Xtreme xr1255 Operation And Safety Manual
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Xtreme xr1255 Operation And Safety Manual

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Operation and
Chapter Description
Safety Manual
Tier 4 Final
1
Operation Manual
PN 24906-003

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Summary of Contents for Xtreme xr1255

  • Page 1 Operation and Chapter Description Safety Manual Tier 4 Final Operation Manual PN 24906-003...
  • Page 2 Xtreme Manufacturing, LLC (w://www.xmfg.com/) is headquartered in Las Vegas, Nevada, and has fabrication facilities in Selma, California. In October 2013, Xtreme became the majority shareholder in Snorkel, a global aerial work platform manufacturer, which has manufacturing facilities in the US, UK & New Zealand, as well as a global sales distribution network. Find out more about Snorkel at www.snorkellifts.com.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Description Page Description Page Operator Seat Controls Introduction Weight Suspension Lever General Replacement Manuals Lumbar Support Fore and Aft Adjustment Lever Model/Serial Plate Backrest Angle Adjustment Lever Orientation Safety Seat Belt Safety Disclaimer Rear View Mirrors Controls and Indicators Signal Words Travel Select Lever...
  • Page 4 Table of Contents Table of Contents Description Page Description Page Starting Travel Load Capacity Charts Shifting Gears Frame Leveling Warning Indicators and Gauges Preventive Maintenance Stopping Travel Establishing a Maintenance Program Changing Travel Direction Maintenance Schedule Shut Down Procedure Boom Emergency Lower Down Valve Refueling Do Not Operate - Accident Prevention Tags Fuel Types...

  • Page 5: Introduction

    RIGHT Replacement Manuals Replacement manuals for the XR1245 Reach Forklift can be obtained by contacting our parts department by phone or visiting our website: Xtreme Manufacturing Phone: (800) 497-1704 LEFT www.XMFG.com Figure 2. Forklift Direction Orientation Operation Manual...

  • Page 6: Safety

    WARNING (Orange) used with the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Xtreme Manufacturing reserves the right to make technical Caution changes for product improvement. This manual may contain...
  • Page 7 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 For Service Or Chemicals And Work site...
  • Page 8 Safety DO NOT DO NOT Fasten Allow Riders Jump While Seat Dismounting On Auxiliary Belt The Telehandler Attachments Set Parking DO NOT Allow DO NOT Allow Brake To OFF Riders On Telehandler Riders On Or In Disengage Frame Or Fenders The Operator Cab Parking Brake Set Parking Brake...

  • Page 9: Employer Responsibility

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

  • Page 10: Mounting/Dismounting

    Safety Warning Mounting/Dismounting • Operate the forklift only on firm, stable surfaces. Holes, Warning obstructions, debris, loose fill, and other work site hazards could result in death or serious injury. Failure to use proper safety procedures when mounting • DO NOT allow bystanders in the work area. and dismounting the forklift could result in death or serious •...

  • Page 11: Before Starting Forklift

    A brief description of controls, indicators, Keep the Operation and Safety Manual and instruments is provided as a convenience on the forklift at all times. Contact Xtreme for the operator. These descriptions DO NOT Manufacturing for replacement manuals. provide complete operation instructions.

  • Page 12: Operation Safety

    Safety the forklift cannot be leveled using the frame sway control, Warning do not attempt to raise or place load. Reposition forklift or have the surface leveled. Operators must be properly trained and qualified to operate this specific forklift. Warning Know the location, learn the specific purpose, and demonstrate safe and proper use of all To prevent death, serious injury, or prop-...
  • Page 13 Safety NEVER allow passengers to ride • Start, stop, travel, steer, and brake smoothly. on the forklift. DO NOT allow • Load, unload, and turn the forklift on level ground, riders on the frame or operator when possible. cab. Allowing passengers to ride •...

  • Page 14: Load Safety

    Safety Load Safety Caution Never attempt to create Diesel Exhaust Fluid by mixing agri- Warning cultural grade urea with water. Agricultural grade urea does not met the specifications required and thye aftertreatment system may be damaged. Failure to follow proper safety procedures when lifting, lowering, and traveling with a Warning load could result in death, serious injury, or...

