Xtreme XR842 Operating instructions

Xtreme XR842 Operating instructions

Tier 4 Final

1

Operation &

Safety Manual

PN 24904-001

(Tier 4 Final)

REV 01

OCTOBER 2015

AUTHOR:

OVY LUNGU

Operation Manual

© 2015 XTREME MANUFACTURING. ALL RIGHTS RESERVED

2

Table of Contents

Table of Contents

Description

Introduction

General

Replacement Manuals

Model/Serial Plate

Orientation

Safety

Safety Disclaimer

Signal Words

Safety Symbols

Employer Responsibility

Operator Responsibility

Operator Qualifications

Modifications

Mounting/Dismounting

Work Site Safety

Before Starting Forklift

Operation Safety

Load Safety

Attachments

Shut Down Procedure

Forklift Maintenance

Dead Engine Towing

Labels

Labels

Replacement Labels

Features

Standard Equipment

Optional Equipment

Specifications

Specifications

Operator Cab

Ignition Switch

Accessory Outlet

Accelerator Pedal

Service Brake Pedal

Steering Wheel

Horn Button

Operator Seat

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30

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10

11

12

14

9

10

9

9

6

9

6

6

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5

5

5

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Description

Operator Seat Controls

Weight Suspension Lever

Lumbar Support

Fore and Aft Adjustment Lever

Backrest Angle Adjustment Lever

Seat Belt

Rear View Mirrors

Controls and Indicators

Travel Select Lever

Gear Select Switch

Parking Brake Switch

Load Capacity Charts

Hydraulic Oil Temperature Indicator

Low Brake Pressure Indicator

Rear Axle Lock Indicator

Engine Warning Indicator

Engine Stop Indicator

Glow Plugs Wait to Start Indicator

Hourmeter

Voltage Gauge

Fuel Gauge

Oil Gauge

Coolant Gauge

Light Switches

Turn Signal and Hazard Switches

Rear Axle Centering Indicator

Steering Select Switch

Declutch Indicator / Declutch Switch

Boom Control

Attachment Tilt Switch

Frame Sway Control Handle

Auxiliary Attachment Control

Windshield Wiper and Washer Switch

Boom Angle Indicator

Boom Extend Letters

Frame Level Indicator

Forklift Lifting Points

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Operation Manual

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Table of Contents

Description

Operation

Pre-Operation Inspection

Pre-Operation Inspection Checklist

Functional Tests

Operator Maintenance

Before Starting Forklift

Starting Forklift

Normal Starting

Jump Starting

Forklift Travel

Steering Modes

Starting Travel

Shifting Gears

Warning Indicators and Gauges

Stopping Travel

Changing Travel Direction

Shut Down Procedure

Refueling

Fuel Types

Diesel Exhaust Fluid (DEF)

Pintle Hook

Attachments

Attachment Disclaimer

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55

56

56

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54

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52

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Table of Contents

Description

Fork Ratings

Standard Carriage Operation

Fork Positioning Carriage Operation

Quick Attach System

Load Handling

Boom Lift Point

Suspended Loads

Pick Up a Load

Carry a Load

Place a Load

Load Shift

Elevating Personnel

Load Capacity Charts

Frame Leveling

Preventive Maintenance

Establishing a Maintenance Program

Maintenance Schedule

Boom Emergency Lower Down Valve

Do Not Operate - Accident Prevention Tags

New or Additional Operators

Lockout / Tagout

Lockout/Tagout Procedure

“Do Not Operate” Tags

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Operation Manual

4

Introduction

General

This Operation and Safety Manual provides the information needed to safely operate the XR842 Reach Forklift.

This manual should be considered a permanent part of the forklift, and kept in the protective manual case located in the operator’s 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 included in this manual for your benefit.

Model / Serial Plate

When contacting our parts department, please have the forklift serial number available. The serial number plate is located in the operator’s cab, at the base of the seat.

For easy reference, you can record the serial number in the space below.

Serial Number:

Warning

Improper operation of this forklift could result in death or serious injury.

BEFORE starting the engine, do the following:

• Read the Operation and Safety Manual

• Read all the Safety Labels on the Forklift

• Clear the area of all other persons

Learn and practice safe use of forklift controls in a safe, clear area, BEFORE you operate this forklift on a work site.

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 XR842 forklift can be obtained by contacting our parts department by phone or visiting our website:

Xtreme Manufacturing

Phone: (800) 497-1704 www.XMFG.com

Figure 1. Serial Number Plate

Orientation

Right side, left side, front, and rear are directional references given from the operator’s seat when facing forward.

RIGHT

LEFT

Figure 2. Forklift Direction Orientation

5

Operation Manual

Safety Disclaimer

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 specifically mentioned by Xtreme

Manufacturing.

The safety of everyone around the forklift 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 maintaining the forklift.

• This manual does not replace any laws and regulations.

• The operator is required to comply with all applicable laws and regulations.

Safety

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.

Caution

It is advised that if operators intend to operate the machine solo, then they shall establish radio communications with appropriate personnel in case of an emergency.

Warning

Tampering with safety devices is prohibited.

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 labels to prevent death, serious injury, or equipment damage. The following two pages include a list of some of the safety symbols that may be used on this forklift.

Operation Manual

6

Safety

General Safety

Alert Symbol

DO NOT OPERATE!

Telehandler Down

For Service Or

Maintenance

Perform

Operator

Inspection

Before Starting

This Telehandler

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 Labels

Are Attached

And Legible

Read Operator

Manual Before

Operating This

Telehandler

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

Labels And Labels

7

Read Maintenance

Manual Before

Working On

This Telehandler

Know First Aid

Instructions And/

Or Locations On

Work site

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 At A Safe

Distance From

Rotating Belts

Use Three Points of Contact When

Entering and

Exiting Telehandler

Operation Manual

Operation Manual

DO NOT

Jump While

Dismounting

The Telehandler

DO NOT Allow

Riders On Telehandler

Frame Or Fenders

Attachment Can

Result In Death Or

Serious Injury

Warning!

Telehandler 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

Warning! Establish

Radio Communication

Before Operating Solo

Fasten

Seat

Belt

DO NOT Allow

Riders On Or In

The Operator Cab

Set Parking Brake

To ON

Engage Parking

Brake

Warning!

Telehandler 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

Warning!

HOT COOLANT.

8

DO NOT

Allow Riders

On Auxiliary

Attachments

Set Parking

Brake To OFF

Disengage

Parking Brake

DO NOT Jump!

If Telehandler Tips,

Keep Seat belt ON

And Brace Yourself

Tip Over Hazard,

Especially

Traveling Up A

Slope Without A

Load

Hot Surface!

Keep Hands Away

Safety

Pinch Points

Body

Have Adequate

Ventilation If

Operating This

Telehandler In An

Enclosed Space

Warning!

Operate With

Caution During

Storms Or High Wind

DO NOT Use As A

Personnel Carrier

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 certification of the Safety Training for Rough

Terrain Forklifts is required.

Additional safety information and training resources can be obtained through these publications, organizations, and/or appropriate sources:

• (29CFR) Code of Federal Regulations.

• (OSHA) Occupational Safety and Health Administration.

• (NIOSH) National Institute for Occupational Health and

Safety.

• (ANSI) American National Standards Institute

• (AEM) Association of Equipment Manufacturers

• (ITSDF) Industrial Truck Standards Development

Foundation

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 manufacturer/ supplier of the fluid.

Operator Qualifications

Operators must be in good physical and mental condition, with appropriate reflexes, reaction time, vision, depth perception, and hearing.

Operators must possess a valid, current driver’s license as required for the work site; 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 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.

Modifications

Operator Responsibility

Warning

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 or can be crushed or caught by the forklift or its parts which could result in death or serious injury if the forklift is not properly operated or maintained.

Read the Operation and Safety

Manual BEFORE operating the forklift. Follow all safety instructions and labels. 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.

9

Warning

Modifications to the forklift or attachments could affect forklift capacity and/or stability which could result in death or serious injury.

DO NOT make modifications 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 labels 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 alteration, including welding or drilling, can impair and weaken the protective capability of the Rollover Protective Structure/Falling

Object Protective Structure (ROPS/FOPS) and could result in death or serious injury.

• Replace the ROPS/FOPS, if it is damaged, before operating the forklift.

Operation Manual

Mounting/Dismounting

Warning

Failure to use proper safety procedures when mounting and dismounting the forklift could result in death or serious injury.

• Keep steps clear of dirt, mud, snow, ice, debris, and other hazards.

Face the forklift for mounting or dismounting. Use hand holds and steps to maintain three (3) points of contact at all times, either both hands and one foot or both feet and one hand.

• DO NOT use the controls, steering wheel, or foot pedals as hand holds 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 could result in death or serious personal injury.

Work Site Safety

Warning

Use proper safety procedures and avoid hazardous situations while operating the forklift to prevent death, serious injury, or property damage.

• Check the work site 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 hot line to mark all underground hazards.

• Learn the location of all underground hazards at the work site, such as:

1. Gas and water pipes

2. Electrical cables

3. Sewers

Underground objects could cause death or serious injury.

Safety

Warning

• Operate the forklift only on firm, stable surfaces. Holes, obstructions, debris, loose fill, and other work site hazards could result in death or serious injury.

• DO NOT allow bystanders in the work area.

• Avoid personnel, machinery, and forklifts in the work area.

• Know the rules for movement of people and forklifts on the work site.

• Follow work site 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.

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 forklift is not equipped for road travel.

Warning

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 could cause death or serious injury.

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.

Caution

Use caution when operating the forklift during storms or strong winds.

Operation Manual

10

Safety

Warning 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. Failure to wear the proper protective clothing could result in death or serious injury.

Before Starting Forklift

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 could cause death or serious injury.

Perform the pre-operation inspection and functional tests in an open area and away from any other obstacles or equipment. Inspections and functional tests may require assistance. Keep the assistant visible and a safe distance from the forklift to prevent death or serious injury.

Become familiar with all safety and hazard labels, regulations, and procedures. Make sure all proper safety and hazard labels are attached to the forklift and remain legible.

Warning

Keep the Operation and Safety Manual on the forklift at all times. Contact Xtreme

Manufacturing for replacement manuals.

Clearly define responsibilities and procedures for operating the forklift and all attachments.

DO NOT proceed until you seek expert assistance from a qualified person if any doubt or question arises about the correct or safe methods for operating the forklift.

To avoid death or serious injury, 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.

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 death, serious injury, or equipment damage.

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 forklift frame while operating the forklift. Doing so can result in death or serious injury.

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 death or serious injury.

Consult Material Safety

Data Sheets (MSDS) for chemical hazards and first aid instructions. MSDS should be available from the manufacturer

• 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 death or serious injury.

or supplier of the fluid.

11

Operation Manual

Warning

Operators must be properly trained and qualified to operate this specific forklift.

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.

Failure to follow these guidelines could result in death or serious injury.

To prevent death or serious injury, 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

Death or serious injury by electrocution will 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.

sources.

Keep the forklift, attachments, and loads a safe distance from electrical power lines.

• Remain at least 10 feet, plus an additional 0.4 inches for each 1,000 volts over 50,000 volts, from active power lines and other power

• Work site operating directives and/or local or state codes might require a greater distance.

• Know the maximum height and reach of this forklift.

Warning

Use of the frame sway control with the boom raised above horizontal could 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

Operation Manual

12

Safety 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 death, serious injury, or property damage, 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 death or serious injury.

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 death or serious injury.

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 firmly.

• Lean away from the point of impact.

• Stay on the forklift and ride out the roll over or tip over.

Warning

It is unlawful to tamper with or remove any component of the aftertreatment system. It is also unlawful to use Diesel

Exhaust Fluid (DEF) that does not meet the specifications provided or to operate the machine with no DEF.

Warning

Diesel Exhaust Fluid contains urea. DO NOT get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. DO NOT swallow internally. In the event the DEF is ingested, contact a physician immediately. Refer to the Material Data Safety Sheet (MSDS) for additional information.

Safety

Caution

Never attempt to create Diesel Exhaust Fluid by mixing agricultural grade urea with water. Agricultural grade urea does not met the specifications required and thye aftertreatment system may be damaged.

Warning

DO NOT use the forklift as a work platform or personnel carrier. Falling of attachments could result in death or serious injury.

NEVER allow passengers to ride on the forklift. DO NOT allow riders on the frame or operator cab. Allowing passengers to ride could result in serious injury.

The 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 steering can cause tip over which could result in death or serious injury.

DO NOT travel with an elevated boom.

