block all four (4) wheels. Failure to do so could result in 7. To reapply parking brake, disconnect the manual hydraulic
death or serious injury from forklift roll away. pump from the parking brake release ports of the axle and
re-connect the hydraulic hose.
1. Block all four wheels to prevent the forklift from moving
once the parking brake is disabled.
2. Position the towing vehicle in place. Attach any chain
needed to secure the disabled forklift.
3. Locate the two (2) parking brake hydraulic connection
ports as shown in Figure 3.
Figure 5. Example of a Manual Hydraulic Pump
8. Repeat steps 4 to 7 for the other hydraulic connection

port (Figure 3)
9. Crawl out from under the forklift and clear the area of any
unnecessary personnel.
10. Carefully remove the blocking from each of the four (4)
tires and tow the vehicle to a secure location.
Figure 3. Parking Brake Ports Location
Warning
4. Remove the hydraulic hose connected to one port
5. Connect a manual HP hydraulic pump to the parking NEVER operate the forklift with the manual hydraulic pump
brake ports using a threaded coupling (9/16” - 18 UNF) connected.
17 Operation Manual
Labels
Labels
Left Side View
Figure 6. Label Legend, Left (Cab) Side
Right Side View
53
Figure 7. Label Legend, Right (Hyd Tank) Side
Operation Manual 18
Labels
Front View Rear View
56
55
Figure 8. Label Legend (Front) Figure 9. Label Legend (Rear)
Cab View
56
17
54 16
Figure 10. Label Legend (Cab)
19 Operation Manual
Labels
Table 1. Labels
Item Qty Part No. Description Item Qty Part No. Description
1 1 18008-000 Data Plate 38 1 18043-000 Xtreme logo

2 1 18004-060 Dash Overlay 39 1 18044-000 Xtreme X
3 1 18010-001 Caution, Slip/Trip Hazard 40 1 18046-000 Boom Swoosh Left Front
4 1 18011-001 Caution, Engine Damage Hazard 41 1 18047-000 Boom Swoosh Left Rear
5 1 18013-001 Diesel Only (Tier 4) 42 1 18048-000 Boom Swoosh Right Front
6 1 18014-001 Check Engine Oil (Tier 4) 43 1 18049-000 Boom Swoosh Right Rear
7 1 18015-001 Check/Fill Coolant 44 2 18372-000 XR1045
8 1 18016-001 Caution, Burn Hazard 45 1 18056-000 Boom Lettering A-B-C-D
9 2 18017-001 Danger, Crushing Hazard 46 1 18057-000 Boom Lettering E-F
10 8 18018-001 Danger, Electrocution Hazard 47 1 18058-000 Boom Lettering G-H
11 1 18018-002 Danger, Electrocution Hazard 48 1 18311-002 Boom Hook 10k (Optional)
12 3 18019-001 Danger, Crushing Hazard 49 1 18331-000 Caution, Adjustable Carriage
13 1 18020-001 Warning, Tip-Over Hazard 50 1 18332-000 Warning, Tow Capacity
14 1 18021-001 Danger, Crushing Hazard 51 1 17020-100 Load Chart, Standard Carriage
15 1 18022-001 Warning, Tip Over Hazard 52 1 17364-100 Load Chart, Lift Point
Warning, Welding and Modification 54 1 18412-000 Caution, Equipment Damage
16 1 18023-001
Hazard
17 1 18025-001 Warning, Falling Hazard
Warning, Unrestrained Operator
18 1 18026-001
Hazard
Danger, Rotating Equipment
19 1 18027-001
Hazard
20 1 18031-001 Warning, Safe Operation Checklist
21 1 18032-001 Warning, Improper Use Hazard
22 1 18033-100 Auxiliary Handle Control
23 1 18347-000 Boom Handle Control
24 1 18039-000 Boom Angle Indicator
25 6 18041-001 Warning, Pinch Point Hazard
26 3 18042-000 Xtreme logo (chassis)
27 2 18066-001 Caution, Crushing Hazard
28 1 18067-100 Frame Sway Handle
29 1 18334-001 Handle Auxiliary Controls
30 1 18069-000 Hydraulic Tank Fluid Level
31 1 18082-001 Warning, Injection Hazard
32 2 18083-001 Warning, Explosion Hazard
33 1 18086-001 Hydraulic Fluid, Use Dexron III
34 4 18090-001 Warning, Tip Over Hazard
37 4 18315-000 Tie Down Point
Operation Manual 20
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
OFF
ON
Boom
Wiper
Rear Wash
Steering
Front and Rear
On Wheels Must Be
Centered Before
Engaging.
Turn Off
Front Left Right Crab
On Up
2W
702-636-2969 www.XMFG.com 800-497-1704 Off Down
Hazard 4W
18004-060 Lights Outriggers
1) 18008-000 2) 18004-060
3) 18010-001 4) 18011-001
DIESEL CHECK
ONLY ENGINE OIL
Ultra Low Sulphur
Fuel Only
Maximum Sulphur
Minimum Oil Specification:
Content: 15ppm API CJ-4 or higher
18013-002 18014-002
5) 18013-002 6) 18014-002
21 Operation Manual
Labels
7) 18015-001 8) 18016-001
9) 18017-001 10) 18018-001
11) 18018-002 12) 18019-001
Operation Manual 22
Labels
13) 18020-001 14) 18021-001
15) 18022-001 16) 18023-001
17) 18025-001 18) 18026-001
23 Operation Manual
Labels
19) 18027-001 20) 18031-001
WARNING
21) 18032-001 22) 18033-000
23) 18034-000 24) 18039-000
Operation Manual 24
Labels
25) 18041-001 26) 18042-000
27) 18066-001 28) 18067-100
FULL
18334-001
18069-000
29) 18334-001 30) 18069-000
25 Operation Manual
Labels
31) 18082-001 32) 18083-001
33) 18086-001 34) 18090-001
35) 18300-001 36) 18312-000
Operation Manual 26
Labels
37) 18315-000 38) 18043-000
39) 18044-000 40) 18046-000
41) 18047-000 42) 18048-000
27 Operation Manual
Labels
43) 18049-000 44) 18070-001
A B C D E F
18056-000 18057-000
46) 18057-000
45) 18056-000
G H
18058-000
47) 18058-000
18311-000
48) 18311-000
CARRIAGE DAMAGE DEATH or SERIOUS INJURY could result from

DAMAGE may result from adjusting forks improper operation when using tow connection.
when carriage is loaded. DO NOT ELEVATE BOOM ABOVE 30 WHEN
TOWING.
ONLY ADJUST FORKS WHEN CARRIAGE DO NOT EXCEED RATED TOW CAPACITY.
IS UNLOADED. 18331-000
Max vertical load 500 LBS.
Max tow capacity 5000 LBS. 18332-000
49) 18331-000 50) 18332-000
Operation Manual 28
Labels
XR1045 LOAD CHART - STANDARD CARRIAGE

50 XR1045 LOAD CHART - BOOM LIFT POINT
68
65
LOAD RATINGS 45 LE 60
H
68
G 45 65
SHOWN ARE FOR N G LOAD RATINGS H
A 55 60
VEHICLES EQUIPPED M SHOWN ARE FOR LE G
40 O 50 40 G 55
VEHICLES EQUIPPED N
BO
WITH FOAM FILLED F A
WITH FOAM FILLED 50
TIRES ONLY. 45 M F
TIRES ONLY. O
BO
35 35 45
40 E
5,000 LBS AT 24 IN 2.0 FT 40 E
STANDARD CARRIAGE
MIN CAPACITY FORK 35 D LOAD 30
30 C CENTER MUST BE ATTACHED 35 D
(10,000 LBS PAIR). AND UNLADEN WHEN C
30 B
B
A BOOM LIFT POINT IS 25 30
A
25 IN USE.
25 25
20
20 20 20
1,800 LBS
2,200 LBS
2.0 FT
3,000 LBS
4,500 LBS
6,000 LBS
8,000 LBS
10,000 LBS
9,000 LBS
15 LOAD 15 15
CENTER
1,800 LBS
15
2,200 LBS
3,000 LBS
4,500 LBS
6,000 LBS
10,000 LBS
10
8,000 LBS
9,000 LBS
10 10
10 5
5 5
0
5 0
0 -5 D C B
A
E
-8 F
5 D C B
A H G
0 E
F -5
H G
30 25 20 15 10 5 0
P/N 17181-000
35 30 25 20 15 10 5 0
P/N 17020-000
51) 17020-000 52) 17181-000
CAUTION
EQUIPMENT DAMAGE
Wait at least two (2) minutes after shutting
engine off before setting the battery disconnect
switch to OFF. Equipment damage may occur if
the engine control systems are not allowed to
shutdown properly. 18412-000R01
54) 18412-000
29 Operation Manual
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
1-1/4 inch main frame plate attach couplers)
Sealed pivot pins for extended service periods Various carriage sizes
High boom mount design Full line of attachments
Sliding engine transmission cowling Turn signals/hazard lights
Low mounted central engine & drive train
Limited slip differential
Cab Lights (front and rear)
12 volt electrical system
Dash mounted Diagnostic Display which
include: fuel level, engine coolant temperature,
voltage and oil pressure indicators, hydraulic oil
pressure, parking brake, axle lock, rear wheel
alignment, transmission oil indicator, transmis-
sion range, tilt interlock, engine warning lights
Easy access drop down electrical panel
12 volt accessory power outlet
Electric horn and backup alarm
Rear view mirror
Adjustable seat with seat belt
Deluxe suspension seat
Boom angle and frame level indicator
3600 visibility
Tires Foam-filled
Hydraulics Auxiliary hydraulic circuit with quick attach
Attachment tilt switch
Frame sway control handle
Frame sway override switch
Operation Manual 30
Specifications
Specifications
Performance Standard Equipment

Capacity . . . . . . . . . . . . 10,000 lbs Heavy-duty Frame/Chassis
Lift Height . . . . . . . . . . . 44’8” Heavy-duty Roller Boom
Forward Reach . . . . . . . . 30’4” Melonite Pins and Rollers
Frame Leveling L/R . . . . . 11°/11° Direct Dual Control Hydraulic Valve Actuation
Operating Weight . . . . . . 27,130 lbs Robust Wiring, No Spades, No Pins
Rear Axle Stabilization (RAS)
Center Inline Engine Drive Train
Full-time Planetary 4-Wheel Drive
Power Train Steering - 4-Wheel Circle, Crab, 2-Wheel Front
Engine . . . . . . . . . . . . . Cummins 74 HP Limited Slip Diferential
Fuel Capacity . . . . . . . . . 48 gal Back-Up Alarm
Transmission . . . . . . . . . 3-Speed With Automatic Open ROPS/FOPS
Brakes . . . . . . . . . . . . . . Inboard Wet Disc Adjustable Hydraulic Operator Controls
Parking Brake . . . . . . . . . SAHR Suspension Seat
Quick Attach (Common Fit)
Rear View Mirrors
Tires Xtreme Service Accessibility
Tires (Standard Eq) Foam Filled

13.00 x 24 E3 Attachments
Standard Carriage - 48” or 72”
+45° Swing Carriage - 48” or 72”
+10° Side Tilt Carriage - 52” or 72”
Hydraulics Pallet Forks - 2.25” X 4” X 48”
Lumber Forks - 1.75” X 7” X 60”
GPM . . . . . . . . . . . . . . 185.4 Block Forks - 2” X 2” X 48”
PSI . . . . . . . . . . . . . . . . 3,500 Utility Bucket - 1.25 cu. yd.
Hydraulic Oil Capacity . . . 45 gal Concrete Bucket - 0.5 cu. yd., or 1.00 cu. yd.
Truss Boom - 12’
Wallboard/Sheet Material Handler
Dimensions
Length to fork face . . . . . . 21’9” Accessories and Options
Width . . . . . . . . . . . . . . 101”
Enclosed Cab
Height . . . . . . . . . . . . . 7’11”
4th Steer Mode, Rear Pivot
Wheel Base . . . . . . . . . . 120”
Air Conditioning
Ground Clearance . . . . . . 16.5”
Work Light Package
Turning Radius . . . . . . . . 12’
Rotating Beacon
31 Operation Manual
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. 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
A key is required to operate the ignition switch.
Figure 12. Accessory Outlet
Accelerator Pedal
Press the accelerator pedal to increase engine speed. The ac-

celerator pedal is spring-loaded to return to idle speed.
Figure 11. Key and Ignition Switch
The ignition switch has three (3) positions: OFF, RUN, and
START.
Ignition Switch
Position Purpose
OFF Shuts down entire electrical system, except
the horn and accessory outlet.
RUN All controls and indicators are operable.
START Engages starter motor to crank engine.
NOTE: The START position is spring-loaded. When the key is

released, the Ignition switch will automatically return to the
RUN position.
Figure 13. Accelerator Pedal
Operation Manual 32
Operator Cab
Service Brake Pedal Horn Button
Press the service brake pedal to slow or stop the forklift. The Press the horn button to sound the horn.
service brake pedal activates the service brakes on all four (4)
wheels.
Figure 16. Horn Button
Figure 14. Service Brake Pedal
Operator Seat
Steering Wheel
Operator Seat Controls
Turn the steering wheel left or right to steer the forklift in the
corresponding direction. The operator seat can be adjusted four (4) ways: weight
suspension, lumbar support, fore and aft, and backrest angle.
Figure 17. Operator Seat
Figure 15. Steering Wheel
33 Operation Manual
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. Slide the seat forward or backward to
and comfort level desired. a comfortable location and release the lever to lock the seat in
the desired position.
Figure 18. Weight Suspension Lever

