Xtreme Manufacturing XRM945, Operation & Safety Manual

Page 1: ... 702 636 2969 800 497 1704 1714 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com XRM945 Operation Safety Manual ...

Page 2: ...ols 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 Sw...

Page 3: ...oad 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 Additio...

Page 4: ...arn 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 ...

Page 5: ...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...

Page 6: ... 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 Instructi...

Page 7: ...s 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 Park...

Page 8: ...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 Qualifications Operators must be in good physical and mental condition with appropriate reflexes reaction t...

Page 9: ...s 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 firm stable surfaces Holes obstructions debris loose fill 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 peo...

Page 10: ... 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 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 assistan...

Page 11: ... 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 Repo...

Page 12: ...f 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 re...

Page 13: ...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 lev...

Page 14: ...bjects 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 ...

Page 15: ...d to check for leaks Always use a board or cardboard when checking for a hydraulic leak Escaping hydraulic fluid 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 hy...

Page 16: ...unds 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 for...

Page 17: ...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 first 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...

Page 18: ...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 ...

Page 19: ...00 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 Hy...

Page 20: ...ls 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 ...

Page 21: ...For information call 800 497 1704 Page 21 XRM945 Decals 6 18027 000 7 18030 000 8 18020 000 9 18021 000 10 18041 000 11 18024 000 ...

Page 22: ...Page 22 Xtreme Manufacturing LLC Decals XRM945 12 18025 000 13 18023 000 14 18022 000 15 18031 000 ...

Page 23: ...il easily punctures skin causing serious injury gangrene or dealth l If injured seek emergency medical help Immediate surgery is required to remove oil l Do not use finger or skin to check for leaks l Lower load or relieve hydraulic pressure before loosening fittings 18 18083 000 EXPLOSIVE GASES can cause serious injury WARNING ...

Page 24: ...Page 24 Xtreme Manufacturing LLC Decals XRM945 19 18010 000 20 18011 000 21 18028 000 22 18016 000 23 10829 000 24 18013 000 ...

Page 25: ...For information call 800 497 1704 Page 25 XRM945 Decals 25 18012 000 26 18015 000 27 18014 000 28 18087 000 29 18033 00 ...

Page 26: ...Page 26 Xtreme Manufacturing LLC Decals XRM945 31 18035 000 32 18039 000 33 18053 000 34 18054 000 35 18055 000 30 18034 000 ...

Page 27: ...For information call 800 497 1704 Page 27 XRM945 Decals 36 18090 000 37 18068 000 ...

Page 28: ...m Switch actuated clutch cut off Rear view mirrors Adjustable suspension seat with seat belt High boom mount design Low mounted central engine drive train Sliding engine transmission cowling 360 panoramic visibility Boom angle and frame level indicator Deluxe suspension seat Tires Foam filled Hydraulics Auxiliary hydraulic circuit with quick attach Attachment Tilt Switch Frame Sway Control Handle ...

Page 29: ...is Heavy duty Roller Boom Melonite Pins and Rollers Direct Dual Control Hydraulic Valve Actuation Robust Wiring No Spades No Pins Rear Axle Stabilization RAS Center Inline Engine Drive Train Full time Planetary 4 Wheel Drive Steering 4 Wheel Circle Crab 2 Wheel Front Back Up Alarm Open ROPS Adjustable Hydraulic Operator Controls Suspension Seat Quick Attach Common Fit Xtreme Service Accessibility ...

Page 30: ...itch Position Purpose OFF Shuts down entire electrical system except the horn and accessory outlet RUN All controls and indicators are operable PREHEAT Use for cold starting conditions START Engages starter motor to crank engine NOTE The PREHEAT and START positions are spring loaded When the key is released the Ignition switch will automatically return to the RUN position Figure 6 2 Ignition Switc...

Page 31: ...orklift in the corresponding direction Figure 6 6 Steering Wheel Horn Button Press the horn button to sound the horn Figure 6 7 Horn Button Operator Seat Operator Seat Controls The operator seat can be adjusted four 4 ways weight suspension height fore and aft and backrest angle Figure 6 8 Operator Seat Weight Suspension Lever Rotate the weight suspension lever to increase or decrease the seat cus...

