Xtreme XRM945 Operating instructions

Type
Operating instructions
(702) 636-2969
(800) 497-1704
1714 W. Bonanza Rd., Las Vegas, NV 89106
www.XtremeManufacturing.com
XRM945
Operation & Safety Manual
For information call (800) 497-1704 Page 1
XRM1045 Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement manuals . . . . . . . . . . . . . . . . . . . . 3
Model/Serial Number Plate . . . . . . . . . . . . . . . . . . 3
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . 4
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 4
Employer Responsibility . . . . . . . . . . . . . . . . . . . 7
Operator Responsibility . . . . . . . . . . . . . . . . . . . . 7
Operator Qualications . . . . . . . . . . . . . . . . . . . . 7
Modications . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting/Dismounting . . . . . . . . . . . . . . . . . . . 8
Worksite Safety . . . . . . . . . . . . . . . . . . . . . . . . . 8
Before Starting Forklift . . . . . . . . . . . . . . . . . . . . . 9
Operation Safety . . . . . . . . . . . . . . . . . . . . . . . 10
Load Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shut Down Procedure . . . . . . . . . . . . . . . . . . . . 13
Forklift Maintenance . . . . . . . . . . . . . . . . . . . . 14
Dead Engine Towing . . . . . . . . . . . . . . . . . . . . . 16
Parking Brake Release (Before Disassembly) . . . . . . 16
Re-activating Parking Brakes . . . . . . . . . . . . . . . . 16
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . 18
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . 18
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . 18
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacement Decals . . . . . . . . . . . . . . . . . . . . . 20
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Standard Equipment . . . . . . . . . . . . . . . . . . . . . 28
Optional Equipment . . . . . . . . . . . . . . . . . . . . . 28
Specications . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 30
Accessory Outlet . . . . . . . . . . . . . . . . . . . . . . . 30
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . 30
Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . 31
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . 31
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operator Seat Controls . . . . . . . . . . . . . . . . . . . 31
Weight Suspension Lever . . . . . . . . . . . . . . . . . . 31
Height Adjustment Knob . . . . . . . . . . . . . . . . . . 32
Fore and Aft Adjustment Lever . . . . . . . . . . . . . . 32
Backrest Angle Adjustment Lever . . . . . . . . . . . . . 32
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear View Mirrors . . . . . . . . . . . . . . . . . . . . . . . 33
Controls and Indicators . . . . . . . . . . . . . . . . . . . 34
Travel Select Lever . . . . . . . . . . . . . . . . . . . . . . 34
Gear Select Switch . . . . . . . . . . . . . . . . . . . . . . 34
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . 34
Load Capacity Charts . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Oil Temperature Indicator . . . . . . . . . . . 35
Low Brake Pressure Indicator . . . . . . . . . . . . . . . 35
Rear Axle Lock Indicator . . . . . . . . . . . . . . . . . . . 35
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . 36
Voltage Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant Gauge. . . . . . . . . . . . . . . . . . . . . . . . . 37
Worklight Switch . . . . . . . . . . . . . . . . . . . . . . . 37
Rear Axle Centering Indicator . . . . . . . . . . . . . . . 37
Steering Select Switch . . . . . . . . . . . . . . . . . . . . 37
Declutch Indicator . . . . . . . . . . . . . . . . . . . . . . 38
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . 38
Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . 38
Attachment Tilt and Frame Sway Control . . . . . . . . 40
Auxiliary Attachment Control . . . . . . . . . . . . . . . 40
Boom Angle Indicator . . . . . . . . . . . . . . . . . . . . 41
Boom Extend Letters . . . . . . . . . . . . . . . . . . . . . 41
Frame Level Indicator . . . . . . . . . . . . . . . . . . . . 41
Optional Controls and Indicators . . . . . . . . . . . . . 41
Two Wheel Rear (2WR) . . . . . . . . . . . . . . . . . . . 41
Steering Switch (Optional) . . . . . . . . . . . . . . . . . 41
Attachment Tilt Switch . . . . . . . . . . . . . . . . . . . 42
Frame Sway Control Handle (Optional) . . . . . . . . . 42
Frame Sway Override Foot Switch . . . . . . . . . . . . 43
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pre-Operation Inspection . . . . . . . . . . . . . . . . . . 44
Pre-Operation Inspection Checklist . . . . . . . . . . . 46
Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . 47
Functional Test Checklist . . . . . . . . . . . . . . . . . . 47
Operator Maintenance . . . . . . . . . . . . . . . . . . . 48
Before Starting Forklift . . . . . . . . . . . . . . . . . . . . 49
Starting Forklift . . . . . . . . . . . . . . . . . . . . . . . . 50
Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . 50
Cold Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 52
Forklift Travel . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Steering Modes . . . . . . . . . . . . . . . . . . . . . . . . 53
Crab Steering . . . . . . . . . . . . . . . . . . . . . . . 53
Two Wheel Steering (2W) . . . . . . . . . . . . . . . . 53
Four Wheel Steering (4W) . . . . . . . . . . . . . . . 54
Two Wheel Rear Steering (2WR) (Optional) . . . . . 54
Maximum Fork Sweep . . . . . . . . . . . . . . . . . . . . 54