Figure 20. Fore and Aft Adjustment Lever
Lumbar Support
Backrest Angle Adjustment Lever
The seat controls include a four (4) position lumbar support
knob. Rotate the lumbar support knob to raise, lower, increase, Pull the backrest angle adjustment lever up to release the seat
or decrease the lumbar support. backrest lock. Adjust the angle of the backrest and release the
lever to lock the backrest to the desired angle.
Figure 19. Lumbar Support

Figure 21. Backrest Angle Adjustment Lever
Operation Manual 34
Operator Cab
Before starting the engine, adjust the seat for position and
Seat Belt comfort (refer to the Operator Seat section of this manual) and
then adjust the seat belt as follows:
Warning 1. Grasp the free end of the seat belt (located on the left side
of the seat) and make sure the belt webbing is not twisted or
Always check the condition of the seat belt entangled in any portion of the seat assembly.
and mounting hardware before operating the
forklift. If the seat belt or mounting hardware 2. Pull the retractable seat belt across your lap. Position the
is defective, it may not properly restrain seat belt as low on your body as possible.
the operator, which could result in death or
serious injury. 3. Insert the latch plate into the buckle (on the right side of
the seat) until a “click” is heard.
• DO NOT operate the forklift until the seat belt or
mounting hardware is replaced, if worn or damaged. 4. Make sure seat belt retracts snugly across your lap.
• The seat belt MUST be worn while operating the forklift.
Failure to wear the seat belt could result in death or
serious injury.
Rear View Mirrors
The forklift is equipped with a standard two inch (2”) wide
retractable seat belt. A three inch (3”) wide retractable seat Two (2) adjustable rear view mirrors are provided to aid the
belt is available where required by local laws and regulations. operator’s rear vision. One (1) rear-view mirror is mounted on
the upper left of the operator’s cab.
Figure 22. Retractable Seat Belt
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 Figure 23. Cab-Mounted Mirror
loss of forklift control which could result in
death or serious injury.
35 Operation Manual
Operator Cab
One (1) rear-view mirror is mounted on the right side of the

chassis.
F
N
R
Figure 25. Travel Select Lever
Figure 24. Chassis-Mounted Mirror

Gear Select Switch
The Gear Select switch has a twist grip handle with the
Controls and Indicators following positions: 1 - FIRST, 2 - SECOND, 3 - THIRD, and
Automatic.
Travel Select Lever NOTE: The forklift can be operated in three (3) forward and
three (3) reverse gears. Automatic should be selected for
The travel select lever has three (3) positions: FORWARD, normal driving.
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)
The travel select lever automatically locks when it is in the

NEUTRAL position. The operator must raise and move the
travel select lever when changing to the FORWARD or REVERSE
position.
NOTE: The travel select lever must be in the NEUTRAL position

to start the forklift.
NOTE: The back-up alarm automatically sounds when the

travel select lever is in the REVERSE position.
Figure 26. Gear Select Switch
Operation Manual 36
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 forklift, including boom angle, height, and reach.
A
B
Figure 28. Load Capacity Charts
Figure 27. Parking Brake

(A) Parking Brake Switch Guard (B) Parking Brake Indicator Display Indicators
Set Parking Brake switch (A) to ON (DOWN) to engage the The display allows the operator to view vital engine
parking brake and to OFF (UP) to disengage the parking brake. information and other critical functions, including gauge
The parking brake indicator (B) illuminates when the parking display, engine diagnostics to monitor engine condition and
brake is set to ON (engaged). performance, fault codes, and warning indicators.
A C E
B D F
J
I
H
G
L M
K O
N
S
Q R
Figure 29. Display Indicators
37 Operation Manual
Operator Cab
A. HIGH HYDRAULIC OIL TEMP red. If the indicator turns red (shows oil pressure below 10psi)
The hydraulic oil temperature indicator illuminates when the and the Oil Pressure Warning (red) is displayed, stop the
oil temperature is above 1800 F. If the hydraulic oil temperature forklift, follow proper shut down procedures, tag forklift with
indicator illuminates, stop and idle the engine to allow time for “Do Not Operate” tags, and have a qualified mechanic service
cooling. If the hydraulic oil temperature indicator does not go or repair the forklift BEFORE placing it into service again.
out after five (5) minutes, stop the forklift, follow proper shut
down procedures, tag the forklift with “Do Not Operate” tags, K. REAR AXLE CENTERED INDICATOR
and have a qualified mechanic service or repair the forklift Indicates that the rear axle is centered.
BEFORE placing it into service again.
L. DIRECTION OF TRAVEL INDICATOR
B. WATER IN FUEL Displays the direction of travel selected: Forward or reverse.
The Water in Fuel Indicator will be displayed when there is
water present in the Diesel fuel. M. FUEL GAUGE
The fuel gauge indicates the percentage of fuel left in the tank.
C. LOW BRAKE PRESSURE INDICATOR AND WARNING The total capacity of the fuel tank is 48 gallons. Above 20%
The Low Brake Pressure indicator illuminates if the hydraulic of fuel left in the tank, the indicator is green, turning yellow
oil pressure gets too low. If the Low Brake Pressure indicator between 10 and 20%. It turns red when the fuel level is very
is illuminated, do not release the parking brake or engage low, 10% and under.
transmission until the indicator is out. If the indicator does not
go out, stop the forklift, follow proper shut down procedures, N. TRANSMISSION GEAR INDICATOR
tag forklift with “Do Not Operate” tags, and have a qualified Displays the transmission gear selected. The available
mechanic service or repair the forklift BEFORE placing it into positions are: 1, 2, 3, and Automatic. Automatic is displayed as
service again. A1, A2, or A3, with the numbers representing the current gear
the transmission is in.
D. LOW OIL PRESSURE WARNING
The Oil Pressure Warning is displayed when the engine oil O. ENGINE COOLANT TEMP INDICATOR
pressure is DANGEROUSLY low, 0-10 psi. If the Oil Pressure The Engine Coolant Temp Indicator monitors the temperature
Warning comes on during normal operation, stop the forklift, of the coolant in the engine cooling system. After starting the
follow proper shut down procedures, tag forklift with “Do Not forklift, allow time for the indicator to display a temperature
Operate” tags, and have a qualified mechanic service or repair close to the normal range before operating the forklift. After
the forklift BEFORE placing it into service again. the engine has sufficiently been warmed up, normal engine
coolant temperature should read between 180 to 2050F.
E. WAIT TO START The Engine Coolant Temp Indicator turns yellow at coolant
The Wait to Start Indicator is displayed when the key switch is temperatures between 205 and 2150F to warn that the engine
moved to the RUN position. Wait until the indicator goes out operates at higher than normal temperature. The Engine
before starting the engine. Coolant Temp Indicator becomes red when the temperature
reaches 2160F, indicating an engine overheating situation.
F. SERVICE REMINDER
The Service Reminder Indicator flashes for 30 seconds at key P. BATTERY VOLTAGE INDICATOR
ON to indicate that Service is required. The Battery Voltage Indicator monitors the amount of charge
in Volts (V). The normal system voltage is between 12.5 and
G. REAR AXLE LOCKED INDICATOR 14 V. The indicator turns yellow if the charge is between 11.5
Indicates that the rear axle is locked. and 12.5 V, and becomes red if the charge drops below 11.5V.
If the voltage indicator shows abnormal readings (below
H. TACHOMETER 11.5V), stop the forklift, follow proper shut down procedures,
The Tachometer indicates engine RPM using an analog display tag forklift with “Do Not Operate” tags, and have a qualified
and below it a digital display. mechanic service or repair the forklift BEFORE placing it into
service again.
I. CLOCK
R. HOUR METER
J. OIL PRESSURE INDICATOR The Hour meter indicates and records engine operating
The Oil Pressure Indicator monitors the engine oil pressure. hours. Use the Hour meter to establish a forklift maintenance
At normal operating pressure it stays green (above 20 psi). schedule.
Between 12-20 psi it turns yellow and below 10 psi it becomes
Operation Manual 38
Operator Cab
S. TRANSMISSION TEMP INDICATOR AND WARNING UTILITIES

The Transmission Temperature Indicator monitors and displays Pressing the UTILITIES soft button will bring up the Hidden
the oil temperature within the transmission. At normal Utilities Menu.
operating temperature it stays green. Between 215 and 224 0F
it turns yellow to warn that the transmission operates above
the recommended temperature range. When the transmission
oil temperature reaches 2250F the display turns red to indicate
an overheating situation.
Display Features
The display allows the operator to view vital engine

information and other critical functions, including gauge
display, engine diagnostics to monitor engine condition and
performance, fault codes, and warning lights. Figure 32. Hidden Utilities
POWER UP SYSTEM SETTINGS

When the ignition is turned on, the display powers up and Pressing the SYSTEM SETTINGS soft button will display engine
defaults to GAUGE DISPLAY mode. The display should remain information. The top left button restores the factory defaults.
in this mode for normal operation. The up/down buttons are used to navigate this menu. Pressing
the MENU soft button will return to the previous menu.
Soft Buttons Soft Buttons
Menu Button Enter Button
Figure 30. Gauge Display
Figure 33. Engine Diagnostics

MAIN MENU
Pressing the MENU button will bring up the MAIN MENU. When making changes to the system settings, you will be
Pressing the MENU button again, or the GAUGE DISPLAY soft prompted to confirm or cancel the new entries.
button, will return to the GAUGE DISPLAY mode.
Figure 31. Main Menu Figure 34. Engine Diagnostics
39 Operation Manual
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
necessary for a successful calibration. It displays a green check
symbol to the right of the condition if it is met.
Figure 35. Clock Setup Menu
SERVICE REMINDERS
Pressing the SERVICE REMINDERS soft button will display data
pertaining to maintenance schedules. Figure 38. Calibration Machine Conditions Check
When all of the machine conditions for calibration are met,

the TCU enters clutch calibration mode.
Figure 36. Service Reminders Menu
If a scheduled service is due, the GAUGE DISPLAY indicates be-

Figure 39. Clutch Calibration
low the tachometer in the hour meter box, the service needed.
It calibrates the first clutch, and upon successful calibration it
moves to the second and so forth. The forklift must be OFF
after calibration is complete.
Figure 37. Service Requested
Operation Manual 40
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 40. First Clutch Calibration Successful
DIAGNOSTICS
Pressing the ENGINE DIAGNOSTICS soft button will display
engine information. Use the up/down buttons to navigate
Pressing the MENU button will return to the GAUGE DISPLAY
mode. Figure 43. User Settings
The default settings can be restored using the top left button.
Each Restore Defaults needs to be confirmed or canceled on
the next screen. Pressing the MENU button will return to the
previous menu.
Figure 41. Diagnostics Menu
CLEAR ALL FAULTS

Pressing the CLEAR ALL FAULTS soft button will remove all
faults displayed.
41 Operation Manual
Operator Cab
Steering Select Switch Boom Control
The boom control handle has variable motions from the

