Xtreme XR1255, Operation Manual

Page 1: ...702 636 2969 800 497 1704 1415 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com XR1255 Operation Safety Manual...

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Page 3: ...ear View Mirrors 37 Controls and Indicators 38 Travel Select Lever 38 Gear Select Switch 38 Parking Brake Switch 38 Load Capacity Charts 39 Hydraulic Oil Temperature Indicator 39 Low Brake Pressure In...

Page 4: ...oad 65 Place A Load 65 Load Shift 65 Elevating Personnel 65 Frame Leveling 67 Load Capacity Charts 68 Using Load Capacity Charts 68 Reading Load Capacity Charts 68 Standard Carriage Load Capacity Char...

Page 5: ...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...

Page 6: ...d regulations Signal Words Signal words are the word or words that call attention to the safety sign and designate a degree or level of hazard seriousness The signal words used in this manual are DANG...

Page 7: ...O 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 Unles...

Page 8: ...On Or In The Operator Cab Set Parking Brake To ON Engage Parking Brake Warning Forklift Tip Over Can Cause Death Or Serious Injury DO NOT Raise Boom While Traveling On A Slope Danger Keep A Safe Dist...

Page 9: ...fety 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 an...

Page 10: ...the work site such as gas and water pipes electrical cables and sewers Underground objects could cause death or serious injury Warning Operate the forklift only on firm stable surfaces Holes obstructi...

Page 11: ...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 runn...

Page 12: ...l or state codes might require a greater distance Know the maximum height and reach of this reach forklift Warning Use of the frame sway control with the boom raised above horizontal could cause tip o...

Page 13: ...mum 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 proper...

Page 14: ...e 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 boo...

Page 15: ...pped 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 th...

Page 16: ...ge 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 pr...

Page 17: ...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 Warnin...

Page 18: ...f axle The following procedure is to be performed per side 5 Remove hex screws from brake release bolts Alternate loosening hex screws 1 2 turn until fully loosened Set aside lock screws 6 Alternately...

Page 19: ...rn until the torque drops to 25 ft lbs 34 Nm 4 Again alternately loosen brake release bolts A B C one half turn until the torque drops off sharply 5 Alternately loosen brake release bolts A B C until...

Page 20: ...Page 18 Xtreme Manufacturing LLC Labels XR1255 Labels Label Legend Left Side View Figure 3 1 Label Legend Left Side View Right Side View Figure 3 2 Label Legend Right Side View...

Page 21: ...For information call 800 497 1704 Page 19 XR1255 Labels Front View Figure 3 4 Label Legend Rear View Rear View Figure 3 5 Label Legend Cab View Cab View Figure 3 3 Label Legend Front View...

Page 22: ...Angle Indicator 25 6 18041 001 Warning Pinch Point Hazard 26 3 18042 000 Xtreme Logo 27 2 18066 001 Caution Crushing Hazard 28 1 18067 100 Frame Sway Handle 29 1 18334 001 Handle Auxiliary Controls 3...

Page 23: ...bel number available when you call 1 18008 000 On Off Lights Rear Axle Centered Parking Brake OFF ON 18001 002 702 636 2969 800 497 1704 Coolant Fuel Oil Volts Hourmeter Steering On Off Declutch Up Do...

Page 24: ...Page 22 Xtreme Manufacturing LLC Labels XR1255 7 18015 001 8 18016 001 9 18017 001 10 18018 001 11 18018 002 12 18019 001...

Page 25: ...For information call 800 497 1704 Page 23 XR1255 Labels 13 18020 001 14 18021 001 15 18022 001 16 18023 001 17 18025 001 18 18026 001...

Page 26: ...Page 24 Xtreme Manufacturing LLC Labels XR1255 19 18027 001 20 18031 001 WARNING 21 18032 001 22 18033 100 23 18347 000 24 18039 000...

Page 27: ...For information call 800 497 1704 Page 25 XR1255 Labels 25 18041 001 26 18042 000 27 18066 001 28 18067 100 18334 001 29 18334 001 30 18069 000...

Page 28: ...Page 26 Xtreme Manufacturing LLC Labels XR1255 31 18082 001 32 18083 001 33 18086 001 34 18090 001 35 18300 001 36 18312 000...