Retract the boom fully. Lower the boom as low as practical for proper visibility. Maintain enough ground clearance for conditions. tip over, which could result in death or serious injury.

Traveling with an elevated boom can cause

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 death, serious injury, or property damage.

Warning

To prevent death, serious injury, or property damage, 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, could 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 death or serious injury.

Operate the forklift for maximum stability.

Unstable forklifts can tip over, resulting in death, serious injury, or property damage.

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.

13

Warning

Become completely familiar with the forklift before operating on slopes. The forklift could overturn due to sudden movement or while operating on a slope resulting in death or serious injury.

DO NOT raise the boom while operating on a slope. Raising the boom on a slope, even without a load, will change the center of gravity, could cause a tip over, and result in death or serious injury.

• DO NOT turn on a steep slope.

• DO NOT drive the forklift across slopes.

• Always drive the forklift straight up and down a slope

(never drive diagonally up or down a slope).

• Drive the forklift forward up a slope (front of forklift facing uphill).

• Back the forklift down a slope when loaded (front of forklift facing uphill).

Operation Manual

Follow appropriate procedures to prevent sudden changes in forklift speed that could result in death or serious injury.

• 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 shutdown procedures.

Engine fuel is flammable and can cause a fire or explosion resulting in death or serious injury. DO NOT smoke while refueling and keep sparks and open flames away from the forklift.

Contact with hot surfaces and the exhaust pipe after the forklift has been operated could 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 tag the forklift with “Do Not Operate” tags, and have a qualified mechanic service or repair the forklift BEFORE placing it into service again. Ignoring warning indicators can result in death, serious injury, or property damage.

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.

Warning

The forklift includes a Frame Sway Override switch. Improper use of the Frame Sway

Override switch could result in death, serious injury, or property damage.

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 and can result in death or serious injury.

• Use the frame sway control to level the forklift before raising the boom.

Operation Manual

14

Safety

• 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 from a tilted forklift.

Load Safety

Warning

Failure to follow proper safety procedures when lifting, lowering, and traveling with a load could result in death, serious injury, or property damage.

DO NOT exceed forklift capacity of 8,000 lbs.

The total rated capacity of the forks being used must equal or exceed forklift capacity. Forks can break causing loss of load and possible death or serious injury.

DO NOT exceed the manufacturer’s rated load for any auxiliary attachment. Any attempt to lift or 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 death or serious injury.

Failure to keep personnel clear of the load area while the load is being raised or lowered could result in death or serious injury. DO

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 specified weights and load centers.

• DO NOT exceed the manufacturer’s 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.

Safety

Attachments Forklift Maintenance

Warning

Improper connection of an auxiliary attachment could result in death or serious injury. Attachments not locked into place can become unstable 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 equipped with a pressure reducing valve, or is rated to be equal or greater than 3,500 psi, which is the maximum pressure of the forklift auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

• Make sure all hydraulic connections are tight (if equipped).

Shut Down Procedure

Warning

To prevent death or serious injury, follow these procedures before leaving the forklift cab:

• Park forklift on a firm, 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), which could result in death, serious injury, or property damage.

• 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.

Warning

Follow the manufacturer’s instructions for proper maintenance to make sure the forklift continues to meet manufacturer’s specifications. Failure to properly maintain the forklift can result in improper performance, which could cause death, serious injury, or property damage.

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.

• DO NOT operate the forklift and attachments if they require repairs.

• Make sure basic maintenance is completed and service problems are corrected.

• Death or serious injury can result from operating a forklift before all repairs have been made and all proper maintenance is completed.

Warning

Pressurized system. HOT COOLANT. Stop engine, wait until radiator is cool to touch, then loosen cap slowly to relieve pressure.

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 fluid under pressure, even a pinhole size leak, can penetrate body tissue, which could cause death or serious injury. If hydraulic oil is injected into your skin, a doctor familiar with this type of injury must treat it immediately.

Serious injury could result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic 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 disconnected or removed.

15

Operation Manual

Safety

It is possible for the forklift to move suddenly when the brakes are released, which could result in death, serious injury, or property damage. To prevent sudden movement of the forklift, place wheel chocks 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 the tow forklift has the braking capacity to stop the forklift.

DO NOT use ether as a starting aid. Ether is flammable and can cause an explosion when starting the engine, which could result in death or serious injury. Follow the cold starting procedures and engine manufacturer’s specifications for using a starting aid.

Tires must have proper ballast. DO NOT replace foam-filled tires with pneumatic tires.

Use of pneumatic tires will severely affect forklift load capacity, which could result in death, serious injury, or property damage.

to dilute stomach contents. Do not induce vomiting.

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.

Jump Starting

Warning

Warning

Warning

Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:

• DO NOT use smoking materials near batteries.

• Keep arcs, sparks, and open flames away from batteries.

• Provide ventilation for flammable vapors.

• Wear proper personal protective equipment, including safety glasses.

Fluid in electric storage batteries contains sulfuric acid, which is poison and could cause severe chemical burns.

Avoid all contact of fluid 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 (including under the eyelids) for at least 15 minutes and get medical attention immediately. Flushing must begin immediately to avoid permanent eye tissue damage.

• Internal contact

- Drink large quantities of water or milk

Operation Manual

16

Wear eye protection when starting a forklift with jump start cables. Improper jump start procedures could cause the battery to explode, which could result in death or serious injury.

• Never jump start a frozen battery, as it can explode. Let the battery thaw out before charging.

• NEVER jump start the forklift when travel select lever is in gear, which can cause the forklift to lurch forward or backward, and could result in death, serious injury, or property damage.

• To avoid injury or death when jump starting with another forklift, make sure the two (2) forklifts are not touching.

• DO NOT allow jump start cable ends to contact each other.

• 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.

• Turn off all lights and accessories on the stalled forklift to prevent them from operating when the power source is connected.

• Electrolyte contains acid and could cause serious personal injury if it contacts the skin or eyes.

Safety

Dead Engine Towing

Parking Brake Release (Front Axle)

Warning

Block all four (4) wheels. Failure to do so could result in death or serious injury from forklift roll away.

1.

Block all four wheels to prevent the forklift from moving once the parking brake is disabled.

2.

Position the towing vehicle in place. Attach any chain needed to secure the disabled forklift.

3.

Under the front of the forklift, locate the four (4) brake release bolts [two (2) per side] at the base of the front axle.

4.

Loosen jam nuts. Loosen brake release bolts. Do not completely remove bolts. Tighten one (1) full turn if bolts completely back out (repeat for each side). Tighten jam nuts.

5.

Crawl out from under the forklift and clear the area of any unnecessary personnel.

6.

Carefully remove the blocking from each of the four (4) tires and tow the vehicle to a secure location.

A

C

B

Figure 3. Brake Release Locations (both sides)

D

Re-Activating Parking Brakes (Front Axle)

Warning

Block all four wheels. Failure to do so could result in death or serious injury from forklift roll away.

1.

After you have blocked all four (4) wheels, under the front of the forklift, locate the four brake release bolts [two (2) per side] at the base of the front axle.

2.

Loosen jam nuts. Tighten brake release bolts until you begin to feel resistance. Tighten jam nuts. Repeat for each side.

3.

The parking brakes should now be re-activated and the front wheels are locked. Remove the blocks from all four (4) wheels.

4.

Verify the parking brake works.

5.

Remove any warning tags from the ignition or steering wheel.

Figure 4. Brake Release Bolts (both sides of axle)

Figure 5. Brake Release Bolt

17

Operation Manual

Labels

Left Side View

Fig 6. Label Legend (Left Side)

Right Side View

3 16 10 17

Labels

Fig 7. Label Legend (Right Side)

Operation Manual

60

18

Labels

Front View

62

Rear View

Fig 8. Label Legend (Front)

Cab View

Fig 9. Label Legend (Rear)

62

Fig 10. Label Legend (Cab)

61

16

19

17

Operation Manual

Labels

Table 1. Labels

Item Qty Part No. Description

1

2

1 18008-000 Data Plate

1 18004-060 Dash Overlay

3

4

5

1 18010-001 Caution, Slip/Trip Hazard

1 18011-001 Caution, Engine Damage Hazard

6

7

1 18013-001 Diesel Only Low Sulfur

1 18014-001 Check Engine Oil CJ-4

8

9

1 18015-001 Check/Fill Coolant

1 18016-001 Caution, Burn Hazard

2 18017-001 Danger, Crushing Hazard

10

8 18018-001 Danger, Electrocution Hazard

11

1 18018-002 Danger, Electrocution Hazard

12

3 18019-001 Danger, Crushing Hazard

13

1 18020-001 Warning, Tip-Over Hazard

14

1 18021-001 Danger, Crushing Hazard

15

1 18022-001 Warning, Tip Over Hazard

16

1 18023-001

Warning, Welding and Modification

Hazard

17

1 18025-001 Warning, Falling Hazard

18

1 18026-001

Warning, Unrestrained Operator

Hazard

19

1 18027-001

Danger, Rotating Equipment

Hazard

20

1 18031-001 Warning, Safe Operation Checklist

21

1 18032-001 Warning, Improper Use Hazard

22

1 18033-000 Auxiliary Handle Control

23

1 18034-000 Boom Handle Control

24

1 18039-000 Boom Angle Indicator

25

6 18041-001 Warning, Pinch Point Hazard

26

3 18042-000 Xtreme logo (chassis)

27

2 18066-001 Caution, Crushing Hazard

28

1 18067-100 Frame Sway Handle

29

1 18334-001 Handle Auxiliary Controls (Opt.)

30

1 18069-000 Hydraulic Tank Fluid Level

Item Qty Part No. Description

31

1

32

2

18082-001 Warning, Injection Hazard

18083-001 Warning, Explosion Hazard

33

1

34

36

37

4

38

40

41

1

42

44

45

1

46

48

49

1

50

4

35

2

2

1

39

1

1

1

43

1

2

1

47

1

1

1

51

1

18086-001 Hydraulic Fluid, Use Dexron III

18090-001 Warning, Tip Over Hazard

18300-001 Warning, Falling Hazard

18312-000 Warning, Falling Hazard

18315-000 Tie Down Point

18043-000 Xtreme logo

18044-000 Xtreme X

18046-000 Boom Swoosh Left Front

18047-000 Boom Swoosh Left Rear

18048-000 Boom Swoosh Right Front

18049-000 Boom Swoosh Right Rear

18080-001 XR842

18050-000 Boom Lettering A-B-C

18051-000 Boom Lettering D-E

18052-000 Boom Lettering F-G

18311-001 Boom Hook 8k (Optional)

18331-000 Caution, Adjustable Carriage (Opt.)

18332-000 Warning, Tow Capacity

17020-100 Load Chart, Standard Carriage

52

1 17364-100 Load Chart, Lift Point

53

1 17016-000 Load Chart, 12ft Truss

54

1 17017-000 Load Chart, 15ft Truss

55

1 17018-000 Load Chart, 3ft Truss with Winch

56

1 17019-000 Load Chart, 12ft Truss with Winch

57

1 17071-000 Load Chart, Personnel Platform

58

1 17128-000 Load Chart, Sling Mount

59

1 17180-000 Load Chart, Boom Hook

60

1 18409-000 “DEF ONLY” Label

61

1 Emission Control Information

62

1 18413-000 Fill DEF Tank

Operation Manual

20

Labels

Replacement Labels

Replacement labels may be obtained by contacting Xtreme

Manufacturing at (702) 636-2969.

From outside Las Vegas, Nev., call Xtreme Manufacturing toll free at (800) 497-1704.

Please have the correct label number available when you call.

1) 18008-000

Parking Brake

OFF

ON

702-636-2969

18004-060 www.XMFG.com

800-497-1704

2) 18004-060

Turn

Hazard

Boom

Rear

Front

On

Off

Lights

Wiper

Wash

On

Off

Left

Up

Right

Down

Outriggers

Steering

Wheels Must Be

Centered Before

Engaging.

