Xtreme XR1255 Operating instructions

Xtreme XR1255 Operating instructions

Operation &

Safety Manual

AUSTRALIA

PN 24907-400

PN 24907-400

REV 02

JUNE 2015

AUTHOR:

OVY LUNGU

© 2015 XTREME MANUFACTURING. ALL RIGHTS RESERVED

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 Telehandler

Operation Safety

Load Safety

Attachments

Shut Down Procedure

Telehandler 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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11

12

14

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9

6

6

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5

5

5

3

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

Hour Meter

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

Outrigger Switches

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

Using the LifeHammer

Telehandler Lifting Points

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Operation Manual

Table of Contents

Description

Operation

Pre-Operation Inspection

Pre-Operation Inspection Checklist

Functional Tests

Operator Maintenance

Before Starting Telehandler

Starting Telehandler

Normal Starting

Jump Starting

Telehandler Travel

Steering Modes

Starting Travel

Warning Indicators and Gauges

Stopping Travel

Changing Travel Direction

Shut Down Procedure

Refueling

Fuel Types

Pintle Hook

Attachments

Attachment Disclaimer

Fork Ratings

Standard Carriage Operation

Fork Positioning Carriage Operation

Page

56

56

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52

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Table of Contents

Description

Quick Attach System

Load Handling

Boom Lift Point

Suspended Loads

Pick Up a Load

Carry a Load

Place a Load

Load Shift

Load Capacity Charts

Frame Leveling

Preventive Maintenance

Establishing a Maintenance Program

Maintenance Schedule

Lockout / Tagout

Boom Emergency Lower Down Valve

Do Not Operate - Accident Prevention Tags

New or Additional Operators

Lockout/Tagout Procedure

“Do Not Operate” Tags

Declarations

Declaration of Noise Emission

Declaration of Vibration Emission Values

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Operation Manual

4

Introduction

General

This Operation and Safety Manual provides the information needed to safely operate the XR1255 Telehandler.

This manual should be considered a permanent part of the telehandler, and kept in the protective manual case located in the operator’s cab.

Notice

Before operating the telehandler, 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 telehandler 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 telehandler 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 Telehandler

• Clear the area of all other persons

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

It is your responsibility to observe applicable laws and regulations and to follow manufacturer’s instructions on telehandler operation and maintenance.

Fig 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

Replacement Manuals

Replacement manuals for the XR1255 Telehandler can be obtained by contacting our parts department by phone or visiting our website:

Xtreme Manufacturing

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

LEFT

Fig 2. Telehandler 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 telehandler are NOT all-inclusive.

You are responsible for safe operation of the telehandler 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 telehandler 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 telehandler.

• 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.

Warning

If operators should 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 telehandler.

Make safety a high priority while operating the telehandler.

Learn and follow all safety messages in this manual and on telehandler 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 telehandler.

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

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

Operation Manual

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

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

Safety

Hot Surface!

Keep Hands Away

Pinch Points

Body

Have Adequate

Ventilation If

Operating This

Telehandler In An

Enclosed Space

DO NOT Operate

During Storms Or

High Wind

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 telehandler. Successful completion and certification of the Safety Training for

Rough Terrain Telehandlers 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 Responsibility

Warning

Telehandlers are potentially dangerous if proper safety procedures are not followed. Workers who operate, maintain, or work near the telehandler can be at risk of roll over and run over incidents or can be crushed or caught by the telehandler or its parts which could result in death or serious injury if the telehandler is not properly operated or maintained.

Read the Operation and Safety

Manual BEFORE operating the telehandler. Follow all safety instructions and labels. Only operate the telehandler 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 telehandler and attachments will not be damaged or made unsafe by any procedures you choose.

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 Telehandlers is required.

• Operators must be properly instructed on how to operate the telehandler and attachments.

• Operators must operate the telehandler according to ALL appropriate safety regulations.

• Operator trainees must remain under constant observation and supervision of an experienced operator.

Modifications

Warning

Modifications to the telehandler or attachments could affect telehandler capacity and/or stability which could result in death or serious injury. DO NOT make modifications to the telehandler 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 telehandler.

9

Operation Manual

Mounting/Dismounting

Warning

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

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

Face the telehandler 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 telehandler. 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 telehandler to prevent death, serious injury, or property damage.

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

• 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:

3. sewers

Underground objects could cause death or serious injury.

1. gas and water pipes

2. electrical cables

Safety

Warning

• Operate the telehandler 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 telehandlers in the work area.

• Know the rules for movement of people and telehandlers 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 telehandler 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 telehandler.

DO NOT operate the telehandler on roads. The telehandler is not equipped for road travel.

Warning

Operate the telehandler 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.

Warning

DO NOT operate the telehandler during storms or if the wind is in excess of 10 m/s.

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 telehandler controls, moving parts, etc. Failure to wear the proper protective clothing could result in death or serious injury.

Before Starting Telehandler

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 telehandler 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 telehandler and remain legible.

Warning

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

Manufacturing for replacement manuals.

Clearly define responsibilities and procedures for operating the telehandler 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 telehandler.

To avoid death or serious injury, carefully read and understand all instructions before operating the telehandler. DO

NOT operate, modify, repair, or maintain the telehandler 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 telehandler frame while operating the telehandler. Doing so can result in death or serious injury.

Always check the condition of the seat belt and mounting hardware before operating the telehandler. 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 or supplier of the fluid or chemical.

• DO NOT operate the telehandler until the seat belt or mounting hardware is replaced, if worn or damaged.

• The seat belt MUST be worn while operating the telehandler. Failure to wear the seat belt could result in death or serious injury.

11

Operation Manual

Warning

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

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 telehandler.

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 telehandler 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 deenergize power lines or take other suitable precautions.

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

• Remain at least 3 meters, plus an additional 10 millimeters 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 telehandler.

Warning

Safety

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 telehandler

BEFORE raising the boom above horizontal.

If the telehandler cannot be leveled using the frame sway control, do not attempt to raise or place load. Reposition telehandler 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 telehandler.

• The seat belt MUST be worn while operating the telehandler. Failure to wear the seat belt could result in death or serious injury.

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

Never try to escape the telehandler 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 telehandler and ride out the roll over or tip over.

Operation Manual

12

Safety

Warning

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

NEVER allow passengers to ride on the telehandler. DO

NOT allow riders on the frame or operator cab. Allowing passengers to ride could result in serious injury. The telehandler 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 telehandler 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.

Traveling with an elevated boom can cause tip over, which could result in death or serious injury.

Allow for adequate clearance between the attachment and other objects when turning.