Warning center position that control boom and tilt functions.
DO NOT change steering modes until the forklift slows The boom control handle is used to raise, lower, extend,
or comes to a complete stop. Align all four (4) wheels retract the boom, tilt the carriage (or attachment), and
perpendicular to the axle, before changing steering mode. control auxiliary functions (when equipped with a carriage or
Changing steering modes at higher travel speeds can make attachment with additional functions).
the forklift unstable, and cause a loss of control, which NOTE: The boom control handle is a variable speed control.
could result in death, serious injury, or property damage. Function speed is proportional to handle movement. The
more the handle is moved in the appropriate direction, the
The Steering Select switch has three (3) steering positions: faster the corresponding function will occur.
Crab, Two Wheel Steering (2W), and Four Wheel Steering (4W). NOTE: Increasing engine speed can increase boom lift and
extend speed.
NOTE: Two (2) boom functions can be performed at the
same time by moving the handle into the corner between (2)
functions
Figure 45. Steering Select and 2-Wheel Rear Switches
Figure 46. Boom Control Handle
Boom Control Handle Functions

Function Purpose
Aux Select Button Control auxiliary functions
Enable Trigger Trigger must be enabled for other
functions of the control handle to
operate
Tilt Switch Control carriage tilt (up/down)
Operation Manual 42
Operator Cab
Attachment Tilt Switch

A The Attachment Tilt Switch located on the top of the boom
control handle controls attachment tilt functions.
B 1 FRONT
OF
C VEHICLE
D 2
E
F
G
H
Figure 47. Boom Control Handle Functions Figure 49. Attachment Tilt Switch
(1) Attachment Tilt Down (2) Attachment Tilt Up
The Attachment Tilt Switch:

• Controls the attachment tilt functions by rolling the
switch upward and downward.
• Is a variable speed switch. Function speed is proportional
to how far the switch is rolled. The more the switch is rolled
in the appropriate direction, the faster the corresponding
function will occur.
Attachment Tilt Switch

Function Purpose
Attachment tilt down Roll switch upward
Attachment tilt up Roll switch downward
NOTE: The attachment carriage will retain any set angle

Figure 48. Boom Control Handle Functions
throughout boom raising, lowering, retracting, or extending
operations.
43 Operation Manual
Operator Cab
Auxiliary
Frame Sway
Attachment
Control Handle
Control Auxiliary Attachment Control
Function Purpose The Auxiliary Attachment Control lever controls the functions
of approved optional attachments that can be mounted to
Frame sway right Move handle right the forklift and require hydraulic supply for operation.
Frame sway left Move handle left
Figure 50. Frame Sway Control Handle
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 Figure 52. Auxiliary Attachment Control Lever
direction, left and right.
Warning Lights Switch

The forklift includes a Frame Sway Override
switch. Improper use of the Frame Sway Flip the toggle switch to ON to turn the front lights on.
Override switch could cause death, serious
injury, or property damage.
Figure 51. Frame Sway Override Switch
The frame sway feature becomes locked and will not operate
when the boom is raised 40° or more. Pressing the Frame
Sway Override switch (the trigger) on the control handle will
override the lockout feature and allow slow frame sway. Figure 53. Lights Switch
Operation Manual 44
Operator Cab
Boom Angle Indicator Frame Level Indicator
The boom angle indicator is located on the left side of the The frame level indicator is mounted on the upper right
boom and is visible from the operator’s seat. Use the boom corner of the operator’s cab. The frame level indicator allows
angle indicator to determine the boom angle when referring the operator to view if the forklift has been positioned in a
to load capacity charts. Refer to the LOAD CAPACITY CHARTS level condition.
section of this manual for more information.
NOTE: The boom angle indicator is a plumb arrow with
angular graduations from -50 to +700
Figure 54. Boom Angle Indicator
Figure 56. Frame Level Indicator
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. These letters
indicate boom extension as it corresponds to the load capacity DO NOT try to lift or handle heavy
charts. components without the use of appropriate
lifting equipment.
Warning
DO NOT use attachments that are corroded

excessively.
• All the attachments should be stored in an appropriate

enclosure as to prevent corrosion and deterioration due
to environmental conditions.
Figure 55. Boom Extend Letters
• Inspect the forklift and the attachments periodically for
corrosion.
45 Operation Manual
Operator Cab
Forklift Lifting Points Warning
The XR1045 lifting points are shown below. The forklift Ensure that no one is in the work radius before
should only be lifted if lifting points are installed. lifting forklift to avoid crushing hazard.
MODEL: XR1045
UNLADEN VEHICLE WEIGHT: 27,130 lbs
UNLADEN CENTER OF GRAVITY

AFT LIFT POINT
FORWARD LIFT POINT
75.0"
APPROX
120.0"
WHEELBASE
18241-003
Figure 57. XR1045 Lifting Points
Boom Maintenance Stand (If Equipped) • Proceed by slowly lowering machine boom to lay on
stand. Verify that hoses and wiring do not contact the
pad. If this occurs, raise the boom and adjust stand as
The Boom Maintenance Stand is an optional safety equipment needed.
used to support the boom during any and maintenance
When not in use, fold the support down and latch it in place.
activities where the boom is raised.
• When preparing to remove boom stand, make sure all
• When preparing to set boom stand, make sure machine
maintenance has been performed and area is clean.
is on a flat level ground and machine has no load on the
forks. • Raise machine boom to 40 degrees for clearance and
remove pin from stand weldment
• Raise machine boom to 40 degrees for clearance and
remove latch and pin from boom stand weldment. • Lay boom stand in the down position and re-latch stand
to secure.
• Position the boom stand in the upright position and re-
apply the pin to secure stand.
Operation Manual 46
Operation
Operation
Pre-Operation Inspection Caution
To perform the pre-operation inspection make sure the Contact with hot surfaces and the exhaust
forklift is NOT running, the engine is cool, the forklift is parked pipe after the forklift has been operated
on level ground, the boom is completely retracted, and the could result in serious personal injury.
frame is level.
NOTE: Copy and use the Pre-Operation Inspection Checklist

in this section.
Warning
Always check the condition of the seat belt
Warning and mounting hardware before operating the
forklift. If the seat belt or mounting hardware
is defective, it may not properly restrain the
operator, resulting in death or serious injury.
• DO NOT operate the forklift until the seat belt or mount-

ing hardware is replaced, if worn or damaged.
Wear appropriate protective clothing. Personal protective
equipment can include, but is not limited to hardhat, • The seat belt MUST be worn while operating the fork-
gloves, footwear, safety glasses or goggles, and hearing lift. Failure to wear the seat belt could result in death or
protection. Make sure clothing is snug and properly belted. serious injury.
DO NOT wear loose clothing, jewelry, watches, or anything
that can catch on forklift controls, moving parts, etc. Failure Check hydraulic oil lines, tubes,
to wear the proper protective clothing could result in death and hoses carefully. DO NOT
or serious injury. use your bare hand to check for
Perform a pre-operation inspection and leaks. Always use a board or
functional tests at the beginning of each work cardboard when checking for
shift. Perform the pre-operation inspection a hydraulic leak. Escaping hydraulic fluid under pressure,
first. DO NOT perform the pre-operation even a pinhole size leak, can penetrate body tissue, which
inspection with the engine running or hot. could cause death or serious injury. If hydraulic oil is inject-
Contact with moving or heated parts could cause death or ed into your skin, a doctor familiar with this type of injury
serious injury. must treat it immediately.
Perform a pre-operation inspection and func-
tional tests in an open area. Serious injury could result from
hydraulic oil pressure or hot
oil. DO NOT remove a hydrau-
lic tank filler cap unless it is
cool enough to touch with bare
Become familiar with all safety and hazard la- hands. Remove the hydraulic tank filler cap slowly to relieve
bels, regulations, and procedures. Make sure pressure. Relieve all pressure in a hydraulic system before
all proper labels are attached to the forklift any caps, lines, fittings, or related items are disconnected
and remain legible. or removed.
Remove forklift from service and place “Do Never remove the radiator cap while the
Not Operate” tags on the Starter switch and engine is hot. The cooling system is under
steering wheel if anything is found to be in pressure. Hot coolant could cause severe
need of repair or maintenance, defective, or burns or eye injury. Wear protective clothing
unsafe in any way. and safety glasses.
47 Operation Manual
Operation
Warning Warning
Wear eye protection when starting a forklift

with jump start cables. Improper jump start
procedures could cause the battery to ex-
plode, 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
the battery thaw out before charging.
• DO NOT use smoking materials near batteries. in gear, which can cause the forklift to lurch forward or
backward, and could result in death, serious injury, or
• Keep arcs, sparks, and open flames away from batteries.
property damage.
• Provide ventilation for flammable vapors.
• To avoid injury or death when jump starting with
• Wear proper personal protective equipment, including another forklift, make sure the two (2) forklifts are not
safety glasses. touching.
Fluid in electric storage batteries contains sulfuric acid, other.
which is poison and could cause severe chemical burns.
• Connect charged battery positive (+) to stalled battery
Avoid all contact of fluid with eyes, skin, or clothing. Use
positive (+).
protective gear when handling batteries. DO NOT tip a bat-
tery beyond a 45° angle in any direction. • Connect charged battery negative (–) to stalled forklift
If contact does occur, follow these First Aid suggestions: ground. Make the connection to the stalled forklift
ground last.
• External contact - Flush with water. • Connect jump start cable to stalled forklift ground a
• Eyes - Flush with water (including under the eyelids)
the battery.
for at least 15 minutes and get medical attention
immediately. Flushing must begin immediately to • Jump start only with a power source with the same
avoid permanent eye tissue damage. voltage as the stalled forklift.
• Internal contact - Drink large quantities of water or milk • Turn off all lights and accessories on the stalled forklift
to dilute stomach contents. Do not induce vomiting. to prevent them from operating when the power source
Get medical attention immediately. is connected.
• Electrolyte contains acid and could cause serious
IMPORTANT - In case of internal contact, DO NOT give fluids personal injury if it contacts the skin or eyes.
Warning
Warning
Tires must have proper ballast. DO NOT
California Proposition 65 replace foam-filled tires with pneumatic tires.
Use of pneumatic tires will severely affect
Battery posts, terminals, and related forklift load capacity, which could result in
accessories contain lead and lead death, serious injury, or property damage.
compounds, chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm. Wash hands after Warning
handling these items.
Use DEF meeting ISO 22241-1. There is NO acceptable
substitute. Using anything other than DEF fluid may result
in permanent aftertreatment damage.
Operation Manual 48
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 match the carriage installed and are legible.
Check that frame level indicator is working properly.
Check condition and operation of the seat belt and mounting hardware.
Check that Operation and Safety Manual is in the protective case and legible.
Check forks for welds, cracks, misalignment, or any other damage.
Check that carriage fork pins are straight and in place to prevent forks from changing position or coming off the carriage.
Check all hydraulic hoses and hose connections for wear or leaks.
Check tilt cylinders for leaks or any other damage
Check boom for straightness or any other damage.
Check all four (4) tires and wheels for:
Punctures, cracks, cuts, gouges, bulges, foreign objects, or any other damage to tires.
Loose or missing lug nuts.
Bent flanges or any other damage to rims.
Check front and rear sway cylinders and hoses for leaks or any other damage.
Check electrical connections on rear sway cylinder.
Check mirrors for cracks, cleanliness, and proper adjustment.
Check hydraulic reservoir sight gauge for proper fluid level. Add hydraulic fluid, if necessary.
Check engine compartment with engine off for:
Loose or damaged belts, hoses, and radiator fan blades.
Check air filter minder (on air filter housing).
Coolant reservoir level. Add radiator coolant, if necessary.
Engine oil level. Add engine oil, if necessary.
Electrical wires and connectors.
Check transmission fluid level while engine is running.
Check front and rear axles for leaks or any other damage.
Check main boom lift cylinder, carriage master tilt cylinders, and hydraulic lines for leaks or any other damage.
Check battery terminals for corrosion.
Check battery for cracked, melted, or damaged case.
Check that all labels are present and legible. Replace
. any damaged or illegible labels.
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: __________________________
49 Operation Manual
Operation
Functional Test Checklist Operate the sway control handle left and right to frame
sway left or right.
Operate the auxiliary attachment control (if an auxiliary
Warning attachment is being used).
Perform a pre-operation inspection and func- Turn work lights on and off.
tional tests at the beginning of each work Press the horn button to sound the horn.
shift. Perform the pre-operation inspection
first. DO NOT perform the pre-operation Place the travel select lever in reverse to sound the
inspection with the engine running or hot. backup alarm.
Contact with moving or heated parts could cause death or Release the parking brake.
serious injury.
Operate the forklift in forward and reverse.
Perform the pre-operation inspection and
Test the service and parking brakes.
functional tests in an open area and away
from any other obstacles or equipment. In- • Apply the service brake pedal after the forklift
spections and functional tests may require begins to move and the forklift should stop
assistance. Keep the assistant visible and a immediately.
safe distance from the forklift to prevent death or serious • Apply the parking brake. Make sure brakes hold
injury. on the steepest incline at the job site. The forklift
If anything is found to be in need of repair or should not move unless the parking brake is re-
maintenance, defective, or unsafe in any way, leased.
remove forklift from service and place “Do Test each steering function. Operate the forklift in
Not Operate” tags on the starter switch and forward and reverse at low idle speed and turn the
steering wheel. steering wheel approximately 1/4 turn in each direction
for each of the following modes:
The safety, efficiency, and service life of your forklift will be
• Align the wheel and set the Steering Select switch
increased by performing functional tests at the beginning
to crab steering.
of each shift. If any of the items in the functional tests are
not operating properly or within set tolerances, stop the • Align the wheel and set the Steering Select switch
forklift, follow proper shut down procedures, tag the forklift to 2 wheel (2W) steering.
with “Do Not Operate” tags, and have a qualified mechanic • Align the wheel and set the Steering Select switch
service or repair the forklift before placing it into service to 4 wheel (4W) steering.
again.
Check the gauges after the engine warms to the proper
operating range.
Operate the boom control handle forward and • Check the voltage gauge. The voltage gauge
backward to lower and raise boom. should read between 11 and 15 volts.
Operate the boom control handle left and right to • Check the engine coolant temperature gauge. The
retract and extend boom. engine coolant temperature gauge should read be-
tween180 to 2000F.
Operate the attachment tilt thumb stick up and down
• Check the engine oil pressure gauge. The engine
to tilt the attachment.
oil pressure gauge should read between 40 to 80
PSI.
Operation Manual 50
Operation
Operator Maintenance
Figure 58. Check Hydraulic Oil Sight Gauge Figure 61. Check Engine Oil Level. Add Engine Oil (API CJ-4), If Neces-
sary.
Figure 59. Add Hydraulic Oil, If Necessary Figure 62. Check Battery Case and Terminals
Figure 60. Check Coolant Reservoir Level. Add Coolant, if Necessary. Figure 63. Store Operation Manual in Protective Case
51 Operation Manual
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. Use hand holds and steps to maintain
three (3) points of contact at all times, either
both hands and one foot or both feet and one
hand. Figure 64. Travel Select Lever Must Be in NEUTRAL (N) to Start the Fork-
lift
• DO NOT use the controls, steering wheel, or foot pedals
as hand holds or steps. Avoid accidentally engaging or
disengaging a control. The Parking Brake switch (A) has two (2) positions: ON and
OFF.
DO NOT jump from the forklift. Clothing
can get caught on pedals, levers, or other
protruding parts. Landing on uneven surfaces
could result in death or serious personal
injury.
1. Master battery disconnect on.

