HANDHELD EZ-CAL -- UPPER CONTROLS BOX

Transcription

1 TROUBLESHOOTING -- EZ-CAL SCAN TOOLS HANDHELD EZ-CAL -- UPPER CONTROLS BOX The handheld EZ-Cal is not provided with the machine and is available from the MEC parts department (part #90888). To use and operate the handheld EZ-Cal at the upper controls station: Set the Base/Platform Key Switch to Platform Open the lid to the Upper Controls Box Plug the EZ-Cal into port P9 of the GP0 module. This plug is on the right side of the module, facing down. Figure -6: Handheld EZ-Cal Tool & GP0 EZ-Cal Handheld Scan Tool MEC P/N GP0 Module P P P P P5 P6 P7 P P9 P0 P P P P P5 Upper Controls Box GP0 Module ART_709 EZ-Cal port on bottom, facing down USING THE EZ-CAL SCAN TOOL Once, powered up, the EZ-Cal display will illuminate and read HELP: PRESS. From this point, use the right and left arrows to scroll through the base menus. Once the desired base menu is obtained (i.e. ADJUSTMENTS) press Enter to access sub menus. Use the right and left arrows to scroll SYMBOL through sub menus, then press Enter again to choose a sub menu. The up/down arrows are used to change settings only. Press ESC to back up one level. Figure -7: EZ-Cal Buttons KEY FUNCTIONS ESC/ BUTTONS To move back and forth between menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values ART_70 Titan Boom 60-S Service and Parts Manual August 0 Page -9

2 TROUBLESHOOTING -- USING THE EZ-CAL WITH THE FLOW CHARTS USING THE EZ-CAL WITH THE FLOW CHARTS Use the EZ-Cal Flow Charts as a guide to locate diagnostic information and make adjustments. Each box in the flow chart will have bits of information. 5C- Identification Number UP MAX Personality 75% Default Setting Figure -8: EZ-Cal Display Example to match with information tables, this number will not appear on the EZ-Cal display The IDENTIFIER (5c): Used to locate this specific personality in the informational charts. Here you can obtain specific information on the individual personalities. The PERSONALITY (Up Max): Identifies the individual personalities. The DEFAULT SETTING: The factory setting. If adjustments are made, they must be returned to default setting. ART_8 ACCESS LEVEL PROVIDES ACCESS TO CHANGE PERSONALITIES NORMALLY PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS. PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION AS LISTED IN THE FOLLOWING TABLES. ERROR MESSAGES To obtain error messages from the EZ-Cal, access the EZ-Cal as mentioned above. The display will read, HELP:PRESS. Press Enter to display the current error message. If an error message is present, use the following list of error messages to better understand the fault. If an error message is not present, the display will show the last operation performed. Pressing Enter twice will provide a log of previous errors and operations that may have occurred within recent operation. The first message will be the most recent. FLASH CODES Flash Codes, provided from the GP00 red LED, will also assist in the event an EZ-Cal is not available. However, the EZ-Cal yields considerably more relevant information. Refer to "EZ-Cal Messages" on page - for flash coded error messages. August 0 Page -0 Titan Boom 60-S Service and Parts Manual