The attachment extends beyond the front of the telehandler. 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 telehandler 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 telehandler tip over/roll over and result in death or serious injury.

Operate the telehandler for maximum stability. Unstable telehandlers can tip over, resulting in death, serious injury, or property damage. Keep the telehandler 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 telehandler 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 telehandler.

Warning

Become completely familiar with the telehandler before operating on slopes. The telehandler 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 telehandler across slopes.

• Always drive the telehandler straight up and down a slope (never drive diagonally up or down a slope).

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

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

13

Operation Manual

Safety

Follow appropriate procedures to prevent sudden changes in telehandler 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 telehandler is moving.

• DO NOT coast downhill. Keep the travel select lever in the appropriate position.

DO NOT exit the telehandler without following proper shut down 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 telehandler.

Contact with hot surfaces and the exhaust pipe after the telehandler 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 telehandler, follow proper shut down tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler 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.

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 telehandler capacity of 5,440 kilograms.

The total rated capacity of the forks being used must equal or exceed telehandler 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 telehandler tip over, loss of load, or structural damage which could result in death or serious injury.

DO NOT use the telehandler to lift people.

The XR1255 is not approved for use with work platforms for elevating personnel.

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 telehandler 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 telehandler 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 telehandler tie-downs and/ or have another person assist with safely steadying the load.

Operation Manual

14

Safety

Attachments Telehandler 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 telehandler.

• Make sure attachment locking devices are always in place.

• DO NOT operate the telehandler 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 268.8 bar, which is the maximum pressure of the telehandler 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

Follow the manufacturer’s instructions for proper maintenance to make sure the telehandler continues to meet manufacturer’s specifications. Failure to properly maintain the telehandler 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 telehandler should not be operated until all service or maintenance is completed.

• Keep two (2) legible “Do Not Operate” tags with the telehandler at all times. “Do Not Operate” tags are provided in this manual.

• DO NOT operate the telehandler 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 telehandler before all repairs have been made and all proper maintenance is completed.

Warning

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

• Park telehandler 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 telehandler. The telehandler 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

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

It is possible for the telehandler to move suddenly when the brakes are released, which could result in death, serious injury, or property damage. To prevent sudden movement of the telehandler, place wheel chocks in front of and behind wheels before the brakes are released.

If the telehandler is to be towed, make sure the released brake(s) can be reapplied or the tow telehandler has the braking capacity to stop the telehandler.

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.

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.

Safety

• 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

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

Wear eye protection when starting a telehandler 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 telehandler when travel select lever is in gear, which can cause the telehandler 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 telehandler, make sure the two (2) telehandlers 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 telehandler ground. Make the connection to the stalled telehandler ground last.

• Connect jump start cable to stalled telehandler 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 telehandler.

• Turn off all lights and accessories on the stalled telehandler 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.

Operation Manual

16

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 telehandler roll away.

1.

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

2.

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

A

C

B

D

3.

Under the front of the telehandler, 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 telehandler 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.

Re-Activating Parking Brakes (Front Axle)

Warning

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

1.

After you have blocked all four (4) wheels, under the front of the telehandler, 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.

Fig 3. Brake Release Locations (both sides)

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

Fig 5. Brake Release Bolt

17

Operation Manual

Labels

Left Side View

36

35

9

52

25

48

45 46 47

INNER BOOM

51

34

40

17

3

10

38

41

Fig 6. Label Legend (Left Side)

Right Side View

39

9

42

38

44

26

12

10

37

8 19

6

34

10

Fig 7. Label Legend (Right Side)

7

4

27

33

31

30

26

34

53

52

Operation Manual

43

18

25

51

53

36

35

44

26

10

12

37

Labels

Labels

Front View

53

37

51

10

53

52

Fig 8. Label Legend (Front)

Cab View

Rear View

26

25

32

12

10

37

12

10

39

Fig 9. Label Legend (Rear)

49

2

55

54

23

28

22

1

21

20

11

15

16

Fig 10. Label Legend (Cab)

10

3

17

5

19

Operation Manual

Labels

Table 1. Labels

Item Qty Part No. Description

1

2

1 18008-100 Data Plate

1 18001-002 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 (Tier 4)

1 18014-001 Check Engine Oil (Tier 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 18033-100 Auxiliary Handle Control

23

1 18347-000 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

30

1 18069-000 Hydraulic Tank Fluid Level

31

1 18082-001 Warning, Injection Hazard

32

2 18083-001 Warning, Explosion Hazard

33

1 18086-001 Hydraulic Fluid, Use Dexron III

34

4 18090-001 Warning, Tip Over Hazard

Item Qty

36

2

37

4

Part No. Description

18312-000 Warning, Falling Hazard

18315-000 Tie Down Point

46

1

47

1

48

1

49

1

50

1

51

1

52

1

53

1

38

1

39

1

40

1

41

1

42

1

43

1

44

2

45

1

18043-000

18044-000

18046-000

18047-000 Boom Swoosh Left Rear

18048-000 Boom Swoosh Right Front

18049-000 Boom Swoosh Right Rear

18372-000 XR1255

18056-000

18057-000

18058-000

18311-402

18331-000

18332-400

18307-001

18306-001

Xtreme logo

Xtreme X

Boom Swoosh Left Front

Boom Lettering A-B-C-D

Boom Lettering E-F

Boom Lettering G-H

Boom Hook 12k

Caution, Adjustable Carriage

Warning, Tow Capacity

Warning, Falling Hazard

Danger, Crushing Hazard

54

55

56

1

1

1

18306-000 Danger, Crushing Hazard

17250-100

Load Chart, Outriggers Up -

Standard Carriage

17251-100

17348-100

Load Chart, Outriggers Down -

Standard Carriage

Load Chart, Outriggers Up-Lift

Point

57

1 17349-100

Load Chart, Outriggers Down-Lift

Point

58

1 18422-004 Authorized Attachment Plate

59

2 18241-401 Lift Points

Operation Manual

20

Labels

Replacement Labels

Replacement labels can be obtained by contacting Xtreme

Manufacturing at (800) 497-1704. Please have the correct label number available when you call.

1) 18008-100

Parking

Brake

OFF

ON

18001-002

702-636-2969

800-497-1704

Hy dr atur

Temper e ak e e

Lo w Br

Pr essur ked

Rear Axle

Volts Fuel

Oil Coolant

Hourmeter

Lights

On

Off

Rear Axle

Centered

Crab

2W

4W

Steering

On

Off

Declutch

Left Right

Up

Down

Outriggers

2) 18001-002

18010-100

3) 18010-100

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

Operation Manual

36) 18312-000

26

32) 18083-001

34) 18090-001

Labels

Labels

37) 18315-000

39) 18044-000

38) 18043-000

40) 18046-000

41) 18047-000

27

42) 18048-000

Operation Manual

Labels

43) 18049-000

A B C D

45) 18056-000

G H

47) 18058-000

18058-000

18056-000

E

CARRIAGE DAMAGE

DAMAGE may result from adjusting forks when carriage is loaded.

