Xtreme XR1255 Operation Manual
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Xtreme XR1255 Operation Manual

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(702) 636-2969
1415 W. Bonanza Rd. Las Vegas, NV 89106
(800) 497-1704
www.XtremeManufacturing.com
XR1255
Operation & Safety Manual

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Summary of Contents for Xtreme XR1255

  • Page 1 XR1255 Operation & Safety Manual (702) 636-2969 1415 W. Bonanza Rd. Las Vegas, NV 89106 (800) 497-1704 www.XtremeManufacturing.com...

  • Page 3: Table Of Contents

    XR1255 Table of Contents Introduction ......3 Seat Belt General Rear View Mirrors Replacement manuals...
  • Page 4 Lockout / Tagout ..... . . 74 Lockout/Tagout Procedure Removing Forklift From Service Returning Forklift To Service “Do Not Operate” Tags Page 2 Xtreme Manufacturing, LLC...

  • Page 5: Introduction

    Right side, left side, front, and rear are directional references given from the operator’s seat while facing in a Replacement manuals forward direction Replacement manuals for the XR1255 Reach Forklifts can be obtained by contacting: Xtreme Manufacturing Phone: (800) 497-1704 Figure 1-2.

  • Page 6: Safety

    Safety information provided in this manual is a basic CAUTION (Yellow) used without the safety alert symbol guide and an attempt to prevent accidents Xtreme indicates a potentially hazardous situation which, if Manufacturing cannot anticipate every circumstance that not avoided, may result in property damage.
  • Page 7 XR1255 Safety Read Operator Read Maintenance General Safety Manual Before Manual Before Alert Symbol Operating This Working On Forklift This Forklift Read Material DO NOT OPERATE! Know First Aid Safety Data Instructions And/ Forklift Down Sheets (MSDS) For Or Locations On...
  • Page 8 DO NOT Allow Pinch Points Pinch Points Anyone Under Hands Body A Raised Load Have Adequate Warning! Ventilation If DO NOT Use Ether Explosion Operating This As A Starting Aid Hazard Forklift In An Enclosed Space Page 6 Xtreme Manufacturing, LLC...

  • Page 9: Employer Responsibility

    XR1255 Safety Employer Responsibility Operator Qualifications Under Occupational Safety and Health Administration Operators must be in good physical and mental condition, (OSHA) rules, employers are required to train workers with appropriate reflexes, reaction time, vision, depth about hazards related to operating and maintaining the...

  • Page 10: Mounting/Dismounting

    • Learn the location of all underground hazards at the defects, and other reproductive harm. work site, such as; gas and water pipes, electrical cables, and sewers. Underground objects could cause death or serious injury. Page 8 Xtreme Manufacturing, LLC...

  • Page 11: Before Starting Forklift

    Keep the Operation and Safety Manual on convenience for the operator. These the forklift at all times. Contact Xtreme descriptions DO NOT provide complete Manufacturing for replacement manuals. operation instructions. Read and understand the...

  • Page 12: Operation Safety

    • Stay on the forklift and ride out the roll over or power sources. tip over. • Work site operating directives and/or local or state codes might require a greater distance. • Know the maximum height and reach of this reach forklift. Page 10 Xtreme Manufacturing, LLC...
  • Page 13 XR1255 Safety  Warning  Warning DO NOT use the forklift as a work To prevent death, serious injury, or platform or personnel carrier. Falling property damage, make sure the forklift of attachments could result in death or comes to a complete stop before moving serious injury.
  • Page 14 DO NOT change steering modes until the forklift comes to a complete stop. Align all four (4) tires “straight-ahead,” or perpendicular to the axle, before changing steering mode. Page 12 Xtreme Manufacturing, LLC...

  • Page 15: Load Safety

    XR1255 Safety Load Safety Attachments  Warning  Warning Failure to follow proper safety procedures Improper connection of an auxiliary attachment could when lifting, lowering, and traveling with result in death or serious injury. Attachments not a load could result in death, serious injury, locked into place can become unstable and fall on the or property damage.

