Xtreme XRM1145 Use and care manual

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 Qualifications
.............••..... 7
Modifications
............•............... 7
MountinglDismounting 8
Works/te Safety 8
Before Starting Vehicle 9
Operation Safety
...........•............ 10
Load Safety
13
Attachments 13
Shut Down Procedure
...........••....... 13
Vehicle Maintenance
14
Decals ........................•........ 16
Decal Legend
......•...........••...... 16
Left Side View
......•................. 16
Right Side View 16
Front View 17
Rear View
...........••.............. 17
Replacement Decals
.....•..........•.... 18
Features
................••.........•.... 26
Standard Equipment
......••............. 26
Optional Equipment 26
Specifications 27
Operator Cab 28
Ignition Switch 28
Accessory Outlet. 28
Accelerator Pedal 28
Service Brake Pedal. .29
Steering
Wheel. . . . . . . . . . . . . . . . . . . . . 29
Horn Button 29
Xtreme Manufacturing 1
Table of Contents
Operator Seat 29
Operator Seat Controls
............•.... 29
Weight Suspension Lever 29
Height Adjustment Knob
30
Fore and Aft Adjustment Lever 30
Backrest Angle Adjustment Lever 30
Seat Belt . . . . . 30
Rear View Mirrors
31
Controls and Indicators 32
Travel Select Lever
32
Gear Select Switch 32
Parking Brake Switch
32
Load Capacity Charts 33
Hydraulic Oil Temperature Indicator 33
Low Brake Pressure Indicator 33
Rear Axle Lock Indicator . .
.. . •........ 33
Hourmeter . .
............•....... 34
Voltage Gauge. ................
.. . ... 34
Fuel Gauge ...................••..... 34
Oil Pressure Gauge.. .., 34
Engine Coolant Temperature Gauge
35
Worklight Switch ... ............... .. .35
Rear Axle Centering Indicator
......•..... 35
Steering Select Switch 35
Declutch Indicator
36
Declutch Switch 36
Boom Control 36
Attachment Tilt and Frame Sway Control 38
Auxiliary Attachment Control 38
Boom Angle Indicator. 39
Boom Extend Letters 39
Frame Level Indicator 39
Optional Controls and Indicators 39
Two Wheel Rear (2WR)
Steering Switch (Optional) 39
Attachment Tilt Switch (Optional) 40
Frame Sway Control Joystick (Optional) 40
Frame Sway Override Foot Switch
(Optional)
41
800-497-1704

Table of Contents
Outriggers Toggle Switches (Standard) . . . . 41
Operation 42
Pre-Operation Inspection 42
Pre-Operation Inspection Checklist 44
Operator Maintenance. . . . . . . . 45
Before Starting Vehicle
......•............ 46
Functional Tests. ............ . 47
Functional Test Checklist 47
Starting Vehicle. . . 48
Normal Starting
............•.......... 48
Cold Starting
.............•.•......... 49
Jump Starting
.............•........... 50
Vehicle Travel
51
Steering Modes .............•......... 51
Crab Steering 51
Two Wheel Steering (2W) 51
Four Wheel Steering (4W) 52
Two Wheel Rear Steering (2WR)
(Optional) 52
Maximum Fork Sweep 52
Starting Travel
................•....... 52
Shifting Gears 53
Warning Indicators and Gauges 53
Changing Travel Direction 54
Stopping Travel
..................•.... 54
Xtreme Manufacturing 2
Shut Down Procedure 54
Refueling 55
Fuel Types 55
Attachments 55
Attachment Disclaimer
..........•....... 55
Fork Ratings 55
Standard Carriage Operation 56
Swing Carriage Operation 56
Quick Attach System 57
Attachment Connection 57
Attachment Removal. 60
Load Handling
.....................•.... 61
Pick Up ALoad ..................•.... 62
Carry ALoad
.........•••........•.... 62
Place ALoad
...........••............ 62
Load Shift 63
Frame Leveling 63
Load Capacity Charts 64
Using Load Capacity Charts 65
Reading Load Capacity Charts 65
Standard Carriage Foam-Filled Tires
Load Capacity Chart 66
Swing Carriage Foam-Filled Tires
Load Capacity Chart 66
"Do Not Operate" Tags
..........•.......... 67
800-497-1704