3 TROUBLESHOOTING -- USING THE EZ-CAL WITH THE FLOW CHARTS Figure -9: EZ-Cal Flow Chart: Adjustments and Setup Adjustments & Setups HELP PRESS DIAGNOSTICS ACCESS LEVEL TITAN BOOM 60-S EZ-CAL MENU ADJUSTMENTS 5 SETUPS EZ-Cal Flow Chart Chart of SYMBOL KEY FUNCTIONS ESC/ BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values ERROR MESSAGE LOGGED MESSAGES PRESS RT & LT ARROWS TO VIEW PREVIOUS ERRORS & MESSAGES A SYSTEM B FUNCTIONS C DIGITALS D ANALOGS E OUTPUTS F LOG SEE CHART # ACCESS LEVEL FOR CALIBRATIONS ACCESS LEVEL FOR ADJUSTMENTS 5A CHANGE DEFAULTS 5B TILT SETUPS 5C EXTENSION SETUPS 5D HEIGHT SETUPS 5E LOAD SETUPS INTERLOCKS 5A- CUSTOMER 5B- CALIBRATE LEVEL 5C- CALIBRATE 5D- 5E- CALIBRATE LOAD 5F- E TIME OUT = TITAN 60 SEE INSTRUCTIONS EXTENSION 6% SEE INSTRUCTIONS 0.0 SEC SEE INSTRUCTIONS 5B- 5D- CALIBRATE HEIGHT 5E- FAULTY LOAD 5F- STARTER DELAY TILT SHUTDOWN 5A- SEE INSTRUCTIONS -00% 0.0 SEC 0= NEVER MODEL = TITAN 60 5B- 5D- TILT CORRECTION 5E- DYNAMIC SCALE 5F- ELEVATED TILT = X-.9 CE DRIVE YES SHUTDOWN =LIFT & DRIVE 5D- MAX LIFT 5E- DELAY UP 5F- 98% (MAX) 0.0 SEC MULTITRIGGER YES 5D-5 SLOW DOWN 5E-5 DELAY DOWN 5F-5 DRIVE WITH BOOM 8% 0.0 SEC NO = DO NOT CHANGE 5D-6 MIN LIFT 5F-6 PP5-0.0 SEC DISABLED 5F A DRIVE A- FWD MIN 6% A- FWD MAX 6% A- REV MIN 6% A- REV MAX 6% A-5 ACCEL.5 SEC A-6 DECEL 0.8 SEC A-7 DRIVE ELEVATED A-8 STEER TO ADJ A-8A STEER MIN 00% A-8B STEER MAX 00% ART_80 B UPPER LIFT B- UP MIN % B- UP MAX % B- DOWN MIN % B- DOWN MAX 7% B-5 ACCEL.0 SEC B-6 DECEL.0 A-7A FWD MIN 6% A-7B FWD MAX 5% A-7C REV MIN 6% A-7D REV MAX 5% A-7E ACCEL 0.5 SEC A-7F DECEL 0.5 SEC C TELESCOPE C- OUT MIN % C- OUT MAX % C- IN MIN % C- IN MAX 9% C-5 ACCEL.0 SEC C-6 DECEL.0 SEC D PLATFORM LEVEL D- UP MIN 8% D- UP MAX 75% D- DOWN MIN 7% D- DOWN MAX 50% D-5 ACCEL.0 SEC D-6 DECEL 0.% D-7 LIFT COMP 0 UP.5 D-8 LIFT COMP O DOWN.50 D-9 LIFT COMP H UP.0 D-0 LIFT COMP H DOWN.5 D- H % D- LIFT COMP 00 UP 0.90 D- LIFT COMP 00 DOWN.05 D- LIFT COMP T 5 D-5 DELAY XXX -0.0 E PLATFORM ROTATE E- LEFT MIN 5% E- LEFT MAX 7% E- RIGHT MIN 5% E- RIGHT MAX 6% E-5 ACCEL.0 SEC E-6 DECEL 0.7 SEC F PLATFORM SLIDE F- FWD MIN 8% F- FWD MAX 9% F- REV MIN 8% F- REV MAX % G OUTRIGGER 60 S G- ORIENTATION G- DEBOUNCE 0.5 SEC G- INITIAL 0.0 SEC G- PRE-LEVEL.8 SEC G-5 TILT FILTER 6 G-6 X TILT TARGET 0.0 DEG G-9 EXTEND 0% G-0 LEVEL 8% H FRAME LEVEL H- LEVEL LT MIN 0% H- LEVEL RT MIN 0% H- LEVEL MAX % I AUTO LEVEL G-7 Y TILT TARGT 0. DEG G-8 TILT SLACK 0. DEG G- RETRACT 00% = DO NOT CHANGE I- TILT FILTER 5 I- TILT MAX 6.0 I- X TILT TARGET 0. I- Y TILT TARGET 0. I-5 TILT SLACK 0. J TILT J- X TRIP.0 J- Y TRIP.0 J- HEIGHT NO- COMP TRIP 05% J- DELAY TRIP.0 SEC J-5 DELAY CLEAR 0.5 SEC J-6 CHASSIS X MAX 0 DEG J-7 HILL ASSIST UP 0 J-8 HILL AST DOWN 0 ** Set to 0 (zero) for machines NOT equipped with optional Overload Sensing System K AXLE K- MAX ABS 0.0 K- MAX DIFF..0 K- CHASSIS DIFF 8.6 DEG L OVERLOAD (CE ONLY) L- 05%** L- 0% L- 0% HEIGHT 0% L-5 LOAD LEVEL SCALE. L-6 SAFE DOWN 9% L-7 DELAY TRIP. SEC L-8 DELAY CLEAR 0. SEC L-9 DELAY DYNAMIC 0.0 SEC C O N T I N U E D M ALARMS M- MAKE SELECTION FROM MENU M- TILT : WHEN ELEV Titan Boom 60-S Service and Parts Manual August 0 Page -