ONLY ADJUST FORKS WHEN CARRIAGE

IS UNLOADED.

18331-000

49) 18331-000

44) 18372-000

F

46) 18057-000

5,440 kg.

48) 18311-402

18311-402

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 226.8 kg.

Max tow capacity 2,268 kg.

18332-400

50) 18332-400

18057-000

51) 18307-001

Operation Manual

52) 18306-001

28

53) 18306-000

Labels

XR1255 LOAD CHART OUTRIGGERS UP - STANDARD CARRIAGE

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

REAR AXLE UNLOCKED.

18

LOAD CENTRE

65

68

H

17

17

16

15

14

BO

OM

A

NG

LE

45

50

55

60

G

F

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TYRES ONLY.

13

12

11

10

30

35

40

E

D

C

B

A

600MM

LOAD

CENTRE

2,720 KG AT

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

9

8

7

6

5

4

10

20

15

25

700 K

G

900 K

G

1,300 K

G

1,900 K

G

2,700 K

G

3,500 K

G

4,250 K

G

5,100 K

G

8.8

600MM

LOAD

CENTRE

5,440 KG MAX FORK

LOAD WITH BOOM

FULLY RETRACTED ONLY.

3 5

LOAD CENTRE

LOAD CENTRE

2

0

1

0

5

7

LOAD CENTRE

H

G

F

E

D

C

13 12 11 10

11.5

9 8 7 6 5

LIFTING (STATIONARY) - RATED LOAD ON FORKS

THE

CHASSIS

MUST

REMAIN

LEVEL

4

B

A

LOAD CENTRE

LOAD CHART

P/N 17250-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25

(G2 or E3 FOAM FILLED)

MAX WHEEL LOADING:

MINIMUM TYRE MASS:

9400 KG

435 KG

IN SERVICE WIND SPEED: 10 M/S - 36KM/H

FORK LOAD CENTRE:

600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED: (AS 1418.19)

3 2 1 0 -1 -2

REACH METER

TRAVELLING (PICK & CARRY) - RATED LOAD ON FORKS

4º MAX 4º

MAX

10º MAX 10º MAX 5º MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

54) 17250-100

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

XR1255 LOAD CHART OUTRIGGERS UP - BOOM LIFT POINT

LOAD CENTRE

17

16

65

68

H

16.3

REAR AXLE UNLOCKED.

LOAD RATINGS

15

14

13

12

BO

OM

A

NG

LE

50

45

40

55

60

G

F

E

STANDARD

CARRIAGE MUST

BE ATTACHED AND

UNLADEN WHEN

BOOM LIFT POINT

IS IN USE.

SHOWN ARE FOR

VEHICLES EQUIPPED

11

35

D

WITH FOAM FILLED

TYRES ONLY.

2,720 KG AT

10

9

8

25

30

C

B

A

8.2

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

7

6

5

4

3

5

20

15

10

700 K

G

LOAD CENTRE

900 K

G

1,300 K

G

1,900 K

G

2,700 K

G

3,500 K

G

4,250 K

G

5,100 K

G

LOAD CENTRE

5,440 KG MAX LIFT POINT

LOAD WITH BOOM

FULLY RETRACTED ONLY.

2

1

0

LOAD CENTRE

LOAD CHART

P/N 17348-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25

(G2 or E3 FOAM FILLED)

MAX WHEEL LOADING:

MINIMUM TYRE MASS:

9400 KG

435 KG

IN SERVICE WIND SPEED:

FORK LOAD CENTRE:

10 M/S - 36KM/H

600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED:

(AS 1418.19)

0

11

5

7

10

H

9

10.3

G

8 7

F

6

E

5 4

D

C

3

LIFTING (STATIONARY) -

RATED LOAD ON BOOM LIFT POINT

THE

CHASSIS

MUST

REMAIN

LEVEL

B

2

A

LOAD CENTRE

1 0 -1 -2

REACH METER

TRAVELLING (PICK & CARRY) -

RATED LOAD ON BOOM LIFT POINT

MAX

MAX

10º

MAX

10º

MAX

MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

56) 17348-100

FIXED LOADS

STANDARD

CARRIAGE

SWING

CARRIAGE

TILT

CARRIAGE

1.65 CU YD

(1.26 m3)

BUCKET

PN 25419-010

PN 25400-003

PN 29942-000

PN 14880-010

FREELY SUSPENDED LOADS

15 FT

(4,572 mm)

TRUSS BOOM

PN 14895-000

BOOM LIFT

POINT

PN 12213-008

AS1418.19 COMPLIANT

58) 18422-404

18422-404

29

XR1255 LOAD CHART OUTRIGGERS DOWN - STANDARD CARRIAGE

18

71

LOAD CENTRE

17.2

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

REAR AXLE UNLOCKED.

17

65

H

16

15

14

BO

OM

A

NG

LE

45

50

55

60

G

F

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TYRES ONLY.

13

12

11 35

40

E

D

10

30

B A

C

B

A

LOAD

CENTRE

2,720 KG AT

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

LOAD CHART

P/N 17251-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25

IN SERVICE WIND SPEED:

FORK LOAD CENTRE:

(G2 or E3 FOAM FILLED)

MAX WHEEL LOADING:

MINIMUM TYRE MASS:

9400 KG

435 KG

10 M/S - 36KM/H

600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED: (AS 1418.19)

9

8

7 20

25

6

15

5

4

10

1,300 K

1,800 K

2,250 K

3,050 K

3,850 K

3

0

5

LOAD CENTRE

2

LOAD CENTRE

1

0

5

11.5

H

G

F

E

D

C

13 12 11 10 9 8 7 6 5

LIFTING (STATIONARY) - RATED LOAD ON FORKS

THE

CHASSIS

MUST

REMAIN

LEVEL

4

4,500 K

5,440 K

LOAD CENTRE

LOAD CENTRE

8.9

600MM

CENTRE

3 2 1 0 -1 -2

REACH METER

TRAVELLING (PICK & CARRY) - RATED LOAD ON FORKS

4º MAX 4º

MAX

10º MAX 10º MAX 5º MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

55) 17251-100

XR1255 LOAD CHART OUTRIGGERS DOWN - BOOM LIFT POINT

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

REAR AXLE UNLOCKED.