2. Use safe mounting/dismounting procedures to enter the
operator cab. B
3. Adjust the operator seat for position and comfort. (Refer
to Seat Adjustment section in this manual)
4. Adjust mirrors (this may require assistance).
A
5. Adjust the side console control panel.
6. Fasten seat belt.
7. Make sure the travel select lever is set to NEUTRAL (N) and
the Parking Brake is ON (engaged).
Figure 65. Parking Brake Switch (A) Must Be ON (Engaged) to Start the
Forklift.
NOTE: The engine will only start when the travel select lever is
in NEUTRAL (N) and the Parking Brake switch is ON (engaged).
Operation Manual 52
Operation
Starting Forklift
Normal Starting
Warning
To prevent death, serious injury, or property
Figure 67. Turn Key in Ignition Switch to START
damage, the operator must be seated with
seat belt fastened, arms, legs, and head com- 7. Release key immediately after the engine starts. The
pletely inside the Rollover Protection Struc- Ignition Switch will automatically return to RUN.
ture/Falling Object Protection Structure
(ROPS/FOPS), the travel select lever in NEUTRAL, and the Caution
Parking Brake switch ON (engaged) BEFORE starting the
forklift. Release the key immediately after the engine starts. DO
NOT crank the engine for more than 15 seconds at a time.
1. Place Key in Ignition Switch. Failure to do so can damage the starter motor.
NOTE: The Start position is spring-loaded. When the key is

released, the ignition switch will automatically return to the
RUN position.
Figure 66. Key and Ignition Switch

Figure 68. Ignition Switch Automatically Returns to RUN
2. Place the parking brake in the ON position and 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
3. Turn the keyswitch to the ON position. the engine again.
4. With the Ignition Switch in the ON position, the engine 8. After the engine starts, allow the engine to idle for
indicator lamps come on momentarily and then go out. The approximately 60 seconds.
engine indicator lamps include:
9. Apply the service brake pedal and disengage the Parking
• WARNING (or CHECK ENGINE) lamp, amber in color
Brake switch.
• STOP (or STOP ENGINE) lamp, red in color
• AFTERTREATMENT DIESEL EXHAUST FLUID lamp, amber Caution
in color
• MALFUNCTION INDICATOR lamp, amber in color. The engine must have adequate oil pressure within 15 sec-
• HIGH EXHAUST SYSTEM TEMPERATURE lamp, amber in onds after starting. If the WARNING lamp indicating low oil
color. pressure has not gone out or there is no oil pressure indi-
5. Under cold conditions, the Wait-to-Start lamp (generally cated on a gauge within 15 seconds, shut OFF the engine
a yellow lamp using a symbol similar to the graphic, or the immediately to avoid engine damage.
words WAIT TO START) will illuminate at Ignition Switch ON 10. Idle the engine 3 to 5 minutes before operating with a
position, and will stay on for a period of up to 30 seconds. load. After starting a cold engine, increase the engine speed
(rpm) slowly to provide adequate lubrication to the bearings
6. Turn key in Ignition Switch clockwise to the START position.
and to allow the oil pressure to stabilize..
53 Operation Manual
Operation
in gear, which can cause the forklift to lurch forward or

Jump Starting backward, and could result in death, serious injury, or
property damage.
Jump Start or replace the battery of the forklift when the • To avoid injury or death when jump starting with an-
battery is discharged to the point that it will not crank the other forklift, make sure the two (2) forklifts are not
starter. touching.
other.
Warning • Connect charged battery positive (+) to stalled battery
positive (+).
• Connect charged battery negative (–) to stalled fork-
lift ground. Make the connection to the stalled forklift
ground last.
• Connect jump start cable to stalled forklift ground a
Lead-acid batteries produce flammable and potentially ex- the battery.
Caution
• DO NOT use smoking materials near batteries.
• Keep arcs, sparks, and open flames away from batteries. Release the key immediately after the engine starts. DO
• Provide ventilation for flammable vapors. NOT crank the engine for more than 15 seconds at a time.
• Wear proper personal protective equipment, including Failure to do so can damage the starter motor.
safety glasses.
• Jump start only with a power source with the same volt-
Fluid in electric storage batteries contains sulfuric acid, age as the stalled forklift.
which is poison and could cause severe chemical burns. • Turn off all lights and accessories on the stalled forklift
Avoid all contact of fluid with eyes, skin, or clothing. Use to prevent them from operating when the power source
protective gear when handling batteries. DO NOT tip a bat- is connected.
tery beyond a 45° angle in any direction. • Remove the jumper cables in reverse order of their
If contact does occur, follow these First Aid suggestions: connection (i.e. negative cable ground first, etc.)
• Electrolyte contains acid and could cause serious
• External contact - Flush with water.
personal injury if it contacts the skin or eyes.
• Eyes - Flush with water (including under the eyelids) for
at least 15 minutes and get medical attention immedi-
ately. Flushing must begin immediately to avoid per-
NOTE: If the engine fails to start on the first try, wait until the
manent eye tissue damage.
engine and starter come to a complete stop before cranking
• Internal contact - Drink large quantities of water or milk
the engine again.
to dilute stomach contents. Do not induce vomiting.
Get medical attention immediately.
IMPORTANT - In case of internal contact, DO NOT give fluids
After Extended Shutdown Or Oil Change
Warning Follow the Normal Starting Procedure in this section. The en-
gine will not start until the minimum cranking oil pressure is
Wear eye protection when starting a forklift detected by the ECM. It can take more cranking time to start
with jump start cables. Improper jump the engine after an extended shut down or oil change.
start procedures could cause the battery
to explode, which could result in death or
Caution
serious injury.
• Never jump start a frozen battery, as it can explode. Let Do not idle for extended periods of time. Excessive idle time
the battery thaw out before charging. can cause poor engine performance.
Operation Manual 54
Operation
Operating the Engine Crab Steering

Crab steering allows all four (4) wheels to turn
in the same direction as the steering wheel,
Monitor the oil pressure and coolant temperature gauges fre- allowing the forklift to move “sideways”. Crab
quently. Shut off the engine if any pressure or temperature steering is useful in a congested work site to
does not meet the specifications. Continuous operation with line up to a loading location.
engine coolant temperature above or below the engine cool-
ant temperature specifications can damage the engine. Two Wheel Front Steering (2W)
If an overheating condition starts to occur, reduce the pow- Two wheel (2W) steering allows the front
er output of the engine by releasing the accelerator pedal or wheels to turn in the same direction as the
shifting the transmission to a lower gear, or both, until the steering wheel. The rear wheels remain in
temperature returns to the normal operating range. If the a fixed forward position. Two wheel (2W)
engine temperature does not return to normal, shut off the steering is useful for traveling at higher speeds.
engine, and refer to Troubleshooting Symptoms, or contact a
Cummins® Authorized Repair Location. Four Wheel Steering (4W)
Four wheel (4W) steering allows the front
Forklift Travel wheels to turn in the same direction and the
rear wheels to turn in the opposite direction
of the steering wheel. The rear wheels follow
Steering Modes the front wheel path. Four wheel (4W) steering
is useful for a short turning radius and in muddy or sandy
conditions.
Warning
Two Wheel Rear Steering (2WR) - OPTIONAL
Never use crab or four wheel (4W) steering for
OPTIONAL two wheel rear (2WR) steering allows
traveling at high speeds. Use only two wheel
the rear wheels to turn in the same direction as
(2W) steering for higher speed travel and slow
the steering wheel. The front wheels remain in a
the forklift before turning. Rapid turning us-
fixed forward position.
ing crab, four wheel (4W), or the optional two
wheel rear (2WR) steering could cause tip over, which could
NOTE: A separate switch is located on the right side of the
result in death, serious injury, or property damage.
dash panel to engage and disengage the optional two wheel
Check the turning radius around the forklift before making rear (2WR) steering mode.
a turn, especially if using four wheel (4W) steering or two
wheel rear (2WR) steering, which provide a tighter turning Warning
radius. Look over your shoulder in the direction of the turn
when backing. Failure to remain aware of your turning ra- Allow for adequate clearance between the
dius area could result in death, serious injury, or equipment attachment and other objects when turning.
damage. The attachment extends beyond the front of
the forklift. The operator must be aware of
Caution the maximum sweep of any attachment being
used, when turning, to avoid hitting personnel and other
DO NOT change steering modes until the forklift slows or objects in the area to prevent
comes to a complete stop. Align all four (4) wheels “straight- death, serious injury, or proper-
ahead”, or perpendicular to the axle, before changing ty damage.
steering mode. Changing steering modes without aligning
all four (4) wheels may result in equipment damage.
The forklift includes three STANDARD modes of steering;
Crab, Two Wheel (2W), and Four Wheel (4W) Steering. Use the
Figure 69. Maximum Fork Sweep
Steering Select switch located on the dash panel to change
steering modes.
55 Operation Manual
Operation
To shift gears rotate the gear select lever to the next gear
Starting Travel while the forklift is traveling.
• Use first gear (1) for highest torque and pulling power.
Warning • Use higher gears for higher ground speed.
• Never travel in top gear (3) when carrying a load.
Use proper safety procedures and avoid
hazardous situations while operating the • Allow the engine speed to slow down before shifting to
forklift to prevent death, serious injury, or a lower gear.
property damage.
• Check the work site for any hazards before
operating the forklift. Warning Indicators
• Check the work surface for loose soil conditions and
overhead power lines.
Warning
Warning A fault condition may trigger a pop-up dialog
box on the display describing the nature of
To prevent death or serious injury, the the fault during operation. Corresponding
operator must be seated with seat belt red or amber warning lights will illuminate to
fastened, the travel select lever set to indicate the severity of the fault. If an Engine
NEUTRAL, the Parking Brake ON (engaged),
Shutdown fault condition is present, stop the forklift, follow
and the area free of people and obstructions
proper shut down procedures, tag the forklift with “Do
BEFORE starting the forklift. Not Operate” tags, and have a qualified mechanic service
1. Start the forklift. Refer to the Starting Forklift section in or repair the forklift BEFORE placing it into service again.
this manual. Report all warning indicators and fault codes to a qualified
2. Apply service brake. mechanic. Ignoring warning indicators or fault codes can
cause improper performance, which could result in death,
3. Insure that the travel select lever is in NEUTRAL position.
serious injury, or property damage.
4. Release parking brake.
Fault condition dialog boxes will pop up and warning lights
5. Rotate the gear select switch to the gear desired. Automatic
on the display will illuminate during critical circumstances.
should be selected for normal driving conditions.
Some of these conditions demand immediate attention and
6. Move the travel select lever to FORWARD or REVERSE for forklift servicing. If an Engine Shutdown fault condition is
the appropriate direction of travel. present, the forklift should be shut down as soon as practical
7. Release the service brake pedal. Slowly press the to prevent serious mechanical failure. For more information
accelerator pedal to start travel. refer to “Display Indicators” section on page 37.
Some of the following indicators are green while the engine
is within normal operation range, turning yellow when the
Shifting Gears normal operating range is exceeded. Some of these indicators
turn red and become warnings when a particular parameter
reaches or exceeds a critical level.
Warning
Battery Voltage Indicator, between 11.5 to 12.5 V.
DO NOT shift through multiple gears with a Normal operating range: 12.6-14V
single turn of the gear select lever. Allow the
engine speed to slow down before shifting to Battery Voltage Warning, below 11.5 V
the next lower gear. Improper use of the gear
select lever could cause transmission damage Coolant Temperature Indicator, between 205 and
or forklift tip over/roll over and could result in death or 2150F. Normal operating range: 180 to 2050F
serious injury.
The transmission has three (3) gears that can be used for trav- Coolant temperature Warning, above 2160F
eling in forward or reverse. Automatic should be selected for
normal driving conditions.
Operation Manual 56
Operation
Fuel Level Indicator, between 10 and 20% fuel left Stopping Travel
in the tank
1. Stop the forklift by applying the service brake pedal.
Low Fuel Level Warning, below 10%
2. Slow the forklift until it comes to a complete stop.
High Hydraulic Temperature Indicator 3. Move the travel select lever to NEUTRAL (N).
4. Set the parking brake to ON (engaged).
Low Brake Pressure Warning
Warning
Low Oil Pressure Warning. Engine must be running
above 500 RPM. It turns red below 10 psi To prevent death, serious injury, or property
Low Oil Pressure Indicator, between 10 and 20 psi. damage, apply service brakes until the forklift
Engine must be running above 500 RPM comes to a complete stop, move travel select
lever to NEUTRAL (N), set the Parking Brake
Low Oil Pressure Warning, below 10 psi switch to ON (engaged), lower and retract the
boom, and shut off the engine before exiting the forklift.
Rear Axle Centered