Page 32: ...est angle adjustment lever up to release the seat backrest lock Adjust the angel of the backrest and release the lever to lock the backrest to the desired angle Figure 6 12 Backrest Angle Adjustment Lever Seat Belt Warning 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 t...

Page 33: ... of the seat assembly 2 Pull the retractable seat belt across your lap Position the seat belt as low on your body as possible 3 Insert the latch plate into the buckle on the right side of the seat until a click is heard 4 Make sure seat belt retracts snugly across your lap NOTE Depress the red push button on the buckle to release the two inch 2 seat belt Pull the clasp on the buckle to release the...

Page 34: ...NOTE The travel select lever must be in the NEUTRAL position to start the reach forklift NOTE The back up alarm automatically sounds when the travel select lever is in the REVERSE position Gear Select Switch The Gear Select switch has a twist grip handle with four 4 positions 1 FIRST 2 SECOND 3 THIRD and 4 FOURTH NOTE The reach forklift can be operated in four 4 forward and four 4 reverse gears Fi...

Page 35: ...e forklift before placing it into service again Figure 6 21 Hydraulic Oil Temperature Indicator Low Brake Pressure Indicator The low brake pressure indicator illuminates if the hydraulic brake oil pressure gets low If the low brake pressure indicator is illuminated stop the forklift follow proper shut down procedures tag the forklift with Do Not Operate tags and have a qualified mechanic service o...

Page 36: ... qualified mechanic service or repair the forklift before placing it into service again Figure 6 25 Voltage Gauge Fuel Gauge The fuel gauge indicates the quantity of fuel in the fuel tank The total capacity of the fuel tank is 48 gallons 180 liters It is recommended that the fuel tank be between1 2 filled and full Figure 6 26 Fuel Gauge Oil Gauge The oil gauge indicates the engine oil pressure Nor...

Page 37: ...30 Front Worklights Rear Axle Centering Indicator The rear axle centering indicator illuminates when the rear wheels are aligned perpendicular to the rear axle The rear axle must be aligned perpendicular to change the Steering Select switch If the rear axle centering indicator does not illuminate stop the forklift follow proper shut down procedures tag the forklift with Do Not Operate tags and hav...

Page 38: ... When the Declutch switch is set to OFF the transmission remains engaged when the travel select lever is set to either FORWARD or REVERSE Figure 6 34 Declutch Switch Boom Control The boom control handle has variable motions from the center to control boom functions Figure 6 35 Boom Control Handle The boom control handle is used to raise lower extend and retract the boom NOTE The boom control handl...

Page 39: ...For information call 800 497 1704 Page 39 XRM945 OperatorCab Figure 6 36 Boom Control Handle Functions Table 7 Boom Control Handle Functions A B C D E F G H ...

Page 40: ...g function will occur To lock frame sway place the travel select lever in NEUTRAL and apply service brake or apply parking brake NOTE The attachment carriage is self leveling and will retain any set angle throughout boom raising lowering retracting or extending operations NOTE Maximum frame sway is 22 overall or 11 each direction left and right Warning The reach forklift includes a Frame Sway Over...

Page 41: ...n the left side of the boom visible to the operator These letters indicate boom extension as it corresponds to the load capacity charts Figure 6 41 Boom Extend Letters Frame Level Indicator The frame level indicator is mounted on the inside top center of the operator s cab The frame level indicator allows the operator to view if the forklift has been positioned in a level condition Always frame sw...

Page 42: ...rd the operator NOTE The attachment carriage is self leveling and will retain any set angle throughout boom raising lowering retracting or extending operations Frame Sway Control Handle Optional An frame sway control handle installed on the adjustable operator control panel controls frame sway functions Figure 6 45 Optional Frame Sway Control Handle The frame sway control handle Controls the frame...

Page 43: ...Frame Sway Override switch can cause property damage injury or death Figure 6 46 Optional Frame Sway Override Foot Switch The frame sway feature becomes locked and will not operate when the boom is raised 40 or more Pressing the Frame Sway Override foot switch located on the cab floor to the left of the service brake pedal will override the lockout feature and allow frame sway ...

Page 44: ...ter switch and steering wheel if anything is found to be in need of repair or maintenance defective or unsafe in any way Caution Contact with hot surfaces and the exhaust pipe after the forklift has been operated can result in serious personal injury Warning Always check the condition of the seat belt and mounting hardware before operating the forklift If the seat belt or mounting hardware is defe...

