Download XTREME Telehandler XR1055-XR1147 Service Manual PDF

Service Manual XR1055/1147

Rev A September 2018 Part #

Model XR1055-XR1147

SEPTEMBER 2018

Xtreme Manufacturing 8350 Eastgate Road Henderson, NV 89015, USA Phone Number (Main)

1-800-497-1704

Service

702- 984-7249

Parts

702-984-7250

Sales

Rev A

702-636-2969

Part Number

2

Model XR1055-XR1147

SEPTEMBER 2018 Table Of Contents

Section 1. Specifications

Page

Machine Specifications XR1147

5

Specifications XR1055

6

Hydraulic System

7

Cummins 74HP

8

Cummins 120 HP

9

Axles

10

Torque Specs

11

Section 2. Hydraulic Components Component Layout

12

Component Legend

13

Hydraulic Pump

14

Main Valve

15

Brake/Steering Manifold

16

Brake/Steer Manifold Legend

17

Service Brake Charge Valve

18

Outrigger Manifold

19

Rear Axle Lock-Up Valve

20

Filter

21

Section 3. Electrical Components GP 400 I/0 Board

22-26

Section 4. Procedures/Adjustments Parking Brake Override

27

Service Brake Bleeding

28

Front Axle Steering Stop

29

Rear Axle Steering Stop

30

Pressure Adjustments

31-32

Brake Circuit Testing

33-34

Cummins Quickserve Setup

35

Boom Chain Inspection/Adjustment Rev A

36-38 Part Number

3

Model XR1055-XR1147

SEPTEMBER 2018 Table Of Contents

Section 5. Display Functions

Page

Utilities/Service Reminder (View Only)

39

Engine Diagnostics

40

User Settings

41

Language

42

EZ Cal

43

Service Menu Access/System Settings

44

Service Reminders (Reset)

45

Transmission Calibration

46

Camera

47

Clear Faults

48

Section 6. Schematics

Rev A

Hydraulic Schematic XR1055

49

Hydraulic Schematic XR1147

50

Electrical Schematic XR 1055/1147

51

Part Number

4

Model XR1055-XR1147

SEPTEMBER 2018 Machine Specifications XR1147

Capacities Fuel tank

48 Gal.

Hydraulic System (including tank)

58 Gal. Dexron III Dimensions

Height

97”

Width

101”

Length (overall)

255”

Weight

30,610 lbs

Travel Speeds 1st

3 MPH

2nd

6 MPH

3rd

15 MPH Function Speeds

Boom Up

17-28 Seconds

Boom Down

24 Seconds

Boom Extend

14-24 Seconds

Boom Retract

20 Seconds

Tilt Forward

13 Seconds

Tilt Backwards

13 Seconds Tire Standard

Tire Size

15.5x25

Tire Ply Rating

12

Pressure

Foam

Lug Nut Torque Rev A

400 ft.lbs.

Part Number

5

Model XR1055-XR1147

SEPTEMBER 2018

Machine Specifications XR1055

Capacities Fuel tank

48 Gal.

Hydraulic System (including tank)

58 Gal. Dexron III

Dimensions Height

105”

Width

101”

Length (overall)

263”

Weight

34,600 lbs Travel Speeds

1st

3 MPH

2nd

6 MPH

3rd

15 MPH Function Speeds

Boom Up

17-28 Seconds

Boom Down

24 Seconds

Boom Extend

14-24 Seconds

Boom Retract

20 Seconds

Tilt Forward

13 Seconds

Tilt Backwards

13 Seconds

Tire Standard Tire Size

15.5x25

Tire Ply Rating

12

Pressure

Foam

Lug Nut Torque Rev A

400 ft.lbs.

Part Number

6

Model XR1055-XR1147

SEPTEMBER 2018

Machine Specifications Hydraulic System Model

XR1055-XR1147

Pump Displacement (Max)

80cc

Flow Rate (Max)

45 GPM

Standby Pressure (GP2)

500PSI

Max System Pressure (GP2)

3500 PSI

Main Relief Pressure (GP2)

4500 PSI

Steering Pressure

2900 PSI

Parking Brake Release Pressure

305 PSI

Service Brake Pressure

0-650 PSI

Parking Brake Release (GPB)

500 PSI

Load Sense (GLS)

0-3500 PSI

Rear Axle Anti-Cavitation Pressure (GAL)

50-70PSI

Boom Up/Down (GP2)

3500PSI

Boom Extend/Retract (GP2)

3500PSI

Fork Tilt Up/Down (GP2

3500PSI

Sway Left/Right (GPS)

3500PSI

Auxiliary Pressure (standard)

2500 PSI

Auxiliary Flow Rate

10.5 GPM

Rev A

Part Number

7

Model XR1055-XR1147

SEPTEMBER 2018

Machine Specifications

Cummins 3.8 74 HP Number of Cylinders

4

Displacement

3.783 cm3

Bore x Stroke

102 mm [4.02 in] x 115 mm [4.53 in]

Firing Order

1-3-4-2

Idle Speed

1000 rpm

Max Speed

2200 rpm

Oil Capacity

8.4 qts

Coolant Type

ASTM D3306 or ASTM D6210

Coolant Capacity

7.3 liters

Battery Group

31

Cold Cranking Amps @ 0F

950 cca

Service Manual

Rev A

See Quickserve setup page

Part Number

8

Model XR1055-XR1147

SEPTEMBER 2018

Machine Specifications

Cummins 3.8 120 HP Number of Cylinders

4

Displacement

3.7853 cm3

Bore x Stroke

102 mm [4.02 in] x 115 mm [4.53 in]