Shut Down Procedure
Rear Axle Locked
Caution
Service Reminder
Failure to follow the correct shutdown procedure may
Transmission Temperature Indicator, between 215
result in damage to the turbocharger and shorten the
and 224 0F
turbocharger life.
Transmission Temperature Warning, above 225 0F 1. Park forklift on level ground, if possible.
Wait To Start Indicator 3. Place the travel select lever in NEUTRAL (N) and set the
parking brake to ON (engaged).
Water In Fuel Indicator 4. Lower the boom and rest carriage on ground.
5. Allow the engine to idle 3 to 5 minutes before shutting it
off after a full-load operation. This allows adequate cool
down of pistons, cylinders, bearings, and turbocharger
Changing Travel Direction components.
NOTE: The engine is equipped with an electronic control

module (ECM). Ensure the Ignition Switch is turned off for a
2. Move the travel select lever to FORWARD or REVERSE. minimum of 2 minutes prior to disconnecting the continuous
(unswitched) battery power supply. If the unswitched battery
Warning power supply is disconnected in less than 2 minutes after the
Ignition Switch is turned off active fault codes and incorrect
Make sure the forklift comes to a complete ECM information can occur.
stop before moving the travel select lever. A 6. Turn the ignition key to OFF and remove the key.
sudden change in direction of travel, while
carrying a load, can reduce stability and/ 7. If the forklift is parked on an incline, block the wheels.
or cause the load to shift or fall, which could
result in death, serious injury, or property damage.
57 Operation Manual
Operation
Refueling Pintle Hook
Warning Death or serious injury could result from im-

proper operation when using tow connection.
Engine fuel is flammable and Do not elevate boom above 30 degrees when
can cause a fire or explosion towing. Do not exceed rated tow capacity
resulting in death or serious (500 lbs vertical load, 5,000 lbs tow capacity.
injury. DO NOT smoke while The Pintle Hook is used for towing trailers and equipment, rat-
refueling and keep sparks and ed at or below 5,000 lbs maximum capacity. Failure to comply
open flames away from the forklift. with this capacity limitation, or elevating the boom above 30
NOTE: The fuel tank capacity is 48 gallons. degrees when towing could result in death or serious injury.
• Make sure the forklift is level to obtain an accurate fuel
level reading.
• Shut off the engine.
• Ground the fuel nozzle against the filler neck to avoid
sparks.
Fuel Types
Use ASTM #2 diesel fuel with a minimum Cetane rating of

40 for better fuel economy and performance under most
operating conditions.
• Use standard #2 diesel fuel for operating at temperatures Figure 70. Pintle Hook
above 32°F (0°C).
• Use a blend of #1 and #2 diesel fuel (“winterized” #2 diesel)
for operating at temperatures below 32°F (0°C).
• Fuels with Cetane ratings higher than 40 may be needed Attachments
in higher altitude or in an extremely low temperature
climate to prevent hard starts and excessive smoke.
Attachment Disclaimer
Engine Protection System
Warning
The engine is equipped with an engine protection system. The
system monitors critical engine temperatures and pressures,
and logs diagnostic faults when an over or under normal con- DO NOT exceed the manufacturer’s rated
dition occurs. If an out-of-range condition exists and engine load for any auxiliary attachment. Any
derate action is to be initiated, the operator is alerted by an attempt to lift or carry loads in excess of the
in-cab WARNING lamp. manufacturer’s rated load may cause forklift
tip over, loss of load, or structural damage
The STOP ENGINE Indicator blinks or flashes when out-of- which could result in death, serious injury, or property
range conditions continue to worsen. The driver must pull to damage.
the side of the road or to a safe area when it is safe to do so, to
reduce the possibility of engine damage. Xtreme Manufacturing makes no representations or warranties,
expressed or implied, as to the design, manufacture, or fitness
NOTE: Engine power and speed will gradually be reduced, for use with this forklift of any third party attachment. This
depending on the level of severity of the observed condition. forklift is not intended to be used and should not be used with an
The engine protection system will not shut down the engine attachment that would alter the center of gravity or stability of
unless the engine protection shutdown feature has been en- this forklift. Xtreme Manufacturing assumes no liability for any
abled. third party attachment that would alter the center of gravity or
stability.
Operation Manual 58
Operation
Fork Ratings Standard Carriage Operation
The standard carriage uses manually adjustable forks and can

Warning be tilted up or down by using the thumb stick on the control
handle.
DO NOT exceed forklift capacity of 10,000 lbs.
A
(4,536 Kilograms). The total rated capacity of
the forks being used must equal or exceed
forklift capacity. Forks can break causing loss
of load and could result in death or serious
injury.
All approved forks for this forklift are marked with a maximum
load capacity rating (A). This rating is stamped on the left edge
of the fork just below the fork pivot shaft. The rating listed is
in pounds and is based upon a 24 inches load center (B). This B
rating specifies the maximum load capacity that the individual
fork can safely carry at a maximum load center of 24 inches.
Figure 72. Attachment Tilt Control Switch.

(A) Attachment Tilt Down (B) Attachment Tilt Up
Fork Positioning Carriage Operation
Caution
Do not adjust forks when Fork Positioning Carriage is load-

ed. Adjusting forks when carriage is loaded may result in
loss of load or carriage damage. Always use the Fork Posi-
tioning control handle to adjust the forks BEFORE loading
the carriage.
Figure 71. Fork Ratings 1

(A) Maximum Load Capacity Rating (B) 24 inch Load Center 2
Because forks are always used in multiples, the total rating
of any combination of forks will be the sum of their rated
capacity. Other than block forks, all forks should be used in
matched pairs. Block forks should be used in matched sets.
The maximum load capacity for this forklift is 8,000 lbs. The
matched pair or set of forks used on this forklift should have
total load ratings which equal or exceed 8,000 lbs. When the
load rating of the forklift differs from the load capacity of the
forks, the lower value becomes the overall load capacity. 3
Figure 73. Fork Positioning Control Handle
59 Operation Manual
Operation
To move the forks outward, press the top button (1) on the • Make sure attachment locking devices are always in
front control handle, or move the auxiliary handle (3) to the place.
left. To move the forks inward, press the lower button (2) on • DO NOT operate the forklift until you have positive
the front control handle, or move the auxiliary handle (3) to indication that the carriage attachment is fully engaged.
the right (figure 69). 1. Position the forklift directly behind the attachment.
NOTE: Allow enough distance to extend the boom ap-
proximately 18 to 20 inches.
Warning
2. Tilt the quick attach adapter forward.
Hydraulic attachments have a 3. Extend the boom and/or drive the forklift forward until
maximum hydraulic pressure the pivot pins (A) are below and between the two (2)
rating. Failure to make sure the attachment hooks (B).
attachment is equipped with
a pressure reducing valve, or
is rated to be equal or greater than 3,500 psi, which is the
maximum pressure of the forklift auxiliary hydraulic system
at the quick-disconnect couplers, could result in death or
serious injury.
B
A
When the auxiliary attachment
control lever is moved right or
left it activates hydraulic pressure
through the quick attach
couplers (A) and (B) to move the
Figure 75. Drive Forklift Forward to Align Pivot Pins (A) with Attachment
carriage.
B Hooks (B)
A 4. Raise the boom until pivot pins (A) have seated fully in at-
tachment hooks (B).
Figure 74. Quick Attach Couplers For Hydraulic Systems.

(A) Female Coupler. (B) Male Coupler.
Quick Attach System
This forklift includes a quick attach system that allows for easy
attachment changes. Perform attachment connection and
removal procedures on level ground.
Attachment Connection
Warning
Improper connection of an auxiliary

Figure 76. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment
attachment can result in death or serious Hooks (B)
injury. Attachments not locked into place
could become unstable and fall on the 5. Tilt the attachment up slightly. The quick attach adapter
operator or other personnel near the forklift, should be tight against the rear of the attachment. Align the
which could result in death or serious injury. holes between the quick attach adapter and attachment.
Operation Manual 60
Operation
C Figure 79. Insert Quick Attach Pin Through Attachment and Quick Attach
Adapter.
B 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 77. Tilt Attachment To Align Holes Between Quick Attach Adapter
(C) and Attachment (B).
6. Raise the quick attach lock lever.
Figure 80. Quick Attach Lock Lever and Quick Attach Pin.
Warning
Hydraulic attachments have a maximum

hydraulic pressure rating. Failure to make
sure the attachment is equipped with a
pressure reducing valve, or is rated to be
Figure 78. Quick Attach Lock Lever.
equal or greater than 3,500 psi, which is the
maximum pressure of the forklift auxiliary hydraulic system
7. With lock lever raised, insert quick attach pin completely at the quick-disconnect couplers, could result in death or
through the attachment and quick attach adapter. serious injury.
61 Operation Manual
Operation
9. Connect the quick attach couplers (this only applies to at- 7. Raise the quick attach lock lever.
tachments with a quick attach hydraulic system).
B
Figure 83. Quick Attach Lock Lever
A
8. Pull out the quick attach pin at the bottom of the quick
Figure 81. Quick Attach Couplers For Hydraulic Systems. attach adapter.
(A) Female Coupler. (B) Male Coupler.
Attachment Removal
NOTE: To remove a standard carriage with forks, spread the
forks apart on the carriage shaft. This provides adequate sup-
port for the carriage to stand alone.
1. Bring the forklift to a complete stop.
2. Move the travel select lever to NEUTRAL (N).
3. Set the parking brake switch to ON (engaged).
4. Extend the boom approximately 18 to 20 inches.
5. With the attachment 10”-12” off of the ground, tilt the
attachment backward.
6. Disconnect the quick attach couplers (this only applies to Figure 84. Pull Quick Attach Pin from Attachment and Quick Attach
attachments with a quick attach hydraulic system). Adapter.
9. Lower the attachment to the ground in a level position.
B
A
Figure 82. Quick Attach Couplers For Hydraulic Systems.
(A) Female Coupler. (B) Male Coupler. Figure 85. Lower Attachment to Ground in Level Position.
Operation Manual 62
Operation
10. Tilt and lower boom until pivot pins (A) have disconnected Keep the forklift, attachments, and loads a
from attachment hooks (B). 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.
• Work site operating directives and/or local or state
codes might require a greater distance.
• Know the maximum height and reach of this forklift.
B
A
Warning
Failure to follow proper safety procedures