  • Page 16: Forklift Maintenance

    Follow the proper maintenance is completed. cold starting procedures and engine manufacturer’s specifications for using a starting aid. Page 14 Xtreme Manufacturing, LLC...
  • Page 17 XR1255 Safety  Warning  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. Lead-acid batteries produce flammable and •...

  • Page 18: Dead Engine Towing

    (Repeat steps 5-9 for each side of axle) 10. Crawl out from under the vehicle and clear the area of any unnecessary personnel 11. Carefully remove the blocking from each of the four tires and tow the vehicle to a secure location Page 16 Xtreme Manufacturing, LLC...

  • Page 19: Re-Activating Parking Brakes (Front Axle)

    XR1255 Safety Re-activating Parking Brakes (Front Axle)  Warning Block all four wheels. Failure to do so could result in death or serious injury from vehicle roll away. 1. After you have blocked all four wheels, crawl under the front axle The following procedure is to be performed per side 2.

  • Page 20: Labels

    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 18 Xtreme Manufacturing, LLC...

  • Page 21: Front View

    XR1255 Labels Front View Rear View Figure 3-3. Label Legend Front View. Figure 3-4. Label Legend Rear View. Cab View Figure 3-5. Label Legend Cab View. Page 19 For information call (800) 497-1704...
  • Page 22 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 Page 20 Xtreme Manufacturing, LLC...

  • Page 23: Replacement Labels

    XR1255 Labels Replacement Labels Replacement labels can be obtained by contacting Xtreme Manufacturing at (800) 497-1704 Please have the appropriate label number available when you call Parking Brake Volts Fuel Coolant Hourmeter 702-636-2969 Rear Axle 800-497-1704 Left Right Lights Centered...
  • Page 24 Labels XR1255 7) 18015-001 8) 18016-001 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 Page 22 Xtreme Manufacturing, LLC...
  • Page 25 XR1255 Labels 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 17) 18025-001 18) 18026-001 Page 23 For information call (800) 497-1704...
  • Page 26 Labels XR1255 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 22) 18033-100 23) 18347-000 24) 18039-000 Page 24 Xtreme Manufacturing, LLC...
  • Page 27 XR1255 Labels 25) 18041-001 26) 18042-000 27) 18066-001 28) 18067-100 18334-001 29) 18334-001 30) 18069-000 Page 25 For information call (800) 497-1704...
  • Page 28 Labels XR1255 31) 18082-001 32) 18083-001 33) 18086-001 34) 18090-001 35) 18300-001 36) 18312-000 Page 26 Xtreme Manufacturing, LLC...
  • Page 29 XR1255 Labels 37) 18315-000 38) 18043-000 39) 18044-000 40) 18046-000 41) 18047-000 42) 18048-000 Page 27 For information call (800) 497-1704...
  • Page 30 Labels XR1255 43) 18049-000 44) 18372-000 45) 18056-000 46) 18057-000 47) 18058-000 48) 18311-002 Page 28 Xtreme Manufacturing, LLC...
  • Page 31 XR1255 Labels DEATH or SERIOUS INJURY could result from CARRIAGE DAMAGE improper operation when using tow connection. DO NOT ELEVATE BOOM ABOVE 30 WHEN DAMAGE may result from adjusting forks TOWING. when carriage is loaded. DO NOT EXCEED RATED TOW CAPACITY.
  • Page 32 Labels XR1255 XR1255 LOAD CHART OUTRIGGERS UP - STANDARD CARRIAGE NO OPERATION ABOVE 55 DEGREES BOOM ANGLE WITH REAR AXLE UNLOCKED. LOAD RATINGS SHOWN ARE FOR VEHICLES EQUIPPED 2.0 FT WITH FOAM FILLED LOAD TIRES ONLY. CENTER 6,000 LBS AT...
  • Page 33 XR1255 Labels THIS PAGE INTENTIONALLY LEFT BLANK Page 31 For information call (800) 497-1704...