General
This Operator's Manual provides the information
needed to safely operate the XRM1145 or XRM1154
Reach Forklifts.
This manual should
be considered apermanent part
of the vehicle
and kept in the plastic, protective case
located
in the operator's cab.
NOTICE
BEFORE operating the vehicle, read this manual
completely and carefUlly
to understand the safe-
ty instructions and the operation of controls and
safety equipment. You
must comply with all
DANGER, WARNING, and CAUTION
notices.
They are for your benefit.
Improper operation of this vehicle can cause
injury or death.
BEFORE starting the engine,
do the following:
•Read this Operator's Manual.
•Read all safety decals on
the vehicle.
•Clear
the area of other persons.
Learn and practice safe use of vehicle controls in
asafe, clear area BEFORE
you operate this vehi-
cle on aworksite.
It is your responsibility to observe applicable
laws and regulations and
to follow manufactur-
er's instructions on vehicle operation and main-
tenance.
Replacement Manuals
Introduction
Model/Serial Number Plate
When contacting the manufacturer, please have the
vehicle 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 num-
bers
in the space provided.
Model Number: _
Serial Number: _
tri': MANUFACTURED BY ~
~
,." ... --. ................. "1"
(JIZ)xz..m1Mll •(JU) __ ~
(lI2J ,.,.,.,-
EOU....-rNO.
ovw
II
_ ...
I,I
iiliLiLlii
IJ
..
lJI
I XRM-03 I •
'.
Figure 1-1. Model/Serial Number Plale.
Right side, left side, front, and rear are directional
references given from the operator's seat while fac-
ing in aforward direction.
RIGHT
a:
<:
w
a:
Figure 1-2. Vehicle Direction Orientation.
Replacement manuals for the XRM1145/XRM1154
Reach Forklifts can
be obtained by contacting:
Xtreme Manufacturing
Phone: (800) 497·1704
Xtreme Manufacturing 3
IXRM-Ozi
LEFT
800-497-1704

Safety
Safety Disclaimer
Thin
Figure 2-1. Think Safety.
Xtreme Manufacturing reserves the right to make
technical changes for product improvement.
This manual may contain illustrations and photo-
graphs, 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 apotential haz-
ard. Warnings in
this manual and on the vehicle
are NOT all-inclusive.
You are responsible
for safe operation of the
vehicle and all attachments. You must satisfy
yourself that the techniques, operating proce-
dures,
work methods, or tools you use are safe;
especially those NOT SPECIFICALLY mentioned
by Xtreme Manufacturing.
The
safety of everyone around the vehicle
depends significantly 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 main-
taining
the vehicle.
•This manual does
not replace any laws and
regulations.
•The operator and the vehicle are required
to
comply with all applicable laws and regula-
tions.
Xtreme Manufacturing 4
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 sig-
nal words used in this manual are DANGER,
WARNING, and CAUTION.
ADANGER
DANGER indicates an imminently hazardous sit-
uation which, if not avoided, will result in death
or serious injury.
~ 7\-'Y';"~11~~f'f"T;.'r - .~~
-'-'--~~~'
WARNING indicates apotentially hazardous situ-
ation which, if not avoided, could result in death
or serious injury.
ACAUTION
CAUTION indicates apotentially hazardous situ-
ation which, if not avoided, could result in minor
or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
"--_....;;S:;.:a::..;fe;,;:~, Symbols
Safety symbols are provided to remind the oper-
ator 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 vehicle.
Make safety ahigh priority while operating the
vehicle. Learn and
follow all safety messages in
this manual and on vehicle decals to prevent
eqUipment damage, injury,
or death.
800-497-1704

General Safety
Alert Symbol
DO NOT
OPERATE!
Vehicle Down
For Service Or
Maintenance
•Read Operator
Manual Before
Operating This
Vehicle
Read Material
Safety Data
Sheets (MSDS)
For Chemicals
And Fluids
Safety
Read
Maintenance
Manual Before
Working On
This Vehicle
Know First Aid
Instructions
And/Or
Locations On
Worksite
INSPECTION
;r--
""--
""--
""--
""--
""--
""--
""
•
Perform
Operator
Inspection
Before Starting
This Vehicle
Personal
Protective
Equipment
Gloves
@
DO NOT Operate
If Using
Alcohol, Drugs,
Or Medications
Personal
Protective
Equipment
Safety Shoes
ePersonal
Protective
Equipment
Hardhat
Personal
Protective
Equipment
Safety Glasses
Personal
Protective
Equipment
Ear Protectors
..
.ii1i.
ULead Acid
Batteries Create
Explosive Gases
No Smoking
Keep
Lit
Cigarettes
Away
Keep Flames
And Ignition
Sources Away £Warning!
Hydraulic Oil
.Under Pressure
\-f
Use ABoard Or
Cardboard To
Check Hydraulic
Leaks.
DO NOT
Use Your Hand!
Hydraulic
System Under
Pressure
Keep Hands A
Safe Distance
From Rotating
Fan Blades
Make Sure All
Safety Decals
Are Attached
And Legible
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
Warning!
Rotating
Fan Blades
Can
Cut
Keep Hands A
Safe Distance
From Rotating
Belts
Use Three (3)
Point Contact
Mounting And
Dismounting
The Vehicle
Xtreme Manufacturing 5800-497-1704