when lifting, lowering, and traveling with
a load could cause death, serious injury, or
property damage.
Figure 86. Tilt and Lower Boom to Release Pivot Pins (A) from Attach- DO NOT exceed forklift capacity of 10,000 lbs. The total
ment Hooks (B). rated capacity of the forks being used must equal or exceed
forklift capacity. Forks can break causing loss of load and
11. Retract the boom to fully disconnect the attachment from
the quick attach link.
Warning
Load Handling
DO NOT exceed the manufacturer’s rated
load for any auxiliary attachment. Any
attempt to lift or carry loads in excess of the
Danger manufacturer’s rated load may cause forklift
tip over, loss of load, or structural damage
Death or serious injury by electrocution which could result in death, serious injury, or property
will result from contact with or inadequate damage.
clearance with energized power lines or
apparatus. Failure to keep personnel clear of the load
area while the load is being raised or lowered
could result in death or serious injury. DO
• Never operate the forklift in an area where active
NOT lift, swing, or move a load over anyone
overhead power lines, overhead or underground
or over a forklift cab.
cables, or other power sources exist.
• Contact the appropriate power or utility company • Review the rated load capacity of each auxiliary
to de-energize power lines or take other suitable attachment before performing any operation.
precautions. • Use the correct load chart and NEVER exceed specified
weights and load centers.
• DO NOT exceed the manufacturer’s recommended load
capacity.
• DO NOT operate the forklift with an unsafe load
distribution.
63 Operation Manual
Operation
• Adjust the load as necessary, especially for nonstandard

loads. Suspended 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 forklift
and watch for sliding material. tie-downs and/or have another person assist
• DO NOT reach a load over posts or other objects that with safely steadying the load. The handling
can enter the cab, if tipped. of suspended loads can introduce dynamic
• Avoid sudden stops, starts, or turns. forces drastically affecting the stability of the forklift.
• Avoid carrying a swinging load. If necessary, secure Grades and sudden starts, stops, and turns can cause the
the load by attaching it to the forklift tie-downs and/ load to swing and create a hazard if not stabilized. Swinging
or have another person assist with safely steadying the loads can become unstable, and could cause death, serious
load. injury, or property damage.
1. Do not exceed the load capacity of the forklift (as noted

Boom Lift Point on the load chart).
2. Only lift the load vertically, and never drag it horizontally.
There may be a lift point on the underside of the boom that
may be used to lift and carry loads. 3. Transport the load with the bottom of the load and the
boom as low as possible.
Warning 4. With the load elevated, move the forklift slowly and
cautiously. Only move the forklift to the extent needed to
Tip Over Hazard. Death or serious injury raise, transport, and place the load.
could result from improper operation. DO 5. Use guy lines to restrain load swing if possible.
NOT exceed rated lift capacity. Refer to the
“Standard Fork Carriage Load Chart” for
vehicle’s load handling capacity. Refer to Pick Up A Load
ANSI/ITSDF B56.6 for information regarding the handling of
suspended loads.
1. Use correct load chart to review the rated load capacity of
Any attempt to lift or carry loads in excess of those shown on the auxiliary attachment being used. NEVER exceed spec-
the load capacity charts could cause forklift tip over, loss of ified weights and load centers.
load, or structural damage which could result in death, serious 2. Approach the load slowly and squarely with the fork tips
injury, or property damage. straight and level.
3. Adjust the spacing of the forks so they engage the pallet
or load at its maximum width. NEVER use just one fork to
lift a load.
4. Tilt the attachment forward so the forks hang freely on
the fork shaft.
5. Insert forks under the load until the load is against the
fork frame. Load should be supported in such a manner
that the forks can be positioned in a resistance free man-
ner.
6. Tilt the forks back, and raise the boom slightly to secure
the load.
Figure 87. Boom Lift Point

All load ratings shown on load capacity charts are based on
the forklift being on firm, level ground, the forks being evenly
positioned on the carriage, the load being centered on the
forks, properly sized tires properly inflated, and the forklift
being in good operating condition.
Operation Manual 64
Operation
Carry A Load Load Shift
1. If the load shifts, stop the forklift immediately.

1. Carry the load as low as possible while maintaining good
ground clearance and visibility. 2. Lower and adjust the load to center its weight.
2. Back away slowly. 3. If the load shift is too great for adjustment, rearrange the
load before attempting to move the forklift.
3. To travel with a load, use first gear (1) for highest torque
and pulling power. NEVER travel in higher gears when
carrying a load.
Elevating Personnel
Place A Load
Warning
1. Before placing the load, refer to the appropriate load
capacity chart to determine safe boom extension range. Use only a compliant work platform to lift or lower
personnel. Never drive the forklift with the work platform
2. Set the Parking Brake switch to ON (engaged). in a raised position or with personnel on board, even for
3. Use the frame sway control to level the forklift. For a short distance. Doing so could result in death, serious
additional information, refer to the Frame Leveling injury, or property damage.
section in this manual.
Please refer to ANSI/ITSDF B56.6 for additional design and

Warning operating information regarding elevating personnel.
Use of the frame sway control with the boom Design Requirements For A Personnel Platform:
frame sway control to level the forklift BE- 1. Platform floor must have a slip resistant surface located
FORE raising the boom above horizontal. not more than 8” above the normal load supporting
If the forklift cannot be leveled using the frame sway con- surface of the fork.
trol, do not attempt to raise or place load. Reposition fork- 2. Platform floor dimensions shall not exceed two times the
lift or have the surface leveled. load center distance. This floor dimension is measured
parallel to the longitudinal center pane of the forklift.
4. Align the forks at the level the load is to be placed. 3. Platform floor width shall not be greater than the overall
5. Extend the boom slowly until the load is just above the width of the forklift, measured across the load bearing
area where it is to be placed. tires, plus 10” on each side.
6. Lower the boom until the pallet rests in position and the 4. Minimum space requirements for each person on the
forks are free to retract. platform shall not be less than 18” in either direction.
7. Retract the forks slowly from under the load. 5. Minimum 4” height toe plate around the perimeter of the
platform which may be omitted at the access opening.
Warning 6. On the overhead protection device, when requested by
the user.
Exercise caution when moving objects con-
7. Protection must be provided for the personnel in their
taining liquids, as the load may shift during
normal working position on the platform from moving
lifting and handling.
parts of the rough terrain forklift that represent a hazard.
65 Operation Manual
Operation
8. Information prominently indicated on the platform; 2. Make sure that the work platform is securely attached to
A) Maximum work load including personnel and equipment. the quick attach or forks. Follow the platform manufacturer’s
B) Weight of empty platform. instructions.
9. Provide a means so that the platform can only be centered 3. Make sure the platform, carriage, and forks are secured to
laterally on the forklift and retained against the vertical face of prevent them from pivoting from side to side.
the forks, carriage, or lifting mechanism.
4. On side tilt or swing carriage, the carriage must be centered
10. Provide a means to securely attach the platform to and/or leveled horizontally and vertically. The hydraulic
the lifting mechanism, and to prevent the platform from system quick disconnects must also be disconnected and the
inadvertent pivoting. carriage securely fastened to prevent any tilting or side to side
swinging motion.
11. Provide restraining means for securing personnel such
as an anchorage for attaching the lanyard of a body belt or 5. Ensure the forklift has a firm footing and is level.
harness.
6. Be sure the forklift is in a level position (side to side) before
12. Provide a guardrail or similar structure with a nominal any operation is begun. Use the frame sway to level the
height to the platform of 42” around its upper periphery and forklift. If the forklift cannot be leveled, reposition the forklift.
include a mid rail. It may be hinged, removable, or of chains,
and used if proper positioning is easily discernible. 7. Place the travel select lever in the NEUTRAL position.
Such restraining means shall be capable of withstanding a
concentrated horizontal force of 200 lbs applied at the point 8. Engage the parking brake switch. Blocking the wheels is
of least resistance without permanent deformation. A body also recommended.
belt and lanyard is to have an attachment point provided for
freedom of movement, and its length is limited to a free-fall of 9. Level the platform in both the side-to-side and front-to-
5 feet, measured from the point of attachment to the operator. back directions before use.
The complete system shall be capable of withstanding three
consecutive drop test to simulate a 250 lbs person free falling 10. Before lifting or lowering personnel, be sure the forklift
6 ft. without allowing the test weight to fall free to the ground. lifting mechanism operates smoothly through the entire
A deceleration device may be included. lifting and lowering of the platform and maintains its self-
leveling function. The forklift must operate smoothly both
13. Lanyards shall be arranged so as not to cause a tripping empty and loaded.
hazard.
11. Lift and lower personnel smoothly, with caution, and only
14. Body belts should have a width of at least 1.75”. at their request.
15. Structural safety factor - all load supporting structural 12. Keep hands and feet clear of controls other than those in
elements of the work platform shall have a structural safety use.
factor of not less than 2 to 1 based on the minimum yield
strength of the material used. 13. Be certain that the path of platform travel is clear of
hazards, e.g., storage racks, scaffolds, overhead obstructions,
Capacity Limitations: and electrical wires.
The combined weight in lbs of the platform, load, and 14. Be sure any lift limiting devices and latches are functioning
personnel shall not exceed 33% of the capacity of the related properly.
load center position indicated on the machine load chart.
15. A trained operator shall be in position to control the
Preparation and Set-Up: forklift. When the operator is not in the operating position,
block the wheels and apply the parking brake with all controls
1. DO NOT alter or modify the work platform in any manner in neutral.
that is detrimental to its safe use.
16. Alert elevated personnel before moving the platform.
Then move the platform smoothly and with caution.
Operation Manual 66
Operation
17. Always lower the platform if you must move the forklift for how far to extend the boom.
adjustment in positioning.
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.
21. Before elevating personnel, the area around and under

the work platform should be marked to warn anyone on the
Figure 88. Load Capacity Chart
ground that overhead work is being done.
22. The platform shall be lowered to ground level for personnel

to enter and exit. Personnel shall not climb on any part of the Using Load Capacity Charts
rough terrain forklift in attempting to enter and exit.
The forklift includes two (2) indicators to assist the operator
23. Protection must be provided for the personnel on the for accurately using the load capacity charts. These indicators
work platform from pinch points or moving parts while in are the Boom Extend Letters and the Boom Angle Indicator.
their normal working position on the platform.
Boom extend letters are located on the left side of the boom
24. Provide overhead protection device as required by work and visible to the operator as the boom is extended. These
site conditions or if requested by the user of the platform. letters indicate boom extension as it corresponds to the load
capacity charts.
NOTE: For example, when letter “A” first appears, the boom
Load Capacity Charts extension corresponds to the arc of line “A” throughout all the
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.
All load ratings shown on load capacity charts are based
on the forklift being on firm, level ground, the forks being
evenly positioned on the carriage, the load being centered
on the forks, properly sized tires properly inflated and/
or foam filled, and the forklift being in good operating
condition. Figure 89. Boom Extend Letters
Load capacity charts, located on the left side of the dash The boom angle indicator is located on the left side of the
panel, are provided to assist the operator in determining how boom and is visible from the operator’s seat. Use the boom
to safely operate the boom to pick up, carry, and set down angle indicator to determine the boom angle when referring
a load with the forklift, including what angle, how high, and to load capacity charts.
67 Operation Manual
Operation
NOTE: The boom angle indicator is a plumb arrow with For example:
angular graduations from -50 to +700.
1. The operator determines load weight and makes sure load
does not exceed fork, attachment, or boom capacity.
The load is 3,000 lbs.
2. The operator safely moves the load to a loading position.
• Places forks under load
• Tilts and raises load safely
• Fully retracts boom
• Drives forklift to position perpendicular to structure
• Levels the forklift
3. The operator determines height of structure where load is
to be placed.
Figure 90. Boom Angle Indicator. The structure height is 30 feet from ground level.
4. The operator determines distance from front tires where
Reading Load Capacity Charts load will be placed.
To accurately read the load capacity charts, you must The distance in front of forklift where load will be placed is 20
determine three (3) things: feet.
• Weight of the load being lifted 5. Operator reads load capacity chart for attachment carriage
• Height of structure where load is to be placed to learn it will be safe to place the load at any boom angle with
• Distance from front tires where load will be placed the boom extend letter “E” showing.
XR1045 LOAD CHART - STANDARD CARRIAGE