Starting Travel . . . . . . . . . . . . . . . . . . . . . . . . . 54
Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . 55
Warning Indicators and Gauges . . . . . . . . . . . . . . 55
Changing Travel Direction . . . . . . . . . . . . . . . . . 56
Stopping Travel . . . . . . . . . . . . . . . . . . . . . . . . 56
Page 2 Xtreme Manufacturing, LLC
Table of Contents XRM945
Shut Down Procedure . . . . . . . . . . . . . . . . . . . . 56
Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Attachment Disclaimer . . . . . . . . . . . . . . . . . . . 57
Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Standard Carriage Operation . . . . . . . . . . . . . . . 58
Swing Carriage Operation . . . . . . . . . . . . . . . . . 58
Quick Attach System . . . . . . . . . . . . . . . . . . . . . 59
Attachment Connection . . . . . . . . . . . . . . . . 59
Attachment Removal . . . . . . . . . . . . . . . . . . 62
Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pick Up A Load . . . . . . . . . . . . . . . . . . . . . . . . . 64
Carry A Load . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Place A Load . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Load Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frame Leveling . . . . . . . . . . . . . . . . . . . . . . . . 65
Load Capacity Charts . . . . . . . . . . . . . . . . . . . . 66
Using Load Capacity Charts . . . . . . . . . . . . . . 67
Reading Load Capacity Charts . . . . . . . . . . . . . 67
Standard Carriage Load Capacity Chart . . . . . . . 68
Swing Carriage Load Capacity Chart . . . . . . . . 68
Preventive Maintenance . . . . . . . . . . . . . . . . . . 69
Establishing A Maintenance Program . . . . . . . . . . 69
Maintenance Schedules . . . . . . . . . . . . . . . . . . . 69
Boom Emergency Lower Down Valve . . . . . . . . . . 71
Do No Operate – Accident Prevention Tags . . . . . . 71
New or Additional Operators . . . . . . . . . . . . . . . 71
Lockout/Tagout Procedure . . . . . . . . . . . . . . . . . 72
Removing Forklift From Service . . . . . . . . . . . . 72
Returning Forklift To Service . . . . . . . . . . . . . . 72
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . 73
For information call (800) 497-1704 Page 3
XRM945 Introduction
Introduction
General
This Operation and Safety Manual provides the
information needed to safely operate the XRM945 Reach
Forklift.
This manual should be considered a permanent part of
the forklift and kept in the plastic, protective case located
in the operators cab.
Notice
BEFORE operating the forklift, read this manual
completely 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 benet.
Warning
Improper operation of this forklift can cause injury
or death.
BEFORE starting the engine, do the following:
• Read this Operation and Safety Manual.
• Read all safety decals on the forklift.
• Clear the area of other persons.
Learn and practice safe use of forklift controls in a
safe clear area, BEFORE you operate this forklift on a
worksite.
It is your responsibility to observe applicable laws and
regulations and to follow manufacturer’s instructions
on forklift operation and maintenance.
Replacement manuals
Replacement manuals for the XRM945 Reach Forklifts
can be obtained by contacting:
Xtreme Manufacturing
Phone: (800) 497-1704
Model/Serial Number Plate
When contacting the manufacturer, please have the
forklift model and serial numbers available. The model/
serial number plate is located on the left side, inside the
operator’s cab.
For easy reference record the model and serial numbers in
the space provided.
Model Number: __________________________________
Serial Number: ___________________________________
Figure 1-1. Model/Serial Number Plate.
Orientation
Right side, left side, front, and rear are directional
references given from the operator’s seat while facing in a
forward direction.
Figure 1-2. Forklift Direction Orientation.
Page 4 Xtreme Manufacturing, LLC
Safety XRM945
Safety
Safety Disclaimer
Figure 2-1. Think Safety.
Xtreme Manufacturing reserves the right to make
technical changes for product improvement. This
manual may contain illustrations and photographs, for
demonstration purposes, which slightly deviate from the
actual product.
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 potential hazard. Warnings in this manual
and on the forklift are NOT all-inclusive.
You are responsible for safe operation of the forklift
and all attachments. You must satisfy yourself that the
techniques, operating procedures, work methods, or
tools you use are safe; especially those not specically
mentioned by Xtreme Manufacturing.
The safety of everyone around the forklift depends
signicantly on your knowledge and understanding of
all correct and safe operating practices and procedures.
You can help prevent accidents by remaining alert and
recognizing potentially hazardous situations.
Follow State and Federal health and safety rules and/
or local regulations for operating and maintaining
the forklift.
This manual does not replace any laws and regulations.
The operator and the forklift are required to comply
with all applicable laws and regulations.
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.
Caution
CAUTION (Yellow) with the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, could result in minor or moderate injury.
Caution
CAUTION (Yellow) used without the safety alert symbol
indicates a potentially hazardous situation which, if
not avoided, may result in property damage.