Crab

2W

4W

3) 18010-001

DIESEL

ONLY

Ultra Low Sulphur

Fuel Only

Maximum Sulphur

Content: 15ppm

18013-002

5) 18013-002

21

4) 18011-001

CHECK

ENGINE OIL

Minimum Oil Specification:

API CJ-4 or higher

18014-002

6) 18014-002

Operation Manual

7) 18015-001

9) 18017-001

8) 18016-001

10) 18018-001

Operation Manual

11) 18018-002

22

12) 18019-001

Labels

Labels

13) 18020-001

15) 18022-001

14) 18021-001

16) 18023-001

17) 18025-001

23

18) 18026-001

Operation Manual

19) 18027-001

WARNING

21) 18032-001

20) 18031-001

22) 18033-100

Operation Manual

23) 18347-000

24

24) 18039-000

Labels

Labels

25) 18041-001 26) 18042-000

27) 18066-001 28) 18067-100

29) 18334-001

18334-001

25

FULL

18069-000

30) 18069-000

Operation Manual

31) 18082-001

33) 18086-001

32) 18083-001

34) 18090-001

Operation Manual

35) 18300-001

26

36) 18312-000

Labels

Labels

37) 18315-000

39) 18044-000

38) 18043-000

40) 18046-000

41) 18047-000

27

42) 18048-000

Operation Manual

A

43) 18049-000

D

44) 18080-001

B

45) 18050-000

C

E

46) 18051-000

18051-000

F G

47) 18052-000

18052-000

18050-000

48) 18311-000

18311-000

CARRIAGE DAMAGE

DAMAGE may result from adjusting forks when carriage is loaded.

ONLY ADJUST FORKS WHEN CARRIAGE

IS UNLOADED.

18331-000

49) 18331-000

Operation Manual

28

DEATH or SERIOUS INJURY could result from improper operation when using tow connection.

DO NOT ELEVATE BOOM ABOVE 30 WHEN

TOWING.

DO NOT EXCEED RATED TOW CAPACITY.

Max vertical load 500 LBS.

Max tow capacity 5000 LBS.

18332-000

50) 18332-000

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

4,000 LBS AT 24 IN

MIN CAPACITY FORK

(8,000 LBS PAIR).

45

XR842 LOAD CHART - STANDARD CARRIAGE

40

35

30

25

BO

OM

A

NG

LE

40

45

50

55

35

60

63

G

F

E

D

C

B

30 A

25

20

20

2.0 FT

LOAD

CENTER

15

15

10 1,850 LBS

2,000 LBS

3,000 LBS

2.0 FT

LOAD

CENTER

10

4,000 LBS

5,000 LBS

6,500 LBS

5

8,000 LBS

5

0

0

5

G

F

E

D

C

B

A

702-636-2969 • 800-497-1704

P/N

17014-000

35 30 25 20 15 10 5 0 REACH FT

51) 17014-000

45

'S' RATING FOR FORKS

STRAIGHT. 'T' RATING

FOR FORKS ROTATED

FROM STRAIGHT.

FORKS MUST BE

STRAIGHT WHEN THE

BOOM IS ABOVE

55 DEGREES.

4,000 LBS AT 24 IN

MIN CAPACITY FORK

(8,000 LBS PAIR).

40

35

30

25

20

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

15

10

5

0

5

0

5

XR842 LOAD CHART - SWING CARRIAGE

60

63

G

BO

OM

A

NG

LE

40

45

50

55

35

30

E

D

C

B

A

S

S

T

T

2.0 FT

LOAD

CENTER

25

20

15

10

1,400 LBS

1,800 LBS

2.0 FT

LOAD

CENTER

2,500 LBS

S=3,500 LBS T=3,000 LBS S=4,500 LBS T=3,750 LBS S=6,000 LBS T=4,500 LBS

S=8,000 LBS T=6,000 LBS

D

C

B

A

G

F

E

702-636-2969 • 800-497-1704

P/N

17015-000

35 30 25 20 15 10 5

52) 17015-000

0 REACH FT

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

LOAD RATING

INCLUDES WEIGHT

OF ANY RIGGING.

702-636-2969 • 800-497-1704

P/N

17016-000

55

50

45

40

35

30

25

20

15

10

5

0

45

XR842 LOAD CHART - 12 FT TRUSS BOOM

20

15

10

30

25

BO

OM

A

NG

LE

50

55

60

63

45

40

35

5

0

5

40

2,000 LBS

G

F

35

E

30

D

C

B

25 20

A

15 10

G

F

E

5

D

C

B

A

0

TRUSS WEIGHT

550 LBS NOMINAL

CG X = 48.33 IN

FORWARD OF

MOUNTING PIN.

REACH FT

53) 17016-000

Labels

Labels

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

LOAD RATING

INCLUDES WEIGHT

OF ANY RIGGING.

702-636-2969 • 800-497-1704

P/N 17017-000

XR842 LOAD CHART - 15 FT TRUSS BOOM

G

55

F

E

50

45

40

35

BO

OM

50

A

NG

LE

60

63

55

40

45

D

C

B

A

30

35

25

20

15

10

5

0

10

5

0

5

20

15

30

25

1,800 LBS

G

F

E

2,000 LBS

D

C

B

A

45 40 35 30 25 20 15 10 5 0

TRUSS WEIGHT

650 LBS NOMINAL

CG X = 65.78 IN

FORWARD OF

MOUNTING PIN.

REACH FT

54) 17017-000

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

LOAD RATING

INCLUDES WEIGHT

OF ANY RIGGING.

XR842 LOAD CHART - 12FT TRUSS BOOM WITH WINCH

45

60

63

G

40

35

30

BO

OM

A

NG

LE

45

40

50

55

F

E

D

C

35

B

25

30

A

TRUSS

WEIGHT

900 LBS

NOMINAL

CG X = 48.88 IN

FORWARD OF

MOUNTING PIN.

20

15

10

5

25

20

15

10

1,500 LBS

5

0

1,700 LBS

2,000 LBS

TRUSS BOOM

LEVEL ONLY

702-636-2969 • 800-497-1704

P/N 17019-000

0

45

40

5

G

35

F

E

30

D

C

25

B

20

A

15

10 5 0

REACH FT

56) 17019-000

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

LOAD RATING

INCLUDES WEIGHT

OF ANY RIGGING.

XR842 LOAD CHART - 3 FT TRUSS BOOM WITH WINCH

45

60

63

G

40

F

35

30

BO

OM

A

NG

LE

40

45

50

55

E

D

C

35

B

25 30

A

TRUSS

WEIGHT

600 LBS

NOMINAL

CG X = 14.64 IN

FORWARD OF

MOUNTING PIN.

20

25

20

15

10

5

5

0

15

10

2,000 LBS

TRUSS BOOM

LEVEL ONLY

0

702-636-2969 • 800-497-1704

P/N

17018-000

45 40 35

5

30

G

F

25

E

20

D

C

15

B

10

A

5 0 REACH FT

55) 17018-000

8 FT PLATFORM

(MAX 475 LB) = P8

10 FT PLATFORM

(MAX 550 LB) = P10

THE PLATFORM SHALL

BE ELEVATED ONLY

WHEN THE CHASSIS

IS LEVEL.

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

50

45

40

35

XR842 LOAD CHART - PERSONNEL PLATFORM

A

BO

OM

40

NG

LE

50

45

55

60

63

G

F

E

D

C

2FT

4FT

NOMINAL

DEPTH

1,000LB

NOMINAL

PLATFORM

CAPACITY

30 35

B

25

30

25

A

3.5FT

NOMINAL

RAILING

20

20

15

15

4,000 LBS AT 24 IN

MIN CAPACITY FORK

(8,000 LBS PAIR).

10

10

5

5

0

P8 = 150LB P10 = 75LB P8 = 200LB P10 = 125LB P8 = 525LB P10 = 450LB

P8 = 860LB P10 = 785LB

P8 = 1,000LB P10 = 1,000LB

0

5

G

F

E

D

C

B

A

702-636-2969 • 800-497-1704

P/N

17071-000

35 30 25 20 15 10 5 0

REACH FT

57) 17071-000

45

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

40

35

30

LOAD RATING

INCLUDES WEIGHT

OF ANY RIGGING.

25

20

15

10

5

0

5

0

25

20

15

10

1,850 LBS

XR842 LOAD CHART - SLING MOUNT

BO

OM

A

NG

LE

40

45

50

55

35

60

63

G

F

E

D

C

B

30 A

2,000 LBS

3,000 LBS

4,000 LBS

5,000 LBS

6,500 LBS

8,000 LBS

5

G

F

E

D

C

B

A

702-636-2969 • 800-497-1704

P/N

17128-000

35 30 25 20 15 10 5

58) 17128-000

0

SLING MOUNT

WEIGHT 270 LBS

NOMINAL

CG X = 26.5 IN

FORWARD OF

MOUNTING PIN.

REACH FT

DIESEL EXHAUST

FLUID (DEF)

ONLY

18409-000

60) 18409-000 61) Emission Control Information

XR842 LOAD CHART - BOOM LIFT POINT

45

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

40

35

30

25

20

15

10

5

0

702-636-2969 • 800-497-1704

P/N

17180-000

30

BO

OM

A

NG

LE

40

45

50

35

55

60

63

G

F

E

D

C

B

30

A

25

20

15

10

1,850 LBS

5

0

2,000 LBS

3,000 LBS

4,000 LBS

5,000 LBS 6,500 LBS

8,000 LBS

5

25

G

F

20

E

15

D

C

10

B

5

A

0

STANDARD CARRIAGE

MUST BE ATTACHED

AND UNLADEN WHEN

BOOM LIFT POINT IS

IN USE.

REACH FT

59) 17180-000

62) 18413-000

29

Operation Manual

Features

Features

Feature

Boom

Chassis

Standard Equipment

Description

Universal quick attach head

Three (3) section boom

Boom equipped with heavy duty boom rollers

Rear axle stabilization

1-1/4 inch main frame plate

Sealed pivot pins for extended service periods

High boom mount design

Sliding engine transmission cowling

Low mounted central engine & drive train

Lights (front)

12 volt electrical system

Fuel level, engine coolant temperature, voltage, and oil pressure gauges

Easy access drop down electrical panel

12 volt accessory power outlet

Display with fuel level, engine coolant temperature, oil pressure, tachometer, DEF level and battery voltage gauges, brake oil pressure, parking brake, axle lock, rear wheel alignment, parking brake, axle lock and rear wheel alignment

Electric horn and backup alarm

Rear view mirror

Adjustable suspension seat with seat belt

Deluxe suspension seat

Boom angle and frame level indicator

3600 panoramic visibility

Feature

Optional Equipment

Description

Tires Foam-filled

Hydraulics Auxiliary hydraulic circuit with quick attach

Attachment tilt switch

Frame sway control handle

Frame sway override switch

Options Enclosed cab with heat and air conditioning

Heater/defroster/windshield wiper

Work light package

Hydraulic side-swing carriage (with quick attach couplers)

Limited slip differential

Various carriage sizes

Full line of attachments

Two-Wheel Rear (2WR) Steering

Turn signals/hazard lights

Operation Manual

30

Specifications

Specifications

Performance

Capacity . . . . . . . . . . . . 8,000 lbs

Lift Height . . . . . . . . . . . 41’5”

Forward Reach . . . . . . . . 28’10”

Frame Leveling L/R . . . . . 11°/11°

Operating Weight . . . . . . 26,850 lbs

Power Train

Engine . . . . . . . . . . . . . Perkins 99.5 hp

Fuel Capacity . . . . . . . . . 48 gal

Transmission . . . . . . . . . 3-Speed

Brakes . . . . . . . . . . . . . . Inboard Wet Disc

Parking Brake . . . . . . . . . SAHR

Tires

Hydraulics

Tires (Standard Eq) Foam Filled

13.00 x 24 E3

GPM . . . . . . . . . . . . . . . 39

PSI . . . . . . . . . . . . . . . . 3,500

Hydraulic Oil Capacity . . . 45 gal

Dimensions

Length to fork face . . . . . . 20’11”

Width . . . . . . . . . . . . . . 101”

Height . . . . . . . . . . . . . 7’11”

Wheel Base . . . . . . . . . . 120”

Ground Clearance . . . . . . 16.5”

Turning Radius . . . . . . . . 12’

Standard Equipment

Heavy-duty Frame/Chassis

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/FOPS

Adjustable Hydraulic Operator Controls

Suspension Seat

Quick Attach (Common Fit)

Xtreme Service Accessibility

Attachments

Standard Carriage - 48” or 72”

Pallet Forks - 2.25” X 4” X 48”

Lumber Forks - 1.75” X 7” X 60”

Utility Bucket - 1.25 cu. yd.

Concrete Bucket - 0.5 cu. yd., or 1.00 cu. yd.

Truss Boom - 12’

Accessories and Options

Enclosed Cab

4th Steer Mode, Rear Pivot

A/C

Work Light Package

Rotating Beacon

31

Operation Manual

Operator Cab

Warning

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 death, serious injury, or equipment damage.

Operator Cab

Accessory Outlet

A 12 volt accessory outlet is provided as a power source for personal items, such as a radio or cell phone.

Ignition Switch

A key is required to operate the ignition switch.