50
68
65
LOAD RATINGS 45 LE 60
H
G
SHOWN ARE FOR N G
A 55
VEHICLES EQUIPPED
40 M
O 50
BO
WITH FOAM FILLED F
TIRES ONLY. 45
35 E
40
5,000 LBS AT 24 IN 2.0 FT
MIN CAPACITY FORK 35 D LOAD
30 C CENTER
(10,000 LBS PAIR).
30 B
A
25
25
20 20
2.0 FT
15 LOAD
Figure 91. Load Capacity CENTER
1,800 LBS
15
2,200 LBS
3,000 LBS
Chart.
4,500 LBS
6,000 LBS
10,000 LBS
8,000 LBS
9,000 LBS
10
10
5
5 0
5 D C B
A
0 E
F
H G
35 30 25 20 15 10 5 0
P/N 17020-000
Operation Manual 68
Operation
level condition. Always frame sway the forklift right or left un-
Frame Leveling til the indicator shows 0° (level).
Warning
Use of the frame sway control with the boom

frame sway control to level the forklift
BEFORE raising the boom above horizontal.
If the forklift cannot be leveled using the frame sway con-
trol, do not attempt to raise or place load. Reposition fork-
lift or have the surface leveled.
The frame sway control handle has variable motions from the
center that control frame sway (right and left). Figure 93. Frame Level Indicator.
Frame Sway Functions

Function Control Handle Action Warning
FRAME SWAY RIGHT Move control handle RIGHT.
FRAME SWAY LEFT Move control handle LEFT. The reach forklift includes a Frame Sway
Override switch. Improper use of the Frame
Sway Override switch could cause death, se-
rious injury, or property damage.
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 trigger on
the Front Control handle) will override the lockout feature and
allow frame sway.
Figure 92. Frame Sway Control Handle.
The frame sway control handle controls the frame sway (right
and left) functions.
To lock the frame sway, place the travel select lever in
NEUTRAL or apply the service or parking brake.
NOTE: Maximum frame sway is 22° overall or 11° each direc-
tion, left and right.
A frame level indicator is mounted on the inside upper right
corner of the operator’s cab. The frame level indicator allows Figure 94. Frame Sway Override Switch.
the operator to view if the forklift has been positioned in a
69 Operation Manual
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. Use the hour meter
Lubricate outrigger pivot point grease fittings
and the schedules contained in this section to establish a
comprehensive preventive maintenance program. Lubricate front and rear axle grease fittings
Change differential oil
Change wheel-end oil
Check wheel lug nuts torqued to 380-420 ft-lbs
Lubricate boom pivot point grease fittings
Lubricate front and rear axle cylinder pivot point
grease fittings
Lubricate boom roller grease fittings and chains
Replace hydraulic return line filter
Replace transmission filter and top off fluid, as required
Figure 95. Hourmeter Lubricate boom pivot point grease fittings
Lubricate front and rear axle cylinder pivot point grease
fittings
Maintenance Schedule
After Every 250 Hours of Operation or 3 Months
Every Day or 8 Hours of Operation
Check structures for damage and cracked welds
All items from Pre-Operation Inspection Checklist
Check pins for wear and damage
Crankcase Breather Tube
Verify that all fasteners are in place and are tight
Fuel-Water Separator Check air cooler and air piping
Lubricating Oil Level Check air filter (replace if necessary)
Coolant Level Check tension and condition of drive belts (use
Fan, Cooling tension meter to check belt tension)
Drive Belts Lubricate front and rear drive shaft grease fittings
Lubricate front and rear axle grease fittings
Air Cleaner Restriction
Check differential oil level
Dust Ejection Valve
Check wheel-end oil level
Air Intake Piping
Check boom chain tension (adjust if necessary)
After First 50 Hours of Operation Inspect boom rollers and slide blocks for condition
Change engine oil and filters and tightness
Check air filter (replace if necessary) Lubricate boom roller grease fittings and chains
Replace fuel filter and pre-filter
After Every 500 Hours of Operation or 6 Months
Check engine hoses and connections for leaks,
damage, and tightness Replace air filters
Check radiator hoses for leaks, damage, and tightness Replace fuel filters
Check electrical cables, leads, and connections for Check cooling system antifreeze
damage and tightness
Operation Manual 70
Check engine hoses and connections for leaks, All fault codes recorded will either be active (fault code is pres-
damage, and tightness ently active on the engine) or inactive (fault code was active at
Check radiator hoses for leaks, damage, and tightness some time, but is not presently active).
Check cooling fan belt tensioner The STOP ENGINE lamp is red and indicates the need to stop
the engine as soon as it can be safely done. The engine must
Check electrical cables, leads, and connections for remain shut down until the engine can be repaired.
damage and tightness
When illuminated, the yellow “WARNING” or “CHECK ENGINE”
Check specific gravity of engine coolant
lamp indicates that the engine is in need of repair at the first
Replace transmission fluid and filters and perform the available opportunity.
required transmission calibration
Another function of the WARNING or CHECK ENGINE lamp
Replace hydraulic reservoir air breather (yellow lamp) is to flash for 30 seconds at key ON when one of
Replace hydraulic return line filter the following occurs:
Replace hydraulic high-pressure filter • Maintenance is required (if the Maintenance Monitor fea-
ture is enabled)
After Every 1,000 Hours of Operation • Water in fuel is detected.
If the warning light flashes for 30 seconds at Ignition Switch
Comply with 50-Hour Maintenance Requirements
ON and water is drained from the primary water-separating
Comply with 250-Hour Maintenance Requirements fuel filter, the secondary fuel filter must be replaced.
Comply with 500-Hour Maintenance Requirements Fault codes can be accessed using the electronic service tool
Change wheel-end oil or by fault code flash out.
Change differential oil To check for active engine electronic fuel system and engine
protection system fault codes, turn the Ignition Switch OFF
Inspect boom chains
and move the diagnostic switch to the ON position.
After Every 2,000 Hours of Operation Turn the vehicle Ignition Switch to the ON position.
If no active fault codes are recorded, both lights will come on
Comply with 50-Hour Maintenance Requirements and stay on.
Comply with 250-Hour Maintenance Requirements If active fault codes are recorded, both lights will come on mo-
Comply with 500-Hour Maintenance Requirements mentarily, then begin to flash the code numbers of the record-
ed fault codes.
Comply with 1000-Hour Maintenance Requirements
The fault code flashes in the following sequence:
Change hydraulic fluid
• A WARNING (amber) light flashes.
Clean or replace hydraulic reservoir strainer
• Following a short one or two second pause, the number
After Every 4,000 Hours of Operation of the recorded fault code flashes in the STOP (red) lamp.
Drain and flush cooling system • There is a one or two second pause between each num-
ber.
Engine Diagnostic Fault Codes • After the number finishes flashing in red, an amber light
appears again.
The electronic engine control system displays and records cer- The lights flash each fault code out three times before advanc-
tain detectable fault conditions. These failures are displayed ing to the next code. To skip to the next fault code, move the
as fault codes, which make troubleshooting easier. The fault Increment/Decrement switch, if equipped, momentarily to
codes are retained in the ECM. the increment (+) position. You can go back to the previous
There are two types of diagnostic codes: fault code by momentarily moving the Increment/Decrement
• Engine electronic control system fault codes inform the switch, if equipped, to the decrement (-) position. If only one
operator that there is a problem with the control system active fault code is recorded, the same fault code will contin-
that requires troubleshooting. uously be displayed when either (+) or (-) switch is depressed.
• Information and engine protection fault codes inform the The diagnostic switch must remain in the OFF position (short-
operator that the control system has detected an engine ing plug removed) while the engine is being operated for all
condition outside the normal operating range. fault codes to be logged.
71 Operation Manual
The diagnostic on/off switch circuit signals the system that the
operator is requesting to read any active fault code recorded
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
ECM. If both warning lights remain on and do not flash, there
are no active fault codes present.
NOTE: The equipment must be stationary. If road speed is
detected, the flashing sequence will not occur.
Turn the diagnostic switch OFF when the diagnostic system
is not in use.
Boom Emergency Lowering
In the event of total loss of engine power or hydraulic pump

failure with an elevated load, the situation must be properly
evaluated and dealt with on an individual basis.
Contact a local Xtreme Authorized Distributor for specific

instructions.
Secure the Telehandler and area by following the procedure
below until the situation has been properly evaluated.
1. Clear the area around the Telehandler of all personnel.

2. Engage the parking brake switch to the ON position and
Place the sift lever in NEUTRAL.
3. Block all four wheels.
4. Section off a large area under the boom with tape to
restrict any personnel from entering this potentially
dangerous area.
Operation Manual 72
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 forklift should not be operated. Do Not
Operate Tags, which can be cut out and used, are included at
the end of this manual. Retain these Tags for use at a later
date.
New or Additional Operators

Figure 96. Battery Disconnect Switch
At the time of original purchase, the purchaser of this forklift

was instructed by the seller on its proper use. If this forklift is Warning
to be used by an employee or is loaned or rented to someone
other than the purchaser, make certain that the new operator If forklift is unsafe for operation or maintenance, the defect
is trained, in accordance with OSHA regulations, and reads and or defects must be clearly documented and posted in a
understands this Operation & Safety Manual before operating conspicuous place on the forklift. Failure to comply could
the forklift. result in death, serious injury, or property damage.
In addition, make sure that the new operator has completed
a walk-around inspection of the forklift, is familiar with all the
labels on the forklift, and has demonstrated the correct use of Return Forklift to Service
all controls.
When the forklift has been repaired and made safe for
operation and maintenance, perform the following procedure
to return forklift to service.
Lockout/Tagout Procedure
1. Remove lock and “DO NOT OPERATE” tag from battery
disconnect switch.
Perform the following procedure to lockout and tag out the
forklift. This procedure, requiring a lock, and danger tags are
2. Close battery access cover.
to be used whenever the forklift is unsafe for operation or
maintenance.
3. Remove “DO NOT OPERATE” tags from steering wheel and
ignition key.
Removing Forklift From Service
1. Attach “DO NOT OPERATE” tags to steering wheel and

ignition key.
2. Open battery access cover.
3. Set battery disconnect switch to OFF.
4. Lock battery disconnect switch.
5. Attach “DO NOT OPERATE” tag to battery disconnect switch.

Figure 97. DO NOT OPERATE Tag
73 Operation Manual
Lockout / Tagout
Do Not Operate Tags
Operation Manual 74
Lockout / Tagout
75 Operation Manual
Warranty
Warranty

Xtreme Manufacturing Product Warranty Policy

1) Xtreme Manufacturing warrants, its authorized sales and service centers (herein referred to as “SSC”), new
product(s) the mainframe and chassis weldments shall be free from defect in material and workmanship for
the period of 10 years or 10,000 hours whichever comes first. The boom weldment and boom rollers shall be
free from defects in material and workmanship for the period of 5 years or 5,000 hours whichever comes first.
The powertrain assemblies consisting of engine, transmission and drive axles and all other components not
listed above shall be free from defects in material and workmanship for the period of 2 year or 2,000 hours
after date of delivery. This warranty is made to the original owner of the new product(s) and is transferable for
the duration of the coverage period, to the subsequent owner with prior written approval from Xtreme
Manufacturing (see limitations).

2) Machines may be held in an authorized Distributor/ SSC’s stock for a maximum period of six (6) months
from the date of shipment from Xtreme, before the warranty period is automatically initiated on each
machine.

3) It is the responsibility of the Distributor/SSC to complete and return to Xtreme Manufacturing a Pre‐delivery
Inspection Record, Warranty Registration Form, before the act of rental / loan / demonstration of the machine
or delivery to an end user. In the case of direct sale to end customers the same responsibility lies with the end
customer.