4 TROUBLESHOOTING -- USING THE EZ-CAL WITH THE FLOW CHARTS Figure -0: EZ-Cal Flow Chart: Diagnostic DIAGNOSTIC TITAN BOOM 60-S EZ-CAL MENU EZ-Cal Flow Chart Chart of Use in conjunction with Diagnostic tables for Thorough explanation Of readout and values DIAGNOSTICS SYMBOL KEY FUNCTIONS ESC/ BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values A SYSTEM B FUNCTIONS C DIGITALS D ANALOGS E OUTPUTS F LOG A- DRIVE ENABLE NO/YES A- BOOM ENABLE NO/YES A- B+ SUPPLY ACTUAL INPUT VOLTAGE A- TILT STATE OF LEVEL IN DEGREES A-5 AXLE AXLE LEVEL INFORMATION A-6 TILTED YES or NO A-7 HEIGHT ACTUAL IN % A-8 EXTENSION ACTUAL IN % A-9 EXTENSION! A-0 LOAD ACTUAL IN % A- LOAD level ACTUAL IN % A- LOAD extention ACTUAL IN % A- OVERLOADED YES or NO A- LAST MOVED UP or DOWN A-5 ELEVATED YES or NO A-6 EXTENDED YES or NO A-7 RETRACTED YES or NO A-8 STABLE YES or NO A-A PLATFORM ACTUAL IN DEGREES LEVEL A-B GP00 ACTUAL IN DEGREES LEVEL A-C CAN TILT 5 ACTUAL IN DEGREES LEVEL A-D CAN TILT 5 ACTUAL IN DEGREES LEVEL A-E CAN TILT 5 ACTUAL IN DEGREES LEVEL A-F CAN TILT 5 ACTUAL IN DEGREES LEVEL A-5A ANGLES ACTUAL IN DEG. A-5B AXLE LEVEL/ OFF LEVEL A-5C AXLE TWISTED LEFT YES/NO A-5D AXLE TWSTED RIGHT YES/NO A-7A HEIGHT ACTUAL IN % A-7B HEIGHT (CE) ACTUAL IN % A-7C HEIGHT no comp ACTUAL IN % A-7D LIFT COMP NO USER INFO A-7E LIFT COMP T NO USER INFO PLATFORM A-7F UD NO USER VALUE A-7G Fabandon YES or NO A-7H Last Stable ACTUAL IN % A-A UNDERLOADED YES or NO A-B CAUSE # YES or NO ART_8 B- DRIVE ACTUAL B- STEER ACTUAL B- UL(upper lift) ACTUAL B- PLTud (Platform up/down) ACTUAL B-5 PLTlr (Platform L/R) ACTUAL B-6 PLTfr (paltform F/R) ACTUAL B-7 TELE ACTUAL B-8 FRAME ACTUAL B-9 O/R (stablzrs) ON or OFF B-9A O/R (stablzrs) O/R left Direction and % B-9-B O/R (stablzers) O/R right Direction and % B-9C O/R (stablzrs) Tleft Time before stable B-9D O/R (stablzrs) Tright Time before stable B-9E AUTORETRAC Autoretract Time B-9F NEUTRAL B-9G STATUS B-0 AUTO PLTud ACTUAL B- AUTO FRAME ACTUAL B- INTERLOCK INFORMATION C- GP00 DIGITALS Lower control box INPUTS C- GP0 Upper control box INPUTS P7- POWER INPUT P7- KEY SWITCH BASE SELECTED P7- KEY SWITCH PLATFORM SEL P7-9 EMERGENCY BATT POWER P7- ENG OIL PRESS SWITCH P0-7 P0-8 P0- P- P- P- P- P-9 P-0 P- M- M- M- STEER LEFT STEER RIGHT DRIVE ENABLE SWITCH CRAB STEER MODE -WHEEL STEER MODE LEFT FRAME LEVEL RIGHT FRAME LEVEL STABILIZER AUTO EXTEND STABILIZER AUTO RETRACT MANUAL PLAT LEVEL UP P- MANUAL PLAT LEVEL DOWN P- EMERG POWER SWITCH P- A/C GENERATOR SWITCH P5- ENGINE START P5- BOOM ENABLE P5- CHOKE OR GLOW PLUG P5-5 DRIVE HIGH SPEED P5-8 HORN C- MATRIX MODULE LOWER CONTROLS CHOKE OR GLOW PLUG IDLE ENABLE HIGH SPEED ENABLE M-/ ENGINE START M-/5 BOOM UP M-/6 BOOM EXTEND M-/7 STABILIZER UP M-/8 FRAME TILT LEFT M-/9 PLATFORM LEVEL UP M-/0 PLATFORM ROTATE CCW M-/ PLATFORM SLIDE OUT M-/ M-/5 ENGINE STOP BOOM DOWN M-/6 BOOM RETRACT M-/7 STABILIZER DOWN M-/8 FRAME TILT RIGHT M-/9 PLATFORM LEVEL DOWN M-/0 PLATFORM ROTATE CW M-/ PLATFORM SLIDE IN D- GP00 ANALOGS Lower control box INPUTS P8- EXTENSION SENSOR P8- BOOM ANGLE TRNSDCR P8- BOOM ANGLE TRNSDCR P8- EXTENSION SENSOR P8-5 LT STBLZER PRESS SW P8-7 LOW FUEL LEVEL SW P8-8 RT STBLZER PRESS SW P8-9 LEVEL CYLINDER PRESS D- GP0 Upper control box ANALOG INPUTS P6- P6- P6- P7- P7- P7- P8- P8- P0- BOOM UP/DWN JSTK TELE IN/OUT JSTK BOOM/TELE ENABLE PLAT SLIDE IN/OUT JSTK PLAT ROTATE JSTK PLAT SLIDE/ROT ENABLE ROTATE SENSOR SIG A ROTATE SENSOR SIG B DRIVE FWD/REV JSTK D- MATRIX MODULE LOWER CONTROLS M-6 VALVE CURRENT MEAS. NOTE: When viewing PROPORTIONAL valve outputs press for actual output % E- GP00 OUTPUTS Lower control box OUTPUTS F- CALDATE CALIBRATION DATE F- SOFTWARE VERSION NUMBER F- MAX BATTERY HIGHEST VOLTAGE P- OUTRIGGER R/L UP P- CRAB STEER VALVE P- -WHEEL STEER VALVE P- OUTRIGGER R/L DOWN P-5 OUTRIGGER R/R UP P-6 AXLE LOCK VALVES P-7 OUTRIGGER R/R DOWN P-8 OUTRIGGER F/L UP P-9 OUTRIGGER F/L DOWN P-0 OUTRIGGER F/R UP P- BRAKE DUMP VALVE P- DUMP VALVE MAIN MANIFOLD P-5 DUMP VALVE AUX MANIFOLD P5- OUTRIGGER F/R DOWN P5- STEER RIGHT VALVE P5- STEER LEFT VALVE P5-5 DRIVING LIGHTS P5-6 ALARM P5-7 FRAME LEVEL LEFT VALVE P5-8 FRAME LEVEL RIGHT VALVE P5-9 -SPEED VALVE P5- BRAKE DUMP (MINING OPT) P5- BATTERY ISOLATER RELAY P6- BOOM EXTEND VALVE P6- A/C GENERATOR (OPTIONAL) P6- AUX HYD TO PLATFORM P6-5 BOOM RETRACT VALVE P6-6 EMERGENCY PUMP MOTOR P6-7 ALTERNATOR EXCITE P6-8 GAS/PROPANE P6-9 CHOKE/GLOW PLUG P6-0 START - ENGINE P6- BOOM UP VALVE P6- BOOM DOWN VALVE P6- FUEL SOLENOID (DIESEL) IGN P6- THROTTLE P6-5 HORN E- GP0 OUTPUTS Upper control box OUTPUTS P5- P5- P5- P5- P5-5 P5-8 LOW FUEL INDICATOR LAMP TILT ALARM (OVERLOAD CE) VOLT SUPPLY TILT INDICATOR LAMP STABILIZER DOWN LAMP STABILIZER LOW PRESS ALARM E- MATRIX MODULE LOWER CONTROLS M- M- M- M-5 TILT LIGHT LOW FUEL LIGHT START INHIBIT LIGHT OVERLOAD LIGHT August 0 Page - Titan Boom 60-S Service and Parts Manual