Safety Symbols
Warning
Safety symbols are provided to remind the operator of
hazardous situations. Xtreme Manufacturing provides
these symbols in an attempt to inform all operators,
regardless of reading and language skills, of as many
potential hazards as possible. These symbols cover many,
but not all, potential dangers and hazards associated with
operating the forklift.
Make safety a high priority while operating the forklift.
Learn and follow all safety messages in this manual
and on forklift decals to prevent equipment damage,
injury, or death. The following two pages include a list of
safety symbols.
For information call (800) 497-1704 Page 5
XRM945 Safety
General Safety
Alert Symbol
DO NOT OPERATE!
Forklift Down
For Service Or
Maintenance
Perform
Operator
Inspection
Before Starting
This Forklift
Personal
Protective
Equipment
Gloves
Personal
Protective
Equipment
Ear Protectors
Keep Flames
And Ignition
Sources Away
Hydraulic System
Under Pressure
Keep Hands
A Safe Distance
From Rotating
Fan Blades
Make Sure All
Safety Decals
Are Attached
And Legible
Read Operator
Manual Before
Operating This
Forklift
Read Material
Safety Data
Sheets (MSDS) For
Chemicals And
Fluids
DO NOT
Operate If Using
Alcohol, Drugs,
Or Medications
Personal
Protective
Equipment
Safety Shoes
Lead Acid
Batteries Create
Explosive Gases
Warning!
Hydraulic Oil
Under Pressure
Hot Oil!
DO NOT Open
Unless Cap Is
Cool To Touch
Warning!
Rotating Belts
Can Cut Or
Entangle
Replace Worn And
Illegible Safety
Decals And Labels
Read Maintenance
Manual Before
Working On
This Forklift
Know First Aid
Instructions And/
Or Locations On
Worksite
Personal
Protective
Equipment
Hardhat
Personal
Protective
Equipment
Safety Glasses
No Smoking
Keep Lit
Cigarettes
Away
Use A Board Or
Cardboard To
Check Hydraulic
Leaks. DO NOT Use
Your Hand!
Warning!
Rotating
Fan Blades
Can Cut
Keep Hands A Safe
Distance From
Rotating Belts
Use Three Points
of Contact When
Entering and
Exiting Forklift
Page 6 Xtreme Manufacturing, LLC
Safety XRM945
DO NOT
Jump While
Dismounting
The Forklift
DO NOT Allow
Riders On Forklift
Frame Or Fenders
Falling O Of
Attachment Can
Result In Death Or
Serious Injury
Warning!
Forklift Roll Away
Can Cause Death
Or Serious Injury
Warning!
DO NOT Travel
With Boom Raised
Warning!
Electrocution Can
Cause Death Or
Serious Injury
DO NOT Allow
Anyone Under
A Raised Load
Warning!
Explosion
Hazard
Fasten
Seat
Belt
DO NOT Allow
Riders On Or In
The Operator Cab
Set Parking Brake
To ON
Engage Parking
Brake
Warning!
Forklift Tip Over
Can Cause Death
Or Serious Injury
DO NOT
Raise Boom While
Traveling On A
Slope
Danger!
Keep A Safe
Distance From
Electrical Lines
Pinch Points
Hands
DO NOT Use Ether
As A Starting Aid
DO NOT Use As A
Personnel Carrier
DO NOT
Allow Riders
On Auxiliary
Attachments
Set Parking
Brake To OFF
Disengage
Parking Brake
DO NOT Jump!
If Forklift Tips,
Keep Seat belt ON
And Brace Yourself
Tip Over Hazard,
Especially
Traveling Up A
Slope Without A
Load
Hot Surface!
Keep Hands Away
Pinch Points
Body
Have Adequate
Ventilation If
Operating This
Forklift In An
Enclosed Space
For information call (800) 497-1704 Page 7
XRM945 Safety
Employer Responsibility
Under Occupational Safety and Health Administration
(OSHA) rules, employers are required to train workers
about hazards related to operating and maintaining the
forklift. Successful completion and certication of Safety
Training for Rough Terrain Forklifts is required.
Additional safety information and training resources can
be obtained through these publications, organizations,
and/or other appropriate sources:
Code of Federal Regulations (29 CFR)
Occupational Safety and Health Administration (OSHA)
National Institute for Occupational Health and Safety
(NIOSH)
American National Standards Institute (ANSI)
Association of Equipment Manufacturers (AEM)
The American Society of Mechanical Engineers (ASME)
Always consult Material Safety Data Sheets (MSDS) for
chemical hazards and rst aid instructions for any oil or
lubricant being used. MSDS should be available from the
manufacturer/supplier of the uid.
Operator Responsibility
Warning
Reach forklifts are potentially dangerous if proper
safety procedures are not followed. Workers who
operate, maintain, or work near the forklift can be at
risk of roll over and run over incidents. Workers can
be crushed or caught by the forklift or its parts if the
forklift is not properly operated or maintained.
Read the Operation and Safety
Manual BEFORE operating
the forklift. Follow all safety
instructions and decals.
Only operate the forklift if you understand the
safety instructions and warnings in all applicable
manuals and technical publications. Always follow
all State and Federal health and safety laws and/or
local regulations.