Figure 12. Accessory Outlet

Accelerator Pedal

Press the accelerator pedal to increase engine speed. The accelerator pedal is spring-loaded to return to idle speed.

Figure 11. Key and Ignition Switch

The ignition switch has three (3) positions: OFF, RUN, and

START.

Position

OFF

RUN

START

Ignition Switch

Purpose

Shuts down entire electrical system, except the horn and accessory outlet.

All controls and indicators are operable.

Engages starter motor to crank engine.

NOTE:

The START position is spring-loaded. When the key is released, the Ignition switch will automatically return to the

RUN position.

Figure 13. Accelerator Pedal

Operation Manual

32

Operator Cab

Service Brake Pedal

Press the service brake pedal to slow or stop the forklift. The service brake pedal activates the service brakes on all four (4) wheels.

Horn Button

Press the horn button to sound the horn.

Figure 16. Horn Button

Figure 14. Service Brake Pedal

Steering Wheel

Turn the steering wheel left or right to steer the forklift in the corresponding direction.

Operator Seat

Operator Seat Controls

The operator seat can be adjusted four (4) ways: weight suspension, lumbar support, fore and aft, and backrest angle.

Figure 15. Steering Wheel

33

Figure 17. Operator Seat

Operation Manual

Weight Suspension Lever

Rotate the weight suspension lever to increase or decrease the seat cushion suspension based on the weight of the operator and comfort level desired.

Operator Cab

Fore and Aft Adjustment Lever

Pull the fore and aft adjustment lever outward from the seat to release the seat lock. Slide the seat forward or backward to a comfortable location and release the lever to lock the seat in the desired position.

Figure 18. Weight Suspension Lever

Figure 20. Fore and Aft Adjustment Lever

Lumbar Support

The seat controls include a four (4) position lumbar support knob. Rotate the lumbar support knob to raise, lower, increase, or decrease the lumbar support.

Backrest Angle Adjustment Lever

Pull the backrest angle adjustment lever up to release the seat backrest lock. Adjust the angle of the backrest and release the lever to lock the backrest to the desired angle.

Figure 19. Lumbar Support

Operation Manual

34

Figure 21. Backrest Angle Adjustment Lever

Operator Cab

Seat Belt

Warning serious injury.

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, which could result in death or

• 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 death or serious injury.

The forklift is equipped with a standard two inch (2”) wide retractable seat belt. A three inch (3”) wide retractable seat belt is available where required by local laws and regulations.

Before starting the engine, adjust the seat for position and comfort (refer to the Operator Seat section of this manual) and then adjust the seat belt as follows:

1.

Grasp the free end of the seat belt (located on the left side of the seat) and make sure the belt webbing is not twisted or entangled in any portion 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.

Rear View Mirrors

Two (2) adjustable rear view mirrors are provided to aid the operator’s rear vision. One (1) rear-view mirror is mounted on the upper left of the operator’s cab.

Figure 22. Retractable Seat Belt

Warning

DO NOT adjust the seat or seat belt while the forklift is moving. Keep both hands on the wheel while the forklift is moving to prevent loss of forklift control which could result in death or serious injury.

Figure 23. Cab-Mounted Mirror

35

Operation Manual

Operator Cab

One (1) rear-view mirror is mounted on the right side of the chassis.

F

N

R

Figure 25. Travel Select Lever

Figure 24. Chassis-Mounted Mirror

Controls and Indicators

Travel Select Lever

The travel select lever has three (3) positions: FORWARD,

NEUTRAL, and REVERSE, which change the direction of travel.

Position

Travel Select Lever

Purpose

F (Forward) UP Position (away from the operator)

N (Neutral) CENTER Position

R (Reverse) DOWN Position (toward the operator)

Gear Select Switch

The Gear Select switch has a twist grip handle with three (3) positions: 1 - FIRST, 2 - SECOND, and 3 - THIRD.

NOTE:

The forklift can be operated in three (3) forward and three (3) reverse gears.

The travel select lever automatically locks when it is in the

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

NOTE: The travel select lever must be in the NEUTRAL position to start the forklift.

NOTE: The back-up alarm automatically sounds when the travel select lever is in the REVERSE position.

Figure 26. Gear Select Switch

Operation Manual

36

Operator Cab

Parking Brake Switch

The Parking Brake switch (A) has two (2) positions: ON and

OFF.

Load Capacity Charts

Load Capacity Charts are located on the left side of the front control panel. Load Capacity Charts are provided to assist the operator in determining how to safely handle loads with the forklift, including boom angle, height, and reach.

A

B

Figure 27. Parking Brake

(A) Parking Brake Switch Guard (B) Parking Brake Indicator

Set Parking Brake switch (A) to ON (DOWN) to engage the parking brake and to OFF (UP) to disengage the parking brake.

The parking brake indicator (B) illuminates when the parking brake is set to ON (engaged).

A B

D

Figure 28. Load Capacity Charts

Display Indicators

The display allows the operator to view vital engine information and other critical functions, including gauge display, engine diagnostics to monitor engine condition and performance, fault codes, and warning indicators.

E

F

C

G

G

H

N

K

M

O

I

L

J

Figure 29. Display Indicators

37

Operation Manual

Operator Cab

A. HIGH HYDRAULIC OIL TEMP

The hydraulic oil temperature indicator illuminates when the oil temperature is above 1800 F. If the hydraulic oil temperature indicator illuminates, stop and idle the engine to allow time for cooling. If the hydraulic oil temperature indicator does not go out after five (5) minutes, 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.

B. WATER IN FUEL

The Water in Fuel Indicator will be displayed when there is water present in the Diesel fuel.

C. LOW DEF LEVEL WARNING

DEF (Diesel Exhaust Fluid) should be added when the Low DEF

Level indicator is displayed. Refer to the Operation section on

Warning Indicators and Fault Codes and the Engine Indicator

Chart (Figure 65).

D. DEF LEVEL GAUGE

The DEF (Diesel Exhaust Fluid) level gauge indicates on a graph and as a percentage the DEF level. The DEF tank capacity is five (5) gallons.

E. FUEL GAUGE

The fuel gauge indicates the approximate quantity of fuel in the tank. The total capacity of the fuel tank is 17 gallons.

F. ENGINE TEMP GAUGE

The Engine Temp Gauge indicates the temperature of the coolant in the engine cooling system. After starting the forklift, allow time for the Engine Temp Gauge to begin moving before operating the forklift. After the engine has sufficiently been warmed up, normal engine coolant temperature should read between 1800 to 2000 F.

G. LOW BRAKE PRESSURE INDICATOR AND WARNING

The Low Brake Pressure indicator illuminates if the hydraulic oil pressure gets too low. If the Low Brake Pressure indicator is illuminated, do not release the parking brake or engage transmission until the indicator is out. If the indicator does not go out, stop the forklift, follow proper shut down procedures, tag forklift with “Do Not Operate” tags, and have a qualified mechanic service or repair the forklift

BEFORE

placing it into service again.

H. OIL PRESSURE

The Oil Pressure Indicator will be displayed when the engine oil pressure is below normal. If the Oil Pressure Indicator comes on during normal operation, stop the forklift, follow proper shut down procedures, tag forklift with “Do Not Operate” tags, and have a qualified mechanic service or repair the forklift

BEFORE

placing it into service again.

Operation Manual

38

I. WAIT TO START

The Wait to Start Indicator is displayed when the key switch is moved to the RUN position. Wait until the indicator goes out before starting the engine.

J. TACHOMETER

The Tachometer indicates engine RPM.

K. ENGINE SERVICE REQUIRED

The Engine Service Required Indicator will be displayed when a maintenance interval has been exceeded.

L. HOURMETER

The Hourmeter indicates and records engine operating hours. Use the hourmeter to establish a forklift maintenance schedule.

M. VOLTAGE GAUGE

The Voltage Gauge indicates the amount of charge (in Volts).

Normal system voltage is between 12.5 and 14 Volts. If the voltage gauge shows abnormal readings, stop the forklift, follow proper shut down procedures, tag forklift with “Do Not

Operate” tags, and have a qualified mechanic service or repair the forklift

BEFORE

placing it into service again.

N. REAL AXLE CENTERED INDICATOR

Indicates that the rear axle is centered.

O. REAR AXLE LOCKED INDICATOR

Indicates that the rear axle is locked.

P. ENGINE SHUTDOWN

The Engine Shutdown Indicator will be displayed when there is a serious engine or DPF fault and the engine should be shut down. Automatic shut down is imminent. Refer to the

Operation section on

Warning Indicators and Fault Codes

and the Engine Indicator Chart (Figure 65).

P

P

Figure 30. Engine Shutdown Indicator

Q. ENGINE WARNING

The Engine Warning Indicator will be displayed when there is an engine or DPF fault. Refer to the Operation section

Operator Cab

on

Warning Indicators and Fault Codes

and the Engine

Indicator Chart (Figure 65).

Q

Q

Figure 31. Engine Warning Indicator

Figure 33. Main Menu

ENGINE DIAGNOSTICS

Pressing the ENGINE DIAGNOSTICS soft button will display engine information. Pressing the MENU button will return to the GAUGE DISPLAY mode (figure 32).

Display Features

The display allows the operator to view vital engine information and other critical functions, including gauge display, engine diagnostics to monitor engine condition and performance, fault codes, and warning lights.

POWER UP

When the ignition is turned on, the display powers up and defaults to GAUGE DISPLAY mode. The display should remain in this mode for normal operation.

Soft Buttons

Soft Buttons

Figure 34. Engine Diagnostics

USER SETTINGS

Pressing the USER SETTINGS soft button will enter a mode where some display settings may be adjusted. Pressing the

MENU button will return to the MAIN MENU.

Menu Button Enter Button

Figure 32. Gauge Display

MAIN MENU

Pressing the MENU button will bring up the MAIN MENU

(figure 33). Pressing the MENU button again, or the GAUGE

DISPLAY soft button, will return to the GAUGE DISPLAY mode.

39

Figure 35. User Settings

Operation Manual

Operator Cab

UTILITIES

Pressing the UTILITIES soft button “A” (figure 36) will bring up the Service Remainders Main Menu (figure 37).

A

Figure 36. Utilities

SERVICE REMINDERS

Pressing the SERVICE REMINDERS soft button “A” (figure 37) will display data pertaining to maintenance schedules (figure

38). Pressing the MENU button “B” (figure 37) will return to the

UTILITIES mode.

Figure 38. Service Reminders

FAULT BUTTON POP-UPS

A fault condition may trigger a pop-up dialog box describing the nature of the fault. A soft button may need to be pressed to acknowledge the fault.

Turn Signal and Hazard Switches

The optional Turn Signal Switch controls the turn signals

(toggle left or right). The optional Hazard Light Switch flashes all four (4) turn signals (toggle up or down).

A

B

Figure 37. Service Reminders Main Menu

Operation Manual

40

Figure 39. Turn Signal and Hazard Light Switches

Operator Cab

Steering Select Switch

Warning

DO NOT change steering modes until the forklift slows or comes to a complete stop. Align all four (4) wheels perpendicular to the axle, before changing steering mode.

Changing steering modes at higher travel speeds can make the forklift unstable, and cause a loss of control, which could result in death, serious injury, or property damage.

The Steering Select switch has three (3) steering positions:

Crab, Two Wheel Steering (2W), and Four Wheel Steering (4W).

NOTE:

Increasing engine speed can increase boom lift and extend speed.

NOTE:

Two (2) boom functions can be performed at the same time by moving the handle into the corner between (2) functions

Figure 40. Steering Select and 2-Wheel Rear Switches

Boom Control

The boom control handle has variable motions from the center position that control boom and tilt functions.

The boom control handle is used to raise, lower, extend, retract the boom, tilt the carriage (or attachment), and control auxiliary functions (when equipped with a carriage or attachment with additional functions).

NOTE:

The boom control handle is a variable speed control.

Function speed is proportional to handle movement. The more the handle is moved in the appropriate direction, the faster the corresponding function will occur.

Figure 41. Boom Control Handle

Boom Control Handle Functions

Function Purpose

Aux Select Button Control auxiliary functions

Enable Trigger Trigger must be enabled for other functions of the control handle to operate

Tilt Switch Control carriage tilt (up/down)

41

Operation Manual

C

D

A

B

E

F

G

H

Figure 42. Boom Control Handle Functions

Operator Cab

Attachment Tilt Switch

The Attachment Tilt Switch located on the top of the boom control handle controls attachment tilt functions.

1

2

Figure 43. Boom Control Handle Functions

Operation Manual

42

Figure 44. Attachment Tilt Switch

(1) Attachment Tilt Down (2) Attachment Tilt Up

The Attachment Tilt Switch:

• Controls the attachment tilt functions by rolling the switch upward and downward.