17

16

15

14

13

BO

OM

A

NG

LE

45

50

55

60

65

71

LOAD CENTRE

H

G

F

16.6

STANDARD

CARRIAGE MUST

BE ATTACHED AND

UNLADEN WHEN

BOOM LIFT POINT

IS IN USE.

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TYRES ONLY.

12

11

40

E

10

9

30

35

D

C

B

A

2,720 KG AT

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

8

7

20

25

8.3

LOAD CENTRE

6

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

5

4

3

15

10

5

1,300 K

LOAD CENTRE

1,800 K

2,250 K

3,050 K

3,850 K

4,500 K

5,440 K

LOAD CENTRE

2

1

0

LOAD CENTRE

0 4

H

G

10.2

F

E

D

C

B A

LOAD CHART

P/N 17349-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25 (G2 or E3 FOAM FILLED)

MAX WHEEL LOADING:

MINIMUM TYRE MASS:

9400 KG

435 KG

IN SERVICE WIND SPEED: 10 M/S - 36KM/H

FORK LOAD CENTRE: 600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED: (AS 1418.19)

11 10 9 8 7 6 5 4 3

LIFTING (STATIONARY) -

RATED LOAD ON BOOM LIFT POINT

THE

CHASSIS

MUST

REMAIN

LEVEL

2 1 0 -1 -2 -3

REACH METER

TRAVELLING (PICK & CARRY) -

RATED LOAD ON BOOM LIFT POINT

MAX

MAX

10º

MAX

10º

MAX

MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

57) 17349-100

MODEL: XR1255

UNLADEN VEHICLE WEIGHT: 16,375 kg

UNLADEN CENTER OF GRAVITY

FORWARD LIFT POINT

AFT LIFT POINT

1,958 mm

APPROX

3,581 mm

WHEEL BASE

59) 18241-401

18241-401

Operation Manual

Features

Feature

Boom

Chassis

Cab

Standard Equipment

Description

Universal quick attach head

Three (3) section boom

Boom equipped with heavy duty boom rollers

Rear axle stabilization

31.75 mm 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 and rear)

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

Brake oil pressure, parking brake, axle lock, rear wheel alignment, declutch indicator, transmission range, tilt interlock, engine warning lights

Electric horn and backup alarm

Declutch switch

Rear view mirror

Adjustable seat with seat belt

Deluxe suspension seat

Boom angle and frame level indicator

3600 visibility

Boom angle and frame level indicator

Tires Foam-filled

Hydraulics Auxiliary hydraulic circuit with quick attach

Attachment tilt switch

Frame sway control handle

Frame sway override switch

Feature

Options

Optional Equipment

Description

Enclosed cab with A/C

Heater/defroster/windshield wiper

Work light package

Turn signals/hazard lights

Features

Operation Manual

30

Specifications

Specifications

Performance

Capacity . . . . . . . . . . . . 5,440 kg

Lift Height . . . . . . . . . . . 16,764 mm

Forward Reach . . . . . . . . 11,583 mm

Frame Leveling L/R . . . . . 11°/11°

Operating Weight . . . . . . 16,193 kg

Wind Speed Rating. . . . . . 10 m/s

Power Train

Engine . . . . . . . . . . . . . Perkins 122 hp

Fuel Capacity . . . . . . . . . 272.5 L

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

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

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

Standard Equipment

Heavy-duty Frame/Chassis

Heavy-duty Roller Boom

Robust Wiring, No Spades, No Pins

Full-time Planetary 4-Wheel Drive

Steering - 4-Wheel Circle, Crab, 2-Wheel Front

Rear Axle Stabilization (RAS)

Back-Up Alarm

Open ROPS/FOPS

Suspension Seat

Rear View Mirrors

Load Management System

Xtreme Service Accessibility

Tires

Tires (Standard Eq)

Hydraulics

Foam Filled

15.5 x 25 E3

Liters Per Minute . . . . . . . 185.4

PSI . . . . . . . . . . . . . . . . 241.3 bar

Hydraulic Oil Capacity . . . 219.5 L

Dimensions

Length to fork face . . . . . . 7,620 mm

Width . . . . . . . . . . . . . . 2,590 mm

Height . . . . . . . . . . . . . 2,460 mm

Wheel Base . . . . . . . . . . 3,580 mm

Ground Clearance . . . . . . . 419 mm

Turning Radius . . . . . . . . 4,260 mm

Attachments

Standard Carriage - 1,829 mm

Swing Carriage - 1,829 mm

Tilt Carriage - 1,829 mm

Standard Fork - 57 x 102 x 1,524 mm

Bucket - 1.26 m3

Truss Boom - 4,572 mm

Accessories and Options

Enclosed Cab

Air Conditioning

Strobe Light on Cab

Boom Work Lights

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 telehandler.

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 telehandler 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

Always check the condition of the seat belt and mounting hardware before operating the telehandler. If the seat belt or mounting hardware is defective, it may not properly restrain the operator, which could result in death or serious injury.

• DO NOT operate the telehandler until the seat belt or mounting hardware is replaced, if worn or damaged.

• The seat belt MUST be worn while operating the telehandler. Failure to wear the seat belt could result in death or serious injury.

The telehandler is equipped with a standard 51 mm wide retractable seat belt. A 76 mm 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 telehandler is moving. Keep both hands on the wheel while the telehandler is moving to prevent loss of telehandler 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 telehandler 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 telehandler.

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.

Hydraulic Oil Temperature Indicator

The Hydraulic Oil Temperature Indicator illuminates when the oil temperature is above 82°C. 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 telehandler, follow proper shut down procedures, tag the telehandler with “Do

Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

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).

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 telehandler, including boom angle, height, and reach.

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 illuminated, do not release parking brake or engage transmission until light is out. If the light does not go out, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

Rear Axle Lock Indicator

The Rear Axle Lock Indicator illuminates when the telehandler is in the axle lock mode. The rear axle locks when the parking brake is set to ON (engaged), or the transmission is in NEUTRAL or the service brake is applied, and when the boom is above

10°. If the Rear Axle Lock Indicator does not illuminate, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

Figure 28. Load Capacity Charts

37

Figure 29. Hydraulic Oil Temperature, Low Brake Pressure, and Rear Axle Lock Indicators

Operation Manual

Engine Warning Indicator

The Engine Warning Indicator illuminates for 5 seconds when the key switch is moved to the RUN position. After that period, a steady LED indicates the engine is operating normally but there is one or more faults with the engine electronic management system. A flashing LED indicates there is one or more faults and the engine is operating in a derated mode.

Operator Cab

Hour meter

The Hour meter indicates and records engine operating hours and has a total readout of 9,999.9 hours. Use the hour meter to establish a telehandler maintenance schedule.