5 TROUBLESHOOTING -- EZ-CAL MESSAGES EZ-CAL MESSAGES "Help Messages" will appear on the EZ-Cal scan tool as a means of explaining operating and non-operating function(s) and system errors or interruptions that are accompanied by flash codes. It can also be used for verifying system operation. On Titan models, the EZ-Cal is conveniently located inside the lower control box. Refer to the EZ-Cal Instruction page for additional help with EZ-Cal operation. To access messages, power the system up, (it is not necessary to have the engine running) the EZ-Cal display will illuminate and read "HELP - PRESS ". Press to view current message. Press a second time then use right and left arrow buttons to access up 0 logged messages from the memory. Many messages simply detail operations being performed by the GP00; other messages detail occurrences that also take place during operation either normal or may be symptomatic of a malfunction. OPERATIONAL MESSAGES The following messages appear as result of normal operation and usually do not represent a problem. EVERYTHING OK Flash Code: None All circuits performing properly, no current operation performed. GROUND MODE ACTIVE Flash Code: None Base/Platform selector switch set to base control station. STARTUP Flash Code: None GP00 performing start up procedure, normally a short sequence. MOVING FRAME Flash Code: None Chassis level in progress. MOVING PLATFORM Flash Code: None Platform level in progress TELESCOPING Flash Code: None Boom extend/retract (telescope) in progress LIFTING Flash Code: None Boom lift up in progress LOWERING Flash Code: None Boom Lower down in progress DRIVING Flash Code: None Drive forward or reverse in progress VEHICLE TILTED Flash Code: None Chassis is tilted beyond pre-set maximum. Use auto-level feature to level chassis or re-position the machine. CAN BUS RELATED MESSAGES CAN bus communication system is the network by which the control modules and CAN Tilt modules communicate with the GP00. August 0 Page - Titan Boom 60-S Service and Parts Manual