Firing Order

1-3-4-2

Idle Speed

1000 rpm

Max Speed

2200 rpm

Oil Capacity

8.4 qts

Coolant Type

ASTM D3306 or ASTM D6210

Coolant Capacity

7.3 liters

Battery Group

31

Cold Cranking Amps @ 0F

950 cca

Service Manual

Rev A

See Quickserve setup page

Part Number

9

Model XR1055-XR1147

SEPTEMBER 2018

Machine Specifications

Front Axle MS-T 3060 II Manufacturer

ZF

Model

MS-T 3060 II

Differential

20 Quarts

Planetary End

1 Quart Each

Fluid Type (Recommendation)

Hydro Trans 100

Service Manual

Part # Rear Axle MS-T 3060 II

Manufacturer

ZF

Model

MS-T 3060 II

Differential

20 Quarts

Planetary End

1 Quart Each

Fluid Type (Recommendation)

Hydro Trans 100

Service Manual

Rev A

Part #

Part Number

10

Model XR1055-XR1147

SEPTEMBER 2018

Fastener Torque Specs

SAE Fastener Torque Chart Grade 5 Size

Grade 8

Thread Lubed

1/4 "

5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"

1 1/8" 1 1/4" 1 1/2"

Rev A

Dry

Lubed

Dry

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

in-lbs

Nm

80 90

9

100

11.3

110

12.4

140

15.8

10.1

120

13.5

120

13.5

160

18

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

18

13

17.6

17

23

18

24

25

33.9

24

14

19

19

25.7

20

27.1

27

36.6

16

23

31.2

31

42

33

44.7

44

59.6

24

26

35.2

35

47.4

37

50.1

49

66.4

14

37

50.1

49

66.4

50

67.8

70

94.7

20

41

55.5

55

74.5

60

81.3

80

108.4

13

57

77.3

75

101.6

80

108.4

110

149

20

64

86.7

85

115

90

122

120

162

12

80

108.4

110

149

120

162

150

203

18

90

122

120

162

130

176

170

230

11

110

146

150

203

160

217

210

284

18

130

176

170

230

180

244

240

325

10

200

271

270

366

280

379

380

515

16

220

298

300

406

310

420

420

569

9

320

433

430

583

450

610

610

827

14

350

474

470

637

500

678

670

908

8

480

650

640

867

680

922

910

1233

12

530

718

710

962

750

1016

990

1342

7

590

800

790

1071

970

1315

1290

1749

12

670

908

890

1206

1080

1464

1440

1952

7

840

1138

1120

1518

1360

1844

1820

2467

12

930

1260

1240

1681

1510

2047

2010

2725

6

1460

1979

1950

2643

2370

3213

3160

4284

12

1640

2223

2190

2969

2670

3620

3560

4826

20 28

Part Number

11

Model XR1055-XR1147

SEPTEMBER 2018

Hydraulic Component Location

G

J

E

I K D C

A H

B

F

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

12

Model XR1055-XR1147

SEPTEMBER 2018

Hydraulic Component Location Legend A

Pump

B

Main Function Manifold

C

Brake/Steer Manifold

D

Brake Charge Valve

E

Priority Valve

F

Rear Axle Valve

G

Outrigger Manifold

H

Return Filter

I

High Pressure Filter

J

Accumulator

K

Torque Limiter Reducing Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

13

Model XR1055-XR1147

SEPTEMBER 2018 Hydraulic Pump

A:A

A:B

A:C

A:D

Hydraulic Pump A:A

Electronics Horse Power Limiter Valve

A:B

Horse Power Limiter Adjustment Valve

A:C

Standby Pressure Adjustment Valve

A:D

Maximum Pressure Adjustment Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

14

Model XR1055-XR1147

SEPTEMBER 2018 Main Function Manifold

B:H

B:G

B:C

B:E

B:A

B:I

B:F

B:D

B:B

Main Function Manifold Legend B:A

Fork Tilt Up Valve

B:B

Fork Tilt Down Valve

B:C

Sway Right Valve

B:D

Sway Left Valve

B:E

AUX A Valve

B:F

AUX B Valve

B:G

Boom Extend / Retract Valve

B:H

Boom Lift/Lower Valve

B:I

System Relief Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

15

Model XR1055-XR1147

SEPTEMBER 2018 Brake/Steer Manifold

C:F

C:E

C:H

C:G

C:D

C:I

C:C C:J

C:B C:A

C.K

C.L * Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

16

Model XR1055-XR1147

SEPTEMBER 2018 Brake/Steer Manifold

C:A

Park Brake Valve

C:B

Enable Load Valve

C:C

GP2 - Test Port

C:D

Crab Steer Valve

C:E

4 Wheel Steer Valve

C:F

Reducing Valve (GLS)

C:G

Load Sense Dump Valve

C:H

Outrigger Pressure Comp Valve

C:I

Reducing Valve (GPB)

C:J

GAL - Test Port

C:K

GPB - Test Port

C:L

GLS - Test Port

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

17

Model XR1055-XR1147

SEPTEMBER 2018

Service Brake Charge Valve

D:A D:B

D:E D:C

D:D

Brake Charge Valve D:A

Brake Charge Adjustment Valve (1800-2300 PSI)

D:B

Pressure Switch 900 PSI

D:C

.030” Orifice

D:D

Check Valve

D:E

Accumulator Balancing Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

18

Model XR1055-XR1147

SEPTEMBER 2018

Outrigger Valve

G:B G:A

G:C G:D

Outrigger Manifold

G:A

Left Outrigger UP Valve

G:B

Right Outrigger Up Valve

G:C

Right Outrigger Down Valve

G:D

Left Outrigger Down Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A Part Number