Engine Stop Indicator

The Engine Stop Indicator illuminates for 5 seconds when the key switch is moved to the RUN position. After that period, the LED indicates the engine is either shutdown or an engine shutdown is imminent.

Glow Plugs Wait to Start Indicator

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

Figure 31. Hour meter

Voltage Gauge

The voltage gauge indicates the amount of charge (in volts).

Normal system voltage is between 11 volts and 15 volts. If the voltage gauge shows abnormal readings, stop the telehandler, follow proper shut down procedures, tag the telehandler with

“Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

Figure 30. Engine Warning, Engine Stop, and Glow Plugs

Wait to Start Indicators

Operation Manual

38

Figure 32. Voltage Gauge

Operator Cab

Fuel Gauge

The fuel gauge indicates the quantity of fuel in the fuel tank.

The total capacity of the fuel tank is 272.5 liters.

Coolant Gauge

The coolant gauge indicates the temperature of the coolant in the engine cooling system. After starting the telehandler, allow time for the coolant temp gauge pointer to begin to move before operating the telehandler. After the engine has sufficiently warmed up, normal engine coolant temperature should read between 82 0C to 93 0C. If the coolant gauge shows abnormal readings, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not

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

BEFORE

placing it into service again.

Figure 33. Fuel Gauge

Oil Gauge

The oil gauge indicates the engine oil pressure. Normal engine oil pressure readings should be between 2.75 bar and

5.5 bar. If the oil gauge shows abnormal readings, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

Figure 35. Coolant Gauge

Light Switches

The Light Switches control the boom and cab lights.

Figure 34. Oil Gauge

39

Figure 36. Light Switches

Operation Manual

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).

Operator Cab

Steering Select Switch

Warning

DO NOT change steering modes until the telehandler 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 telehandler 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).

Figure 37. Turn Signal and Hazard Light Switches

Rear Axle Centering Indicator

The Rear Axle Centering Indicator illuminates when the rear wheels are aligned perpendicular 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 telehandler, follow proper shut down procedures, tag the telehandler with “Do

Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

Figure 39. Steering Select and 2-Wheel Rear Switches

Declutch Indicator / Declutch Switch

The Declutch indicator illuminates when the Declutch switch is set to the ON position. If the declutch indicator does not illuminate, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE

placing it into service again.

The Declutch switch (in conjunction with the service brake) disengages the transmission to prevent the telehandler from moving while raising or lowering a load.

• When the Declutch switch is set to ON and the service

brake applied, the transmission is disengaged.

Figure 38. Rear Axle Centering Indicator

Operation Manual

40

Operator Cab

• When the Declutch switch is set to OFF, the transmission

remains engaged when the travel select lever is set to

either FORWARD or REVERSE.

Boom Control

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

Figure 40. Declutch Indicator / Declutch Switch

Outrigger Switches

The Outrigger Switches are used to lower and raise the outriggers. The outrigger indicator illuminates when the outriggers are fully extended and on the ground. Once outriggers are fully extended, the transmission is disengaged, and the frame sway is locked. Frame sway lock can be overridden with the Frame Sway Override Switch.

Figure 41. Outrigger Switches

Figure 42. Boom Control Handle

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.

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

Boom Control Handle Functions

Function Purpose

Aux Select Button Auxiliary functions control

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 43. 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 45. 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.

Figure 44. Boom Control Handle Functions

Operation Manual

42

Operator Cab

Auxiliary Attachment Control

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

Figure 46. 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 telehandler includes a Frame Sway

Override switch. Improper use of the Frame

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

Figure 48. Auxiliary Attachment Control Lever

Windshield Washer and Wiper Switch

Flip the toggle switch to WASH to spray windshield washer fluid onto the windshield; flip the switch to ON to turn the windshield wiper on. The OFF position turns the wiper off.

Figure 47. Frame Sway Control Handle

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 49. Windshield Washer and Wiper 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 telehandler has been positioned in a level condition.

Figure 50. 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 52. Frame Level Indicator

Warning

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

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 telehandler and the attachments periodically for corrosion.

Figure 51. Boom Extend Letters

Operation Manual

44

Operator Cab

Warning

IN CASE OF AN EMERGENCY, IF YOU ARE

TRAPPED INSIDE THE CABIN, EXIT BY BREAK-

ING GLASS

USING ANY AND ALL AVAILABLE

MEANS

INCLUDING THE LIFEHAMMER PRO-

VIDED. BE FAMILIAR WITH ITS LOCATION IN-

SIDE THE CABIN

Using the LifeHammer

This telehandler is equipped with LifeHammer, a safety device designed to break glass in case of an emergency if the operator is trapped inside the cabin with no other way out.

When seconds count and you must escape from a sinking or burning telehandler...

• LOCATE

LifeHammer by looking for its luminescent pin.

• HOLD

LifeHammer by the easy-grip handle, with the hammer head pointing up.

• RELEASE

the tightness of your seatbelt as much as possible, hook the seatbelt into the blade, and pull up/down, continuing to pull as the blade cuts through the belt.

• RELEASE

other passengers, small children first, from their restraints.

• SMASH

a side window by swinging LifeHammer overhand, like a household hammer. One or two strikes should shatter the glass. Any of the two heads of the hammer can be used for this purpose.

• SHIELD

your eyes and face from the glass, and instruct others to do the same. Still using LifeHammer, scrape the remaining glass from the window edges.

• ESCAPE!

Telehandler Lifting Points

The XR 1255 lifting points are shown in the figure 54 below.

The telehandler should only be lifted if lifting points are installed.

Warning

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

Figure 53. Emergency LifeHammer For Breaking Glass

UNLADEN VEHICLE WEIGHT: 16,375 kg

AFT LIFT POINT

UNLADEN CENTER OF GRAVITY

FORWARD LIFT POINT

Figure 54. XR1255 Lifting Points

45

1,956 mm

APPROX.

3,581 mm

WHEEL BASE

Operation Manual

Operation

Pre-Operation Inspection

To perform the pre-operation inspection make sure the telehandler is NOT running, the engine is cool, the telehandler 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.

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 telehandler 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 telehandler and remain legible.

Remove telehandler 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

Caution

Operation

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

Warning

Always check the condition of the seat belt and mounting hardware before operating the telehandler. 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 telehandler until the seat belt or mounting hardware is replaced, if worn or damaged.

• The seat belt MUST be worn while operating the telehandler. Failure to wear the seat belt could result in death or serious injury.