• Is a variable speed switch. Function speed is proportional to how far the switch is rolled. The more the switch is rolled in the appropriate direction, the faster the corresponding function will occur.

Function

Attachment Tilt Switch

Purpose

Attachment tilt down Roll switch upward

Attachment tilt up Roll switch downward

NOTE:

The attachment carriage will retain any set angle throughout boom raising, lowering, retracting, or extending operations.

Operator Cab

Auxiliary Attachment Control

The Auxiliary Attachment Control lever controls the functions of approved optional attachments that can be mounted to the forklift and require hydraulic supply for operation.

Figure 45. Frame Sway Control Handle

Function

Frame Sway Control Handle

Purpose

Frame sway right

Frame sway left

Move handle right

Move handle left

NOTE:

Lock the frame sway by placing the travel select lever in NEUTRAL or applying the service or parking brake.

NOTE:

Maximum frame sway is 220 overall or 110 each direction, left and right.

Warning

The forklift includes a Frame Sway Override switch. Improper use of the Frame Sway

Override switch could cause death, serious injury, or property damage.

Figure 47. Auxiliary Attachment Control Lever

Lights Switch

Flip the toggle switch to ON to turn the front lights on.

Figure 46. Frame Sway Override Switch

The frame sway feature becomes locked and will not operate when the boom is raised 40° or more. Pressing the Frame

Sway Override switch (the trigger) on the control handle will override the lockout feature and allow slow frame sway.

Figure 48. Lights Switch

43

Operation Manual

Boom Angle Indicator

The boom angle indicator is located on the left side of the boom and is visible from the operator’s seat. Use the boom angle indicator to determine the boom angle when referring to load capacity charts. Refer to the LOAD CAPACITY CHARTS section of this manual for more information.

NOTE:

The boom angle indicator is a plumb arrow with angular graduations from -50 to +700

Operator Cab

Frame Level Indicator

The frame level indicator is mounted on the upper right corner of the operator’s cab. The frame level indicator allows the operator to view if the forklift has been positioned in a level condition.

Figure 49. Boom Angle Indicator

Boom Extend Letters

As the boom is extended, the boom extend letters on the left side of the boom are visible to the operator. These letters indicate boom extension as it corresponds to the load capacity charts.

Figure 51. Frame Level Indicator

Warning

DO NOT try to lift or handle heavy components without the use of appropriate lifting equipment.

Figure 50. Boom Extend Letters

Operation Manual

44

Warning

DO NOT use attachments that are corroded excessively.

• All the attachments should be stored in an appropriate enclosure as to prevent corrosion and deterioration due to environmental conditions.

• Inspect the forklift and the attachments periodically for corrosion.

Operator Cab

Forklift Lifting Points

The XR842 lifting points are shown below. The forklift should only be lifted if lifting points are installed.

Warning

Ensure that no one is in the work radius before lifting forklift to avoid crushing hazard.

MODEL: XR842

UNLADEN VEHICLE WEIGHT: 26,850 lbs

UNLADEN CENTER OF GRAVITY

AFT LIFT POINT

FORWARD LIFT POINT

75.0"

APPROX

120.0"

WHEELBASE

Figure 52. XR842 Lifting Points

18241-011

45

Operation Manual

Operation

Operation

Pre-Operation Inspection

To perform the pre-operation inspection make sure the forklift is NOT running, the engine is cool, the forklift is parked on level ground, the boom is completely retracted, and the frame is level.

NOTE:

Copy and use the Pre-Operation Inspection Checklist in this section.

Caution

Contact with hot surfaces and the exhaust pipe after the forklift has been operated could result in serious personal injury.

Warning

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 the operator, resulting in death or serious injury.

• 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 death or serious injury.

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. Failure to wear the proper protective clothing could result in death or serious injury.

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 could cause death or serious injury.

Perform a pre-operation inspection and functional tests in an open area.

Become familiar with all safety and hazard labels, regulations, and procedures. Make sure all proper labels are attached to the forklift and remain legible.

Remove forklift from service and place “Do

Not Operate” tags on the Starter switch and steering wheel if anything is found to be in need of repair or maintenance, defective, or unsafe in any way.

Operation Manual

46

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 fluid under pressure, even a pinhole size leak, can penetrate body tissue, which could cause death or serious injury. If hydraulic oil is injected into your skin, a doctor familiar with this type of injury must treat it immediately.

Serious injury could result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic 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 disconnected or removed.

Never remove the radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant could cause severe burns or eye injury. Wear protective clothing and safety glasses.

Operation

Warning

Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:

• DO NOT use smoking materials near batteries.

• Keep arcs, sparks, and open flames away from batteries.

• Provide ventilation for flammable vapors.

• Wear proper personal protective equipment, including safety glasses.

Fluid in electric storage batteries contains sulfuric acid, which is poison and could cause severe chemical burns.

Avoid all contact of fluid 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 (including under the eyelids) for at least 15 minutes and get medical attention immediately. Flushing must begin immediately to avoid permanent eye tissue damage.

• Internal contact

- Drink large quantities of water or milk to dilute stomach contents. Do not induce vomiting.

Get medical attention 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 could cause the battery to explode, which could result in death or serious injury.

• Never jump start a frozen battery, as it can explode. Let the battery thaw out before charging.

• NEVER jump start the forklift when travel select lever is in gear, which can cause the forklift to lurch forward or backward, and could result in death, serious injury, or property damage.

• To avoid injury or death when jump starting with another forklift, make sure the two (2) forklifts are not touching.

• DO NOT allow jump start cable ends to contact each other.

• 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.

• Turn off all lights and accessories on the stalled forklift to prevent them from operating when the power source is connected.

• Electrolyte contains acid and could cause serious personal injury if it contacts the skin or eyes.

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

Tires must have proper ballast. DO NOT replace foam-filled tires with pneumatic tires.

Use of pneumatic tires will severely affect forklift load capacity, which could result in death, serious injury, or property damage.

Warning

Use DEF meeting ISO 22241-1. There is NO acceptable substitute. Using anything other than DEF fluid may result in permanent aftertreatment damage.

47

Operation Manual

Pre-Operation Inspection Checklist

Walk around the ENTIRE forklift while visually performing the pre-operation inspection.

Check that “Do Not Operate” tags have not been placed on the forklift.

Check that load capacity charts are legible.

Check that frame level indicator is working properly.

Check condition and operation of the seat belt and mounting hardware.

Check that Operation and Safety Manual is in the protective case and legible.

Check forks for welds, cracks, misalignment, or any other damage.

the carriage.

Check all hydraulic hoses and hose connections for wear or leaks.

Check tilt cylinder for leaks or any other damage.

Check boom for straightness or any other damage.

Check all four (4) tires and wheels for:

Punctures, cracks, cuts, gouges, bulges, foreign objects, or any other damage to tires.

Loose or missing lug nuts.

.

Check front and rear sway cylinders and hoses for leaks or any other damage.

Check mirrors for cracks, cleanliness, and proper adjustment.

Check hydraulic reservoir sight

Check engine compartment for:

. Add

Loose or damaged belts, hoses, and radiator blades.

Coolant reservoir level. Add radiator coolant, if necessary.

Engine oil level. Add engine oil, if necessary.

Electrical wires and connectors.

.

Check front and rear axles for leaks or any other damage.

Check main boom cylinders and hydraulic lines for leaks or any other damage.

Check battery terminals for corrosion.

Check battery for cracked, melted, or damaged case.

Check electrical connections on rear sway cylinder.

Check that all labels are legible. Replace any damaged or illegible labels.

Check that operator’s cab is empty of all trash, debris, or any loose items.

Check that personal belongings are secured in the personal storage box.

Check that pedals, and non-skid surfaces are clean and free of grease, oil, dirt, snow, or ice.

.

Date: __________________________ Initials: __________________________

Operation Manual

48

Operation

Operation

Functional Test Checklist

Warning

Perform a pre-operation inspection and functional tests at the beginning of each work shift. Perform the pre-operation inspection first. DO NOT perform the pre-operation inspection with the engine running or hot.

Contact with moving or heated parts could cause death or serious injury.

Perform the pre-operation inspection and functional tests in an open area and away from any other obstacles or equipment. Inspections and functional tests may require assistance. Keep the assistant visible and a safe distance from the forklift to prevent death or serious injury.

If anything is found to be in need of repair or maintenance, defective, or unsafe in any way, remove forklift from service and place “Do

Not Operate” tags on the starter switch and steering wheel.

The safety, efficiency, and service life of your forklift will be increased by performing functional tests at the beginning of each shift. If any of the items in the functional tests are not operating properly or within set tolerances, 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.

Operate the boom control handle forward and backward to lower and raise boom.

Operate the boom control handle left and right to retract and extend boom.

Operate the attachment tilt thumb stick up and down to tilt the attachment.

Operate the sway control handle left and right to frame sway left or right.

Operate the auxiliary attachment control (if an auxiliary attachment is being used).

Turn work lights on and off.

Press the horn button to sound the horn.

Place the travel select lever in reverse to sound the backup alarm.

Release the parking brake.

Operate the forklift in forward and reverse.

Test the service and parking brakes.

• Apply the service brake pedal after the forklift begins to move and the forklift should stop immediately.

• Apply the parking brake. The forklift should not move unless the parking brake is released.

Test each steering function. Operate the forklift in forward and reverse at low idle speed and turn the steering wheel approximately 1/4 turn in each direction for each of the following modes:

• Align the wheel and set the Steering Select switch to crab steering.

• Align the wheel and set the Steering Select switch to 2 wheel (2W) steering.

• Align the wheel and set the Steering Select switch to 4 wheel (4W) steering.

Check the gauges after the engine warms to the proper operating range.

• Check the voltage gauge. The voltage gauge should read between 11 and 15 volts.

• Check the engine coolant temperature gauge. The engine coolant temperature gauge should read between180 to 2000F.

• Check the engine oil pressure gauge. The engine oil pressure gauge should read between 40 to 80

PSI.

49

Operation Manual

Operation

Operator Maintenance

B

A

Figure 53. Check Hydraulic Oil Sight Gauge (A);

Add Hydraulic Oil, if Necessary (B).

DO NOT remove a hydraulic tank filler cap unless it is cool enough to touch with bare hands.

Figure 56. Check Engine Oil Level. Add Engine Oil (API CJ-

4), If Necessary.

Figure 54. Add DEF (Diesel Exhaust Fluid) when the Low

DEF Level indicator is displayed.

Figure 57. Check Battery Case and Terminals

Figure 55. Check Coolant Reservoir Level. Add Coolant, if

Necessary. DO NOT OPEN WHEN HOT.

Operation Manual

50

Figure 58. Store Operation Manual in Protective Case

Operation

Before Starting Forklift

Warning

Failure to use proper safety procedures when mounting and dismounting the forklift could result in death or serious injury.

• Keep steps clear of dirt, mud, snow, ice, debris, and other hazards.

Face the forklift for mounting or dismounting. Use hand holds and steps to maintain three (3) points of contact at all times, either both hands and one foot or both feet and one hand.

• DO NOT use the controls, steering wheel, or foot pedals as hand holds 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 could result in death or serious personal injury.

1. Master battery disconnect on.

2. Use safe mounting/dismounting procedures to enter the operator cab.

3. Adjust the operator seat for position and comfort. (Refer to Seat Adjustment section in this manual)

4. Adjust mirrors (this may require assistance).

5. Adjust the side console control panel.

6. Fasten seat belt.

7. Make sure the travel select lever is set to NEUTRAL (N) and the Parking Brake is ON (engaged).

NOTE:

The engine will only start when the travel select lever is in NEUTRAL (N) and the Parking Brake switch is ON (engaged).

F

N

R

Figure 59. Travel Select Lever Must Be in NEUTRAL (N) to

Start the Forklift

B

A

Figure 60. Parking Brake Switch (A) Must Be ON (Engaged) to Start the Forklift.

The Parking Brake switch (A) has two (2) positions: ON and

OFF.

51

Operation Manual

Operation

2.

Turn key in ignition switch clockwise to the START position.

Starting Forklift

Normal Starting

Warning

To prevent death, serious injury, or property damage, 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, and the

Parking Brake switch ON (engaged) BEFORE starting the forklift.

1.

Place Key in Ignition Switch.

Figure 62. Turn Key in Ignition Switch to START

3.

Release key immediately after the engine starts. The

Ignition Switch will automatically return to RUN.

NOTE:

The Start position is spring-loaded. When the key is released, the ignition switch will automatically return to the

RUN position.