19

Model XR1055-XR1147

SEPTEMBER 2018

Rear Axle Lock-Up Valve

F:B

F:A

F:C

F:D

Rear Axle Lock-Up Valve

F:A

Check Valve

F:B

Check Valve

F:C

Rear Axle Fast Float Valve

F:D

Rear Axle Slow Float Valve

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

20

Model XR1055-XR1147

SEPTEMBER 2018

Hydraulic Filter Locations

H:B

H:A Hydraulic Filter Locations

H.A

Return Filter

H.B

High Pressure Filter

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A Part Number

21

Model XR1055-XR1147

SEPTEMBER 2018

GP400 I/O Board GP 400 Legend

4 Pin Plug

3 Pin Plug

15 Pin Plug

Plug 4 P4-1 P4-2 P4-3 P4-4 P4-5 P4-6 P4-7 P4-8 P4-9 P4-10 P4-11 P4-12 P4-13 P4-14 P4-15

% % % % % % % % % % % % % % %

Aux A (Not Used) (Not Used) Boom Up Boom Down Crank LS Dump Aux B Extend Retract Tilt Up Tilt Down (Not Used) Start Enable Relay Enable LS Dump Parking Brake Release

Plug 5 P5-1 P5-2 P5-3 P5-4 P5-5 P5-6 P5-7 P5-8 P5-9 P5-10 P5-11 P5-11 P5-12 P5-13 P5-14 P5-15

% % % % % % % % % % % % % % % %

Outrigger Pressure Comp Left Outrigger Up Left Outrigger Down Right Outrigger Up Right OutRigger Down Frame Sway Left Frame Sway Right (Not Used) HP Limiter (Not Used) Left Rear Turn Horn (Not Used) (Not Used) Right Rear Turn

% = Variable 0-12 Volts Off/On = 0 or 12 Volts Rev A

Part Number

22

Model XR1055-XR1147

SEPTEMBER 2018

GP400 I/O Board GP 400 Legend

4 Pin Plug

3 Pin Plug

15 Pin Plug

Plug 6 P6-1 Off/On P6-2 Off/On P6-3 Off/On P6-4 Off/On P6-5 Off/On P6-6 Off/On P6-7 Off/On P6-8 Off/On P6-9 Off/On P6-10 Off/On P6-11 Off/On P6-12 Off/On P6-13 Off/On P6-14 Off/On P6-15 Off/On

Left Front Turn Right Front Turn (Not Used) Backup Alarm/Light (Not Used) (Not Used) Rear Axle Slow Float (Not Used) (Not Used) Rear Axle Float (Not Used) (Not Used) (Not Used) (Not Used) (Not Used)

Plug 7 P7-1 P7-2 P7-3 P7-4 P7-5 P7-6 P7-7 P7-8 P7-9 P7-10 P7-11 P7-12 P7-13 P7-14 P7-15

Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On

TBM TBM Enable TBM Aux A Aux B Sway Select Parking Brake Off Hyd Oil Temp High Boom Angle Proxy Low Brake Pressure (Not Used) Horn Button (Not Used) (Not Used)

% = Variable 0-12 Volts Off/On = 0 or 12 Volts Rev A

Part Number

23

Model XR1055-XR1147

SEPTEMBER 2018

GP400 I/O Board GP 400 Legend

4 Pin Plug

3 Pin Plug

15 Pin Plug

Plug 8 P8-1 P8-2 P8-3 P8-4 P8-5 P8-6 P8-7 P8-8 P8-9

0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V

Plug 9 Fuel Level (Not Used) Joystick Y Joystick X Joystick Tilt (Not Used) Sway Joystick (Not Used) TBM #3

P9-1 P9-2 P9-3 P9-4

Supply Receive Transmit 0V Return

% = Variable 0-12 Volts Off/On = 0 or 12 Volts Rev A

Part Number

24

Model XR1055-XR1147

SEPTEMBER 2018

GP400 I/O Board GP 400 Legend

4 Pin Plug

3 Pin Plug

15 Pin Plug

Plug 12 P12-1 P12-2 P12-3

Plug 14 CAN High CAN Low Shield/Ground

P14-1 P14-2 P14-3 P14-4 P14-5 P14-6 P14-7 P14-8 P14-9 P14-10 P14-11 P14-12

Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On

Turn Signal Left Turn Signal Right Hazard Switch Front Cab Lights Service Brake Switch (Not Used) (Not Used) (Not Used) (Not Used) Crank Signal (Not Used) (Not Used)

% = Variable 0-12 Volts Off/On = 0 or 12 Volts Rev A

Part Number

25

Model XR1055-XR1147

SEPTEMBER 2018

GP400 I/O Board GP 400 Legend

3 Pin Plug

4 Pin Plug

15 Pin Plug

Plug 15 P15-1 P15-2 P15-3 P15-4 P15-5 P15-6 P15-7 P15-8 P15-9

Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On Off/On

LH Out Rig Down RH Out Rig Down LH Out Rig Up LH Out Rig Down RH Out Rig Up RH Out Rig Down (Not Used) (Not Used) (Not Used)

% = Variable 0-12 Volts Off/On = 0 or 12 Volts Rev A

Part Number

26

Model XR1055-XR1147

SEPTEMBER 2018

Procedures/Adjustments Parking Brake Override 1. Chock Wheels.

2. Remove parking brake release hose (A) from axle, leave tee and jumper line connected.

3. Hook up Porta-Power with gauge to tee where hose was removed.

4. Pressurize brakes to 500psi.

5. Remove wheel chocks.

To reset parking brake remove pressure.

A

Rev A

Part Number

27

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustment Front and Rear Service Brake Bleeding Procedure 1. Chock wheels.