You must have the required training, skills, and tools
to perform installation, operation, maintenance, or
repair procedures properly and safely. Make sure the
forklift and attachments will not be damaged or made
unsafe by any procedures you choose.
Operator Qualications
Operators must be in good physical and mental condition,
with appropriate reexes, reaction time, vision, depth
perception, and hearing.
Operators must possess a valid, current driver’s license
as required for the worksite; plus those required by
applicable State, Federal, and/or local laws.
Successful completion and certication of Safety Training
for Rough Terrain Forklifts is required.
Operators must be properly instructed on how to
operate the forklift and attachments.
Operators must operate the forklift according to ALL
appropriate safety regulations.
Operator trainees must remain under
constant observation and supervision of an
experienced operator.
Modications
Warning
Modications to the forklift or
attachments could aect forklift
capacity and/or stability. DO NOT
make modications to the forklift or
attachments without prior written approval from the
manufacturer. Where such authorization is granted,
capacity, operation, and maintenance instruction
plates, tags, or decals shall be changed accordingly.
Unauthorized modications or alterations will void
the warranty.
DO NOT modify, disable, or bypass any safety
devices.
DO NOT burn or drill holes in forks or other
attachments.
Structural damage, modication, or
alteration, including welding or drilling,
can impair and weaken the protective
capability of the Rollover Protective
Structure/Falling Object Protective Structure (ROPS/
FOPS) and can result in injury or death.
Replace the ROPS/FOPS, if it is damaged, before
operating the forklift.
Page 8 Xtreme Manufacturing, LLC
Safety XRM945
Mounting/Dismounting
Warning
Failure to use proper safety procedures when
mounting and dismounting the forklift could result in
injury or death.
Keep steps clear of dirt, mud, snow, ice, debris, and
other hazards.
Face the forklift for mounting or
dismounting. Use handholds and steps to
maintain three (3) points of contact at all
times, either both hands and one foot or
both feet and one hand.
DO NOT use the controls, steering wheel, or foot
pedals as handholds or steps. Avoid accidentally
engaging or disengaging a control.
DO NOT jump from the forklift.
Clothing can get caught on pedals, levers,
or other protruding parts. Landing on
uneven surfaces can result in serious
personal injury.
Worksite Safety
Warning
Use proper safety procedures and avoid
hazardous situations while operating
the forklift to prevent property damage,
injury, or death.
Check the worksite for any hazards before operating
the forklift.
Check the work surface for loose soil conditions and
overhead power lines.
Contact your local underground utility service or
digging hotline to mark all underground hazards.
Learn the location of all underground hazards at
the worksite, such as; gas and water pipes, electrical
cables, and sewers. Underground objects can cause
injury or death.
Warning
Operate the forklift only on rm, stable surfaces.
Holes, obstructions, debris, loose ll, and other
worksite hazards can cause injury or death.
DO NOT allow bystanders in the work area.
Avoid personnel, machinery, and vehicles in the
work area.
Know the rules for movement of people and vehicles
on the worksite.
Follow worksite signs and signals.
Check boom clearance before driving under a door
opening, bridge, etc.
Slow down when approaching obstructions. Use a
spotter, if necessary.
Stop for poor visibility conditions, such as dust,
smoke, fog, etc. Wait until visibility improves before
continuing.
Operate the forklift in an enclosed area
only if there is a ventilation system capable
of routing hazardous fumes outside.
Engine exhaust contains products of
combustion that can cause injury or death.
DO NOT operate the forklift if you are using
drugs, alcohol, or any medication that
might impair your judgment or ability.
You must be 18 years of age or older to operate
the forklift.
DO NOT operate the forklift on roads. The reach
forklift is not equipped for road travel.
Warning
California Proposition 65
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
For information call (800) 497-1704 Page 9
XRM945 Safety
Warning
Wear appropriate protective clothing. Personal
protective equipment can include, but is not limited to
hardhat, gloves, footwear, safety glasses or goggles,
and hearing protection. Make sure clothing is snug
and properly belted. DO NOT wear loose clothing,
jewelry, watches, or anything that can catch on forklift
controls, moving parts, etc.
Before Starting Forklift
Warning
Keep the Operation and Safety Manual on
the forklift at all times. Contact Xtreme
Manufacturing for any replacement
manuals.
Clearly dene responsibilities and
procedures for operating the forklift and
all attachments. DO NOT proceed until
you seek expert assistance from a qualied
person if any doubt or question arises about the
correct or safe methods for operating the forklift.
To avoid injury or death,
carefully read and understand
all instructions before
operating the forklift. DO
NOT operate, modify, repair, or maintain the forklift
unless you read and understand the instructions and
warnings in this and all other applicable manuals and
technical publications. Follow all State and Federal
health and safety laws and/or local regulations.
Consult Material Safety
Data Sheets (MSDS) for
chemical hazards and rst aid
instructions. MSDS should
be available from the manufacturer or supplier of
the uid.
Warning
Perform a pre-operation inspection and
functional tests at the beginning of each
work shift. Perform the pre-operation
inspection rst. DO NOT perform the pre-
operation inspection with the engine running or hot.