6 TROUBLESHOOTING -- EZ-CAL MESSAGES NO DATA FROM CAN TILT # Flash Code: None CAN Tilt module mounted to front of main boom (located behind panel, Left Module) has malfunctioned or wiring is damaged. NO DATA FROM CAN TILT # Flash Code: None CAN Tilt module mounted to Front axle has malfunctioned or wiring is damaged. NO DATA FROM CAN TILT # Flash Code: None CAN Tilt module mounted to front of main boom (located behind panel, Right Module) has malfunctioned or wiring is damaged. NO DATA FROM CAN TILT # Flash Code: None CAN Tilt module mounted to Rear axle has malfunctioned or wiring is damaged. FAULT: CAN BUS! Flash Code: 6/6 The CAN bus cable may be damaged or disconnected from one or more of the modules. All modules must be connected to the CAN bus for machine operation. CALIBRATION RELATED MESSAGES The following messages appear when the GP00 microprocessor has not been calibrated or was improperly calibrated. FACTORY OVERRIDE FAST FLASH GP00 is shipped in this condition to allow temporary operation of the machine without interruption from the safety system so that calibration procedures can be performed. The GP00 must be prepared for the machine to which it will be installed, including calibration and Customer/model selection. See "GP00 Setup" for instructions. Once Calibrated, Factory Override is gone forever. ALL SAFETY SETTINGS ARE INACTIVE WHEN THE GP00 IS IN FACTORY OVERRIDE, NEVER OPERATE MACHINE IN FACTORY OVERRIDE EXCEPT TO CALIBRATE THE GP00. NOT CALIBRATED Flash Code: / The GP 00 microprocessor has not been calibrated. Operation will be restricted until calibration is completed. Refer to "Set up procedures" in this section for calibration information and instructions. HEIGHT NOT CALIBRATED Flash Code: / The Height portion of the calibration has not been completed. Operation will be restricted until calibration is completed. Refer to "Set up procedures" in this section for calibration information and instructions. FUNCTIONS LOCKED - NOT CALIBRATED Flash Code: / The GP 00 microprocessor has not been calibrated. Operation will be restricted until calibration is completed. Refer to "Set up procedures" in this section for calibration instructions. FAULT: CUSTOMER Flash Code: / Customer vs. Model settings not correct. Using the EZ-Cal, go to SETUPS/CHANGE DEFAULTS/CUSTOMER to correct. Changing customer or model will require access level code. NOTE: all adjustments and settings return to default value when Customer or Model is changed, ensure proper settings and adjustments after changing Customer or Model. Titan Boom 60-S Service and Parts Manual August 0 Page -

7 TROUBLESHOOTING -- EZ-CAL MESSAGES INTERLOCK MESSAGES The following messages appear as result of perceived improper operation, machine positioning, or other incorrect operation. Interlock messages may be the result of a part failure if the part in question provides incorrect information to the GP00. FUNCTIONS LOCKED - LIMIT REACHED Flash Code: / Rotating platform not centered; Certain operations require centered platform Rotating platform at extreme CW or CCW; no further rotation possible in that direction FUNCTIONS LOCKED - TEST MODE SELECTED Flash Code: / Calibration in progress or internal test mode active. Cycle EMS to clear. FUNCTIONS LOCKED - OUTRIGGERS Flash Code: / Stabilizers must be set before operation is allowed. FUNCTIONS LOCKED - OVERLOADED Flash Code: / Platform overloaded - reduce weight in platform until alarms stop (Overload option only) FUNCTIONS LOCKED - UNDERLOADED Flash Code: / Overload system detects less then normal lift cylinder pressure. Platform resting atop a fixed object, possible pressure switch failure or not calibrated correctly. FUNCTIONS LOCKED - TILTED Flash Code: / Platform sensors indicate platform out of level; level platform or chassis until alarm stops or re-position machine FUNCTIONS LOCKED - AUTO PLATFORM LEVEL Flash Code: / Auto Platform Level operation running, wait until completed to operate other functions. FUNCTIONS LOCKED - TOO HIGH Flash Code: / Elevation sensor indicating elevation beyond 98%. Height Calibration performed incorrectly; Angle Transducer loose or remounted incorrectly or extend proximity switch/s failure. Use EZ- Cal in conjunction with EZ-Cal Flow Charts to identify GP00 or GP0 for sensor's inputs to check sensor readings. FUNCTIONS LOCKED - EXTERNAL SHUTDOWN Flash Code: / Boom not retracted or axle/s off level. Boom must be retracted to allow frame level, drive or outrigger operation. Axles must be centered before drive is allowed when the platform is elevated. Also, drive will be interrupted if Stabilizer pressure sensor output is below 0. volts (possible sensor failure or sensor wiring issue). CHECK DRIVE/STEER SWITCHES Flash Code: / Drive joystick output without enable or during power up. Check drive joystick analog output and steer switch digital output using the EZ-Cal. CHECK LIFT SWITCHES Flash Code: / Lift joystick or toggle switch movement without enable or during power up. Check joystick analog output using the EZ-Cal. CHECK PLATFORM SWITCHES Flash Code / Platform Rotate/slide joystick or toggle switch movement without enable or during power up. Check joystick analog output and switch digital outputs using the EZ-Cal. August 0 Page - Titan Boom 60-S Service and Parts Manual