2. Start unit and apply and hold the service brakes.

3. Starting at the rear axle crack bleeders (A) and let bleed till all air is removed.

4. Continue on three remaining bleeders.

5. Release Brake and turn unit off.

6. Remove wheel chocks.

A

A

Rev A

Part Number

28

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Front Steering Stop Inspection 1. Place unit in two wheel steer mode 2. Turn the wheels fully to the right.

3. Steering stops (A) must both make contact with the axle housing.

4. Sway the machine fully left and right to verify there is interference with components.

5. Turn the wheels fully to the left.

6. Steering stops (B) must both make contact with the axle housing.

7. Sway the machine fully left and right to verify there is interference with components.

8. If there is interference or stops are not both making contact with axle housing, see front steering stop adjustment.

Front Steering Stop Adjustment 1. Center the wheels and loosen jam nuts on all for adjustment screws.

2. Place unit in two wheel steer mode 3. Turn the wheels fully to the right to the desired angle until there is no interference when swaying left or right.

4. Adjust steering stop screws (A) until both are contacting the axle housing.

5. Turn the wheels fully to the left to the desired angle until there is no interference when swaying left or right.

6. Adjust steering stop screws (B) until both are contacting the axle housing.

7. Center the wheels and tighten all four jam nuts. Perform “Front Steering stop inspection” to verify correct adjustments.

Front Axle

Rev A

B

A

A

B Part Number

29

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Rear Steering Stop Inspection 1. Place unit in four wheel steer mode 2. Turn the wheels fully to the right.

3. Steering stops (A) must both make contact with the axle housing.

4. Sway the machine fully left and right to verify there is interference with components.

5. Turn the wheels fully to the left.

6. Steering stops (B) must both make contact with the axle housing.

7. Sway the machine fully left and right to verify there is interference with components.

8. If there is interference or stops are not both making contact with axle housing, see rear steering stop adjustment.

Rear Steering Stop Adjustment 1. Center the wheels and loosen jam nuts on all for adjustment screws.

2. Place unit in four wheel steer mode 3. Turn the wheels fully to the right to the desired angle until there is no interference when swaying left or right.

4. Adjust steering stop screws (A) until both are contacting the axle housing.

5. Turn the wheels fully to the left to the desired angle until there is no interference when swaying left or right.

6. Adjust steering stop screws (B) until both are contacting the axle housing.

7. Center the wheels and tighten all four jam nuts. Perform “Rear steering stop inspection” to verify correct adjustments.

Rear Axle

Rev A

A

B

B

A Part Number

30

Model XR1055-XR1147

SEPTEMBER 2018 Procedures / Adjustments Set Stand-By Pressure Adjustment

1. Install 0-5000 psi gauge on GP2 (C:C) 2. Located valve (A:C) on hydraulic pump 3. Loosen jam nut on valve 4. Start engine. Do not operate any functions 5. Adjust screw to 500 psi, clockwise to increase, counterclockwise to decrease.

6. Tighten jam nut 7. Turn off engine and remove gauge.

Set Max System Pressure Adjustment 1. Install 0-5000 psi gauge on GP2 (C:C) 2. Located valve (A:D) on hydraulic pump 3. Loosen jam nut on valve 4. Start engine, fully retract boom, clockwise to increase, counterclockwise to decrease. and hold.

5. Adjust screw to 3500 psi, clockwise to increase, counterclockwise to decrease.

6. Tighten jam nut 7. Turn off engine and remove gauge.

Parking Brake Pressure Adjustment 1. Chock wheels 2. 0-1000 psi gauge on Steering/Brake manifold test port GPB (C:K).

3. Start unit and release parking brake, pressure should be 500psi.

4. If adjustment is needed, loosen jam nut on parking brake reducing pressure valve (C:I).

5. Adjust screw to 500 psi, clockwise to increase, counterclockwise to decrease.

6. Tighten jam nut.

7. Turn off engine, remove gauge and wheel chocks.

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

31

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Rear Axle Anti-Cavitation Pressure Adjustment 1. Chock wheels 2. Install 0-1000 psi gauge on Steering/Brake manifold test port GAL (CJ).

3. Start unit, and release parking brake, pressure should be 50-70 psi.

4. If adjustment is needed, loosen jam nut on parking brake reducing pressure valve (CF).

5. Adjust screw to adjust pressure to 50-70 psi, clockwise to increase, counterclockwise to decrease.

6. Tighten jam nut.

7. Turn off engine, remove gauge and wheel chocks.

Main Relief Valve Adjustment 1. Install 0-5000 psi gauge on Steering/Brake manifold on port GP2 (C:C) 2. Locate main relief valve (B:I) on main valve (B), remove acorn nut and loosen jam nut.

3. Turn main relief valve adjustment (B:I) in fully clockwise till lightly seated.

4. Loosen max pressure adjustment valve on pump (A:D) 5. Start unit, fully retract boom, and hold.

6. Adjust max pressure adjustment on pump (A:D) to 4600 psi, clockwise to increase, counterclockwise to decrease.

7. While continuing to hold boom retract, back main relief valve (B:I) out until pressure drops to 4500 psi on gauge.

8. Lock down jam nut on main relief valve (B:I) and reinstall the acorn nut.

9. Lower the max pressure adjustment (A:D) until pressure is at 3500 psi while holding boom retract.

10. Tighten jam nut, turn off unit, and remove gauges

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

32

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments

Accumulator Charge Pressure Test 1. Chock wheels.

2. Install tee fittings with 0-5000 psi gauges on both accumulator lines coming off the service brake charge valve (D) ports FA and RA. 3. Start engine. Pressure should climb to 2300 psi.

4. Pump brakes multiple times to consume brake charge pressure. When pressure falls below 1800 psi pump should activate and pressure should climb up to 2300 psi.