Page 29: ...For information call 800 497 1704 Page 27 XR1255 Labels 37 18315 000 38 18043 000 39 18044 000 40 18046 000 41 18047 000 42 18048 000...

Page 30: ...Page 28 Xtreme Manufacturing LLC Labels XR1255 43 18049 000 44 18372 000 45 18056 000 46 18057 000 47 18058 000 48 18311 002...

Page 31: ...Y ADJUST FORKS WHEN CARRIAGE IS UNLOADED 18331 000 49 18331 000 18332 000 DEATH or SERIOUS INJURY could result from improper operation when using tow connection DO NOT EXCEED RATED TOW CAPACITY Max ve...

Page 32: ...A LOAD RATINGS SHOWN ARE FOR VEHICLES EQUIPPED WITH FOAM FILLED TIRES ONLY 45 6 000 LBS AT 24 IN MIN CAPACITY FORK 12 000 LBS PAIR 55 17251 000 XR1255 LOAD CHART OUTRIGGERS DOWN STANDARD CARRIAGE P N...

Page 33: ...For information call 800 497 1704 Page 31 XR1255 Labels THIS PAGE INTENTIONALLY LEFT BLANK...

Page 34: ...ges Easy access drop down electrical panel 12 Volt accessory power outlet Brake oil pressure parking brake axle lock rear wheel alignment and declutch indicator lights Electric horn and backup alarm D...

Page 35: ...vy 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 Dr...

Page 36: ...Switch Position Purpose OFF Shuts down entire electrical system except the horn and accessory outlet RUN All controls and indicators are operable PREHEAT Use for cold starting conditions START Engage...

Page 37: ...orklift in the corresponding direction Figure 6 6 Steering Wheel Horn Button Press the horn button to sound the horn Figure 6 7 Horn Button Operator Seat Operator Seat Controls The operator seat can b...

Page 38: ...stment 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 6 12 Backrest Angle Adjustment Lever Seat Belt...

Page 39: ...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...

Page 40: ...OTE The travel select lever must be in the NEUTRAL position to start the reach forklift NOTE The back up alarm automatically sounds when the travel select lever is in the REVERSE position Gear Select...

Page 41: ...ydraulic Oil Temperature Indicator Low Brake Pressure Indicator The low brake pressure indicator illuminates if the hydraulic brake oil pressure gets low If the low brake pressure indicator is illumin...

Page 42: ...fuel gauge indicates the quantity of fuel in the fuel tank The total capacity of the fuel tank is 72 gallons Figure 6 25 Fuel Gauge Oil Gauge The oil gauge indicates the engine oil pressure Normal eng...

Page 43: ...cular to the rear axle The rear wheels must be aligned perpendicular to axle in order to change the Steering Select switch If the rear axle centering indicator does not illuminate stop the forklift fo...

Page 44: ...s disengaged and the frame sway is locked Frame sway lock can be overridden with the Frame Sway Override Switch Figure 6 33 Outrigger Toggle Switches Boom Control The boom control handle has variable...

Page 45: ...For information call 800 497 1704 Page 43 XR1255 OperatorCab Figure 6 35 Boom Control Handle Functions Table 7 Boom Control Handle Functions A B C D E F G H...

Page 46: ...operator NOTE The attachment carriage will retain any set angle throughout boom raising lowering retracting or extending operations Frame Sway Control Handle The Frame Sway Control Handle installed o...

Page 47: ...lever controls the functions of approved optional attachments that can be mounted to the forklift and require hydraulic supply for operation Figure 6 39 Auxiliary Attachment Control Lever Optional Co...

Page 48: ...ons from 5 to 70 Figure 6 41 Boom Angle Indicator Boom Extend Letters As the boom is extended boom extend letters appear on the left side of the boom visible to the operator These letters indicate boo...

Page 49: ...to be in need of repair or maintenance defective or unsafe in any way Caution Contact with hot surfaces or the exhaust pipe after the forklift has been operated could result in minor or moderate perso...

Page 50: ...e State of California to cause cancer birth defects or other reproductive harm Wash hands after handling these items Warning Wear eye protection when starting a forklift with jump start cables Imprope...