Contact with moving or heated parts can cause injury
or death.
Perform the pre-operation inspection
and functional tests in an open area.
Inspections and functional tests may
require assistance. Keep the assistant
visible and a safe distance from the forklift to prevent
injury or death.
Become familiar with all safety and hazard
decals, regulations, and procedures. Make
sure all proper safety and hazard decals are
attached to the forklift and remain legible.
A brief description of controls, indicators,
and instruments is provided as a
convenience for the operator. These
descriptions DO NOT provide complete
operation instructions. Read and understand the
entire manual to prevent equipment damage, injury,
or death.
Keep ngers and feet away
from moving parts or pinch
points to prevent pinching
or crushing. DO NOT allow
anyone between the tires and the forklift frame while
operating the forklift.
Always check the condition of the seat belt
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 injury or death.
DO NOT operate the forklift until the seat belt or
mounting hardware is replaced, if worn or damaged.
The seat belt MUST be worn while operating the
forklift. Failure to wear the seat belt could result in
injury or death.
Page 10 Xtreme Manufacturing, LLC
Safety XRM945
Warning
Operators must be properly trained
and qualied to operate this specic
forklift. Know the location, learn the
specic purpose, and demonstrate safe
and proper use of all controls, instruments, indicator
lights, and safety and instruction labels. Safety is
your responsibility.
To prevent injury or death the operator
must be seated with seat belt fastened,
the travel select lever set to NEUTRAL, the
Parking Brake switch ON (engaged), the
service brake applied, and the area free of people and
obstructions BEFORE starting the forklift.
Operation Safety
Danger
Injury or death by electrocution can result
from contact with or inadequate clearance
with energized power lines or apparatus.
Never operate the forklift in an area where active
overhead power lines, overhead or underground
cables, or other power sources exist.
Contact the appropriate power or utility company
to de-energize power lines or take other suitable
precautions.
Keep the forklift, attachments, and loads a
safe distance from electrical power lines.
Remain at least 10 feet (3 meters), plus an additional
0.4 inches (10 millimeters) for each 1,000 Volts over
50,000 Volts, from active power lines and other
power sources.
Worksite operating directives and/or local or state
codes might require a greater distance.
Know the maximum height and reach of this
reach forklift.
Danger
Use of the frame sway control with the
boom raised above horizontal can cause
tip over resulting in death or injury.
Always use the frame sway control to level
the forklift BEFORE raising the boom above horizontal.
If the forklift cannot be leveled using the frame
sway control, do not attempt to raise or place load.
Reposition forklift or have the surface leveled.
Warning
To prevent property damage, injury, or
death the operator must be seated with
seat belt fastened, arms, legs, and head
completely inside the Rollover Protection
Structure/Falling Object Protection Structure (ROPS/
FOPS), the travel select lever in NEUTRAL, the Parking
Brake switch ON (engaged), and the service brakes
applied BEFORE starting the forklift.
The seat belt MUST be worn while operating the
forklift. Failure to wear the seat belt could result in
injury or death.
DO NOT adjust the seat or seat belt while
the forklift is moving. Keep both hands on
the wheel while the forklift is moving to
prevent loss of forklift control which could
result in injury or death.
Never try to escape the forklift if it
becomes unstable. Learn and practice
these safety procedures to protect yourself
from a roll over or tip over incident:
Remain securely fastened in the seat belt.
Keep your head, body, and limbs within the ROPS/
FOPS structure.
Brace yourself and hold on rmly.
Lean away from the point of impact.
Stay on the forklift and ride out the roll over or
tip over.
For information call (800) 497-1704 Page 11
XRM945 Safety
Warning
DO NOT use the forklift as a
work platform or personnel
carrier. Falling o of
attachments can result in
injury or death.
NEVER allow passengers to
ride on the forklift. DO NOT
allow riders on the frame or
operator cab. The reach forklift
is designed for the safety of the operator only.
NEVER use crab or four wheel (4W)
steering for traveling at high speeds. Use
only two wheel (2W) steering for higher
speed travel and slow the forklift before
turning. Rapid turning while using crab or four wheel
(4W) steering can cause tip over.
DO NOT travel with an elevated boom.
Retract the boom fully. Lower the boom
as low as practical for proper visibility.
Maintain enough ground clearance
for conditions.
Retract and lower the boom at the same time to
prevent forklift tip over or roll over. Retracting the
boom without lowering it OR lowering the boom
without retracting it can change the center of gravity,
reduce stability, cause forklift tip over or roll over, and
result in injury or death.
Allow for adequate clearance between
the attachment and other objects when
turning. The attachment extends beyond
the front of the forklift. The operator
must be aware of the maximum sweep of any
attachment being used to avoid hitting personnel
and other objects in the area and to prevent property
damage, injury, or death.
Warning
To prevent property damage, injury, or
death, make sure the forklift comes to a
complete stop before moving the travel
select lever. A sudden change in direction
of travel, while carrying a load, can reduce stability
and/or cause the load to shift or fall.
