Redesigned for Maximum Performance
April 5, 2006 • Since launching its first telehandler product line in 2001, Don Ahern, owner of Xtreme Manufacturing in
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Images and 1 and 2: The new XRM 1045 has a redesigned fork leveling system. Its predecessor is shown without it.
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Xtreme Act 2
I recently tested the 10,000-pound capacity XRM 1045, which replaces the XRM 945 (Images 1 and 2). It is representative of all the changes that have been made throughout Xtreme's pick-and-carry product line. On the surface, the most notable modification is the upgraded capacity, which has been increased by 1,000 pounds. But what sets this particular model apart from the others in the line is its ability to handle 5 tons without the use of outriggers.
The capacity increase is directly related to the redesign of the fork carriage leveling system. Xtreme's engineers made the decision to abandon their unique integrated fork-leveling system in favor of a more conventional master-slave cylinder configuration. Feedback from customers indicated that the old system didn't give them precise control in high-capacity situations. The original system shared the action and flow from the main tilt cylinder to level the fork carriage. Isolating the lift cylinders from the tilt cylinder and the addition of separate master cylinders provided additional lift capacity and improved control in extreme load conditions. Note that all the main components, including axles, boom assembly, and chassis, were initially over-designed, so little, if any, alterations were required for the units to handle the added capacity.
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As a separate issue, Xtreme also upgraded its axles. The Carraro 26.43 axle (Image 3) has vastly improved the Ackermann steering geometry in the four-wheel mode, and it is significantly more robust. Increased spacing in the wheel bearings reduce stress and prolong life. Larger ball joints are also part of the new design.
Image 3: The new Carraro axle is significantly stronger than the old design.
Other changes include a 50 percent thicker trumpet flange (the part that bolts up to the differential box), increased material in the yokes, and a higher tensile strength for all castings to address some cracking and bending experienced during high-speed roading.
Don't fix what ain't broke!
Having reviewed several Xtreme machines in the past, I am familiar with what makes them attractive to both owners and operators. The enhancements have had little effect on what was already right with these units.
Most important is the machine's key feature • visibility. According to Ahern, “Visibility was the key driver of this design through the entire product line.”
You cannot ignore, however, that the addition of the master cylinders has obstructed the rearward line of sight some. But as I sat in the operator's seat, I found the difference to be minimal.
Another major selling point of the original design was its robustness. Material, welds, paint, and components remain of the highest quality on the new generation. I had a chance to see the new models as they were being assembled. The entire chassis is pre-painted. Chassis upright sections along the length of the XRM 1045's frame are fabricated from 1-1/4 inch plate steel. The high gloss finish includes a two-part epoxy etching primer, which allows the primer to penetrate into the metal for maximum adherence. The topcoat includes a two-part urethane enamel. The finish is simply lustrous to both the eye and the touch.
Keeping with the company's original low cost-of-ownership philosophy, a few service issues have been thoughtfully addressed. Access to the engine bay is exceptional, and the majority of engine-related service points, including the water separator, engine coolant, oil, and engine starter are mounted on the same side of the engine, opposite the cab (Image 4).
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Image 4: All engine-related service points are located together and are easy to access.
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As with all other Xtreme telehandlers, the XRM 1045 uses a roller boom assembly. The load-bearing surface of the dry boom rides on huge heavy-duty rollers (Image 5). All the boom rollers and pivot points feature sealed bearings. Melonite-treated steel pins, a rust inhibitor, are mated with bronze bushings, which also ride on sealed bearings. These are intended to last the life of the machine. An internal extend/retract cylinder works with massive extension and retraction roller chains. The cylinder is accessible from the back of the boom. I was told that all that is required to slide the cylinder out is to remove three pins, four bolts, and two hydraulic fittings. In the event that the boom needs to be lowered manually, the lift and telescope cylinders are fitted with valves featuring bleed-off capabilities. Designing it this way eliminates the potential for large hydraulic spills and injury associated with cracking a highly pressurized line.
Image 5: Sealed bearing rollers carry the loadbearing surface of the boom; bronze bushings are used in critical pivot points.
The carriage's tilt cylinder (Image 6) is positioned on top of the boom head to minimize the chance of damage to the rod. But just in case something was to be dropped on it, the rod is induction heat treated for increased hardness.
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Image 6: The induction hardened carriage tilt cylinder is located on top of the boom head to limit its exposure to potential damage.
Xtreme utilizes an innovative three-section aluminum radiator supplied by Radiator Specialties of Moreno Valley, Calif. The top section is a normal engine block cooler, and the middle section is the transmission oil cooler. The lower section, however, is dedicated to the turbocharger. Pre-cooling the air boosts engine performance, but also helps the 108-hp Perkins 1104 diesel engine meet Tier II emissions. The engine, which is mounted mid-chassis and inline with the frame, is mounted directly to a Carraro TLB2 four-speed forward and reverse power-shift transmission. An independent electric fuel pump self-primes the injectors when, not if, the unit runs out of diesel fuel.
The engine, hydraulic pump, and hydraulic distribution manifolds are housed under fiberglass covers, but this isn't your everyday fiberglass. A product similar to Kevlar is woven into the fibers for additional reinforcement. The starter battery is stored in a rear compartment under a heavy steel cover designed to protect it from damage. Although no lock was present during the review, Xtreme has since designed a battery-mount retainer that allows easy service access but resists against theft.
A by-product of the revised hydraulic design was a customization of the hydraulic control system supplied by HAWE Hydraulics,
Next issue, look for my first-hand assessment of the redesigned XRM 1045.