  • Page 34: Features

    Features XR1255 Features Optional Equipment Table 3. XR1255 Optional Equipment Standard Equipment Description Feature Table 2. XR1255 Standard Equipment Options Hydraulic side-swing carriage (with quick attach couplers) Description Feature Heater/Defroster/Windshield wiper Boom Universal quick attach head Limited Slip Differential Three (3) section boom...

  • Page 35: Specifications

    XR1255 Specifications Specifications XR1255 Specifications Standard Equipment Heavy-duty Frame/Chassis Performance Heavy-duty Roller Boom Capacity 12,000 lbs Melonite Pins and Rollers Lift Height 54’6” Direct Dual Control Hydraulic Valve Actuation Forward Reach 38’ Robust Wiring, No Spades, No Pins Frame Leveling L/R 11°/11°...

  • Page 36: Operator Cab

    START Engages starter motor to crank engine NOTE: The PREHEAT and START positions are spring- loaded When the key is released, the Ignition switch will automatically return to the RUN position Figure 6-4. Accelerator Pedal. Page 34 Xtreme Manufacturing, LLC...

  • Page 37: Service Brake Pedal

    XR1255 Operator Cab Service Brake Pedal Operator Seat Press the service brake pedal to slow or stop the forklift Operator Seat Controls The service brake pedal activates the service brakes on all four (4) wheels The operator seat can be adjusted four (4) ways: weight suspension, height, fore and aft, and backrest angle Figure 6-5.

  • Page 38: Lumbar Support

    Failure to wear the seat belt could result in death or serious injury. The reach forklift is equipped with a three inch (3”) wide Figure 6-11. Fore and Aft Adjustment Lever. retractable seat belt Figure 6-13. Retractable Seat Belt. Page 36 Xtreme Manufacturing, LLC...

  • Page 39: Rear View Mirrors

    XR1255 Operator Cab  Warning Rear View Mirrors DO NOT adjust the seat or seat belt while Two (2) adjustable rear view mirrors are provided to aid the forklift is moving. Keep both hands on the operator’s rear vision One (1) rear-view mirror is the wheel while the forklift is moving to mounted on the upper left of the operator’s cab...

  • Page 40: Controls And Indicators

    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) Page 38 Xtreme Manufacturing, LLC...

  • Page 41: Load Capacity Charts

    XR1255 Operator Cab Load Capacity Charts Low Brake Pressure Indicator Load capacity charts are located on the left side of the The low brake pressure indicator illuminates if the front control panel Load capacity charts are provided to hydraulic brake oil pressure gets low...

  • Page 42: Hourmeter

    The fuel gauge indicates the quantity of fuel in the fuel temperature should read between 180 to 200°F tank The total capacity of the fuel tank is 72 gallons Page 40 Xtreme Manufacturing, LLC...

  • Page 43: Light Switch

    XR1255 Operator Cab If the coolant gauge shows abnormal readings, stop the Rear Axle Centering Indicator forklift, follow proper shut down procedures, tag the forklift with “Do Not Operate” tags, and have a qualified The rear axle centering indicator illuminates when the rear...

  • Page 44: Declutch Switch

    (2) functions For example, moving the handle to the Figure 6-33. Outrigger Toggle Switches. forward, left corner will lower and retract the boom at the same time Page 42 Xtreme Manufacturing, LLC...
  • Page 45 XR1255 Operator Cab Table 7. Boom Control Handle Functions Figure 6-35. Boom Control Handle Functions. Page 43 For information call (800) 497-1704...

  • Page 46: Attachment Tilt Switch

    (toward the operator) brake NOTE: Maximum frame sway is 22° overall or 11° each NOTE: The attachment carriage will retain any set direction, left and right angle throughout boom raising, lowering, retracting, or extending operations Page 44 Xtreme Manufacturing, LLC...