Figure 61. Key and Ignition Switch

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.

Figure 63. Ignition Switch Automatically Returns to RUN

NOTE:

If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before cranking the engine again.

4.

After the engine starts, allow the engine to idle for approximately 60 seconds.

5.

Apply the service brake pedal and disengage the Parking

Brake switch.

Operation Manual

52

Operation

Jump Starting

Jump Start or replace the battery of the forklift when the battery is discharged to the point that it will not crank the starter.

Warning

Lead-acid batteries produce flammable and potentially explosive gases. To avoid death or serious injury when checking, testing, or charging batteries:

• DO NOT use smoking materials near batteries.

• Keep arcs, sparks, and open flames away from batteries.

• Provide ventilation for flammable vapors.

• Wear proper personal protective equipment, including safety glasses.

Fluid in electric storage batteries contains sulfuric acid, which is poison and could cause severe chemical burns.

Avoid all contact of fluid 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 (including under the eyelids) for at least 15 minutes and get medical attention immediately. Flushing must begin immediately to avoid permanent eye tissue damage.

• Internal contact

- Drink large quantities of water or milk to dilute stomach contents. Do not induce vomiting.

Get medical attention immediately.

IMPORTANT - In case of internal contact, DO NOT give fluids that induce vomiting.

• Never jump start a frozen battery, as it can explode. Let the battery thaw out before charging.

• NEVER jump start the forklift when travel select lever is in gear, which can cause the forklift to lurch forward or backward, and could result in death, serious injury, or property damage.

• To avoid injury or death when jump starting with another forklift, make sure the two (2) forklifts are not touching.

• DO NOT allow jump start cable ends to contact each other.

• 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.

• Turn off all lights and accessories on the stalled forklift to prevent them from operating when the power source is connected.

• Electrolyte contains acid and could cause serious personal injury if it contacts the skin or eyes.

1. Connect one end of the positive (+) jumper cable to the positive (+) post of the discharged battery.

2. Connect the other end of the positive (+) jumper cable to the positive (+) post of the charged battery.

3. Connect one end of the negative (-) jumper cable to the negative (-) post of the charged battery.

4. Make the final jumper cable connection to the stalled forklift ground at the furthest point from the battery.

5. Start the forklift. Refer to the Starting Forklift section in this manual.

Warning

Wear eye protection when starting a forklift with jump start cables. Improper jump start procedures could cause the battery to explode, which could result in death or serious injury.

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.

53

Operation Manual

NOTE:

If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before cranking the engine again.

6.

After the engine starts, allow the engine to idle for approximately 60 seconds.

7.

Remove the jumper cables in reverse order of their connection (i.e. negative cable ground connection first, etc)

Forklift Travel

Steering Modes

Warning

Operation

Crab Steering

Crab steering allows all four (4) wheels to turn in the same direction as the steering wheel, allowing the forklift to move “sideways”. Crab steering is useful in a congested work site to line up to a loading location.

Two Wheel Front Steering (2W)

Two wheel (2W) steering allows the front wheels to turn in the same direction as the steering wheel. The rear wheels remain in a fixed forward position. Two wheel (2W) steering is useful for traveling at higher speeds.

Four Wheel Steering (4W)

Four wheel (4W) steering allows the front wheels to turn in the same direction and the rear wheels to turn in the opposite direction of the steering wheel. The rear wheels follow the front wheel path. Four wheel (4W) steering is useful for a short turning radius and in muddy or sandy conditions.

Two Wheel Rear Steering (2WR) - OPTIONAL

OPTIONAL two wheel rear (2WR) steering allows the rear wheels to turn in the same direction as the steering wheel. The front wheels remain in a fixed forward position.

NOTE: A separate switch is located on the right side of the dash panel to engage and disengage the optional two wheel rear (2WR) steering mode.

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 using crab, four wheel (4W), or the optional two wheel rear (2WR) steering could cause tip over, which could result in death, serious injury, or property damage.

Check the turning radius around the forklift before making a turn, especially if using four wheel (4W) steering or two wheel rear (2WR) steering, which provide a tighter turning radius. Look over your shoulder in the direction of the turn when backing. Failure to remain aware of your turning radius area could result in death, serious injury, or equipment damage.

Caution

DO NOT change steering modes until the forklift slows or comes to a complete stop. Align all four (4) wheels “straightahead”, or perpendicular to the axle, before changing steering mode. Changing steering modes without aligning all four (4) wheels may result in equipment damage.

Warning

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, when turning, to avoid hitting personnel and other objects in the area to prevent death, serious injury, or property damage.

The forklift includes three

STANDARD

modes of steering;

Crab, Two Wheel (2W), and Four Wheel (4W) Steering. Use the

Steering Select switch located on the dash panel to change steering modes.

Operation Manual

54

Figure 64. Maximum

Fork Sweep

Operation

Starting Travel

Warning

Use proper safety procedures and avoid hazardous situations while operating the forklift to prevent death, serious injury, or property damage.

• Check the work site for any hazards before operating the forklift.

• Check the work surface for loose soil conditions and overhead power lines.

Warning

To prevent death or serious injury, the operator must be seated with seat belt fastened, the travel select lever set to

NEUTRAL, the Parking Brake ON (engaged), and the area free of people and obstructions

BEFORE starting the forklift.

1. Start the forklift. Refer to the Starting Forklift section in this manual.

2. Apply service brake.

3. Release parking brake.

4. Rotate the gear select switch to the gear desired.

5. Move the travel select lever to FORWARD or REVERSE for the appropriate direction of travel.

6. Release the service brake pedal.

7. Slowly press the accelerator pedal to start travel.

Shifting Gears

Warning

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 could result in death or serious injury.

The transmission has three (3) gears that can be used for traveling in forward or reverse.

To shift gears rotate the gear select lever to the next gear while the forklift is traveling.

• Use first gear (1) for highest torque and pulling power.

• Use higher gears for higher ground speed.

• Never travel in top gear (3) when carrying a load.

• Allow the engine speed to slow down before shifting to a lower gear.

Warning Indicators and Gauges

55

Warning

A fault condition may trigger a pop-up dialog box on the display describing the nature of the fault during operation. Corresponding red or amber warning lights will illuminate to indicate the severity of the fault. If an Engine

Shutdown fault condition is present, 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.

Report all warning indicators and fault codes to a qualified mechanic. Ignoring warning indicators or fault codes can cause improper performance, which could result in death, serious injury, or property damage.

Fault condition dialog boxes will pop up and warning lights on the display will illuminate during critical circumstances.

Some of these conditions demand immediate attention and forklift servicing. If an Engine Shutdown fault condition is present, the forklift should be shut down as soon as practical to prevent serious mechanical failure.

TIER IV FINAL ENGINE

ENGINE WARNING INDICATOR

A steady Engine Warning Indicator by itself shows the engine is operating normally but there are one or more minor faults with the engine electronic management system.

A flashing Engine Warning Indicator by itself shows there are one or more serious faults and the engine is operating in at reduced power. A flashing Engine Warning Indicator is displayed with the Engine Stop Indicator when the engine is either shut down or an automatic engine shutdown is imminent.

A flashing Engine Warning Indicator displayed with both the

Oil Pressure Indicator and Engine Stop Indicator shows the oil pressure is low The engine should be shutdown. Automatic engine shutdown is imminent.

Operation Manual

Operation

ENGINE STOP INDICATOR

The Engine Stop Indicator is displayed with a flashing Engine Warning Indicator when the engine is either shut down or an engine shutdown is imminent.

An Engine Stop Indicator displayed with both the Oil Pressure

Indicator and flashing Engine Warning Indicator shows the oil pressure is low The engine should be shutdown.

High Exhaust

Warning

Par

Diesel

Stop

High Exhaust Diesel

Temperature

(HEST)

Par ti culate

Filter

ON ON

Automatic engine shutdown is imminent.

OIL PRESSURE INDICATOR

An Oil Pressure Indicator displayed with both the Engine Stop Indicator and flashing Engine

Warning Indicator shows the oil pressure is low

The engine should be shutdown. Automatic engine shutdown is imminent.

Engine should be shutdown by operator. Automa occur a ft ti Shutdown er a short period of ti me.

Figure 65. Engine Indicator Chart

er a short period of ti me.

Active Descrip ti on ti on

Engine opera

Active or manual regenera ti on

ON ON

ON ON Ac ti ve Diagnos ti c

Normal opera ti on No Faults Engine opera ti Normal opera ti on

ON ti on disabled by operator or ti c

Engine is Regenera ti on disabled by operator or

ON ON Manual regenera Engine opera ti Manual regenera ti on required

ON

ON ON

ON

Low Oil Pressure

Stopping Travel

1. Stop the forklift by applying the service brake pedal.

2. Slow the forklift until it comes to a complete stop.

3. Move the travel select lever to NEUTRAL (N).

4. Set the parking brake to ON (engaged).

Warning

To prevent death, serious injury, or property damage, apply service brakes until the forklift comes to a complete stop, move travel select lever to NEUTRAL (N), set the Parking Brake switch to ON (engaged), lower and retract the boom, and shut off the engine before exiting the forklift.

Changing Travel Direction

1. Stop the forklift by applying the service brake pedal.

2. Move the travel select lever to FORWARD or REVERSE.

Operation Manual

operator. Automa occur a ft ti Shutdown er a short period of ti me.

ti c shutdown is imminent ti me.

Engine should be shutdown by operator. Automa occur a ft ti Low Oil Pressure er a short period of ti me.

rate or during forced regenera ti on ti ti on me.

Warning

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, which could result in death, serious injury, or property damage.

3. Release the service brake pedal.

4. Slowly press the accelerator pedal to start travel.

56

Shut Down Procedure

1. Park forklift on level ground, if possible.

2. Stop the forklift by applying the service brake pedal.

3. Place the travel select lever in NEUTRAL (N) and set the parking brake to ON (engaged).

4. Lower the boom and rest carriage on ground.

5. Turn the ignition key to OFF and remove the key.

6. If the forklift is parked on an incline, block the wheels.

Operation

Refueling

Pintle Hook

Warning

Engine fuel is flammable and can cause a fire or explosion resulting in death or serious injury. DO NOT smoke while refueling and keep sparks and open flames away from the forklift.

NOTE:

The fuel tank capacity is 72 gallons.

• Make sure the forklift is level to obtain an accurate fuel level reading.

• Shut off the engine.

• Ground the fuel nozzle against the filler neck to avoid sparks.

Fuel Types

Use ASTM #2 diesel fuel with a minimum Cetane rating of

40 for better fuel economy and performance under most operating conditions.

• Use standard #2 diesel fuel for operating at temperatures above 32°F (0°C).

• Use a blend of #1 and #2 diesel fuel (“winterized” #2 diesel) for operating at temperatures below 32°F (0°C).

• Fuels with Cetane ratings higher than 40 may be needed in higher altitude or in an extremely low temperature climate to prevent hard starts and excessive smoke.

Death or serious injury could result from improper operation when using tow connection.

Do not elevate boom above 30 degrees when towing. Do not exceed rated tow capacity

(500 lbs vertical load, 5,000 lbs tow capacity.

The Pintle Hook is used for towing trailers and equipment, rated at or below 5,000 lbs maximum capacity. Failure to comply with this capacity limitation, or elevating the boom above 30 degrees when towing could result in death or serious injury.

Figure 66. Pintle Hook

Attachments

Attachment Disclaimer

Diesel Exhaust Fluid (DEF)

The DEF tank should be filled after every fuel refill.

DEF should be added when the Low DEFLevel indicator is displayed.

Refer to the Operation section on

Warning Indicators and

Fault Codes

and the Engine Indicator Chart (Fig. 65). The total capacity of the DEF tank is 5 gallons.

Warning

If no DEF reagent is available in the DEF tank, the emission requirements cannot be fulfilled and the machine derates eventually to idle only, following a predetermined schedule.

Use DEF meeting ISO 22241-1. There is NO acceptable substitute. Using anything other than DEF fluid may result in permanent aftertreatment damage.

57

Warning

DO NOT exceed the manufacturer’s rated load for any auxiliary attachment. Any attempt to lift or 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 death, serious injury, or property damage.

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 with an attachment that would alter the center of gravity or stability of this forklift. Xtreme Manufacturing assumes no liability for any third party attachment that would alter the center of gravity or stability.

Operation Manual

Fork Ratings

Warning

DO NOT exceed forklift capacity of 8,000 lbs.

(3,629 Kilograms). The total rated capacity of the forks being used must equal or exceed forklift capacity. Forks can break causing loss of load and could result in death or serious injury.