5. If pressure fails to reach 2300 psi see accumulator charge adjustment.

Caution!!!!! Lines will have trapped pressure. Loosen fittings slowly to allow pressure to bleed off. Pumping brakes will help to release pressure.

Accumulator Charge Adjustment 1. Follow Accumulator Charge Pressure Test to hook up gauges and test.

2. Loosen jam nut on brake charge adjustment valve (D:A).

3. Start engine and adjust brake charge adjustment valve (D:A) on brake charge valve (D) till accumulator pressure is 2300 psi, clockwise to increase, counterclockwise to decrease.

4. Tighten jam nuts.

Caution!!!!! Lines will have trapped pressure. Loosen fittings slowly to allow pressure to bleed off. Pumping brakes will help to release pressure.

Accumulator Bleed Down Test 1. Follow Accumulator Charge Pressure Test to hook up gauges.

2. Start unit and let brake pressure charge as per accumulator charge pressure test.

3. Turn off engine. Pressure will gradually drop from set pressure.

4. Pump brakes and pressure should drop 50-300 psi each brake pump.

If test fails, contact Xtreme Service Support team for additional assistance.

Caution!!!!! Lines will have trapped pressure. Loosen fittings slowly to allow pressure to bleed off. Pumping brakes will help to release pressure. * Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

33

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments

Service Brake Applied Pressure Test 1. Chock wheels.

2. This procedure must be performed on front and rear axles independently.

3. Remove service brake line from axle and install a tee with 0-1000 psi. gauge.

4. Start unit and verify pressure is ~0 psi.

5. Slowly apply the service brake, pressure should slowly climb and max at 650 psi. +-50 psi. when brakes are fully applied.

If test fails, contact Xtreme Service Support team for additional assistance.

* Letter call outs are reference between diagrams, legends, and instruction pages.

Rev A

Part Number

34

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments

Quickserve Setup Cummins service and parts information is available for free on the Quickserve website and mobile app.

Documentation included:

Parts look up Engine code conversion Troubleshooting Electrical diagrams Assembly and disassembly instructions

1. Go to https://quickserve.cummins.com/ 2. Select new user.

3. Fill out required information.

4. Once complete an email will be sent to activate account.

Sample Serial Number List 73778559 QSL9 CM2350 L102 300HP Quickserve is free of charge for up to 5 serial numbers. If more models are required, con73986957 QSB CM2350 B106 173HP tact your local Cummins dealer to set up.

89289145

QSF3.8 CM2350 F107 74HP

89726792 QSF2.8 CM2880 F114 64HP Please contact your local Cummins dealer to order hard copies of the service manuals.

89840713 QSF3.8 CM2350 F107 120HP

Rev A

Part Number

35

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Boom Assembly Legend A. Main Boom B. Large Middle Boom C. Small Middle Boom D. Small Boom

1

2 3 4

Boom Assembly Legend 1. Outer Boom 2. Outer Intermediate Boom 3. Inner Intermediate Boom 4. Tip Boom

Rev A

Part Number

36

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Extension Chain Adjustment Location

A

B Extension Chain Adjustment

1. Level boom to 0 degrees 2. Fully extend boom.

3. Retract boom about 3 inches.

4. Measure chain sag in the middle. Sag should be between 1/4 to 1/2 inch.

If adjustment is required: Rear Chains (A) 1. Remove jam nuts on chain anchor A and remove bracket to access adjustment nuts.

2. Adjust both chains evenly till chain sag is equal on both and between 1/4 to 1/2 inch.

3. Once adjusted, reinstall bracket and jam nuts and torque.

Front Chain (B) 1. Remove jam nut on chain anchor B. 2. Adjust chain till sag is between 1/4 and 1/2 inch.

3. Reinstall jam nut and torque.

Rev A

Part Number

37

Model XR1055-XR1147

SEPTEMBER 2018

Procedures / Adjustments Chain Stretch

Chain Stretch Inspection 1. Count and mark out 20 total links of chain.

2. Measure pin to pin distance between 20 links.

3. Measurement should be between 15 and 15.45 inches.

4. If chain measures over 15.45 inches, the chain will need to be replaced.

Rev A

Part Number

38

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions

Button Legend

1

5

2

6

3

7

4

8

Utilities Clock Settings 1. From gauge display screen press button 4.

2. Press button 1 to access clock setup.

3. Press button 1 increase hours and button 2 to decrease hours.

4. Press button 5 to increase minutes and button 6 to decrease minutes.

5. Press button 3 to change between DST time on or off.

6. Press button 7 to change between 12/24 hour display 7. Press button 4 to return to the main menu without saving changes

8. Press button 8 to save changes. Display will reboot upon pressing.

Service Reminders ( View only) 1. From gauge display screen press button 4.

2. Press button 2 to view service reminder status. (If resetting is required after a service see “Service reminder reset” instructions

Rev A

Part Number

39

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Engine/Transmission Diagnostics 1. From gauge display screen press button 4.

2. Press button 2 to access stored codes.

3. Press button 6 to scroll up and 7 to scroll down through codes.

4. Press button 8 to request codes. If no stored codes are present the status will display “Timeout”.

Engine codes will be a 2-4 digit SPN. ( Refer to Cummins Quickserve for code conversion and troubleshooting).

Transmission codes will be a 6 digit number starting with 523000. (Refer to ZF Service Manual for fault conversion).

Diagnostic Message - Displays current viewed code and total stored codes.

Description - Generic description of code. Please refer to SPN/FMI below with the correct manual to convert and troubleshoot.

Correction - Description of level of fault and how to proceed with operation of unit.

Examples: De-rated power or shutdown required.

Source - Source address.

SPN - Suspect Parameter Number.

FMI - Failure Mode Indicator.