Page 51: ...ssing lug nuts Bent flanges or any other damage to rims Check front and rear sway cylinders and hoses for leaks or any other damage Check mirrors for cracks cleanliness and proper adjustment Check hyd...

Page 52: ...dle left and right to extend and retract boom Operate the attachment tilt thumb switch up and down to tilt the attachment Operate the sway control handle left and right to sway frame left and right Op...

Page 53: ...raulic Oil Sight Gauge Figure 7 2 Add Hydraulic Oil If Necessary Figure 7 3 Check Coolant Reservoir Level Add Coolant If Necessary Figure 7 4 Check Engine Oil Level Add Engine Oil If Necessary Figure...

Page 54: ...lothing can get caught on pedals levers or other protruding parts Landing on uneven surfaces could result in death or serious injury 1 Master battery disconnect on 2 Use safe mounting dismounting proc...

Page 55: ...tinuous cranking may damage the starter motor Cold Starting 2 Turn key in Ignition switch clockwise to the PREHEAT position and hold the key at PREHEAT for approximately one 1 minute Figure 7 10 Hold...

Page 56: ...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 l...

Page 57: ...ring 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 locati...

Page 58: ...The transmission has four 4 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 fo...

Page 59: ...to service again Figure 7 16 Rear Axle Lock Indicator Pintle Hook Warning Death or serious injury could result from improper operation when using tow connection Do not elevate boom above 30 degrees wh...

Page 60: ...180 liters 1 Make sure the forklift is level to obtain an accurate fuel level reading 2 Shut off the engine 3 Ground the fuel nozzle against the filler neck to avoid sparks Fuel Types Use ASTM 2 dies...

Page 61: ...gure 7 18 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 capac...

Page 62: ...at the quick disconnect couplers could result in death or serious injury When the auxiliary attachment control lever is moved right or left it activates hydraulic pressure through the quick attach cou...

Page 63: ...Raise the boom until pivot pins A have seated fully in attachment hooks B Figure 7 23 Raise Boom To Seat Pivot Pins A In Attachment Hooks B 5 Tilt the attachment up slightly The quick attach adapter s...

Page 64: ...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 9 Connect the quick attach co...

Page 65: ...f the quick attach adapter Figure 7 31 Pull Quick Attach Pin from Attachment and Quick Attach Adapter 9 Lower the attachment to the ground in a level position Figure 7 32 Lower Attachment to Ground in...

Page 66: ...rsonnel clear of the load area while the load is being raised or lowered could cause death or serious injury DO NOT lift swing or move a load over anyone or over a forklift cab Review the rated load c...

Page 67: ...For additional information refer to the Frame Leveling section in this manual 5 Align the forks at the level the load is to be placed 6 Extend the boom slowly until the load is just above the area wh...

Page 68: ...sition 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 sec...

Page 69: ...ad Reposition forklift or have surface leveled The frame sway control handle has variable motions from the center that control frame sway right and left Table 12 Frame Sway Functions Function Control...

Page 70: ...apacity Charts The reach 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 Indicat...

Page 71: ...in front of forklift where load will be placed is 20 feet 6 meters 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 b...

Page 72: ...ubricate 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...

Page 73: ...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 Requi...

Page 74: ...e 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...

Page 75: ...For information call 800 497 1704 Page 73 XR1255 PreventiveMaintenance THIS PAGE INTENTIONALLY LEFT BLANK...

Page 76: ...Not Operate tag to battery disconnect switch Figure 8 5 Battery Disconnect Switch Warning If forklift is unsafe for operation or maintenance the defect or defects must be clearly documented and poste...

Page 77: ...For information call 800 497 1704 Page 75 XR1255 Lockout Tagout Do Not Operate Tags...

Page 78: ...Page 76 Xtreme Manufacturing LLC Lockout Tagout XR1255...

Page 79: ...For information call 800 497 1704 Page 77 XR1255 Lockout Tagout...

Page 80: ...1415 W Bonanza Rd Las Vegas NV 89106 www XtremeManufacturing com 702 636 2969 800 497 1704 24907 001 2 11...