All approved forks for this forklift are marked with a maximum load capacity rating (A). This rating is stamped on the left edge of the fork just below the fork pivot shaft. The rating listed is in pounds and is based upon a 24 inches load center (B). This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center of 24 inches.

Operation

Standard Carriage Operation

The standard carriage uses manually adjustable forks and can be tilted up or down by using the thumb stick on the control handle.

A

B

Figure 68. Attachment Tilt Control Switch.

(A) Attachment Tilt Down (B) Attachment Tilt Up

Figure 67. Fork Ratings

(A) Maximum Load Capacity Rating (B) 24 inch Load Center

Because forks are always used in multiples, the total rating of any combination of forks will be the sum of their rated capacity. Other than block forks, all forks should be used in matched pairs. Block forks should be used in matched sets.

The maximum load capacity for this forklift is 8,000 lbs. The matched pair or set of forks used on this forklift should have total load ratings which equal or exceed 8,000 lbs. When the load rating of the forklift differs from the load capacity of the forks, the lower value becomes the overall load capacity.

Fork Positioning Carriage Operation

Caution

Do not adjust forks when Fork Positioning Carriage is loaded. Adjusting forks when carriage is loaded may result in loss of load or carriage damage. Always use the Fork Positioning control handle to adjust the forks BEFORE loading the carriage.

1

2

3

Operation Manual

58

Figure 69. Fork Positioning Control Handle

Operation

To move the forks outward, press the top button (1) on the front control handle, or move the auxiliary handle (3) to the left. To move the forks inward, press the lower button (2) on the front control handle, or move the auxiliary handle (3) to the right (figure 69).

Warning

Hydraulic attachments have a maximum hydraulic pressure rating. Failure to make sure the attachment is equipped with a pressure reducing valve, or is rated to be equal or greater than 3,500 psi, which is the maximum pressure of the forklift auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

• Make sure attachment locking devices are always in place.

• DO NOT operate the forklift until you have positive indication that the carriage attachment is fully engaged.

1. Position the forklift directly behind the attachment.

NOTE:

Allow enough distance to extend the boom approximately 18 to 20 inches.

2. Tilt the quick attach adapter forward.

3. Extend the boom and/or drive the forklift forward until the pivot pins (A) are below and between the two (2) attachment hooks (B).

B

A

When the auxiliary attachment control lever is moved right or left it activates hydraulic pressure through the quick attach couplers (A) and (B) to move the carriage.

B

A

Figure 70. Quick Attach Couplers For Hydraulic Systems.

(A) Female Coupler. (B) Male Coupler.

Figure 71. Drive Forklift Forward to Align Pivot Pins (A) with

Attachment Hooks (B)

4.

Raise the boom until pivot pins (A) have seated fully in attachment hooks (B).

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 death or serious injury. Attachments not locked into place could become unstable and fall on the operator or other personnel near the forklift, which could result in death or serious injury.

Figure 72. Raise Boom Until Pivot Pins (A) Are Fully Seated in Attachment Hooks (B)

5.

Tilt the attachment up slightly. The quick attach adapter should be tight against the rear of the attachment. Align the holes between the quick attach adapter and attachment.

59

Operation Manual

Operation

C

B

Figure 73. Tilt Attachment To Align Holes Between Quick Attach Adapter (C) and Attachment (B).

6.

Raise the quick attach lock lever.

Figure 75. Insert Quick Attach Pin Through Attachment and

Quick Attach Adapter.

8.

Release the quick attach lock lever and make sure it has lowered and seated itself in groove (A) of the quick attach pin.

Figure 76. Quick Attach Lock Lever and Quick Attach Pin.

Figure 74. Quick Attach Lock Lever.

7.

With lock lever raised, insert quick attach pin completely through the attachment and quick attach adapter.

Operation Manual

60

Warning

Hydraulic attachments have a maximum hydraulic pressure rating. Failure to make sure the attachment is equipped with a pressure reducing valve, or is rated to be equal or greater than 3,500 psi, which is the maximum pressure of the forklift auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

Operation

9.

Connect the quick attach couplers (this only applies to attachments with a quick attach hydraulic system).

7.

Raise the quick attach lock lever.

Figure 77. Quick Attach Couplers For Hydraulic Systems.

(A) Female Coupler. (B) Male Coupler.

Attachment Removal

NOTE:

To remove a standard carriage with forks, spread the forks apart on the carriage shaft. This provides adequate support for the carriage to stand alone.

1. Bring the forklift to a complete stop.

2. Move the travel select lever to NEUTRAL (N).

3. Set the parking brake switch to ON (engaged).

4. Extend the boom approximately 18 to 20 inches.

5. With the attachment 10”-12” off of the ground, tilt the attachment backward.

6. Disconnect the quick attach couplers (this only applies to attachments with a quick attach hydraulic system).

Figure 79. Quick Attach Lock Lever

8.

Pull out the quick attach pin at the bottom of the quick attach adapter.

Figure 80. Pull Quick Attach Pin from Attachment and Quick

Attach Adapter.

9.

Lower the attachment to the ground in a level position.

B

A

Figure 78. Quick Attach Couplers For Hydraulic Systems.

(A) Female Coupler. (B) Male Coupler.

61

Figure 81. Lower Attachment to Ground in Level Position

Operation Manual

10.

Tilt and lower boom until pivot pins (A) have disconnected from attachment hooks (B).

Operation

• Remain at least 10 feet, plus an additional 0.4 inches for each 1,000 volts over 50,000 volts, from active power lines and other power sources.

• Work site operating directives and/or local or state codes might require a greater distance.

• Know the maximum height and reach of this forklift.

B

A

Warning

Failure to follow proper safety procedures when lifting, lowering, and traveling with a load could cause death, serious injury, or property damage.

DO NOT exceed forklift capacity of 8,000 lbs. The total rated capacity of the forks being used must equal or exceed forklift capacity. Forks can break causing loss of load and could result in death or serious injury.

Figure 82. Tilt and Lower Boom to Release Pivot Pins (A) from Attachment Hooks (B).

11.

Retract the boom to fully disconnect the attachment from the quick attach link.

Load Handling

Danger

Death or serious injury by electrocution will 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.

Warning

DO NOT exceed the manufacturer’s rated load for any auxiliary attachment. Any attempt to lift or 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 death, serious injury, or property damage.

Failure to keep personnel clear of the load area while the load is being raised or lowered could result in death or serious injury. DO

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 specified weights and load centers.

• DO NOT exceed the manufacturer’s 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.

Operation Manual

62

Operation

• 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.

Suspended Loads

Avoid carrying a suspended 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. The handling of suspended loads can introduce dynamic forces drastically affecting the stability of the forklift.

Grades and sudden starts, stops, and turns can cause the load to swing and create a hazard if not stabilized. Swinging loads can become unstable, and could cause death, serious injury, or property damage.

Boom Lift Point

Warning

DO NOT exceed rated capacities. Any attempt to lift or carry loads in excess of those shown on the load capacity charts could cause forklift tip over, loss of load, or structural damage which could result in death, serious injury, or property damage.

There is boom lift point on the underside of the boom that may be used to lift and carry loads.

There is a dedicated boom lift point load chart on the forklift, which should be referenced when using the boom lift point. Refer to the suspended loads section of this manual when handling suspended loads for specific warnings and instructions unique to this type of operation.

1. Do not exceed the load capacity of the forklift (as noted on the load chart).

2. Only lift the load vertically, and never drag it horizontally.

3. Transport the load with the bottom of the load and the boom as low as possible.

4. With the load elevated, move the forklift slowly and cautiously. Only move the forklift to the extent needed to raise, transport, and place the load.

5. Use guy lines to restrain load swing if possible.

Pick Up A Load

1. Use correct load chart to review the rated load capacity of the auxiliary attachment being used. NEVER exceed specified weights and load centers.

2. Approach the load slowly and squarely with the fork tips straight and level.

3. Adjust the spacing of the forks so they engage the pallet or load at its maximum width. NEVER use just one fork to lift a load.

4. Tilt the attachment forward so the forks hang freely on the fork shaft.

5. Insert forks under the load until the load is against the fork frame.

6. Tilt the forks back, and raise the boom slightly to secure the load.

Figure 83. Boom Lift Point

63

Operation Manual

Carry A Load

1. Carry the load as low as possible while maintaining good ground clearance and visibility.

2. Back away slowly.

3. To travel with a load, use first gear (1) for highest torque and pulling power. NEVER travel in higher gears when carrying a load.

Load Shift

Operation

1. If the load shifts, stop the forklift immediately.

2. Lower and adjust the load to center its weight.

3. If the load shift is too great for adjustment, rearrange the load before attempting to move the forklift.

Elevating Personnel

Place A Load

1. Before placing the load, refer to the appropriate load capacity chart to determine safe boom extension range.

2. Set the Parking Brake switch to ON (engaged).

3. Use the frame sway control to level the forklift. For additional information, refer to the Frame Leveling section in this manual.

Warning

Use of the frame sway control with the boom raised above horizontal could cause tip over resulting in death or injury. Always use the frame sway control to level the forklift BE-

FORE 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.

4. Align the forks at the level the load is to be placed.

5. Extend the boom slowly until the load is just above the area where it is to be placed.

6. Lower the boom until the pallet rests in position and the forks are free to retract.

7. Retract the forks slowly from under the load.

Warning

Exercise caution when moving objects containing liquids, as the load may shift during lifting and handling.

Warning

Use only a compliant work platform to lift or lower personnel. Never drive the forklift with the work platform in a raised position or with personnel on board, even for a short distance. Doing so could result in death, serious injury, or property damage.

Please refer to ANSI/ITSDF B56.6 for additional design and operating information regarding elevating personnel.

Design Requirements For A Personnel Platform:

1. Platform floor must have a slip resistant surface located not more than 8” above the normal load supporting surface of the fork.

2. Platform floor dimensions shall not exceed two times the load center distance. This floor dimension is measured parallel to the longitudinal center pane of the forklift.

3. Platform floor width shall not be greater than the overall width of the forklift, measured across the load bearing tires, plus 10” on each side.

4. Minimum space requirements for each person on the platform shall not be less than 18” in either direction.

5. Minimum 4” height toe plate around the perimeter of the platform which may be omitted at the access opening.

6. On the overhead protection device, when requested by the user.

7. Protection must be provided for the personnel in their normal working position on the platform from moving

Operation Manual

64

Operation

parts of the rough terrain forklift that represent a hazard.

8. Information prominently indicated on the platform;

A)

Maximum work load including personnel and equipment.

B)

Weight of empty platform.

9. Provide a means so that the platform can only be centered laterally on the forklift and retained against the vertical face of the forks, carriage, or lifting mechanism.

10. Provide a means to securely attach the platform to the lifting mechanism, and to prevent the platform from inadvertent pivoting.

11. Provide restraining means for securing personnel such as an anchorage for attaching the lanyard of a body belt or harness.

12. Provide a guardrail or similar structure with a nominal height to the platform of 42” around its upper periphery and include a mid rail. It may be hinged, removable, or of chains, and used if proper positioning is easily discernible.

13. Such restraining means shall be capable of withstanding a concentrated horizontal force of 200 lbs applied at the point of least resistance without permanent deformation.

A body belt and lanyard is to have an attachment point provided for freedom of movement, and its length is limited to a free-fall of 5 feet, measured from the point of attachment to the operator. The complete system shall be capable of withstanding three consecutive drop test to simulate a 250 lbs person free falling 6 ft. without allowing the test weight to fall free to the ground. A deceleration device may be included.

14. Lanyards shall be arranged so as not to cause a tripping hazard.

15. Body belts should have a width of at least 1.75”.

16. Structural safety factor - all load supporting structural elements of the work platform shall have a structural safety factor of not less than 2 to 1 based on the minimum yield strength of the material used.

Capacity Limitations:

The combined weight in lbs of the platform, load, and personnel shall not exceed 33% of the capacity of the related load center position indicated on the machine load chart.

Preparation and Set-Up:

1. DO NOT

alter or modify the work platform in any manner that is detrimental to its safe use

2. Make sure that the work platform is securely attached to the quick attach or forks. Follow the platform manufacturer’s instructions.

3. Make sure the platform, carriage, and forks are secured to prevent them from pivoting from side to side.

4. On side tilt or swing carriage, the carriage must be centered and/or leveled horizontally and vertically. The hydraulic system quick disconnects must also be disconnected and the carriage securely fastened to prevent any tilting or side to side swinging motion.