Safety
@
DO NOT
•@
DO NOT
~
Fasten
Jump While Seat Use As A
Dismounting Belt Personnel
The Vehicle Carrier
<II
DO NOT Allow
e 00 '0"'"'"
(i) DO NOT
Riders
On Riders On Or In
Allow Riders
Vehicle Frame The Operator
On Auxiliary
Or Fenders Cab Attachments
~
Falling Off Of
Set Parking Set Parking
Attachment
~(®
Brake To ON
~(®
Brake To OFF
Can Result In
Death Or Engage Disengage
Serious Injury Parking Brake Parking Brake
£. .".,,,,,
~ '~'".,
.,
DO NOT Jump!
Vehicle Roll Vehicle Tip Over If Vehicle Tips,
Away Can
~ Can Cause Keep Seat belt
Cause Death Or "Death Or
ON And Brace
Serious Injury Serious Injury Yourself
~®
00'0>
~ '" o..'"~",
DO NOT Especially
Travel With Raise Boom :') Traveling
While Traveling
Boom Raised
On ASlope Up ASlope
Without ALoad
~
Warningl
~ Danger!
~
Electrocution Hot Surfacel
Can Cause
~ ...... Keep ASafe Keep Hands
Death Or Distance From
Il!llIl!ll Il!l\
Away
Serious Injury Electrical Lines
(1)
DO NOT Allow
.,.Pinch Points
"*
Pinch Points
Anyone Under Hands Body
ARaised Load
~
<l'
~""oA"'"~
Warning! DO NOT Use Ventilation
If
Explosion Ether As AOperating This
Hazard Starting Aid Vehicle In
An
Enclosed Space
Xtreme Manufacturing 6800-497-1704

Employer Responsibility
Under OSHA rules, employers are required to
train workers about hazards related to operating
and maintaining
the vehicle. Successful comple-
tion and certification of Safety Training for
Rough Terrain Forklifts is required.
Additional safety information and training
resources can be obtained through these publi-
cations, 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 first aid
instructions for any oil or lubricant being used.
MSDS
should be available from the manufactur-
er/supplier
of the fluid.
Operator Responsibility
Reach forklifts are potentially dangerous if prop-
er safety procedures are not followed. Workers
who operate, maintain, or work near the vehicle
can
be at risk of roll over and run over incidents.
Workers can be crushed
or caught by the vehicle
or its parts if the vehicle is not properly operated
or maintained.
11_Read the Operator Manual
~ ~ BEFORE operating the
~ vehicle. Follow all safety
~ instructions and decals.
Only operate the vehicle
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, mainte-
nance,
or repair procedures properly and safely.
Make sure the vehicle and attachments
will not
be damaged or made unsafe by any procedures
you choose.
Xtreme Manufacturing 7
Safety
Operator Qualifications
Operators must be in good physical and mental
condition, with appropriate reflexes, reaction
time, vision, depth perception, and hearing.
Operators
must possess avalid, current driver's
license as required for the worksite; plus those
required by applicable State, Federal, and/or
local laws.
Successful completion and certification of
Safety Training for Rough Terrain Forklifts is
required.
•Operators
must be properly instructed on
how to operate the vehicle and attachments.
•Operators must operate the vehicle according
to ALL appropriate safety regulations.
•Operator trainees must remain under con-
stant observation and
supervision of an expe-
rienced operator.
Modifications
---
AModifications
to the vehicle or attach-
ments could affect vehicle capacity
and/orstability.
DO NOT make modifi-
cations to the vehicle 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
modifications 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, modification, or
A
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 vehicle.
800-497-1704