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

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

Wear eye protection when starting a telehandler 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 telehandler when travel select lever is in gear, which can cause the telehandler 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 telehandler, make sure the two (2) telehandlers 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 telehandler ground. Make the connection to the stalled telehandler ground last.

• Connect jump start cable to stalled telehandler 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 telehandler.

• Turn off all lights and accessories on the stalled telehandler 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.

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

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

47

Operation Manual

Operation

Pre-Operation Inspection Checklist

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

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 for loose and/or missing pivot pins.

.

Check that carriage fork pins are straight and in place to prevent forks from changing position or coming off the carriage.

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

Check tilt cylinders 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.

Bent flanges or any other damage to rims.

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

Check electrical connections on rear sway cylinder.

Check mirrors for cracks, cleanliness, and proper adjustment.

Check hydraulic reservoir sight gauge for proper fluid level. Add hydraulic fluid, if necessary.

Check engine compartment for:

Loose or damaged belts, hoses, and radiator fan blades.

Coolant reservoir level. Add radiator coolant, if necessary.

Engine oil level. Add engine oil, if necessary.

Electrical wires and connectors.

Check transmission fluid level.

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

Check boom lift and carriage master tilt cylinders and hydraulic lines for leaks or any other damage.

Check battery terminals for corrosion.

Check battery for cracked, melted, or damaged case.

.

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.

Check that all the fasteners are in place and in good operational condition.

Date: __________________________

Operation Manual

Initials: __________________________

48

Operation

Functional Tests

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 telehandler 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 telehandler from service and place

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

The safety, efficiency, and service life of your telehandler 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 telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler 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 telehandler in forward and reverse.

Test the service and parking brakes.

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

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

Test each steering function. Operate the telehandler 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 volts and 15 volts.

• Check the engine coolant temperature gauge. The engine coolant temperature gauge should read between 82.3

0C

to 93.4

0

C.

• Check the engine oil pressure gauge. The engine oil pressure gauge should read between 2.76 bar to 5.52 bar.

49

Operation Manual

Operation

Operator Maintenance

Figure 55. Check Hydraulic Oil Sight Gauge

Figure 58. Check Engine Oil Level. Add Engine Oil (API CJ-

4), If Necessary.

Figure 56. Add Hydraulic Oil, if Necessary Figure 59. Check Battery Case and Terminals

Figure 57. Check Coolant Reservoir Level. Add Coolant, if

Necessary.

Operation Manual

50

Figure 60. Store Operation Manual in Protective Case

Operation

Before Starting Telehandler

Warning

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

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

Face the telehandler 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 telehandler. 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 61. Travel Select Lever Must Be in NEUTRAL (N) to

Start the Telehandler

B

A

Figure 62. Parking Brake Switch (A) Must Be ON (Engaged) to Start the Telehandler.

51

Operation Manual

Starting Telehandler

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 telehandler.

1.

Place Key in Ignition Switch.

Operation

2.

Turn key in ignition switch clockwise to the START position.

Figure 64. 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 63. 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 65. 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 telehandler 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.

Warning

Wear eye protection when starting a telehandler 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 telehandler when travel select lever is in gear, which can cause the telehandler 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 telehandler, make sure the two (2) telehandlers 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 telehandler ground. Make the connection to the stalled telehandler ground last.

• Connect jump start cable to stalled telehandler 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 telehandler.

• Turn off all lights and accessories on the stalled telehandler 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 telehandler ground at the furthest point from the battery.

5.

Start the telehandler. Refer to the Starting Telehandler section in this manual.

53

Operation Manual

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.

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)

Telehandler Travel

Steering Modes

Operation

The telehandler 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.

Crab Steering

Crab steering allows all four (4) wheels to turn in the same direction as the steering wheel, allowing the telehandler 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.

Warning

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 telehandler 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 telehandler 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 telehandler slows or comes to a complete stop. Align all four (4) wheels

“straight-ahead”, 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 telehandler. 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.

Operation Manual

54

Operation

Warning Indicators and Gauges

Figure 66. Maximum Fork Sweep

Warning

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 telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler BEFORE placing it into service again. Ignoring warning indicators can cause improper performance, which could result in death, serious injury, or property damage.

Starting Travel

Warning

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

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

• 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 telehandler.

1.

Start the telehandler. Refer to the Starting Telehandler section in this manual.

2.

Apply service brake.

3.

Release parking brake.

4.

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

5.

Release the service brake pedal.

6.

Slowly press the accelerator pedal to start travel.

There are three (3) warning indicator lights on the dash panel that illuminate during critical circumstances. All three

(3) warning indicators demand immediate attention and telehandler servicing. In many cases the telehandler should be shut down as soon as practical to prevent serious mechanical failure.

The hydraulic oil temperature indicator illuminates when the oil temperature is above 82°C. Stop and idle the engine, allowing time for cooling. If the indicator does not go out after five (5) minutes, shut the engine down.

Figure 67. Hydraulic Oil Temperature Indicator

55

Operation Manual

The low brake pressure indicator illuminates if the hydraulic brake oil pressure gets low. If the low brake pressure indicator is illuminated, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler

BEFORE placing it into service again.

Operation

Warning

To prevent death, serious injury, or property damage, apply service brakes until the telehandler 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 telehandler.

Changing Travel Direction

Figure 68. Low Brake Pressure Indicator

The rear axle lock indicator illuminates when the telehandler is in the axle lock mode. The rear axle locks when the parking brake is set to ON (engaged), the transmission is in NEUTRAL or the service brake applied, and when the boom is above 40 degrees. If the rear axle lock indicator does not illuminate, stop the telehandler, follow proper shut down procedures, tag the telehandler with “Do Not Operate” tags, and have a qualified mechanic service or repair the telehandler before placing it into service again.

Warning

Make sure the telehandler 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.

1.

Stop the telehandler by applying the service brake pedal.

2.

Move the travel select lever to FORWARD (F) or REVERSE (R).

3.

Release the service brake pedal.

4.

Slowly press the accelerator pedal to start travel.

Shut Down Procedure

1.

Park telehandler on level ground, if possible.

2.

Stop the telehandler 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 telehandler is parked on an incline, block the wheels.

Refueling

Figure 69. Rear Axle Lock Indicator

Stopping Travel

1.

Stop the telehandler by applying the service brake pedal.

2.

Slow the telehandler until it comes to a complete stop.

3.

Move the travel select lever to NEUTRAL (N).

4.

Set the parking brake to ON (engaged).

Operation Manual

56

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 telehandler.

Operation

NOTE:

The fuel tank capacity is 272 liters.

1.

Make sure the telehandler 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 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 00 C .

• Use a blend of #1 and #2 diesel fuel (“winterized” #2 diesel) for operating at temperatures below 00 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.