DO NOT shift through multiple gears with
a single turn of the gear select lever. Allow
the engine speed to slow down before
shifting to the next lower gear. Improper
use of the gear select lever could cause transmission
damage or forklift tip over/roll over and result in
injury or death.
Operate the forklift for maximum stability.
Unstable forklifts can tip over, resulting in
property damage, injury, or death. Keep
the forklift stable by following these and
other appropriate guidelines:
Adjust speed for terrain and conditions.
Avoid obstacles by driving around them rather than
over them, when possible.
Start, stop, travel, steer, and brake smoothly.
Load, unload, and turn the forklift on level ground,
when possible.
Slow down for turns.
Slow down for rough, slippery, or soft terrain.
Use caution around steep slopes, creeks, gullies,
ridges, ditches, and ravines.
Stay away from soft edges that could collapse under
the forklift.
Page 12 Xtreme Manufacturing, LLC
Safety XRM945
Warning
Become completely familiar with the
forklift before operating on slopes. The
reach forklift can overturn due to sudden
movement or while operating on a slope.
DO NOT raise the boom while
operating on a slope. Raising
the boom on a slope, even
without a load, can change
the center of gravity, cause a tip over, and result in
injury or death.
DO NOT turn on a steep slope.
DO NOT drive the forklift across slopes.
Always drive the forklift straight up and down the
slope (never drive diagonally up or down a slope).
Drive the forklift forward up the slope (front of
forklift facing uphill).
Back the forklift down the slope when loaded (front
of forklift facing uphill).
Follow appropriate procedures to prevent
sudden changes in forklift speed that can
result in personal injury or death.
Turn the gear select lever to the lowest speed
before descending a slope and before loading or
unloading a trailer.
DO NOT adjust the travel select lever while the
forklift is moving.
DO NOT coast downhill. Keep the travel select lever
in the appropriate position.
DO NOT exit the forklift without following
proper shut down procedures.
Engine fuel is ammable and
can cause a re or explosion.
DO NOT smoke while refueling
and keep sparks and open
ames away from the forklift.
Warning
The reach forklift includes a Frame Sway
Override switch. Improper use of the
Frame Sway Override switch can cause
property damage, injury, or death.
Make sure the forklift frame is level before
raising and extending the boom. Frame
swaying left or right with the boom raised
is extremely dangerous.
Use the frame sway control to level the forklift
before raising the boom.
Reposition the forklift if it cannot be leveled using
the frame sway control.
DO NOT enter or exit a tilted cab.
Remain seated with the seat belt securely fastened
while the cab is tilted.
Keep personnel at least 30 feet (9.14 meters) from a
tilted forklift.
Caution
Contact with hot surfaces and the exhaust
pipe after the forklift has been operated
can result in serious personal injury.
Check warning indicators and gauges
on the dash panel frequently during
operation. If a warning indicator is
illuminated or a gauge shows abnormal
readings, stop the forklift, follow proper shut down
procedures, tag the forklift with “Do Not Operate
tags, and have a qualied mechanic service or repair
the forklift BEFORE placing it into service again.
Caution
Release the key immediately once the motor starts.
If the motor does not start, DO NOT crank the starter
motor continuously for more than 15 seconds. Failure
to release the key after the motor has started or
continuous cranking can damage the starter motor.
DO NOT change steering modes until the forklift
comes to a complete stop. Align all four (4) tires
straight-ahead, or perpendicular to the axle, before
changing steering mode.
For information call (800) 497-1704 Page 13
XRM945 Safety
Load Safety
Warning
Failure to follow proper safety procedures
when lifting, lowering, and traveling
with a load can cause property damage,
injury, or death.
DO NOT exceed forklift capacity of 9,000 pounds
(4082 Kilograms). The total rated capacity of the
forks being used must equal or exceed forklift
capacity. Forks can break causing loss of load and
possible injury or death.
DO NOT exceed the manufacturers rated
load for any auxiliary attachment. Any
attempt to lift or carry loads in excess of
the manufacturers rated load may cause
forklift tip over, loss of load, or structural damage
which could result in injury or death.
Failure to keep personnel clear of the
load area while the load is being raised or
lowered can result in injury or death. DO
NOT lift, swing, or move a load over anyone
or over a forklift cab.
Review the rated load capacity of each auxiliary
attachment before performing any operation.
Use the correct load chart and NEVER exceed
specied weights and load centers.
DO NOT exceed the manufacturers recommended
load capacity.
DO NOT operate the forklift with an unsafe load
distribution.
Adjust the load as necessary, especially for
nonstandard loads.
Use caution when handling loose material that can
fall into the cab.
Remove overhanging load materials, when possible,
and watch for sliding material.
DO NOT reach a load over posts or other objects that
can enter the cab, if tipped.
Avoid sudden stops, starts, or turns.
Avoid carrying a swinging load. If necessary, secure
the load by attaching it to the forklift tie-downs and/
or have another person assist with safely steadying
the load.
Attachments
Warning
Improper connection of an auxiliary attachment can
result in injury or death. Attachments not locked into
place can break free and fall on the operator or other
personnel near the forklift.