Safety
MOl!lnting~Dismounting
Failure to use proper safety procedures when
mounting and dismounting the vehicle could
result in injury or death.
•Keep
steps clear of dirt, mud, snow, ice,
debris, and
other hazards.
!1
Face the vehicle for mounting or dis-
mounting. 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 hand holds or steps. Avoid
accidentally engaging or disengaging a con-
trol.
(f!)
DO NOT jump from the vehicle.
Clothing can get caught on pedals,
levers,
or other protruding parts.
Landing on uneven surfaces can
result in serious personal injury.
'-- __ Worksite Safety
Use proper safety procedures and
A
avoid hazardous situations while
operating the vehicle to prevent prop-
erty damage, injury, or death.
•Check
the worksite for any hazards before
operating the vehicle.
•Check
the work surface for loose soil condi-
tions 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.
Xtreme Manufacturing 8
•Operate the vehicle only on firm, stable sur-
faces. 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 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 aspotter, if necessary.
•Stop for poor visibility conditions, such as
dust, smoke, fog, etc. Wait until
visibility
improves before continuing.
~
Operate the vehicle in an enclosed
area
only if there is aventilation sys-
tem capable of routing hazardous
fumes outside. Engine exhaust con-
tains products of combustion that can
cause
injury or death.
@
DO NOT operate the vehicle if you are
using drugs, alcohol, or any medica-
tion that might impair your jUdgment
or ability.
•You
must be 18 years of age or older to oper-
ate
the vehicle.
•
DO NOT operate the vehicle on roads. The
reach
forklift is not equipped for road travel.
California Proposition 65
Engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, and other reproduc-
tive harm.
800-497-1704

Safety
INSPEcnQN
..--
"'--
"'--
"'--
"'--
"'--
"'--
'"
Perform apre-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.
"""'COON Perform the pre-operation inspection
~ and functional tests in an open area.
&: Inspections and functional tests may
"'-- require assistance. Keep the assis-
:;--
tant visible and asafe distance from
the vehicle
to prevent injury or death.
Become familiar with all safety and
hazard decals, regulations, and pro-
cedures. Make
sure all proper safety
and hazard decals are attached
to the
~=!.=.!Jvehicle and remain legible.
AA
brief description of controls, indica-
tors, and instruments is provided
as a
convenience
for the operator. These
descriptions DO NOT provide com-
plete operation
instructions. Read
and understand the entire manual
to prevent
equipment damage, injury, or death.
~ "Keep fingers and feet away
'\\
from moving parts or pinch
~ points to prevent pinching
~, or crushing. DO NOT allow
anyone between the tires
and the vehicle frame
while operating the vehi-
cle.
a WAR
• Always check the condition of the
~
seat belt and mounting hardware
before operating the vehicle. 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 vehicle until the seat belt
or mounting hardware is replaced, if worn or
damaged.
•The seat belt MUST be worn while operating
the vehicle. Failure
to wearthe seat beltcould
result
in injury or death.
aWARM
Keep the Operator Manual on the
A
vehicle at all times. Contact Xtreme
Manufacturing for any replacement
manuals.
Before Starting Vehicle
OWear 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 vehicle controls,
moving parts, etc.
~
Consult Material Safety
Data Sheets (MSDS)
for
chemical hazards and first
aid instructions. MSDS
should be available from
the manufacturer or supplier of the fluid.
A
Clearly define responsibilities and
procedures for operating the vehicle
and all attachments.
DO NOT proceed
until you seek expert assistance from
aqualified person if any doubt or
question arises about the correct or safe meth-
ods for operating the vehicle.
1111
To avoid injury or death,
~ :::::: ::::: carefully read and under-
- stand all instructions
before operating the vehi-
cle. DO NOT operate, mod-
ify, repair, or maintain the vehicle unless you
read and understand the instructions and warn-
ings in
this and all other applicable manuals and
technical publications. Follow all State and
Federal health and safety laws and/or local regu-
lations.
Xtreme Manufacturing 9800-497-1704