8 TROUBLESHOOTING -- EZ-CAL MESSAGES CHECK TELE SWITCHES Flash Code / Telescope joystick or toggle switch movement without enable or during power up. Check joystick analog output and switch digital output using the EZ-Cal. RELEASE ENABLE SWITCH Flash Code / One or more enable switches activated for extended period of time without corresponding function or during start up. Check enable switches digital outputs using the EZ-Cal. OTHER MESSAGES The following messages are the result of various possible failures or occurrences which may result in machine interruption. FUNCTIONS LOCKED - NO VALVE SUPPLY! Flash Code / GP00 detects no power on P7- of the GP00. Check wiring to plug connection; possible GP00 internal failure. FAULT: ENERGIZED VALVE Flash Code: / Power on valve output wire at GP00 plugs P, P5 or P6. Unplug these connectors and cycle e-stop switch to clear code. Plug in one-at-a-time until code reappears then isolate the circuit (with voltage) within that plug. If code does not clear, possible GP00 failure. EZ-Cal not useful for this procedure. FAULT: VALVE FEEDBACK HIGH! Flash Code: / On start-up GP00 p-5 pin voltage incorrect, check P5-X wiring for voltage feed back. Possible GP00 internal fault FAULT: BAD INTERNAL SAFETY SWITCH! Flash Code: / At startup, internal feedback of output incorrect, possibly failed output driver; check wiring to P6-///5; possible GP00 internal failure FAULT: LOW OIL PRESSURE! Flash Code: / Oil pressure switch opened during operation or time out. Check oil pressure, pressure switch, wiring. Message will appear if engine stops running for reasons other then normal shut down. FAULT: BAD INTERNAL SLAVE! Flash Code: / Malfunction within the GP00 possibly caused by a short circuit in the wiring or high voltage surge. Replace GP00 FAULT: BAD INTERNAL 5 VOLTS! Flash Code: / 5 volt circuit that provides voltage to sensors had failed. Possible short in the wiring or high voltage surge on supply. FAULT: BATTERY VOLTAGE TOO LOW! Flash Code: / Charge battery and battery connections, check charging system and voltage source connections. FAULT: BATTERY VOLTAGE TOO HIGH! Flash Code: / GP00 input voltage should be volts. Check battery and battery connections, alternator output. FAULT: CHECK HEIGHT SENSOR! Flash Code 6/ Height sensor output over.5 volts or under.5 volts. Check height sensor output using the EZ-Cal (height sensor on CE option only). Possible sensor failure or wire connection failure. Titan Boom 60-S Service and Parts Manual August 0 Page -5

9 TROUBLESHOOTING -- EZ-CAL MESSAGES FAULT: CHECK HEIGHT SENSOR! Flash Code 6/ Height sensor output over.5 volts or under.5 volts. Check height sensor output using the EZ-Cal. Possible sensor failure or wire connection failure. FAULT: CHECK HEIGHT SENSORS! Flash Code 6/ Voltage from Height sensors out of range, should be.5 volts to.5 volts FAULT: CHECK PRESSURE SENSOR! Flash Code 6/ Voltage from Pressure sensor out of range, should be.5 to.5 volts (Overload option only). FAULT: CHECK ELEVATION SWITCH! Flash Code 6/ This message should not occur on Titan models; check for incorrect GP 00 part. FAULT: SOME BIG BAD PROBLEM! Flash Code 9/9 A failure happened that has no message associated with it. This should never occur. August 0 Page -6 Titan Boom 60-S Service and Parts Manual

10 TROUBLESHOOTING -- TROUBLESHOOTING CHART TROUBLESHOOTING CHART The following chart describes the possible causes for inoperation of the different functions of the Titan Boom 60-S. The Causes and Solutions columns list various points of references that can be found in the Hydraulic, Electrical, Schematics and Troubleshooting sections of this manual. The majority of electrical troubleshooting on this model will require the use of the onboard EZ-Cal scan tool, located inside the lower control box door. Please refer to "EZ- Cal Scan Tools" on page -8 for further instructions on the use of the EZ-Cal scan tool. Perform a full assessment of machine operations prior to troubleshooting this model and using this chart. This model is operated by a Microprocessor Control System equipped with a variety of built-in safety interlocks to prevent continued operation in the event of a failure or misoperation. Some interlocks may only be detected through the use of the EZ-Cal. Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION General Power Issue No operation from upper or lower control station Operates from lower controls but not from upper controls Main battery switch turned off Emergency stop switch pushed in; Ignition switch turned off; Faulty switches Battery discharged or faulty cables Circuit breaker tripped Damaged upper control box harness-- Should be able to operate from Lower Controls Box Blown supply fuse Other fault in system monitored by GP00 Base/Platform select switch not set to Platform position or switch malfunction Interlock switch (joystick) Damaged upper control box harness Malfunctioning Matrix Module-- machines with optional Overload Sensing System only System interlock Located left of lower control box Upper or lower e-stop switch or ignition switch will cut all power as will the ignition switch in the platform control box Will receive - or 7-7 flash on GP00. Clean, service and charge battery - repair cables Located in lower control box. Look for short circuit and/or damage in wiring or high amperage draw at valve coils or engine actuators. Inspect the harnesses and harness plugs for damage or broken wires - May receive 6-6 flash code on GP-00 (CANbus) or no power at all Locate source of short circuit. Inspect/replace fuse located just below Main Battery Switch. Check Help message on EZ-Cal or check flash code for error Ensure that the switch is in the Platform position; Check switch function. Check power to red wire (power to switch) and power to purple wire (power out of switch) at joystick plug Inspect the harnesses and harness plugs for damage or broken wires. Check help messages using the EZ-Cal tool. Also check for joystick inputs (see b - b7 in diagnostic chart) Check EZ-Cal HELP messages for interlock Titan Boom 60-S Service and Parts Manual August 0 Page -7