Page 45: ...ornia 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 whi...

Page 46: ... other damage to rims Check frame sway cylinder and hoses for leaks or any other damage Check mirrors for cracks cleanliness and proper adjustment Check hydraulic sight gauge for proper fluid level Add hydraulic fluid if necessary Check engine compartment for Damaged belts hoses and radiator blades Coolant reservoir level Add radiator coolant if necessary Engine oil level Add engine oil if necessa...

Page 47: ...attachment tilt and frame sway control handle forward and backward to tilt attachment up and down Operate the attachment tilt and frame sway control handle left and right to sway frame left and right Operate the auxiliary attachment control lever if a hydraulic attachment is being used Turn worklights off and on Press the horn button to sound horn Place the travel select lever in reverse to sound ...

Page 48: ...ic Oil Sight Gauge Figure 7 2 Add Hydraulic Oil If Necessary Figure 7 3 Check Coolant Reservoir Level Add Coolant If Necessary Figure 7 4 Check Engine Oil Level Add Engine Oil If Necessary Figure 7 5 Check Battery Case and Terminals Figure 7 6 Store Operation and Safety Manual In Protective Case ...

Page 49: ...t Clothing can get caught on pedals levers or other protruding parts Landing on uneven surfaces can result in serious personal injury 1 Use safe mounting dismounting procedures to enter the operator cab 2 Adjust the operator seat for position and comfort Refer to Seat Adjustment section in this manual 3 Fasten seat belt 4 Adjust mirrors this may require assistance 5 Adjust the operator control pan...

Page 50: ...ey after the motor has started or continuous cranking can damage the starter motor 2 Turn key in Ignition switch clockwise to the START position Figure 7 10 Turn Key In Ignition Switch To START 3 Release the key immediately after the engine starts The Ignition switch will automatically return to RUN NOTE The PREHEAT and START positions are spring loaded When the key is released the Ignition switch...

Page 51: ...in Ignition switch clockwise to the PREHEAT position and hold the key at PREHEAT for approximately one 1 minute Figure 7 13 Hold Key At PREHEAT 3 Turn key in Ignition switch clockwise to the START position Figure 7 14 Turn Key In Ignition Switch To START 4 Release the key immediately after the engine starts The Ignition switch will automatically return to RUN NOTE The PREHEAT and START positions o...

Page 52: ... immediately Important In case of internal contact do not give fluids that induce vomiting 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 c...

Page 53: ...eel 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 using crab four wheel 4W or the optional two wheel rear 2WR steering can cause tip over Check the turning radius area around the forklift before making a turn especially if using four wheel 4W steering or two wheel rear 2WR steering which provide a ...

Page 54: ...ting personnel and other objects in the area to prevent property damage injury or death Figure 7 16 Maximum Fork Sweep Starting Travel 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 overhea...

Page 55: ...al readings stop the forklift follow proper shut down procedures tag the forklift with Do Not Operate tags and have a qualified mechanic service or repair the forklift BEFORE placing it into service again There are three 3 warning indicator lights on the dash panel that illuminate during critical circumstances All three 3 warning indicators demand immediate attention and forklift servicing In many...

Page 56: ...brake pedal 4 Slowly press the accelerator pedal to start travel Stopping Travel 1 Stop the forklift by applying the service brake pedal 2 Downshift the forklift to a lower gear if necessary to slow the forklift until it comes to a complete stop 3 Move the travel select lever to NEUTRAL N 4 Set the Parking Brake switch to ON engaged Warning To prevent property damage injury or death apply service ...

Page 57: ... carry loads in excess of the manufacturer s rated load may cause forklift tip over loss of load or structural damage which could result in injury or death Xtreme Manufacturing makes no representations or warranties expressed or implied as to the design manufacture or fitness for use with this forklift of any third party attachment This forklift is not intended to be used and should not be used wi...

Page 58: ...ft differs from the load capacity of the forks the lower value becomes the overall load capacity Standard Carriage Operation The standard carriage uses manually adjustable forks and can be tilted up or down using the attachment tilt and frame sway control handle Figure 7 21 Attachment Tilt and Frame Sway Control Handle The standard carriage can also be tilted up or down using the optional Attachme...