Attachments

Attachment Disclaimer

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 telehandler 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 telehandler of any third party attachment.

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

Pintle Hook

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 (226.8 kilograms vertical load, 2,268 kilograms tow capacity).

The Pintle Hook is used for towing trailers and equipment, rated at or below 2,268 kg 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.

Fork Ratings

Warning

DO NOT exceed telehandler capacity of 5,440 kilograms. The total rated capacity of the forks being used must equal or exceed telehandler capacity. Forks can break causing loss of load and could result in death or serious injury.

All approved forks for this telehandler 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 kilograms and is based upon a 600 mm load center (B). This rating specifies the maximum load capacity that the individual fork can safely carry at a maximum load center of 600 mm.

Figure 70. Pintle Hook

57

Operation Manual

Operation

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.

To move the forks outward, press the top button on the front control handle, or move the auxiliary handle to the left. To move the forks inward, press the lower button on the front control handle, or move the auxiliary handle to the right.

Figure 71. Fork Ratings

(A) Maximum Load Capacity Rating (B) 600 mm 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 telehandler is 5,440 kilograms. The matched pair or set of forks used on this telehandler should have total load ratings which equal or exceed 5,440 kilograms. When the load rating of the telehandler differs from the load capacity of the forks, the lower value becomes the overall load capacity.

Figure 73. Fork Positioning Control Handle

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

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 268.8 bar, which is the maximum pressure of the telehandler auxiliary hydraulic system 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 couplers to move the carriage.

B

Figure 72. Attachment Tilt Control Switch.

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

Operation Manual

58

Operation

B

A

B

A

Figure 74. Quick Attach Couplers For Hydraulic Systems.

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

Figure 75. Drive Telehandler Forward to Align Pivot Pins (A) with Attachment Hooks (B)

Quick Attach System

This telehandler includes a quick attach system that allows for easy attachment changes. Perform attachment connection and removal procedures on level ground.

Attachment Connection

4.

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

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 telehandler, which could result in death or serious injury.

• Make sure attachment locking devices are always in place.

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

Figure 76. 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.

1.

Position the telehandler directly behind the attachment.

NOTE:

Allow enough distance to extend the boom approximately 0.4 to 0.5 meters.

2.

Tilt the quick attach adapter forward.

3.

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

59

Operation Manual

Operation

C

B

Figure 77. Tilt Attachment To Align Holes Between Quick Attach Adapter (C) and Attachment (B).

6.

Raise the quick attach lock lever.

Figure 79. 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 78. Quick Attach Lock Lever.

7.

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

Figure 80. Quick Attach Lock Lever and Quick Attach Pin.

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 268.8 bar, which is the maximum pressure of the telehandler auxiliary hydraulic system at the quick-disconnect couplers, could result in death or serious injury.

Operation Manual

60

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 81. 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 telehandler 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 0.4 to 0.5 meters.

5.

With attachment 0.25 to 0.3 meters 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 83. Quick Attach Lock Lever

8.

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

Figure 84. Pull Quick Attach Pin from Attachment and Quick

Attach Adapter.

9.

Lower the attachment to the ground in a level position.

B

A

Figure 82. Quick Attach Couplers For Hydraulic Systems.

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

61

Figure 85. Lower Attachment to Ground in Level Position

Operation Manual

Operation

10.

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

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

• Remain at least 3 meters, plus an additional 10 millimeters 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 telehandler.

B

A

Figure 86. 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.

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 telehandler capacity of 5,440 kilograms.

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

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 telehandler 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 deenergize power lines or take other suitable precautions.

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 telehandler 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 telehandler 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 telehandler with an unsafe load distribution.

Operation Manual

62

Operation

• 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 telehandler 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 telehandler 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 telehandler. 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 telehandler 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 telehandler, 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 telehandler (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 telehandler slowly and cautiously. Only move the telehandler 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 87. Boom Lift Point

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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.

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.

Set the Declutch switch to ON.

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 telehandler

BEFORE raising the boom above horizontal.

If the telehandler cannot be leveled using the frame sway control, do not attempt to raise or place load. Reposition telehandler or have the surface leveled.

4.

Use the frame sway control to level the telehandler. 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 where it is to be placed.

7.

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

8.

Retract the forks slowly from under the load.

Operation

Load Shift

1.

If the load shifts, stop the telehandler 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 telehandler.

Warning

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

Operation Manual

64

Operation

Load Capacity Charts

Warning

DO NOT exceed rated capacity. Any attempt to lift or carry loads in excess of those shown on the load capacity charts could cause telehandler 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 telehandler 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 telehandler being in good operating condition.

XR1255 LOAD CHART OUTRIGGERS DOWN - STANDARD CARRIAGE

18

71

LOAD CENTRE

17.2

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

REAR AXLE UNLOCKED.

17 65

H

16

15

14

BO

OM

A

NG

LE

45

50

55

60

G

F

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TYRES ONLY.

13

12

40

E

11

10

30

35

D

C

B

A

600MM

LOAD

CENTRE

2,720 KG AT

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

LOAD CHART

P/N 17251-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25 (G2 or E3 FOAM FILLED)

MAX WHEEL LOADING: 9400 KG

MINIMUM TYRE MASS: 435 KG

IN SERVICE WIND SPEED: 10 M/S - 36KM/H

FORK LOAD CENTRE:

600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED: (AS 1418.19)

9

8

7

25

20

6

5

15

G

G

G

G

G

4

10

1,300 K

1,800 K

2,250 K

3,050 K

3,850 K

3

0

5

LOAD CENTRE

2

LOAD CENTRE

1

0

5

H

G

F

E

D

11.5

13 12 11 10 9 8 7 6 5

LIFTING (STATIONARY) - RATED LOAD ON FORKS

THE

CHASSIS

MUST

REMAIN

LEVEL

C

4

4,500 K

G

B

5,440 K

3

G

A

LOAD CENTRE

LOAD CENTRE

2 1 0 -1 -2

8.9

600MM

LOAD

CENTRE

REACH METER

TRAVELLING (PICK & CARRY) - RATED LOAD ON FORKS

MAX

MAX

10º

MAX

10º

MAX

MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

Figure 88. Load Capacity Chart

Figure 89. Load Capacity Chart Location

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 telehandler, including what angle, how high, and how far to extend the boom.

Using Load Capacity Charts

The telehandler 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.

Figure 90. 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.

65

Operation Manual

NOTE:

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

Figure 91. 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

Operation

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 kg.

2.

The operator safely moves the load to a loading position.

• Places forks under load

• Tilts and raises load safely

• Fully retracts boom

• Drives telehandler to position perpendicular to structure

• Levels the telehandler

3.