11 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION ENGINE RELATED ISSUES Starter will not crank from upper or lower stations Starter cranks but engine will not start No high throttle Battery discharged or faulty cables Will receive - or 7-7 flash on GP00. Clean, service and charge battery; repair cables. Malfunctioning start relay or fuse Test/replace relay located on left hand side of engine and fuse located near starter. Malfunctioning starter Test/replace starter. Faulty start switch either location Test; replace as necessary. Oil pressure switch failure Check that oil pressure switch is not shorted, closed. Starter interrupt system initiated Check for red "Start Disable" light on lower panel Starter may be operated for 0 seconds before a 0 second "cool down" is initiated. See "Starter cranks but engine will not start" below. Poor ground on GP00 Check wiring and connections; replace Low fuel Check/fill fuel reservoir. Air trapped in the fuel system Purge air from the fuel system (see section of this manual for instructions). Restriction in the fuel system Replace Fuel Filter; Check fuel supply hoses. Malfunctioning fuel solenoid Check/replace fuel solenoid located on the front of the engine, accessed from right hand side. Malfunctioning Glow plugs (cold climates) Test/replace glow plug relay, fuse and glow plugs. Obstructed air filter Clean/replace air filter. Contaminated fuel Test/replace fuel. Other engine issues See engine manufacturers troubleshooting guide. Malfunctioning Throttle Relay, Solenoid or Test/replace throttle relay and/or throttle solenoid and fuse. blown fuse Restriction in the fuel system Replace Fuel Filter; Check fuel supply hoses. Obstructed air filter Clean/replace air filter. Other engine issues See engine manufacturers troubleshooting guide. August 0 Page -8 Titan Boom 60-S Service and Parts Manual

12 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION BOOM LIFT/LOWER Platform will not raise Excessive weight on platform Reduce weight to specified platform capacity Boom extended excessively with Retract boom until boom up/down operates. outriggers not deployed Main Relief Valve out of adjustment Adjust Main Relief Valve to rated platform capacity located on function manifold - see hydraulic section. Lift Valve SVD not energized Check wiring to lift valve, Check for EZ-Cal message or flash code. Lift Valve SVD not shifting Clean debris, Check for damage, replace. Proportional valve SP not energizing Check wiring to lift valve, Check for EZ-Cal message or flash code. Proportional valve SP not shifting Clean debris; Check for damage; Replace. Solenoid Valve SV (load sense dump) not Check wiring to valve; Check EZ-Cal ref. P- for output. energized Solenoid Valve SV (load sense dump) not shifting Clean debris; Check for damage; Replace. Platform will not lower or lowers slowly Emergency Lowering not working Level sensor out of level (platform elevated above 0 ft. (m)) Main system pressure is inadequate Lift/Lower joystick inoperative Battery discharged/no charge output System interlock Maintenance lock in maintenance position Boom extended excessively with stabilizers not deployed Lowering valve SVD not energized Lowering valve SVD not shifting System interlock Emergency Battery discharged/not charging Auxiliary power unit malfunction Emergency Down switch failure Lowering valve not shifting Battery discharged/no charge output Reposition or level platform using platform level toggle. Check level sensor signal using EZ-Cal ID#s a6 and a. Check pump output flow and pressure. Check joystick output using EZ-Cal ref. d-, P6- for analog output signal. Check battery voltage, alternator output (.5 volts). Check GP00 for - flash code. Check EZ-Cal HELP messages for interlock. Return maintenance lock to the stowed position. Retract boom until boom up/down operates. Check wiring to lowering valve located inside control module - see Section of this manual for exact location. Clean debris; Check for damage; Replace. Check EZ-Cal HELP messages for interlock. Check/charge battery; Check charge Isolator relay and fuse; Check alternator output (.5 volts). Check Auxiliary power unit, located below lower control box. Check/replace switch. Clean debris; Check for damage; Replace. Check battery voltage, alternator output (.5 volts); Clean, service and charge battery. Titan Boom 60-S Service and Parts Manual August 0 Page -9

13 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION BOOM EXTEND/ RETRACT No Boom Extension Excessive weight on Platform Reduce weight to specified platform capacity. Boom extends/retracts slowly Boom extended too far without stabilizer deployment (Boom extension beyond approximately 8 ft.* (m)* requires deployment) *7 ft (. m) on machines equipped with optional Overload Sensing System. Level sensor out of level (platform elevated above 0 ft. (.5 m) Extend Relief Valve RV out of adjustment Proportional Valve SP not energized Solenoid Valve SV (load sense dump) not energized Proportional Valve SP not shifting Ext/Retract joystick inoperative Battery discharged/no charge output System interlock Excessive weight on Platform Extend Relief Valve RV out of adjustment Proportional Valve SP not shifting completely Flow Control Valve EP not shifting completely Joystick output restricted Return boom to fully stowed position and deploy stabilizers before attempting to extend boom further. Reposition or level platform using platform level toggle. Check level sensor signal using EZ-Cal ID#s a7 and a. Adjust Extend relief valve (see Section - Hydraulics) located on function manifold. Check wiring to lift valve, Check for EZ-Cal message or flash code. Check wiring to valve, Check EZ-Cal ref.p- for output. Clean debris; Check for damage; Replace. Check Joystick output using EZ-Cal ref. d-, P6- for upper control analog output signal. Check battery voltage, alternator output (.5 volts) Check GP00 for - flash code. Check EZ-Cal HELP messages for interlock. Reduce weight to specified platform capacity. Adjust Extend Relief Valve (see hydraulics section) located on function manifold. Clean debris; Check for damage; Replace. Clean debris; Check for damage; Replace. Check Joystick output using EZ-Cal ref. d-, P6- for upper control analog output signal. No Boom Retract Proportional Valve SP not energized Check wiring to lift valve; Check for EZ-Cal message or flash code. Proportional valve SP not shifting Clean debris; Check for damage; Replace. Solenoid Valve SV (load sense dump) not Check wiring to valve; Check EZ-Cal ref. P- for output. energized Solenoid Valve SV (load sense dump) not Clean debris; Check for damage; Replace. shifting Ext/Retract joystick inoperative Check Joystick output using EZ-Cal ref. d-, P6- for upper control analog output signal. Battery discharged/no charge output Check battery voltage, alternator output (.5 volts) Check GP00 for - flash code. System interlock Check EZ-Cal HELP messages for interlock. August 0 Page -0 Titan Boom 60-S Service and Parts Manual