5. Ensure the forklift has a firm footing and is level.

6. Be sure the forklift is in a level position (side to side) before any operation is begun. Use the frame sway to level the forklift. If the forklift cannot be leveled, reposition the forklift.

7. Place the travel select lever in the NEUTRAL position.

8. Engage the parking brake switch. Blocking the wheels is also recommended.

9. Level the platform in both the side-to-side and front-toback directions before use.

10. Before lifting or lowering personnel, be sure the forklift lifting mechanism operates smoothly through the entire lifting and lowering of the platform and maintains its selfleveling function. The forklift must operate smoothly both empty and loaded.

11. Lift and lower personnel smoothly, with caution, and only at their request.

12. Keep hands and feet clear of controls other than those in use.

13. Be certain that the path of platform travel is clear of hazards, e.g., storage racks, scaffolds, overhead obstructions, and electrical wires.

14. Be sure any lift limiting devices and latches are functioning properly.

15. A trained operator shall be in position to control the forklift. When the operator is not in the operating position, block the wheels and apply the parking brake with all controls in neutral.

16. Alert elevated personnel before moving the platform.

Then move the platform smoothly and with caution.

17. Always lower the platform if you must move the forklift for adjustment in positioning.

18. Be certain that personnel and equipment on the platform do not exceed the available space.

19. Any body belt, lanyard, or deceleration devices which has sustained permanent deformation or is otherwise damaged shall be replaced.

65

Operation Manual

Operation

20. Use of railings, planks, ladder, etc. on the platform for purpose of achieving additional reach or height is prohibited.

21. Before elevating personnel, the area around and under the work platform should be marked to warn anyone on the ground that overhead work is being done.

22. The platform shall be lowered to ground level for personnel to enter and exit. Personnel shall not climb on any part of the rough terrain forklift in attempting to enter and exit.

23. Protection must be provided for the personnel on the work platform from pinch points or moving parts while in their normal working position on the platform.

24. Provide overhead protection device as required by work site conditions or if requested by the user of the platform.

Figure 84. Load Capacity Chart

Load Capacity Charts

Warning

Using Load Capacity Charts

The forklift includes two (2) indicators to assist the operator for accurately using the load capacity charts. These indicators are the Boom Extend Letters and the Boom Angle Indicator.

Boom extend letters are located on the left side of the boom and visible to the operator as the boom is extended. These letters indicate boom extension as it corresponds to the load capacity charts.

NOTE:

For example, when letter “A” first appears, the boom extension corresponds to the arc of line “A” throughout all the load capacity charts.

DO NOT exceed rated capacity. Any attempt to lift or carry loads in excess of those shown on the load capacity charts could cause forklift tip over, loss of load, or structural damage which could result in death, serious injury, or property damage.

All load ratings shown on load capacity charts are based on the forklift being on firm, level ground, the forks being evenly positioned on the carriage, the load being centered on the forks, properly sized tires properly inflated and/ or foam filled, and the forklift being in good operating condition.

Load capacity charts, located on the left side of the dash panel, are provided to assist the operator in determining how to safely operate the boom to pick up, carry, and set down a load with the forklift, including what angle, how high, and how far to extend the boom.

Figure 85. Boom Extend Letters

The boom angle indicator is located on the left side of the boom and is visible from the operator’s seat. Use the boom angle indicator to determine the boom angle when referring to load capacity charts.

Operation Manual

66

Operation

NOTE:

The boom angle indicator is a plumb arrow with angular graduations from -50 to +700.

Figure 86. Boom Angle Indicator

Reading Load Capacity Charts

To accurately read the load capacity charts, you must determine three (3) things:

• Weight of the 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 3,000 lbs.

2.

The operator safely moves the load to a loading position.

• Places forks under load

• Tilts and raises load safely

• Fully retracts boom

• Drives forklift to position perpendicular to structure

• Levels the forklift

3.

The operator determines height of structure where load is to be placed.

The structure height is 30 feet from ground level.

4.

The operator determines distance from front tires where load will be placed.

The distance in front of forklift where load will be placed is 20 feet.

5.

Operator reads load capacity chart for attachment carriage to learn it will be safe to place the load at any boom angle with the boom extend letter “E” showing.

Figure 87. Load Capacity

Chart

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TIRES ONLY.

4,000 LBS AT 24 IN

MIN CAPACITY FORK

(8,000 LBS PAIR).

45

XR842 LOAD CHART - STANDARD CARRIAGE

40

35

30

25

BO

OM

A

NG

LE

40

45

50

55

60

63

G

F

E

D

C

35

B

30 A

25

20

20

2.0 FT

LOAD

CENTER

15

15

2.0 FT

LOAD

CENTER

10

1,850 LBS

2,000 LBS

3,000 LBS

10

4,000 LBS

5,000 LBS

6,500 LBS

5

8,000 LBS

5 0

5 A

0

G

F

E

D

C

B

702-636-2969 • 800-497-1704

P/N

17014-000

35

30

25

20

15

10

5

0

REACH FT

67

Operation Manual

Frame Leveling

Warning

Use of the frame sway control with the boom raised above horizontal could 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.

Operation

level condition. Always frame sway the forklift right or left until the indicator shows 0° (level).

The frame sway control handle has variable motions from the center that control frame sway (right and left).

Figure 89. Frame Level Indicator.

Function

Frame Sway Functions

Control Handle Action

FRAME SWAY RIGHT Move control handle RIGHT.

FRAME SWAY LEFT Move control handle LEFT.

Warning

The reach forklift includes a Frame Sway

Override switch. Improper use of the Frame

Sway Override switch could cause death, serious injury, or property damage.

The frame sway feature becomes locked and will not operate when the boom is raised 40° or more. Applying service brake, parking brake, and placing travel select lever in NEUTRAL, then pressing the Frame Sway Override switch (the trigger on the Front Control handle) will override the lockout feature and allow frame sway.

Figure 88. Frame Sway Control Handle.

The frame sway control handle controls the frame sway (right and left) functions.

To lock the frame sway, place the travel select lever in

NEUTRAL or apply the service or parking brake.

NOTE: Maximum frame sway is 22° overall or 11° each direction, left and right.

A frame level indicator is mounted on the inside upper right corner of the operator’s cab. The frame level indicator allows the operator to view if the forklift has been positioned in a

Figure 90. Frame Sway Override Switch.

Operation Manual

68

Preventive Maintenance

Preventive Maintenance

Establishing a Maintenance Program

The hourmeter displays elapsed engine operating hours and has a total readout of 9,999.9 hours. Use the hourmeter and the schedules contained in this section to establish a comprehensive preventive maintenance program.

Check condition and tension of drive belts (use tension meter to check belt tension)

Lubricate front and rear drive shaft 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 grease fittings

Lubricate front and rear axle cylinder pivot point grease fittings

Lubricate boom roller grease fittings and chains

Replace hydraulic return line filter

Replace transmission filter and top off fluid, as required

Figure 91. Hourmeter

Maintenance Schedule

Every Day or 8 Hours of Operation

See

Pre-Operation Inspection Checklist

After First 50 Hours of Operation

Change engine oil and filters

Check air filter (replace if necessary)

Replace fuel filter and pre-filter

Check engine hoses and connections for leaks, damage, and tightness

Check radiator hoses for leaks, damage, and tightness

Check electrical cables, leads, and connections for damage and tightness

Check for oil and coolant leaks

After Every 50 Hours of Operation

Lubricate boom pivot point grease fittings

Lubricate front and rear axle cylinder pivot point grease fittings

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Operation Manual

After Every 250 Hours of Operation

Comply with 50-Hour Maintenance Requirements

Change engine oil and filter

Check air filter (replace if necessary)

Check tension and condition of drive belts (use tension meter to check belt tension)

Lubricate front and rear drive shaft grease fittings

Lubricate front and rear axle grease fittings

Check differential oil level

Check wheel-end oil level

Check boom chain tension (adjust if necessary)

Inspect boom rollers and slide blocks for condition and tightness

Lubricate boom roller grease fittings and chains

After Every 500 Hours of Operation

Comply with 50-Hour Maintenance Requirements

Comply with 250-Hour Maintenance Requirements

Replace air filters

Replace fuel filters

Empty air filter dust cup

Check engine hoses and connections for leaks, damage, and tightness

Check radiator hoses for leaks, damage, and tightness

Check electrical cables, leads, and connections for damage and tightness

Preventive Maintenance

Check specific gravity of engine coolant

Replace transmission fluid and filters

Replace hydraulic reservoir air breather

Replace hydraulic return line filter

Replace hydraulic high-pressure filter

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 wheel-end oil

Change differential oil

Inspect boom chains

After Every 2,000 Hours of Operation

Comply with 50-Hour Maintenance Requirements

Comply with 250-Hour Maintenance Requirements

Comply with 500-Hour Maintenance Requirements

Comply with 1000-Hour Maintenance Requirements

Change hydraulic fluid

Clean or replace hydraulic reservoir strainer

After Every 4,000 Hours of Operation

Drain and flush cooling system

Operation Manual

70

Lockout / Tagout

Boom Emergency Lower Down Valve

Both of the lift and extend cylinders are equipped with a needle valve which allows the cylinder to retract without the direct assist of the machine’s hydraulic power. This feature is intended to be used only in the event of total loss of engine or hydraulic pump failure with an elevated boom.

In any event, the forklift should be secured until the situation has been properly evaluated. Secure the forklift and area by following the procedures below:

1. Clear the area around the forklift of all personnel.

2. Place the sift lever in NEUTRAL and engage the parking brake switch to the ON position.

3. Section off a large area under the boom with tape to restrict any personnel from entering this potentially dangerous area.

4. If the load is in a position where it can be removed safely, completely remove the load from the carriage and/or attachment. Otherwise leave the load in place.

5. Remove boom access cover on back of boom.

6. Locate needle valve on extend cylinder. Loosen nut on valve, then loosen valve with hex wrench.

7. Fully retract boom with control handle in cab.

8. When boom is fully retracted, tighten valve with hex wrench, then tighten nut to secure valve.

9. Locate needle valves on lift cylinders. Loosen nut on valve, then loosen valve with hex wrench (repeat for both sides).

10. Fully lower boom with control handle in cab.

11. When boom is fully lowered, tighten valve with hex wrench, then tighten nut to secure valve (repeat for both sides).

Figure 92. Boom Access Cover

Figure 93. Extend Cylinder Lower Down Valve

Figure 94. Lift Cylinder Lower Down Valve

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Operation Manual

Lockout / Tagout

Do Not Operate - Accident Prevention Tags

Before beginning any maintenance or service, place a Do Not

Operate Tag on both the starter key switch and the steering wheel, stating that the forklift should not be operated. Do Not

Operate Tags, which can be cut out and used, are included at the end of this manual. Retain these Tags for use at a later date.

New or Additional Operators

At the time of original purchase, the purchaser of this forklift was instructed by the seller on its proper use. If this forklift is to be used by an employee or is loaned or rented to someone other than the purchaser, make certain that the new operator is trained, in accordance with OSHA regulations, and reads and understands this Operation & Safety Manual before operating the forklift.

In addition, make sure that the new operator has completed a walk-around inspection of the forklift, is familiar with all the labels on the forklift, and has demonstrated the correct use of all controls.

Figure 95. Battery Disconnect Switch

Warning

If forklift is unsafe for operation or maintenance, the defect or defects must be clearly documented and posted in a conspicuous place on the forklift. Failure to comply could result in death, serious injury, or property damage.

Lockout / Tagout

Lockout/Tagout Procedure

Perform the following procedure to lockout and tag out the forklift. This procedure, requiring a lock, and danger tags are to be used whenever the forklift is unsafe for operation or maintenance.

Removing Forklift From Service

1. Attach “DO NOT OPERATE” tags to steering wheel and ignition key.

2. Open battery access cover.

3. Set battery disconnect switch to OFF.

4. Lock battery disconnect switch.

5. Attach “DO NOT OPERATE” tag to battery disconnect switch.

Return Forklift To Service

When the forklift has been repaired and made safe for operation and maintenance, perform the following procedure to return forklift to service.

1. Remove lock and “DO NOT OPERATE” tag from battery disconnect switch.

2. Close battery access cover.

3. Remove “DO NOT OPERATE” tags from steering wheel and ignition key.

Figure 96. DO NOT OPERATE Tag

Operation Manual

72

Lockout / Tagout

Do Not Operate Tags

73

Operation Manual

Operation Manual

74

Lockout / Tagout

Lockout / Tagout

75

Operation Manual

Operation Manual

1415 W. BONANZA RD LAS VEGAS, NV 89106

(702) 636-2969 (800) 497-1704 www.XMFG.com

76 PN 24904-001

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