Safety
Operators must be properly trained
Aand qualified
to operate this specific
vehicle. Know the location, learn the
specific 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 opera-
A
tor must be seated with seat belt fas-
tened,
the travel select lever set to
NEUTRAL, the parking brake switch
ON (engaged), the service brake
applied, and the area free of people and obstruc-
tions BEFORE starting the vehicle.
L...- __ O_peration Safe~~~_-.J
ADANGER
~
Injury or death by electrocution can
result from contact with or inade-
-_
quate clearance with energized
power lines or apparatus.
•NEVER operate
the vehicle in an area where
active overhead
power lines, overhead or
underground cables, or other power sources
exist.
•Contact the appropriate
power or utility com-
pany to de-energize power lines or take other
suitable precautions.
it
Keep the vehicle, 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 agreater distance.
• Know the maximum height and reach of this
reach forklift.
Xtreme Manufacturing 10
ADANGER
~
Use of the frame sway control with the
boom raised above horizontal can
L/ cause tip over resulting in death or
~ injury. Always use the frame sway
control to level the vehicle BEFORE
raising the boom above horizontal.
If the vehicle
cannot be leveled using the frame sway control,
do not attempt to raise or place load. Reposition
vehicle
or have the surface leveled.
•
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 vehicle.
•The seat belt MUST be worn while operating
the vehicle. Failure
to wearthe seat beltcould
result in
injury or death.
• DO NOT adjust the seat or seat belt
~
while the vehicle is moving. Keep
both hands on the wheel while the
vehicle is
moving to prevent loss of
vehicle control which could result in
injury or death.
lP
Never try to escape the vehicle if it
"" becomes unstable. Learn and prac-
tice these safety procedures to pro-
tect yourself from aroll 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 firmly.
•Lean away from the point of impact.
•Stay on the vehicle and ride out the roll over
or tip over.
800-497-1704

AWARMIN
• DO NOT use the vehicle as
~
a work platform or person-
h Inel carrier. Falling off of
~ attachments can result in
injury or death.
~
eNEVER
allow passengers
• •
to ride on the vehicle.
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)
Asteering
for traveling at high speeds.
Use
only two wheel (2W) steering for
higher speed travel and slow the vehi-
cle 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 vehicle 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 vehicle tip over
or roll over, and result in injury or death.
A
Allow for adequate clearance between
the attachment and other objects
when turning. The attachment
extends beyond the front of the vehi-
cle. 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.
Xtreme Manufacturing 11
Safety
To prevent property damage, injUry, or
Adeath, make
sure the vehicle comes to
acomplete stop before moving the
travel
select lever. Asudden 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
Awith 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 vehi-
cle
tip over/roll over and result in injury or death.
Operate the vehicle
for maximum sta-
~
bility. Unstable vehicles can tip over,
L /' resulting in property damage, injUry,
~ or death. Keep the vehicle 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 vehicle on level
ground, when possible.
•
Slow down for turns.
• Slow down for rough, slippery, or soft terrain.
•Use caution around steep slopes, creeks, gul-
lies, ridges, ditches, and ravines.
•Stay away
from soft edges that could collapse
under the vehicle.
800-497-1704

Safety
Become completely familiar with the
~
vehicle before operating on slopes.
L/The reach forklift can overturn due to
~ sudden movement or while operating
on aslope.
®
~
DO NOT raise the boom
! ! while operating on aslope.
Raising the boom on a
:'l slope, even without aload,
can change the center
of
gravity, cause a tip over, and result in injury or
death.
o DO NOT turn on asteep slope.
o DO NOT drive the vehicle across slopes.
o Always drivethe vehicle straight up and down
the
slope (NEVER drive diagonally up or down
aslope).
oDrive the vehicle forward up the slope (front
of vehicle facing uphill).
oBack the vehicle down the slope when loaded
(front of vehicle facing uphill).
A
Follow appropriate procedures to pre-
vent sudden changes in vehicle speed
that can result in personal injury or
death.
oTurn the gear select lever to the lowest speed
before descending a
slope and before loading
or unloading atrailer.
o DO NOT adjust the travel select lever while
the vehicle is mOVing.
o DO NOT coast downhill. Keep the travel
select lever in the appropriate position.
DO NOT exit the vehicle without fol-
A lowing proper shut down procedures.
@
~i) ~~~;~~b:~·"~:
~ can cause a.fire
or explOSion.
DO NOT smoke
while refueling and keep sparks and open flames
away
from the vehicle.
Xtreme Manufacturing
12
~
The reach forklift includes aframe
sway
override switch. Improper use
L/ of the frame sway override switch can
~ cause property damage, injury, or
death.
AMake
sure the vehicle frame is level
before raising and extending the
boom. Frame swaying left or right
with the boom raised is extremely
dangerous.
oUse the frame sway control to level the vehi-
cle before raising the boom.
oReposition the vehicle if it cannot be leveled
using the frame sway control.
o DO NOT enter or exit atilted cab.
oRemain seated with the seat belt securely fas-
tened while
the cab is tilted.
oKeep personnel at least 30 feet (9.14 meters)
from atilted vehicle.
ACAUTION
~ Contact with hot surfaces and the
~ exhaust pipe after the vehicle has
I) I )1) been operated can result in serious
Ill\IIMII\I\1 personal injury.
Check
warning indicators and gauges
Aon
the dash panel frequently during
operation. If awarning indicator is
illuminated
or agauge shows abnor-
mal readings,
stop the vehicle, follow
proper shut down procedures, tag the vehicle
with
"Do Not Operate" tags, and have aqualified
mechanic service or repair the vehicle 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 vehicle
comes
to acomplete stop. Align all four (4) tires
"straight-ahead,"
or perpendicular to the axle,
before changing steering mode.
800-497-1704