OC - Occurrence Count. Amount of times of failure since last ECU/TCU code reset was performed.

Refer to “Clear Faults” instructions on how to clear codes.

Active codes will display as a pop up over the main gauge screen.

Rev A

Part Number

40

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions User Settings Overview 1. From gauge display screen press button 4.

2. Press button 3 to access User Settings.

3. Press button 1 to restore to defaults.

4. Press button 2 to scroll up and button 3 to scroll down.

5. Press button 4 to exit screen.

Ambient Light 1. Highlight with buttons 2 or 3.

2. Press buttons 6 or 7 to switch between Day or Night Modes.

Brightness 1. Highlight with buttons 2 or 3.

2. Press buttons 6 or 7 to change brightness of whichever Day/Night mode is selected.

Units 1. Highlight with buttons 2 or 3.

2. Press buttons 6 or 7 to switch between USA Standard, British Standard, Metric kPa, or Metric Bar.

Rev A

Part Number

41

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Language 1. From gauge display screen press button 4.

2. Press button 6 or 7 to scroll through available languages.

Rev A

Part Number

42

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions EZcal 1. From gauge display screen press button 4.

2. Press button 8 to access EZcal.

EZcal Navigation 1. Press button 1 to navigate left.

2. Press button 2 to navigate right.

3. Press button 3 to escape back to previous menu level.

4. Press button 4 to return back to main menu.

5. Press button 5 to navigate/change value up.

6. Press button 6 to navigate/ change value down.

7. Press button 7 to enter.

8. Press button 8 to toggle between EZcal Enable/Disable.

Note: To use handheld EZcal, display must be disabled.

Rev A

Part Number

43

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Service Menu Access 1. From gauge display screen press button 4.

2. From buttons 6,6,7,7 to access service menu.

If done correctly screen will change to the following options depending on display software revision level.

System Settings Service Reminders Transmission Calibration PDM Diagnostics System Settings 1.

FromDisable/Enable Service Menu Screen press button 1.

Camera 2.

Press button 1 to restore defaults.

Clear Faults 3. Press button 2 to scroll up and button 3 to scroll down.

4. Press buttons 6 to increase and 7 to decrease selected options.

5. Press button 4 to return to previous menu.

Default Settings Source Address A - 242 Source Address B - 242 Fault Conversion - J1939 V-1 Can Data - CAN Data Fault Code DM1 - CAN Data Fault Code DM2 - CAN Data

Warning!!!! Changing any value will result in display not working properly and /or failure of functions, including drive.

Rev A

Part Number

44

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Service Reminders Access 1. From Service Menu Screen press button 2.

2. Press button 2 to scroll up and button 3 to scroll down.

3. Press button 8 to reset highlight field to default interval value.

4. Press button 6 to edit default interval value.

5. Press button 7 to turn off highlighted service reminder.

6. Press button 4 to return to previous menu.

Rev A

Part Number

45

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Transmission Calibration Access 1. From Service Menu Screen press button 3.

2. Press button 2 to scroll up and button 3 to scroll down.

Transmission Calibration 1. Chock the wheels 2. Highlight Clutch Cal. 3. Once a requirement is meet a green check mark display next to the field 4. Once a requirements are meet, press button 6 to start calibration.

5. Once started display will change to the 5 clutch packs and will show as active or complete as the calibration process is performed.

6. Once complete a message will display on the screen to cycle key power. Once this is displayed turn the unit off and back on.

While calibration is in process do not operate functions, apply the throttle, release parking brake or place shifter into gear. Unintended movement can happen and will end the calibration procedure.

While calibration process is active, the operator may feel the unit try to drive. This is normal.

To get Transmission temperature high enough to calibrate: 1. Turn off the parking brake 2. Apply the service brake fully 3. Please unit into 2nd gear manual forward.

4. Give the unit full throttle till above 60 C.

If unit is in colder climates the transmission can cool down out of range during calibration. If this happen a message will display letting you know. Start from step 1 and increase transmission temperature higher then the failed attempt.

Transmission calibration in not possible with active codes.

If calibration fails refer to the ZF Service manual to find the failure and repair.

Inching Cal is not in use on these transmission.

Rev A

Part Number

46

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Camera Enable/Disable 1. From Service Menu Screen press button 6 to toggle between Enables and Disabled 2. Press button 4 to return to the previous screen.

Display will show current status of camera

Rev A

Part Number

47

Model XR1055-XR1147

SEPTEMBER 2018

Murphy PV450 Display Functions Clean ECU/TCU Faults 1. From Service Menu Screen press button 7.

2. Once pressed turn key off for at least 2 minutes to fully clear codes.

3. Once complete check the stored diagnostics codes to verify.

Once codes are cleared from history they may not be able to be pulled from ECU/TCU fault history. Please document listed codes in your work order to document.

Active codes can not be cleared.

Rev A

Part Number

48

0853+< ',63/$< 39 39 3257 % 3,1 3529,'(6 *5281' $)7(5 6(& 21 67$57 83

9 ,1

&$1 /

;

9 *1'

;

5($5 $;/( &(17(5(' %

$

'20( /,*+7

5($5 /,*+76 237,21

%

86% 3257

$

0

3

$ /(1*7+ 6(1625 9

$1*/( 6(1625

9

%

:,1'6+,(/' :,3(5 (1&/26(' &$1 21/<

3 3

3

3

3$5. %5$.( /('

3 %5$.( 5(/($6( 5(/$< 5

3

6752%(

)5217

237,21

&$%

$

675

STR

7+277/( -

/,*+76

32:(5 5(&(37$&/(

3

-2<67,&.