  • Page 15: Attachments

    Safety Attachments Forklift Maintenance Warning Warning Improper connection of an auxiliary attachment could Follow manufacturer’s instructions proper result in death or serious injury. Attachments not locked maintenance to make sure the forklift continues to meet into place can become unstable and fall on the operator or manufacturer’s specifications.
  • Page 16 Safety It is possible for the forklift to move suddenly Warning when the brakes are released, which could result in death, serious injury, or property Tires must have proper ballast. DO NOT replace damage. To prevent sudden movement of foam-filled tires with pneumatic tires. Use of the forklift, place wheel chocks in front of and pneumatic tires will severely affect vehicle load behind wheels before the brakes are released.

  • Page 17: Dead Engine Towing

    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.

  • Page 18: Labels

    Labels Labels Left Side View 46 47 INNER BOOM ON CHASSIS, BEHIND WHEEL igure 6. Label Legend (Left Side) Right Side View ON CHASSIS Figure 7. Label Legend (Right Side) Operation Manual...
  • Page 19 Labels Front View Rear View Figure 8. Label Legend (Front) Figure 9. Label Legend (Rear) Cab View REAR GLASS Figure 10. Label Legend (Cab) Operation Manual...
  • Page 20 Fill DEF Tank 18033-000 Auxiliary Handle Control 18034-000 Boom Handle Control 18039-000 Boom Angle Indicator 18041-001 Warning, Pinch Point Hazard 18042-000 Xtreme logo (chassis) 18066-001 Caution, Crushing Hazard 18067-100 Frame Sway Handle 18334-001 Handle Auxiliary Controls 18069-000 Hydraulic Tank Fluid Level 18082-001...

  • Page 21: Replacement Labels

    Labels From outside Las Vegas, Nev., call Xtreme Manufacturing toll Replacement Labels free at (800) 497-1704. Replacement labels can be obtained by contacting Xtreme Please have the correct label number available when you call. Manufacturing directly at (702) 636-2969. Parking Brake...
  • Page 22 Labels 7) 18015-001 8) 18016-001 9) 18017-001 10) 18018-001 11) 18018-002 12) 18019-001 Operation Manual...
  • Page 23 Labels 13) 18020-001 14) 18021-001 15) 18022-001 16) 18023-001 17) 18025-001 18) 18026-001 Operation Manual...
  • Page 24 Labels 19) 18027-001 20) 18031-001 WARNING 21) 18032-001 22) 18033-000 23) 18034-000 24) 18039-000 Operation Manual...
  • Page 25 Labels 25) 18041-001 26) 18042-000 27) 18066-001 28) 18067-100 FULL 18334-001 18069-000 29) 18334-001 30) 18069-000 Operation Manual...
  • Page 26 Labels 31) 18082-001 32) 18083-001 33) 18086-001 34) 18090-001 35) 18300-001 36) 18312-000 Operation Manual...
  • Page 27 Labels 37) 18315-000 38) 18043-000 39) 18044-000 40) 18046-000 41) 18047-000 42) 18048-000 Operation Manual...
  • Page 28 Labels 43) 18049-000 44) 18073-001 18056-000 45) 18053-000 18057-000 46) 18054-000 18058-000 47) 18055-000 CARRIAGE DAMAGE DAMAGE may result from adjusting forks when carriage is loaded. ONLY ADJUST FORKS WHEN CARRIAGE IS UNLOADED. 18331-000 49) 18331-000 48) 18311-002 DEATH or SERIOUS INJURY could result from improper operation when using tow connection.
  • Page 29 Labels 53) 18306-000 XR1245 LOAD CHART OUTRIGGERS DOWN- STANDARD CARRIAGE 52) 18306-001 THE REAR AXLE MUST BE LOCKED AND THE OUTRIGGERS FIRMLY AGAINST THE GROUND. XR1245 LOAD CHART OUTRIGGERS UP - STANDARD CARRIAGE LOAD RATINGS 2.0 FT SHOWN ARE FOR LOAD VEHICLES EQUIPPED CENTER...