Page 59: ... 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 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...

Page 60: ...Raise the boom until pivot pins A have seated fully in attachment hooks B Figure 7 27 Raise Boom To Seat Pivot Pins A In Attachment Hooks B 5 Tilt the attachment up slightly The quick attach link should be tight against the rear of the attachment Align the holes between the quick attach link and attachment Figure 7 28 Tilt Attachment To Align Holes Between Quick Attach Link and Attachment A Not Al...

Page 61: ...ver Is Seated In Groove A Of Quick Attach Pin Warning 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 attach couplers could result in injury or death Make sure all hydraulic connections are tight if equippe...

Page 62: ...ake switch to ON engaged 4 Extend the boom approximately 18 to 20 inches 0 46 to 0 5 meters 5 Tilt the attachment backward 6 Disconnect the quick attach couplers this only applies to attachments with a quick attach hydraulic system Figure 7 33 Disconnect Quick Attach Couplers A Female Coupler B Male Coupler 7 Raise the quick attach lock lever Figure 7 34 Raise Quick Attach Lock Lever 8 Pull out th...

Page 63: ...ns 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 ...

Page 64: ... 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 6 Tilt the forks back slightly to secure the load Carry A Load 1 Carry the load as low as possible while maintaining good ground clearance and visibility 2 Back awa...

Page 65: ...e has variable motions from the center that control the frame sway right and left functions Table 11 Frame Sway Functions Function Control Handle Action FRAME SWAY RIGHT Move control handle RIGHT FRAME SWAY LEFT Move control handle LEFT Figure 7 38 Attachment Tilt and Frame Sway Control Control Handle An frame sway control handle also controls the frame sway right and left functions Figure 7 39 Fr...

Page 66: ...T exceed rated capacities Any attempt to lift or carry loads in excess of those shown on the load capacity charts may cause forklift tip over loss of load or structural damage which could result in injury or death 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...

Page 67: ...tely read the load capacity charts you must determine three 3 things Weight of load being lifted Height of structure where load is to be placed Distance from front tires where load will be placed For example 1 The operator determines load weight and makes sure load does not exceed fork attachment or boom capacity The load is 4000 pounds 1814 kg 2 The operator safely moves the load to a loading pos...

Page 68: ...Page 68 Xtreme Manufacturing LLC Operation XRM945 Standard Carriage Load Capacity Chart Foam Filled Tires Figure 7 46 Swing Carriage Load Capacity Chart Foam Filled Tires Figure 7 47 ...

Page 69: ...gine electrical cables leads and connections for damage and tightness Check for oil and coolant leaks Check condition and tension of drive belts Use tensionmeter to check belt tension Lubricate front and rear driveshaft grease fittings Lubricate front and rear axle grease fittings Change differential oil Change wheel end oil Check wheel lug nuts torqued to 380 420 ft lbs Lubricate boom pivot point...

Page 70: ...turn line filter Inspect wheel tire assemblies After Every 1 000 Hours of Operation Comply with 50 Hour Maintenance Requirements Comply with 250 Hour Maintenance Requirements Comply with 500 Hour Maintenance Requirements Change transmission fluid Change wheel end oil Change differential oil Check valve tip clearance Adjust if necessary Inspect boom chains Replace hydraulic high pressure filter Aft...

Page 71: ...f the cylinder After the extend cylinder is fully retracted loosen the needle valve in the valve block at the base of both lift cylinders allowing it to retract in a slow and controlled manner Do No 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 vehicle should not be oper...

Page 72: ...e defect or defects must be clearly documented and posted in a conspicuous place on the forklift Failure to comply may result in death serious injury and property damage 6 Attach condition tag Figure 8 3 to battery disconnect switch Condition tag should clearly state why forklift is unsafe for operation or maintenance Returning Forklift To Service When the forklift has been repaired and made safe ...

Page 73: ...For information call 800 497 1704 Page 73 XRM945 DoNotOperate Tags Do Not Operate Tags ...

Page 74: ...Page 74 Xtreme Manufacturing LLC DoNotOperate Tags XRM945 ...

Page 75: ...Page 74 Xtreme Manufacturing LLC XRM945 DoNotOperate Tags ...

Page 76: ...1714 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com 702 636 2969 800 497 1704 24901 000 Rev 6 07 ...