Load Safety
A
Failure to follow proper safety
procedures when lifting, lowering,
and traveling with aload can cause
property damage, injury, or death.
DO NOT exceed vehicle capacity of 11,000
pounds (4989.5 Kilograms). The total rated
capacity
of the forks being used must equal or
exceed vehicle capacity. Forks can break caus-
ing loss of load and possible injury or death.
DO NOT exceed the manufacturer's
~
rated load for any auxiliary attach-
L/ ment. Any attempt to lift or carry
~ loads in excess of the manufacturer's
rated load may cause vehicle 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
aload
over anyone or over avehicle
cab.
oReview the rated load capacity of each auxil-
iary attachment before performing any opera-
tion.
oUse the correct load chart and NEVER exceed
specified weights and load centers.
o DO NOT exceed the manufacturer's recom-
mended load capacity.
o DO NOT operate the vehicle with an unsafe
load
distribution.
o Adjust the load as necessary, especially for
nonstandard loads.
oUse caution when handling loose material
that can fall into the cab.
oRemove overhanging load materials, when
possible, and watch
for sliding material.
o DO NOT reach aload over posts or other
objects that can enter the cab, if tipped.
oAvoid sudden stops, starts, or turns.
o Avoid carrying asWinging load. If necessary,
secure
the load by attaching it to the vehicle
tie-downs and/or have
another person assist
with safely steadying the load.
Xtreme Manufacturing 13
Safety
Attachments
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 vehicle.
oMake sure attachment locking devices are
always in place.
o DO NOT operate the vehicle until you have
positive indication that the coupler pin and
lever are
fully engaged.
o Hydraulic attachments have a maximum
hydraulic pressure rating. Failure to make
sure the attachment is equal to or slightly
greaterthan 3,000 psi (206.8 bar), which is the
maximum pressure
of the vehicle auxiliary
hydraulic system at the qUick-disconnect
couplers, could result in injury or death.
oMake sure all hydraulic connections are tight
(if equipped).
Shut Down Procedure
To prevent injury or death, follow these
procedures before leaving the vehicle cab:
oPark vehicle on afirm, level surface.
oMove travel select lever to NEUTRAL (N).
oSet parking brake to ON (engaged).
o Lower forks and attachments to the ground.
Always engage
the parking
~®
£brake before leaving the
~ Pvehicle. The vehicle can
roll
if the parking brake is
not ON (engaged) resulting
in
injury or death.
oTurn ignition switch to the OFF position.
oRemove the key.
oUnbuckle the seat belt.
oPlace "Do Not Operate" tags on the starter
switch and steering wheel when maintenance
or service is required.
o Block wheels when maintenance is required.
800-497-1704