  • Page 30: Features

    Features Features Standard Equipment Optional Equipment Feature Description Feature Description Boom Universal quick attach head Options Enclosed cab with A/C Three (3) section boom Heater/defroster/windshield wiper Boom equipped with heavy duty boom rollers Work light package Chassis Rear axle stabilization Turn signals/hazard lights 1-1/4 inch main frame plate Sealed pivot pins for extended service periods...

  • Page 31: Standard Equipment

    Rear View Mirrors Tires (Standard Eq) Foam Filled Quick Attach (Common t) 15.5 x 25 E3 Xtreme Service Accessibility Attachments Hydraulics Standard Carriage - 48“ or 72” ....49 +10°...

  • Page 32: Operator Cab

    Operator Cab Operator Cab Accessory Outlet A 12 Volt accessory outlet is provided as a power source for Warning personal items, such as a radio or cell phone. A brief description of controls, indicators, and instruments is provided as a convenience for the operator.

  • Page 33: Service Brake Pedal

    Operator Cab Service Brake Pedal Horn Button Press the service brake pedal to slow or stop the forklift. The Press the horn button to sound the horn. service brake pedal activates the service brakes on all four (4) wheels. Figure 16. Horn Button Figure 14.

  • Page 34: Weight Suspension Lever

    Operator Cab Weight Suspension Lever Fore and Aft Adjustment Lever Rotate the weight suspension lever to increase or decrease the Pull the fore and aft adjustment lever outward from the seat seat cushion suspension based on the weight of the operator to release the seat lock.

  • Page 35: Seat Belt

    Operator Cab Before starting the engine, adjust the seat for position and Seat Belt comfort (refer to the Operator Seat section of this manual) and then adjust the seat belt as follows: Warning 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 Always check the condition of the seat belt entangled in any portion of the seat assembly.

  • Page 36: Controls And Indicators

    Operator Cab One (1) rear-view mirror is mounted on the right side of the chassis. Figure 25. Travel Select Lever Figure 24. Chassis-Mounted Mirror Gear Select Switch The Gear Select switch has a twist grip handle with three (3) Controls and Indicators positions: 1 - FIRST, 2 - SECOND, and 3 - THIRD.

  • Page 37: Parking Brake Switch

    Operator Cab Parking Brake Switch Load Capacity Charts The Parking Brake switch (A) has two (2) positions: ON and Load Capacity Charts are located on the left side of the front OFF. 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.
  • Page 38 Operator Cab A. HIGH HYDRAULIC OIL TEMP I. REAR AXLE LOCKED The hydraulic oil temperature indicator illuminates when the The Rear Axle Locked Indicator illuminates when the forklift oil temperature is above 1800 F (820 C). If the hydraulic oil is in the axle lock mode.

  • Page 39: Display Features

    Operator Cab R. OIL PRESSURE GAUGE Z. ENGINE WARNING The Oil Pressure Gauge indicates the engine oil pressure. The Engine Warning Indicator will be displayed when there is Normal engine oil pressure is between 40 and 80 psi. If the an engine or DPF fault.
  • Page 40 Operator Cab ENGINE DIAGNOSTICS Pressing the ENGINE DIAGNOSTICS soft button will display engine information. Pressing the MENU button will return to the GAUGE DISPLAY mode. Fig 35. Utilities SERVICE REMINDERS Pressing the SERVICE REMINDERS soft button will display data pertaining to maintenance schedules. Pressing the MENU Fig 32.

  • Page 41: Steering Select Switch

    Operator Cab Outrigger Control The outrigger toggle switches are used to lower and raise the outriggers. The outrigger indicators illuminate when the out- riggers are fully extended and on the ground (Figure 29). Fig 38. Regeneration Menu FAULT CONDITION POP-UPS A fault condition may trigger a pop-up dialog box describing the nature of the fault.

  • Page 42: Boom Control

    Operator Cab 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).

  • Page 43: Attachment Tilt Switch

    Operator Cab Frame Sway Control Handle Attachment Tilt Switch Function Purpose The Attachment Tilt Switch located on the top of the boom Frame sway right Move handle right control handle controls attachment tilt functions. Frame sway left Move handle left NOTE: Lock the frame sway by placing the travel select lever FRONT in NEUTRAL or applying the service or parking brake.