Make sure attachment locking devices are always
in place.
DO NOT operate the forklift until you have positive
indication that the coupler pin and lever are fully
engaged.
Hydraulic attachments have a maximum hydraulic
pressure rating. Failure to make sure the attachment
is equal to or slightly greater than 3,500 psi (241.4
bar), which is the maximum pressure of the forklift
auxiliary hydraulic system at the quick-disconnect
couplers, could result in injury or death.
Make sure all hydraulic connections are tight
(if equipped).
Shut Down Procedure
Warning
To prevent injury or death, follow these procedures
before leaving the forklift cab:
Park forklift on a rm, level surface.
Move travel select lever to NEUTRAL (N).
Set parking brake to ON (engaged).
Lower forks and attachments to the ground.
Always engage the parking
brake before leaving the
forklift. The forklift can roll
if the parking brake is not ON (engaged) resulting in
injury or death.
Turn Ignition switch to the OFF position.
Remove the key.
Unbuckle the seat belt.
Place “Do Not Operate tags on the Starter
switch and steering wheel when maintenance
or service is required.
Block wheels when maintenance is required.
Page 14 Xtreme Manufacturing, LLC
Safety XRM945
Forklift Maintenance
Warning
Follow the manufacturers instructions for proper
maintenance to make sure the forklift continues to
meet manufacturers specications.
Attach “Do Not Operate tags to the
Ignition switch and steering wheel before
beginning any service or maintenance.
“Do Not Operate tags indicate the forklift should
not be operated until all service or maintenance is
completed.
Keep two (2) legible “Do Not Operate tags with
the forklift at all times. “Do Not Operate tags are
provided in this manual.
Figure 2-1. Do Not Operate Tag.
DO NOT operate the forklift and attachments if they
require repairs.
Make sure basic maintenance is completed and
service problems are corrected.
Injury or death can result from operating a forklift
before all repairs have been made and all proper
maintenance is completed.
Warning
Tires must have proper ballast. DO
NOT replace foam-lled tires with
pneumatic tires.
Check hydraulic oil lines, tubes,
and hoses carefully. DO NOT
use your bare hand to check
for leaks. Always use a board
or cardboard when checking for a hydraulic leak.
Escaping hydraulic uid under pressure, even a
pinhole size leak, can penetrate body tissue, causing
injury or death. If hydraulic oil is injected into your
skin, a doctor familiar with this type of injury must
treat it immediately.
Personal injury can result from
hydraulic oil pressure or hot oil.
DO NOT remove a hydraulic tank
ller cap unless it is cool enough
to touch with bare hands. Remove the hydraulic
tank ller cap slowly to relieve pressure. Relieve all
pressure in a hydraulic system before any caps, lines,
ttings, or related items are disconnected or removed.
It is possible for the forklift to move
suddenly when the brakes are released
resulting in injury or death. To prevent
sudden movement of the forklift, put
blocks in front of and behind wheels before the brakes
are released.
If the forklift is to be towed, make sure the
released brake(s) can be reapplied or that
the towing vehicle can stop the forklift
being towed.
DO NOT use ether as a starting
aid. Ether is ammable and
can cause an explosion when
starting the engine. Follow the
cold starting procedures and engine manufacturer’s
specications for using a starting aid.
For information call (800) 497-1704 Page 15
XRM945 Safety
Warning
Lead-acid batteries produce ammable and
potentially explosive gases. To avoid injury or death
when checking, testing, or charging batteries:
DO NOT use smoking materials near batteries.
Keep arcs, sparks, and open ames away from
batteries.
Provide ventilation for ammable vapors.
Wear proper personal protective equipment,
including safety glasses.
Fluid in electric storage batteries contains sulfuric
acid, which is poison and can cause severe chemical
burns. Avoid all contact of uid with eyes, skin,
or clothing. Use protective gear when handling
batteries. DO NOT tip a battery beyond a 45° angle in
any direction.
If contact does occur, follow these First Aid
suggestions:
External contact - Flush with water.
Eyes - Flush with water for at least 15 minutes and
get medical attention immediately.
Internal contact - Drink large quantities of water.
Follow with Milk of Magnesia, beaten egg, or
vegetable oil. Get medical attention immediately.
Important - In case of internal contact, do not give
uids that induce vomiting.
Warning
California Proposition 65
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer, birth
defects, or other reproductive harm. Wash hands after
handling these items.
Warning
Wear eye protection when starting a
forklift with jump start cables. Improper
jump start procedures can cause the
battery to explode.
Never jump start a frozen battery, as it can explode.
Let the battery thaw out before charging.
NEVER jump start the forklift directly at the starter
solenoid, which could cause the forklift to lurch
forward or backward, resulting in injury or death.
To avoid injury or death when jump starting with
another forklift, make sure the two (2) forklifts are
not touching.
DO NOT allow jump start cable ends to contact each
other near the battery.
Connect charged battery positive (+) to stalled
battery positive (+).
Connect charged battery negative (–) to stalled
forklift ground. Make the connection to the stalled
forklift ground last.
Connect jump start cable to stalled forklift ground
a safe distance from the battery to prevent sparks
near the battery.