Safety
Vehicle Maintenance
L...-_
Follow the manufacturer's instructions for prop-
er maintenance to make sure the vehicle contin-
ues to meet manufacturer's specifications.
~
AttaCh "Do Not Operate" tags to the
~ starter switch and steering wheel
~.... BEFORE beginning any service or
Zmaintenance.
•
"Do Not Operate" tags indicate the vehicle
should not be operated until all service or
maintenance is completed.
•Keep
two (2) legible "Do Not Operate" tags
with the vehicle atall times.
"Do Not Operate"
tags are provided in
this manual.
IXRM-15I
Figure 2-2. Do Not Operate Tag.
• DO NOT operate the vehicle 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
vehicle before all repairs have been made and
all
proper maintenance is completed.
Xtreme Manufacturing 14
8
Tires must have proper ballast.
DO NOT replace foam-filled tires with
¢e¢ pneumatic tires.
ur
Check hydraulic oil lines,
£tubes, and hoses carefully.
1-.\ DO NOT use your bare
~ hand to check for leaks.
Always use a board or
cardboard when checking for ahydraulic leak.
Escaping
hydraulic fluid under pressure, even a
pinhole size leak, can penetrate
body tissue,
causing
injury or death. If hydraulic oil is inject-
ed into
your skin, a doctor familiar with this type
of injury must treat it immediately.
~ Personal injury can result
1-1-1 ~ from hydraulic oil pressure
¢6¢ or hot oil. DO NOT remove
IiIIiIIiI ahydraulic tank filler cap
unless
it is cool enough to
touch with bare hands. Remove the hydraulic
tank filler cap slowly to relieve pressure. Relieve
all pressure in a
hydraulic system before any
caps, lines,
fittings, or related items are discon-
nected or removed.
It is possible for the vehicle to move
~®
suddenly when the brakes are
¢I Preleased resulting in injury or death.
To prevent sudden movement of the
vehicle,
put blocks in front of and
behind wheels before the brakes are released.
If the vehicle is to be towed, make
~®
sure the released brake(s) can be
<> Preapplied or that the towing vehicle
can
stop the vehicle being towed.
~
.... DO NOT use ether as a
A·i(ii< ~:~:;ga~i~. c;~h~a~s:a~~
~ explosion when starting
the engine. Follow the cold
starting procedures and engine manufacturer's
specifications for using astarting aid.
800-497-1704

Safety
Wear eye protection when starting a
vehicle with jump start cables.
Improper
jump start procedures can
cause the battery
to explode.
A WARNING
Lead-acid batteries produce flammable and
potentially explosive gases.
To avoid injury or
death when checking, testing, or charging batter-
ies:
o DO NOT use smoking materials near batter-
ies.
oKeep arcs, sparks, and open flames away
from batteries.
oProvide ventilation for flammable vapors.
oWear proper personal protective equipment,
including safety glasses.
Fluid in electric storage batteries contains
sulfu-
ric acid, which is POISON and can cause
SEVERE CHEMICAL BURNS. Avoid all contact of
fluid with eyes, skin, or clothing. Use protective
gear when handling batteries.
DO NOT tip abat-
tery beyond a45° angle in any direction.
If contact does occur, follow these First Aid sug-
gestions:
oExternal contact -Flush with water.
oEyes -Flush with water for at least 15 min-
utes and get medical attention immediately.
oInternal 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 fluids that induce vomiting.
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.
Xtreme Manufacturing 15
oNever jump start afrozen battery, as it can
explode. Let the battery
thaw out before
charging.
oNEVER jump start the vehicle directly at the
starter solenoid, which could cause the vehi-
cle
to lurch forward or backward, resulting in
injury or death.
o To avoid injury or death when jump starting
with another vehicle, make
sure the two (2)
vehicles are
not touching.
o DO NOT allow jump start cable ends to con-
tact each other near the battery.
oConnect charged battery positive (+) to stalled
battery positive (+).
o Connect charged battery negative (-) to
stalled vehicle ground. Make the connection
to the stalled vehicle ground LAST.
oConnect jump start cable to stalled vehicle
ground asafe distance from the battery to
PREVENT sparks near the battery.
Jump start only with a power source with the
same voltage
as the stalled vehicle.
o Jump start power source must have anega-
tive ground electrical system.
oTurn off all lights and accessories on the
stalled vehicle
to preventthem from operating
when the power
source is connected.
ACAUTION
Electrolyte is an acid and can cause injury if it
contacts the skin or eyes.
800-497-1704

Decals
Decal Legend
Left Side View
I XRM-11S!
Figure 3-1. Decal Legend Left Side View.
Right Side View
IXRM·119I
Figure 3-2. Decal Legend Right Side View.
Xtreme Manufacturing 16 800-497-1704