  • Page 47: Auxiliary Attachment Control

    XR1255 Operator Cab  Warning Optional Controls and Indicators The reach forklift includes a Frame Sway Two Wheel Rear (2WR) Steering Switch Override switch. Improper use of the Frame Sway Override switch could cause A Two Wheel Rear (2WR) Steering switch is used to engage...

  • Page 48: Boom Angle Indicator

    As the boom is extended, boom extend letters appear on the left side of the boom visible to the operator These letters indicate boom extension as it corresponds to the load capacity charts Figure 6-42. Boom Extend Letters. Page 46 Xtreme Manufacturing, LLC...

  • Page 49: Operation

    XR1255 Operation Operation  Caution Pre-Operation Inspection Contact with hot surfaces or the exhaust pipe after the forklift has been operated To perform the pre-operation inspection make sure the could result in minor or moderate personal forklift is NOT running, the engine is cool, the forklift is injury.
  • Page 50 Battery posts, terminals, and related tires. 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. Page 48 Xtreme Manufacturing, LLC...

  • Page 51: Pre-Operation Inspection Checklist

    XR1255 Operation 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...

  • Page 52: Functional Tests

    • Check the engine coolant temperature gauge The engine coolant temperature gauge should read between 180 to 200°F • Check the engine oil pressure gauge The engine oil pressure gauge should read between 40 to 80 Page 50 Xtreme Manufacturing, LLC...

  • Page 53: Operator Maintenance

    XR1255 Operation Operator Maintenance Figure 7-1. Check Hydraulic Oil Sight Gauge. Figure 7-4. Check Engine Oil Level. Add Engine Oil, If Necessary. Figure 7-2. Add Hydraulic Oil, If Necessary. Figure 7-5. Check Battery Case and Terminals. Figure 7-3. Check Coolant Reservoir Level. Add Coolant, If Figure 7-6.

  • Page 54: Before Starting Forklift

    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) Page 52 Xtreme Manufacturing, LLC...

  • Page 55: Starting Forklift

    XR1255 Operation 3. Turn key in Ignition switch clockwise to the Starting Forklift START position 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...

  • Page 56: Jump Starting

    6. After the engine starts, let idle for 30 to 60 seconds 7. Remove the jumper cables in the reverse order of their connection (i e negative cable ground connection first, etc ) Page 54 Xtreme Manufacturing, LLC...

  • Page 57: Forklift Travel

    XR1255 Operation Forklift Travel Four Wheel Steering (4W) Four wheel (4W) steering allows the front Steering Modes wheels to turn in the same direction and the rear wheels to turn in the opposite direction of  Warning the steering wheel The rear wheels follow the...

  • Page 58: Starting Travel

    Figure 7-14. Hydraulic Oil Temperature Indicator. 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 Page 56 Xtreme Manufacturing, LLC...

  • Page 59: Pintle Hook

    XR1255 Operation The low brake pressure indicator illuminates if the Pintle Hook hydraulic brake oil pressure gets low If the low brake pressure indicator is illuminated, stop  Warning the forklift, follow proper shut down procedures, tag the forklift with “Do Not Operate” tags, and have a qualified...

  • Page 60: Changing Travel Direction

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

  • Page 61: Fork Ratings

    XR1255 Operation The maximum load capacity for this forklift is 12,000 Fork Ratings pounds (5,443 Kilograms) The matched pair or set of forks used on this forklift should have total load ratings  Warning which equal or exceed 12,000 pounds (5,443 Kilograms)

  • Page 62: Fork Positioning Carriage Operation

    18 to 20 inches (0 46 to 0 5 meters) When the auxiliary attachment control lever is moved right or left it activates hydraulic pressure through the quick attach couplers to move the carriage Page 60 Xtreme Manufacturing, LLC...
  • Page 63 XR1255 Operation 2. Tilt the quick attach adapter forward 5. Tilt the attachment up slightly The quick attach adapter should be tight against the rear of the 3. Extend the boom and/or drive the forklift forward attachment Align the holes between the quick attach...