Jump start only with a power source with the same
voltage as the stalled forklift.
Jump start power source must have a negative
ground electrical system.
Turn o all lights and accessories on the stalled
forklift to prevent them from operating when the
power source is connected.
Caution
Electrolyte contains acid and can cause injury if it
contacts the skin or eyes.
Safety XRM945
Page 16 Xtreme Manufacturing, LLC
Dead Engine Towing
Parking Brake Release (Front Axle)
Warning
Block all four wheels. Failure to do so could result in
death or serious injury from vehicle roll away.
1. Block all four wheels to prevent the vehicle from
moving once the parking brake is disabled.
2. Position the towing vehicle in place. Attach any chain
needed to secure the disabled vehicle.
3. An 8mm Allen head socket and torque wrench will be
needed to properly disable the parking brakes. Mark
a line on the socket so you can accurately count the
number of turns each bolt makes when performing
this procedure.
4. Crawl under the front of the vehicle. Locate the six
brake release bolts under the front axle (three bolts
per side) at the base of the front axle. (Bolt A is on the
top of axle, Bolt B is on the rear side of axle, Bolt C is
on the front side of axle). The following procedure is
to be performed per side.
5. Remove hex screws from brake release bolts.
Alternate loosening hex screws 1/2 turn until fully
loosened. Set aside lock screws.
6. Alternately tighten brake release bolts A, B & C
until you rst begin to feel resistance. This will take
approximately two to three turns.
7. Using a torque wrench, alternately tighten bolts A, B
& C one-half turn until a torque of 25 ft-lbs (34 Nm) is
reached.
8. Again, using the torque wrench, alternately tighten
bolts A, B & C until a minimum torque of 30 ft-lbs (41
Nm) is reached. This will take approximately one-half
turn. Do not exceed 50 ft-lbs (68 Nm).
9. Insert hex screws into brake release bolts A, B, & C.
Alternate tighten each hex screw 1/2 turn until secure.
(Repeat steps 5-9 for each side of axle)
10. Crawl out from under the vehicle and clear the area of
any unnecessary personnel.
11. Carefully remove the blocking from each of the four
tires and tow the vehicle to a secure location.
Figure 2-1. Brake Release Bolt A.
Figure 2-2. Brake Release Bolt B.
Figure 2-3. Brake Release Bolt C.
Page 18 Xtreme Manufacturing, LLC
Decals XRM945
Decals
Decal Legend
Left Side View
Figure 3-1. Decal Legend Left Side View.
Right Side View
Figure 3-2. Decal Legend Right Side View.
For information call (800) 497-1704 Page 19
XRM945 Decals
Front View
Figure 3-3. Decal Legend Front View.
Rear View
Figure 3-4. Decal Legend Rear View.
Table 1. Decals
Item Qty. Part No. Description
1 1 18018-000 Danger, Electrocution
2 1 18040-000 Danger, Not A Man Lift
3 1 18017-000 Danger, Falling Boom Or Load
4 1 18019-000 Danger, Stay Clear
5 1 18026-000 Seat Belt
6 1 18027-000 Install Cover
7 2 18030-000 No Feet
8 1 18020-000 Warning, Backward Tip Over
9 1 18021-000 Warning, Forklift Roll Away
10 5 18041-000 Warning, Pinch Point Area
11 1 18024-000 Warning, No Riding
12 1 18025-000 Warning, No Riders
13 1 18023-000 Warning, Welding/Modication
14 1 18022-000 Warning, Forklift Tip Over
15 1 18031-000 Warning, Safe Operation
16 1 18032-000 Warning, Untrained Personnel
17 1 18082-000 Warning, Leaks
18 1 18083-000 Warning, Explosive Gases
19 1 18010-000 Caution, Watch Your Step
20 1 18011-000 Caution, No Ether
21 1 18028-000 Caution, Diesel Fuel
22 1 18016-000 Caution, Hot
23 1 18029-000 Caution, Hydraulic Oil
24 1 18013-000 Caution, Diesel Only
25 1 18012-000 Hydraulic Oil Only
26 1 18015-000 Check/Fill Coolant
27 1 18014-000 Check/Fill Engine Oil
28 1 18087-000 Transmission Fluid
29 1 18033-000 Control, Auxiliary
30 1 18034-000 Control, Boom
31 1 18035-000 Control, Attachment Tilt and
Frame Sway
32 1 18039-000 Indicator, Boom Angle
33 1 18053-000 Lettering (A-C), Boom
34 1 18054-000 Lettering (D-E), Boom
35 1 18055-000 Lettering (F-G), Boom
36 4 18090-000 Caution, Machine Stability
37 1 18068-000 Control, Attachment Tilt
Page 20 Xtreme Manufacturing, LLC
Decals XRM945
Replacement Decals
Replacement decals can be obtained by contacting
Xtreme Manufacturing at (800) 497-1704. Please have the
appropriate decal number available when you call.
1. 18018-000
2. 18040-000
3. 18017-000
4. 18019-000
5. 18026-000
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Xtreme XRM945 Operating instructions

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