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

The structure height is 8 meters from ground level.

4.

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

The distance in front of telehandler where load will be placed is 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 boom extend letter “E” showing.

Operation Manual

66

Operation

XR1255 LOAD CHART OUTRIGGERS DOWN - STANDARD CARRIAGE

18

71

LOAD CENTRE

17.2

NO OPERATION

ABOVE 55 DEGREES

BOOM ANGLE WITH

REAR AXLE UNLOCKED.

17 65

H

16

15

14

BO

OM

A

NG

LE

45

50

55

60

G

F

LOAD RATINGS

SHOWN ARE FOR

VEHICLES EQUIPPED

WITH FOAM FILLED

TYRES ONLY.

13

35

40

E

2,720 KG AT

600MM MIN

CAPACITY FORK

(5,440 KG PAIR).

FORK DIMENSIONS (MM)

102 X 57 X 1524

CARRIAGE P/N

25419-010

LOAD CHART

P/N 17251-100

REV

00

SPECIFICATIONS FOR SAFE USE

TYRE SIZE: 15.5 X 25

(G2 or E3 FOAM FILLED)

MAX WHEEL LOADING:

9400 KG

MINIMUM TYRE MASS: 435 KG

IN SERVICE WIND SPEED: 10 M/S - 36KM/H

FORK LOAD CENTRE: 600 MM

GROUND CONDITIONS: SOLID SURFACES

FOR BOTH LIFTING AND TRAVELLING, SLOPE

RATINGS LISTED FOR BOTH CONDITIONS

STANDARD USED:

(AS 1418.19)

12

11

10

9

8

7

20

25

30

6

5

15

G

G

G

G

G

4

10

1,300 K

1,800 K

2,250 K

3,050 K

3,850 K

3

0

5

LOAD CENTRE

2

LOAD CENTRE

1

0

5

11.5

H

G

F

E

D

13 12 11 10 9 8 7 6 5

LIFTING (STATIONARY) - RATED LOAD ON FORKS

THE

CHASSIS

MUST

REMAIN

LEVEL

C

4

4,500 K

G

B

5,440 K

G

A

LOAD CENTRE

LOAD CENTRE

D

C

B

A

600MM

LOAD

CENTRE

8.9

600MM

LOAD

CENTRE

3 2 1 0 -1

-2

REACH METER

TRAVELLING (PICK & CARRY) - RATED LOAD ON FORKS

MAX

MAX

10º

MAX

10º

MAX

MAX

PICK & CARRY INFORMATION: MACHINE POSITION - BOOM FULLY RETRACTED WITH RATED LOAD NO MORE THAN 300MM ABOVE GROUND

TRAVEL SPEED WITH RATED LOAD - 0.4M/S WALKING SPEED

Figure 92. Load Capacity Chart

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 telehandler

BEFORE raising the boom above horizontal.

If the telehandler cannot be leveled using the frame sway control, do not attempt to raise or place load. Reposition telehandler or have the surface leveled.

Preventive Maintenance

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

Figure 94. Frame Level Indicator.

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

Function

Frame Sway Functions

Control Handle Action

FRAME SWAY RIGHT Move control handle RIGHT.

FRAME SWAY LEFT Move control handle LEFT.

Warning

The reach telehandler 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 93. 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 telehandler has been positioned in

Operation Manual

68

Figure 95. Frame Sway Override Switch.

Preventive Maintenance

Preventive Maintenance

Establishing a Maintenance Program

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

Figure 96. Hour Meter

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

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

Lubricate front and rear drive shaft grease fittings

Lubricate outrigger pivot point grease fittings

Lubricate front and rear axle grease fittings

Change differential oil

Change wheel-end oil

Check wheel lug nuts torqued to 515-570 N·m

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

After Every 50 Hours of Operation

Lubricate boom pivot point grease fittings

Lubricate front and rear axle cylinder pivot point grease fittings

Lubricate outrigger pivot point grease fittings

69

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

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 telehandler should be secured until the situation has been properly evaluated. Secure the telehandler and area by following the procedures below:

1.

Clear the area around the telehandler 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 97. Boom Access Cover

Figure 98. Extend Cylinder Lower Down Valve

Figure 99. Lift Cylinder Lower Down Valve

71

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 telehandler 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 telehandler was instructed by the seller on its proper use. If this telehandler 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 telehandler.

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

Lockout/Tagout Procedure

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

Removing Telehandler 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.

Figure 100. Battery Disconnect Switch

Warning

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

Return Telehandler to Service

When the telehandler has been repaired and made safe for operation and maintenance, perform the following procedure to return telehandler 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 101. DO NOT OPERATE Tag

Operation Manual

72

Lockout / Tagout

Do Not Operate Tags

73

Operation Manual

Operation Manual

74

Lockout / Tagout

Declarations

Declarations

Declaration of Noise Emission

Noise emission values have been obtained according to EN 12053:2001 and EN ISO 4871. The declared noise emission for an operating cycle is a combination of the values from the

“Lift”

,

“Idle”,

and

“Drive”

conditions weighted with proportion factors, in accordance with the time proportion used. Higher noise values may occur than those declared. This can be due to operating mode, environmental influences and additional noise sources.

The A-weighted time averaged emission sound pressure level at the operator’s position:

L

pa

=A-weighted emission sound pressure level for

L

pb

Lift

condition

=A-weighted emission sound pressure level for

L

pc

Idle

condition

=A-weighted emission sound pressure level for

Drive

condition

L

L

L

pa pb

=88.6 dB

=72.7 dB

pc

=86.6 dB

Emission sound pressure level in an Operational Cycle

L

pAZ

=82.2 dB

Measurement uncertainty

K

Pa

=4 dB

The A-weighted time averaged emission sound power level:

L

WAa

=A-weighted sound power level for Lift condition

L

WAb

= A-weighted sound power level for Idle condition

L

WAc

=A-weighted sound power level for Drive condition

L

L

WAa

L

WAb

WAc

=104 dB

=90.8 dB

=106.6 dB

Emission sound power level in an Operational Cycle

L

WAZ

=99.4 dB

Measurement uncertainty

K

WA

=2 dB

Declaration of Vibration Emission Values

Vibration emission values have been obtained in accordance with the vibration test code in EN 13059 and EN 12096.

The r.m.s weight whole-body vertical vibration measured with a seated operator: a

w,zS

=2.2 m⁄s

2

Measurement uncertainty according to EN 13059,

Clause 11:

K=0.7

75 Operation Manual

1415 W. BONANZA RD LAS VEGAS, NV 89106

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

PN 24907-400

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