67$57 /2&.287 5

7,/7

X2-8

$

67$57(5 32:(5 $ ,1 /,1( ,1 (1* +$51 5

X2-5 X2-2

$ $

B1

ENGINE SPEED SENSOR

2

X1-19

1

X1-8

B2

*/2: 3/8* 62/

B3 $ ,1 /,1( ,1 (1*,1( +$51(66

%$77 6:

*3

TURBINE SPEED SENSOR

1

X1-17 X1-15 X1-16

2

INTERNAL 2 SPEED SENSOR 1

X1-6 X1-18

B4

B6

BRAKE INCHING SENSOR

9

1 2

X1-25 X1-1

3 4 5 6

X1-23

X1-27

B

B15

S10

X1-2

2

X1-4

CONVERTER 1 TEMP SENSOR

X1-3

REV

3

3

WHT/BRN

3

3

%220 (;7(1'

5(75$&7

83

3

'2:1

3 3

3

3

)5$0( 6:$<

5,*+7

$

X2-1 X2-18

3

3

3 3

7851 6,*1$/

5,*+7

3

11 6 5

DIAG CONN 7

1

8

3

3 3

)8(/ /(9(/

+251

3

3

/()7 )5217 7851 +$=$5' 5,*+7 )5217 7 +

3

&$1 + &

%

3$5. %5$.( 5(/($6(

3

%$&. 83 /,*+7

3

&$1 /

(&0 - $

%$&.83 $/$50

3

7(50 5(6

9

2875,**(5 35(6685( &203

%$&. 83 /,*+7 5(/$< 3

3

+$=$5'

&$1 /

3

3

&$1 +

3

/()7

9

&5$1. /2$' 6(16( '803

(1$%/( /2$' 6(16( '803

3

+25,=217$/

2

3

X2-4

3 3

3 7(50 5(6 3

%5$.( 5811,1* 7851 +$=$5'

/()7 5($5

5,*+7 5($5

3

'

6:$< -2<67,&.

9

9 $

3 3

3 3 3

/+

$ ,1 /,1( )86(

$8;

%

%

/()7

3 3

5+ 287 5,**(5 6:,7&+ 6+2:1 83

)25.

7,/7

3

%

(;7(1'

3

+251

&800,16 ',$* &211

X2-9

'2:1

3

9(57,&$/

A -Y5 TRANS B COIL

10 5 X2-17

2

X1-20

3

VIOLET

&25' 027,21

A -Y4 TRANS B COIL

X1-30

X2-20

FILTER 1 RESTRICTION 2 SWITCH

3

X1-22

1

SUMP TEMP SENSOR

3

3

&

%220 /,)7 /2:(5

3 BLK

A -Y3 TRANS B COIL

X1-28

B7

3

A -Y2

SHIFTER

6:$< 6(/(&7 %87721

&

83

(1$%/(

X1-29

2

%

A -Y1 FWD B

X1-7

1

&22/$17 /(9(/

2+0

X1-33 OUTPUT SPEED SENSOR

WHT/GRN

$

3

$8; % 6:,7&+

2+0

X1-32 X1-5

WHT

WHT/RED

X1-26 $

3

X2-16 X1-14

WHT/YEL

3

$

$8; $ 6:,7&+

=) 7&8

$ ,1 /,1( =) 75$1 +$51

BLUE

WHT 3

%

&

(;7 5(7 6:$<

6

3

3

%220 /,)7

RED

67$57 62/

/+ 287 5,**(5 6:,7&+ 6+2:1 83

3 3

3

3

/2: %5$.( 35(66

3

/+ 287 5,*

35

$

3

3

'2:1

$ ,1 /,1( =) 75$1 +$51

& $

3

83

:$7(5 ,1 )8(/ -

67$57 (1$%/( 5

$

$

5+ 287 5,*

&800,16

(&0

:+/ CRAB

%

%5$.( 6:,7&+ 6+2:1 %5$.(6 2))

3

3

$

,*1,7,21 6:,7&+

%220 $1*/( 352; 6+2:1 %220 83

&

3

67((5

$

35

$

3

$

6(/(&7

$

7

3

$

35

+,*+ 2,/ 7(03

3 3

$

$& &203 &/87&+

3

:,3(5

9,'

&

3

3

3$5. %5$.( 6+2:1 21

$

5($5 $;/( /2&.

6/2: )/2$7 3

3

$ 6%

&$% +($7(5 $&

5($5 $;/( /2&. )/2$7

:$6+(5

$

%$&.83 &$0(5$

3

3

0

+<' 3803 +3 /,0,7(5 62/(12,'

3* 75,21,&6 *3 &

&

3* 75,21,&6 7%0

%220 /,*+76 237,21

6+/'

9

;

*1'

;

'

;

'