  • Page 44: Lights Switch

    Operator Cab Lights Switch Boom Extend Letters As the boom is extended, the boom extend letters on the left Flip the toggle switch to ON to turn the front lights on. side of the boom are visible to the operator. These letters indicate boom extension as it corresponds to the load capacity charts.

  • Page 45: Boom Maintenance Stand

    Operator Cab Boom Maintenance Stand (If Equipped) Forklift Lifting Points The XR1245 lifting points are shown below (Figure 54). The The Boom Maintenance Stand is an optional safety equipment forklift should only be lifted if lifting points are installed. used support boom during...

  • Page 46: Operation

    Operation Operation Pre-Operation Inspection Caution Contact with hot surfaces and the exhaust To perform the pre-operation inspection make sure the pipe after the forklift has been operated forklift is NOT running, the engine is cool, the forklift is parked could result in serious personal injury. on level ground, the boom is completely retracted, and the frame is level.
  • Page 47 Operation Warning Warning Wear eye protection when starting a fork- lift with jump start cables. Improper jump start procedures could cause the battery to explode, which could result in death or seri- ous injury. Lead-acid batteries produce flammable and potentially ex- •...

  • Page 48: Pre-Operation Inspection Checklist

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

  • Page 49: Functional Tests

    Operation Operate the boom control handle forward and Functional Tests backward to lower and raise boom. Operate the boom control handle left and right to Warning retract and extend boom. Operate the attachment tilt thumb stick up and down Perform a pre-operation inspection and func- to tilt the attachment.

  • Page 50: Operator Maintenance

    Operation Operator Maintenance Figure 55. Check Hydraulic Oil Sight Gauge (A); Add Hydraulic Oil, if Nec- Figure 58. Check Engine Oil Level. Add Engine Oil (API CJ-4), If Necessary. essary (B). DO NOT remove a hydraulic tank filler cap un- less it is cool enough to touch with bare hands.

  • Page 51: Before Starting Forklift

    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 oth- er hazards. Face the forklift for mounting or dismount- ing.

  • Page 52: Starting Forklift

    Operation 2. To start the engine, turn key in ignition switch clockwise Starting Forklift to the RUN position. Wait until the Glow Plugs Wait to Start Indicator (LED) goes off and then turn the key to the START position to crank the engine. Normal Starting Warning To prevent death, serious injury, or prop-...

  • Page 53: Jump Starting

    Operation • Never jump start a frozen battery, as it can explode. Let Jump Starting the battery thaw out before charging. • NEVER jump start the forklift when travel select lever is Jump start or replace the battery of the forklift when the in gear, which can cause the forklift to lurch forward or battery is discharged to the point that it will not crank the backward, and could result in death, serious injury, or...

  • Page 54: Forklift Travel

    Operation Crab Steering NOTE: If the engine fails to start on the first try, wait until the engine and starter come to a complete stop before cranking Crab steering allows all four (4) wheels to turn the engine again. in the same direction as the steering wheel, allowing the forklift to move “sideways”.

  • Page 55: Starting Travel

    Operation To shift gears rotate the gear select lever to the next gear Starting Travel while the forklift is traveling. • Use first gear (1) for highest torque and pulling power. Warning • Use higher gears for higher ground speed. •...
  • Page 56 Operation CHECK ENGINE INDICATOR LIGHT is empty and the engine power is operating The Check Engine Indicator displayed by itself at reduced power or limited to idle; add DEF shows the engine is operating normally but immediately. there are one or more minor faults with the engine electronic management system.
  • Page 57 Operation EXHAUST SYSTEM CLEANING (ESC) is no concern for operating with high exhaust INDICATOR temperature. The ESC Indicator will be displayed by itself The HEST Indicator will be displayed with when a manual regeneration is recommended. a flashing ESC Indicator when the exhaust temperature is elevated due to a manual The ESC Indicator will be displayed with the Check Engine Indicator when a manual...

  • Page 58: Stopping Travel

    Operation Manual Regeneration Changing Travel Direction Stop the forklift by applying the service brake pedal. Caution Move the travel select lever to FORWARD or REVERSE. DO NOT leave forklift unattended during manual regeneration. Warning The manual regeneration should be performed by qualified Make sure the forklift comes to a complete personnel.