  • Page 64: Attachment Removal

    4. Extend the boom approximately 18 to 20 inches (0 46 to 0 5 meters) 5. With 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) Page 62 Xtreme Manufacturing, LLC...
  • Page 65 XR1255 Operation 9. Lower the attachment to the ground in a level position Figure 7-29. Disconnect Quick Attach Couplers. (A) Female Coupler. (B) Male Coupler. 7. Raise the quick attach lock lever Figure 7-32. Lower Attachment to Ground in Level Position.

  • Page 66: Load Handling

    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 Page 64 Xtreme Manufacturing, LLC...

  • Page 67: Pick Up A Load

    XR1255 Operation 4. Use the frame sway control to level the forklift For Pick Up A Load additional information, refer to the Frame Leveling section in this manual 1. Use the correct load chart to review the rated load capacity of the auxiliary attachment being used.
  • Page 68 17) Always lower the platform if you must move the rough terrain forklift truck 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 Page 66 Xtreme Manufacturing, LLC...

  • Page 69: Frame Leveling

    XR1255 Operation has sustained permanent deformation or is otherwise The frame sway control handle controls the frame sway damaged shall be replaced (right and left) functions 20) Use of railings, planks, ladders, etc on the platform To lock the frame sway, place the travel select lever in...

  • Page 70: Load Capacity Charts

    These letters indicate boom extension as it corresponds to • Height of structure where load is to be placed the load capacity charts • Distance from front tires where load will be placed Page 68 Xtreme Manufacturing, LLC...

  • Page 71: Standard Carriage Load Capacity Chart

    “E” showing • drives forklift to position perpendicular to structure • lowers outriggers and levels forklift Standard Carriage Load Capacity Chart XR1255 LOAD CHART OUTRIGGERS DOWN - STANDARD CARRIAGE THE REAR AXLE MUST BE LOCKED AND THE OUTRIGGERS FIRMLY AGAINST THE GROUND.

  • Page 72: Preventive Maintenance

    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 Page 70 Xtreme Manufacturing, LLC...
  • Page 73 XR1255 Preventive Maintenance After Every 500 Hours of Operation After Every 1,000 Hours of Operation Comply with 50-Hour Maintenance Requirements Comply with 50-Hour Maintenance Requirements Comply with 250-Hour Maintenance Requirements Comply with 250-Hour Maintenance Requirements Replace air filter Comply with 500-Hour Maintenance Requirements...

  • Page 74: Boom Emergency Lower Down Valve

    In addition, make sure that the new operator has completed a walk-around inspection of the vehicle, Figure 8-2. Boom Access Cover. is familiar with all Labels on the vehicle, and has demonstrated the correct use of all controls Page 72 Xtreme Manufacturing, LLC...
  • Page 75 XR1255 Preventive Maintenance THIS PAGE INTENTIONALLY LEFT BLANK Page 73 For information call (800) 497-1704...

  • Page 76: Lockout / Tagout

    1. Remove lock and “Do Not Operate” tag from battery disconnect switch 2. Raise and secure battery cover 3. Remove “Do Not Operate” tags from steering wheel and ignition key Page 74 Xtreme Manufacturing, LLC...

  • Page 77: Do Not Operate Tags

    XR1255 Lockout / Tagout Do Not Operate Tags Page 75 For information call (800) 497-1704...
  • Page 78 Lockout / Tagout XR1255 Page 76 Xtreme Manufacturing, LLC...
  • Page 79 XR1255 Lockout / Tagout Page 77 For information call (800) 497-1704...
  • Page 80 24907-001 2/11 (702) 636-2969 1415 W. Bonanza Rd. Las Vegas, NV 89106 (800) 497-1704 www.XtremeManufacturing.com...

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