&$1 +

39 3257 &

83

'1

XR1055-1147 ELECTRICAL SCHEMATIC Rev A

2875,*

83

'1

5+ 2875,*

ACCUMULATOR 14301-000 800 PSI PRE-CHARGE 45

45

CU IN

CU IN

FA

IN

OIL COOLER

RA

27349-000 MASTER CYLINDERS

TRANSMISSION E

F

OUT

R

REAR AXLE LOCK 25213-000

4500 PSI

FRAME LEVEL 29362-000

2300/1800 PSI

5:1

FALLING

.030

BRAKE CHARGE VALVE 27434-002

P

T

LS

SERVICE BRAKES REAR AXLE

SERVICE BRAKES FRONT AXLE FOOT BRAKE VALVE

FRONT STEER CYL

REAR STEER CYL

R

R

E LEFT

E RIGHT

R

4.5:1 .060

PARK BRAKES FRONT AXLE 305 PSI MIN RELEASE

.040

E

5:1

4.5:1

900 PSI

FORK TILT 34240-000

4500 PSI

.070

R

4500 PSI

4500 PSI

R

ALS

29362-000 FRAME LEVEL FRONT AXLE

3500 PSI

3:1

E

BRAKE LIGHT

OUTRIGGER CYLINDERS 25848-001

LIFT CYLINDERS 26595-004 750 PSI

650 PSI

750 PSI

3:1

14206-000

3:1

R

BOOM EXTEND 27883-002 2500 PSI

R

3:1

LEFT

L

10:1

4500 PSI E

4500 PSI

RIGHT

1500 PSI

R

3200 PSI

10:1

E 5.6:1

1500 PSI

0.7:1

3335 PSI

R

3200 PSI

E

B 10.5 GPM

A 10.5 GPM

AUX FUNCTION QD'S SEE 25226-000 FOR OPTIONS 2500

PSI

STEER CONTROL 14006-010

2500 PSI

19.3 CIR

T LS

P

A 9 GPM

STEER MODE VALVE CRANKING SENSE DUMP

LS

400 PSI

2900 PSI

PARK

110 PSI LS2 .040

T T2 PRESSURE FILTER 14359-000

GP2

BRAKE/STEER 34315-000 GP1

GLS

LS1

2500 RPM

500 PSI 14011-000 4,88 CIR PUMP

350 PSI

HP LIMIT REDUCE VLV 14171-100

B A

T

P

T

P2 T6

P

OR2A

A

290 PSI

M

BOOM LIFT

B 28 GPM

A 10.5 GPM

EXTEND/RET

b

b

a

a

B 10.5 GPM

T

B 10.5 GPM

AUX b

SWAY b

OUTRIGGER VALVE 34329-000

DW

a

a

LS

LS T Z P R

R

HAWE VALVE ASSEMBLY - SIZE 3 PSV & SIZE 2 EDL 14170-000

RETURN FILTER 14383-000

HIGH OIL TEMP LIGHT

A 10.5 GPM

D2

D2

FORK TILT b

P

P

BREATHER 14368-000

A 14 GPM

4500 PSI

LS5

FUNCTION ENABLE SENSE DUMP

SUCTION STRAINER 14365-000

3500 PSI ENG

B

T 70 PSI

STEER PRIORITY 14242-010

GAL

ALS

GPB

OUTRIGGER PRESSURE COMP

ACCUM CHARGE

OR2B

P1

P

OR1A

EF

T

PARK BRAKE

OR1B

B A

CF

PBR

T4

T5

LS4

LS3

SVR

RSA

RSB

T3

FSB

Z

B 28 GPM

XR1055 Hydraulic Schematic Rev A

a

T

ACCUMULATOR 14301-000 800 PSI PRE-CHARGE 45

45

CU IN

CU IN

FA

IN

OIL COOLER

RA

27349-000 MASTER CYLINDERS

TRANSMISSION E

F

OUT

R

REAR AXLE LOCK 25213-000

4500 PSI

FRAME LEVEL 29362-000

2300/1800 PSI

5:1

FALLING

.030

BRAKE CHARGE VALVE 27434-002

T

LS

SERVICE BRAKES FRONT AXLE

SERVICE BRAKES REAR AXLE

FOOT BRAKE VALVE

FRONT STEER CYL

REAR STEER CYL

R

R

E LEFT

E RIGHT

R

4.5:1 .060

PARK BRAKES FRONT AXLE 305 PSI MIN RELEASE

.040 P

E

5:1

4.5:1

900 PSI

FORK TILT 34240-000

4500 PSI

.070

R

4500 PSI

4500 PSI

R

ALS

29362-000 FRAME LEVEL FRONT AXLE

3500 PSI

3:1

E

BRAKE LIGHT

LIFT CYLINDERS 26595-004

650 PSI

R

14206-000

BOOM EXTEND 27883-002 2500 PSI

R

3:1 10:1

10:1

4500 PSI E

4500 PSI E

L

5.6:1

R

3200 PSI

0.7:1

3335 PSI

R

3200 PSI

E

B 10.5 GPM

A 10.5 GPM

AUX FUNCTION QD'S SEE 25226-000 FOR OPTIONS 2500

PSI

STEER CONTROL 14006-010

2500 PSI

19.3 CIR

T LS

P

A 9 GPM

B A

CF EF

T

P1

CRANKING SENSE DUMP

400 PSI

PARK

DW

110 PSI LS2 .040 T2 PRESSURE FILTER 14359-000

GP2

BRAKE/STEER 34315-000 GP1

GLS

LS1

2500 RPM

500 PSI 14011-000 4,88 CIR PUMP

350 PSI

HP LIMIT REDUCE VLV 14171-100

P2 T6

LS

A 10.5 GPM

EXTEND/RET

b

b

a

a

B 10.5 GPM

A 10.5 GPM

B 10.5 GPM

AUX b

SWAY b

a

a

LS T Z P R

LS5

FUNCTION ENABLE SENSE DUMP

P

BREATHER 14368-000

R

HAWE VALVE ASSEMBLY - SIZE 3 PSV & SIZE 2 EDL 14170-000

RETURN FILTER 14383-000

SUCTION STRAINER 14365-000

3500 PSI ENG

BOOM LIFT

B 28 GPM

D2

D2

FORK TILT b

4500 PSI

70 PSI

T

A 14 GPM

OUTRIGGER PRESSURE COMP

ACCUM CHARGE

2900 PSI

STEER PRIORITY 14242-010

GAL

ALS

GPB

P

290 PSI

M

PARK BRAKE

STEER MODE VALVE

LS

PBR

T4

T5

LS4

LS3

SVR

RSA

RSB

T3

FSB

Z

B 28 GPM

T HIGH OIL TEMP LIGHT

XR Hydraulic Schematic Rev A

a

T