  • Page 59: Fuel Types

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

  • Page 60: Fork Ratings

    Operation Fork Ratings Standard Carriage Operation The standard carriage uses manually adjustable forks and can Warning be tilted up or down by using the thumb stick on the control handle. DO NOT exceed forklift capacity of 12,000 pounds. The total rated capacity of the forks being used must equal or exceed forklift capacity.

  • Page 61: Quick Attach System

    Operation To move the forks outward, press the top button (1) on the • Make sure attachment locking devices are always in place. front control handle, or move the auxiliary handle (3) to the • DO NOT operate the forklift until you have positive left.
  • Page 62 Operation 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 (C) and attachment (B). Figure 74. Insert Quick Attach Pin Through Attachment and Quick Attach Adapter.
  • Page 63 Operation Connect the quick attach couplers (this only applies to Raise the quick attach lock lever. attachments with a quick attach hydraulic system). Figure 78. Quick Attach Lock Lever Pull out the quick attach pin at the bottom of the quick Figure 76.

  • Page 64: Load Handling

    Operation Tilt and lower boom until pivot pins (A) have disconnect- Keep the forklift, attachments, and loads a ed from attachment hooks (B). 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 pow- er lines and other power sources.

  • Page 65: Boom Lift Point

    Operation • Adjust the load as necessary, especially for nonstandard Suspended Loads loads. • Use caution when handling loose material that can fall into the cab. Avoid carrying a suspended load. If necessary, • Remove overhanging load materials, when possible, secure the load by attaching it to the forklift and watch for sliding material.

  • Page 66: Place A Load

    Operation Place A Load Before placing the load, refer to the appropriate load capacity chart to determine safe boom extension range. Set the Parking Brake switch to ON (engaged). Use the frame sway control to level the forklift. For additional information, refer to the Frame Leveling section in this manual.
  • Page 67 Operation On the overhead protection device, when requested by Make sure that the work platform is securely attached the user. to the quick attach or forks. Follow the platform manufacturer’s instructions. Protection must be provided for the personnel in their normal working position on the platform from moving Make sure the platform, carriage, and forks are secured to parts of the rough terrain forklift that represent a hazard.

  • Page 68: Load Capacity Charts

    Operation Use of railings, planks, ladder, etc. on the platform for purpose of achieving additional reach or height is prohibited. 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. The platform shall be lowered to ground level for personnel to enter and exit.
  • Page 69 Preventive Maintenance NOTE: The boom angle indicator is a plumb arrow with For example: angular graduations from -5 to +700. The operator determines load weight and makes sure load does not exceed fork, attachment, or boom capacity. • The load is 6,614 lbs. The operator safely moves the load to a loading position.

  • Page 70: Frame Leveling

    Preventive Maintenance 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 con- trol, do not attempt to raise or place load.

  • Page 71: Establishing A Maintenance Program

    Preventive Maintenance Preventive Maintenance Check condition and tension of drive belts (use Establishing a Maintenance Program tension meter to check belt tension) The hour meter displays elapsed engine operating hours Lubricate front and rear drive shaft grease fittings and has a total readout of 9,999.9 hours. Use the hour meter Lubricate outrigger pivot point grease fittings and the schedules contained in this section to establish a comprehensive preventive maintenance program.
  • Page 72 Lockout / Tagout After Every 250 Hours of Operation Check specific gravity of engine coolant Comply with 50-Hour Maintenance Requirements Replace transmission fluid and filters Change engine oil and filter Replace hydraulic reservoir air breather Check air filter (replace if necessary) Replace hydraulic return line filter Check tension and condition of drive belts (use Replace hydraulic high-pressure filter...

  • Page 73: Boom Emergency Lower Down Valve

    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.

  • Page 74: Do Not Operate - Accident Prevention Tags

    Lockout / Tagout 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.

  • Page 75: Do Not Operate Tags

    Lockout / Tagout Do Not Operate Tags Operation Manual Operation Manual...
  • Page 76 Chapter Description 8350 EASTGATE ROAD HENDERSON, NV 89015 (702) 636-2969 (800) 497-1704 www.XMFG.com PN 24906-003 Operation Manual...

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Xr1245

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