Decals
Table 1.
Front View Decals
Item Qty. Part No. Description
®1 1 XRM-DAN-1-03
Danger, Electrocution
2 1 XRM-DAN-2·03
Danger, Not AMan Lift
\-
,/
-
(j)
3 1 XRM-DAN-3-03 Danger, Falling 800m Or Load
-/
-~
4 1 XRM-DAN-4-03 Danger, Stay Clear
rt
5 1 XRM-PIC·1-03 Seat Bell
FI!
6 1 XRM·PIC-2-03
InSlall Cover
772XRM·PIC-3-03
No Feet
.b
Ih~1
61XRM·WARN-1-03
Warning, Backward Tip Over
9 1 XRM-WARN·2.Q3
Warning, Vehide Roll Away
J
IL
10 5XRM-WARN·3.Q3 Warning, Pinch Point Area
~
II
11 1XRM-WARN·4-03 Warning, No Riding
12 1XRM-WARN-5-03 Warning, No Riders
I~ ~
~Ii
13 1XRM-WARN-6-03
Warning, Welding/Modification
jitl[
~!)Jf IkIIIIIJ
]>
14
1XRM-WARN·7-03
Warning, Vehicle Tip Over
15 1XRM-WARN-6-03 Warning. Safe Operation
16 1XRM-WARN-9.Q3 Warning, Untrained Personnel
317 1XRM-CAU-1-03
Caution, Walch Your Step
11
16 1XRM·CAU·2·03 Caution, No Ether
19 1XRM·CAU·3-03 Caution, Diesel Fuel
IXRM-
12
01
20 1XRM-CAU-4.Q3 Caution, Hot
21 1XRM-CAU-5-03 Caution, Hydraulic Oil
Figure 3-3. Decal Legend Front View.
22 1XRM-CAU-6-03
Caution, Diesel Only
23 1XRM·HO-03
Hydraulic Oil Only
Rear View 24 1XRM·CFC.Q3
Check/Fill Coolant
25 1XRM·CFEO.Q3
Check/Fill Engine Oil
26 1XRM-TRANS-03 Transmission Fluid
27 1XRM·CON·1-03 Control. Auxiliary
26 1XRM-CON·2-03 Control, 800m
~
(S
29 1XRM-CON-3·03 Control, Attachment Tilt and
~~~
Frame Sway
~
30 1XRM-1145-DF'
Indicator, 800m Angle
L30 1
XRM-1154-DP Indicator, 800m Angle
""
F
31 1XRM·1145·BOOM-1 Lettering (A.c), 800m
\0
IliIlr
31 1XRM-1154-BOOM-1 Lettering (A-C), 800m
032 1XRM-1145-BOOM-2
Lettering (D-E), 800m
lr:=:
BaB [fl..-
~
32 1XRM-1154-BOOM-2 Lettering (D-E), 800m
-33 1XRM-1145-BOOM-3 Lettering (F-H), Boom
ni
• ....• I~
33 1XRM-1154-BOOM·3 Lettering (F-H), Boom
'\I
34
4XRM·CAU-5-04
Caution, Machine Stability
{!
I II
Ii I
JIll]JI
35 1XRM-CON-5-03 Control, Attachment Till
4
•Decals 30, 31, 32 and 33 WIll depend on which machine you are
operating.
Figure 3-4. Decal Legend Rear View.
Xtreme Manufacturing 17 800-497-1704

Decals
Replacement Decals
Replacement decals can be obtained by contacting
Xtreme Manufacturing at [phone]. Please
have the appropriate decal number available when
you call.
1. XRM-DAN-1-03
A DANGER
3. XRM-DAN-3-03
A DANGER
---
FALLING BOOM OR LOAD
Will cause death or severe injury
Stay Clear of raised boom and load. XRM-77
4. XRM-DAN-4-03
IXRM-75I
ELECTROCUTION HAZARD
Will cause death or severe Injury.
Stayclear.
00 not allow vehicle or load
within 10 ft. (3m) p-Ius 2times line
Insulatorlength of any power line.
Notify power company
to de-
energIZe lines before operating
vehicle.
)(RM...DAN-l.(1:J
A DANGER
STAY CLEAR
-
IXRM·78 I
2. XRM-DAN-2-03
DO NOT USE THIS VEHiCLE AS It MAN U"
OR EQUIP VEHIlCLE WITM ANY FOIItM Of'
PERSONNEL WDItK PLATFORM
fAILURE TO HEED COULD RESULT IN
DEATH 011 IEJl,IOUIIMJURY
XRM-76
5. XRM-PIC-1-03
IXRM-79I
Xtreme Manufacturing 18 800-497-1704