4) Any end customer, SSC, distributor or dealer shall not be entitled to the benefits of this warranty and
Xtreme Manufacturing shall have no obligations here under unless the “Pre‐Delivery and Inspection Record”
has been properly completed and returned to the Xtreme Manufacturing Warranty department within fifteen
(15) days after delivery of the Xtreme Manufacturing product to the Customer or Dealer’s demonstration /
rental fleet. Xtreme Manufacturing must be notified, in writing, within ten (10) days, of any machine sold to a
Customer from a Dealer/SSC’s rental fleet during the warranty period.

5) Any part or parts which upon examination by the Xtreme Product Support Department are found to be
defective within the specified warranty period, will be replaced or repaired at the sole discretion of Xtreme
Manufacturing, through its local Authorized Distributor/SSC, at no charge. Any parts replaced under warranty
must be original Xtreme parts obtained through an authorized Xtreme Manufacturing Distributor/SSC unless
expressly agreed otherwise in writing and in advance by Xtreme Manufacturing’s warranty department.

Xtreme Warranty Statement Effective: 1/1/2017
Operation Manual 76
Warranty


6) All parts claimed under warranty must be held available for return and inspection upon request for a period
of 90 days from date of claim submission, it is necessary that all parts are individually tagged or marked with
their part number and the warranty claim number. All parts returning should be still in a factory state, free of
any alteration to the original design. If the parts are subject to repair it will need to be pre authorized by the
Xtreme Product Support Group and or Warranty Department prior to the repair being completed. After 90
days all parts replaced under warranty which have not been returned, to Xtreme Manufacturing should be
destroyed. Failure to produce parts requested by the Warranty Administrator for inspection within a period of
14 days will result in the claim being automatically rejected in full. Materials returned for warranty inspection
must have the following procedure:

Carefully packaged to prevent additional damage during shipping
Drained of all contents and all open ports capped or plugged
Shipped in a container tagged or marked with the RMA number
Shipped PREPAID (ground service only). Any item(s) returned for warranty by any other means may
be refused and returned, unless prior approval is agreed with Xtreme.

7) At the direction of the Xtreme Manufacturing Warranty department, any component part(s) of Xtreme
Manufacturing products to be replaced or repaired under this warranty program must be returned freight
prepaid for inspection. An RMA (Returns material authorization) must be requested from Xtreme
Manufacturing Warranty department, a copy to be placed with the returning component part(s).

8) All warranty replacement parts will be shipped freight prepaid (standard charges, ground shipping only)
from the Xtreme Manufacturing Parts department, Service Department or from the Vendor to Dealer/SSC or
Customer. Any other shipping method is the customer responsibility.

9) All warranty claims are subject to approval by Xtreme Manufacturing Service department. Xtreme
Manufacturing reserves the right to limit or adjust claims with regard to defective parts, labor or travel time
based on usual and customary guidelines.

10) Reimbursement policy, labor will be paid at 75% of posted hourly shop rate. Travel time will be paid at $50
per hour up to a maximum of 3 hours. Xtreme Manufacturing will pay 1 hour of troubleshooting time per
warranty claim, unless expressly agreed otherwise in writing and in advance by Xtreme’s Warranty
Department. An annual rate declaration must to be supplied to the Xtreme Warranty administrator by January
31st and will be used as the reimbursable rate for that calendar year.

77 Operation Manual
Warranty

REPLACEMENT PARTS WARRANTY

1. Any part replaced under this limited warranty is not subject to further warranty cover beyond the normal
warranty period of the machine upon which the part was installed.
2. Any replacement parts sold (not delivered under a warranty claim) will be subject to a warranty period of
(6) six months from the date of invoice.
3. Parts held by an authorized Distributor/SSC are covered under warranty for a period of (12) twelve months
from the date of invoice, provided that those parts have been subject to appropriate storage to prevent
damage and deterioration (conditional on Xtreme Manufacturing review).

CLAIM PROCEDURE

The Xtreme Manufacturing Warranty department must be notified within forty‐eight hours (48) of any
possible warranty situation during the applicable warranty period. Personnel performing major warranty
repair or parts replacement must obtain specific approval by the Xtreme Manufacturing Warranty department
prior to performing the warranty repair or replacement.
When a Distributor/SSC / Customer perceive a warranty issue to exist the following steps must be adhered to:
• Customer/SSC / Distributor to place a purchase order for genuine Xtreme Manufacturing replacement
parts.
• Xtreme Manufacturing to dispatch parts via the requested method (in line with the required response
time).
• Confirmation that a qualified technician is available to replace the part and that this person has been
accepted by Xtreme Manufacturing to carry out such work under the warranty of the machine. Failure
to do this may nullify the warranty.
• Customer /SSC / Distributor to allocate a warranty claim number to the repair.
• All correspondence in respect of the claim to be on an official Xtreme Manufacturing warranty claim
form as supplied by Xtreme Manufacturing’s warranty department.
• All warranty claims must be submitted within 30 days of the date of the machine repair.

FREIGHT DAMAGE

• If a machine is received in a damaged condition, then the damage must be noted on the bill of lading
and /or delivery documents and photographs must be taken at the point of delivery, prior to signing
acceptance of the consignment.
• The freight company and Xtreme Manufacturing must be contacted by the Distributor and a damage
claim registered by either party immediately.
Operation Manual 78
Warranty

• The above requirements apply only to freight damage associated with equipment supplied by Xtreme
Manufacturing transport. Customer freight issues are excluded from this warranty policy.
THIS PRODUCT WARRANTY POLICY SPECIFICALLY EXCLUDES:

1. Engines, motors, tires and batteries are manufactured by specialist suppliers to Xtreme Manufacturing, who
furnish their own warranty policies. Xtreme Manufacturing will, however, to the extent permitted pass
through any such warranty protection to the Distributor/SSC / Customer.

2. Xtreme Manufacturing products which has been modified or altered outside Xtreme Manufacturing
factories without written approval, if such modification or alteration, in the sole judgment of Xtreme
Manufacturing Engineering and/or Service Departments, adversely affects the stability, reliability or service
life of the Xtreme Manufacturing product or any component thereof.

3. Any Xtreme Manufacturing product which has been subject to misuse and abuse, improper maintenance or
accident. “Misuse” includes but is not limited to operation beyond the factory‐rated load capacity and speeds.
“Improper maintenance” includes but is not limited to failure to follow the recommendations contained in the
Xtreme Manufacturing Operation, Maintenance, and repair Parts Manuals.

4. Normal wear of any Xtreme Manufacturing component part(s). Normal wear of component parts may vary
with the type, application or type of environment in which the machine may be used; such as, but not limited
to sandblasting applications.

5. Routine maintenance, routine maintenance items and minor adjustments are not covered by this warranty,
including but not limited to hydraulic fluid, filters and lubrication, paint and decals engine tune‐up, brake
adjustments etc. Xtreme Manufacturing will not cover leaks from fittings, hoses and any other connection
points after the unit has been in service for 90 days or 150 hours of operation which ever comes first.

6. Any Xtreme Manufacturing product that has come into direct contact with any chemical or abrasive
material.

7. Incidental or consequential expenses, losses, or damages related to any part or equipment failure, including
but not limited to freight cost to transport the machine to a repair facility, downtime of the machine, lost time
for workers, lost orders, lost rental revenue, lost profits, expenses or increased cost. This warranty is expressly
in lieu of all other warranties, representations or liabilities of Xtreme Manufacturing, either expressed or
implied, unless otherwise amended in writing by Xtreme Manufacturing.

8. Xtreme Manufacturing warranty policy does not cover any duties, taxes, environmental fees including
without limitation, disposal or handling of tires, batteries and petrochemical items.

9. Items specifically excluded are: fuel injectors, motor brushes, glow plugs, contactor tips and springs, filters,
lamp bulbs, lamp lenses, coolants, lubricants, brake pads and cleaning materials.

10. Failure of replacement parts due to fault misdiagnosis or incorrect fitting by the
79 Operation Manual
Warranty

Distributor/SSC / Customer.

XTREME MANUFACTURING MAKES NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THIS
LIMITED WARRANTY. XTREME MANUFACTURING MAKES NO IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE AND DISCLAIMS ALL LIABILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO INJURY TO PERSONS OR PROPERTY.

Wherever possible the end customer shall obtain all warranty support & make all warranty claims through the
local Xtreme Manufacturing authorized Distributor /SSC / Dealer. Warranty support should be from the
Distributor /SSC / Dealer from whom the Xtreme Manufacturing product was purchased. Where Xtreme
Manufacturing equipment is supplied directly from the factory, the end customer, if unable to contact a
Distributor/SSC / Dealer, may contact the Xtreme Manufacturing Warranty Department for further assistance.

APPEAL
The buyer may appeal in writing against a rejected or adjusted claim to Xtreme Manufacturing warranty
department within a period of 21 days of receiving the rejection or adjustment notice. The appeal should be
grounded on express reasons and supported by relevant evidence. Appeals received outside of this time limit
will not be considered.

Operation Manual 80
Warranty

XTREME MANUFACTURING WARRANTY SCHEDULE

Limited Warranty Periods

Item Warranty Period
10 years or 10,000 hours, parts
Main Frame and Chassis
replacement or repair
5 years or 5,000 hours, parts replacement
Boom weldment and rollers
or repair
2 years or 2,000 hours, parts replacement
Powertrain and all other components not listed above
or repair
12 months from date of invoice, subject
Parts held in a Distributor’s stock
to adequate storage / protection.
Parts sold (non warranty) 6 months from date of invoice
Batteries supplied on new machines 6 months from warranty registration date

Other specifically excluded parts: Not covered by Warranty
Fuel injectors
Brake pads
Glow plugs
Springs
Oils
Filters
Lamp bulbs
Lamp lenses
Coolants
Lubricants
Cleaning materials
All consumable / wear parts.

81 Operation Manual
8350 EASTGATE ROAD HENDERSON, NV 89015
(702) 636-2969 (800) 497-1704
www.XMFG.com
Pre-delivery Inspection Report must be completed upon placing

unit in service. Please use QR link or visit
www.xmfg.com/warranty/pre-delivery-inspection-report
to register online.
PN 24905-002 Rev C

XR1045 Comprimido

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Operation and

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Pre-delivery Inspection Report must be completed upon placing unit in service.

© 2021 XTREME MANUFACTURING. ALL RIGHTS RESERVED

Description Page Description Page

General Model / Serial Plate

Improper operation of this forklift could result in death or

Learn and practice safe use of forklift controls in a safe,

Replacement manuals for the XR1045 Reach Forklift can be

obtained by contacting our parts department by phone or

Safety Disclaimer Signal Words

Signal words are the word or words that call attention to

WARNING (Orange) used with the safety alert symbol

Xtreme Manufacturing reserves the right to make technical Caution

Read Operator Read Maintenance

DO NOT OPERATE! Read Material

Personal Personal Personal

Warning! Use A Board Or

Keep Hands Warning!

Make Sure All Use Three Points

Set Parking Brake DO NOT Jump!

Warning! Warning! Tip Over Hazard,

Warning! Establish Warning! DO NOT Use As A

Employer Responsibility Operator Qualifications

Modifications to the forklift or attachments

• Operate the forklift only on firm, stable surfaces. Holes,

Work Site Safety Warning

Perform a pre-operation inspection and

the forklift cannot be leveled using the frame sway control,

• Know the maximum height and reach of this forklift.

DO NOT shift through multiple gears with a

DO NOT travel with an elevated boom.

Attachments Forklift Maintenance

To prevent death or serious injury, follow these procedures

DO NOT use ether as a starting Battery posts, terminals, and related

Tires must have proper ballast. DO NOT Warning

and a collector bottle, as shown in Figure 4.

NEVER perform this procedure with the engine running. The

Warning Figure 4. Connect HP Pump to HP Parking Brake Ports (both sides of

Figure 5. Example of a Manual Hydraulic Pump

8. Repeat steps 4 to 7 for the other hydraulic connection

Left Side View

Figure 6. Label Legend, Left (Cab) Side

Right Side View

Figure 7. Label Legend, Right (Hyd Tank) Side

Front View Rear View

Figure 8. Label Legend (Front) Figure 9. Label Legend (Rear)

Figure 10. Label Legend (Cab)

1 1 18008-000 Data Plate 38 1 18043-000 Xtreme logo

From outside Las Vegas, Nev., call Xtreme Manufacturing toll

9) 18017-001 10) 18018-001

11) 18018-002 12) 18019-001

13) 18020-001 14) 18021-001

15) 18022-001 16) 18023-001

17) 18025-001 18) 18026-001

19) 18027-001 20) 18031-001

21) 18032-001 22) 18033-000