14 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION PLATFORM AUTO- LEVEL Platform will not remain level while elevating or lowering platform (level cylinder not moving at all) Platform will not remain level while elevating or lowering platform (level cylinder moving slowly) Platform Level solenoid valve not energized Platform Level solenoid valve not shifting Platform Level proportional valve SP7 not energized Platform Level proportional valve SP7 not shifting Counterbalance valve CBV9 or CBV0 faulty Flow Compensator valve EP not shifting Flow Regulator valve EPFR not shifting Obstruction in Platform Level Valve Platform Level Valve not energized Platform in excess of 7 out of level Excessive weight on platform Low Flow Relief Valve RV out of adjustment Platform Level solenoid valve SP7 not shifting completely Check wiring to valve, Check EZ-Cal ref. e, P- (up) and P-5 (down) for output. Clean debris; Check for damage; Replace. Check wiring to valve from Valve Constant Current Module (VCCM). Clean debris; Check for damage; Replace. CBV5 (extend) CBV6 (retract) must not be adjusted, replace if suspected. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Clean debris; Check for damage; Replace. Check wiring to valve. Use the Manual Platform Level function to return the platform to level. Reduce weight to specified platform capacity. Adjust low flow relief valve (see Section of this manual) located on function manifold. Clean debris; Check for damage; Replace. PLATFORM MANUAL LEVEL Platform level operates automatically but not manually Flow Compensator valve EP not shifting completely Flow regulator valve EPFR not shifting completely Pump P faulty Obstruction in Platform Level Valve Platform Level Valve not energized Platform in excess of 7 out of level Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Test; replace pump. Clean debris; Check for damage; Replace. Check wiring to valve. Use the Manual Platform Level function to return the platform to level. Platform Level toggle switch inoperative Check output from toggle using EZ-Cal --Lower Controls -- see I.D. #c-, P5- (up) or c-, P5-6 (down) --Upper Controls -- see I.D. #c-, P- (up) or c, P- (down) System Interlock Check EZ-Cal HELP message for interlock. Titan Boom 60-S Service and Parts Manual August 0 Page -

15 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION PLATFORM ROTATE Platform will not rotate either direction Platform will rotate in one direction only PLATFORM SLIDE Platform will not slide either direction Platform will slide in one direction only Rotate Valve SP8 not energizing Rotate Valve SP8 not shifting Mechanical interference in rotator Flow Compensator valve EP not shifting Flow Regulator valve EPFR not shifting System interlock Rotate Valve SP8 not energizing Rotate Valve SP8 not shifting Mechanical interference in rotator System interlock Excessive weight in platform or weight not distributed correctly Slide Valve SP9 not energizing Slide Valve SP9 not shifting Mechanical interference on slide path Slide Brake BR5 not releasing Flow Compensator valve EP not shifting Flow regulator valve EPFR not shifting System interlock Check wiring to valve from Valve Constant Current Module (VCCM). Clean debris; Check for damage; Replace. Inspect, clean or repair. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Check EZ-Cal HELP messages for interlock. Check wiring to valve from Valve Constant Current Module (VCCM). Clean debris; Check for damage; Replace. Inspect, clean or repair. Check EZ-Cal HELP messages for interlock. Reduce weight or redistribute weight in platform, not to exceed 000 lbs in the load zone and 000 lbs distributed evenly outside the load zone. Check wiring to valve from Valve Constant Current Module (VCCM) Clean debris; Check for damage; Replace. Inspect, clean or repair. Check for hydraulic pressure to brake; Check brake unit for mechanical issue Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Clean debris; Check for damage; Replace. Use GLS port on secondary manifold to test valve signal pressure. Check EZ-Cal HELP messages for interlock Shims too tight Check shim clearance of Platform Carriage; should be.00" (.76 mm) total clearance top-to-bottom and side-to-side Excessive weight in platform or weight not distributed correctly Slide Valve SP9 not energizing Slide valve SP9 not shifting Mechanical interference in slide path System interlock reduce weight or redistribute weight in platform not to exceed 000 lbs in the load zone and 000 lbs distributed evenly Check wiring to valve from Valve Constant Current Module (VCCM) Clean debris; Check for damage; Replace. Inspect, clean or repair Check EZ-Cal HELP messages for interlock Shims too tight Check shim clearance of Platform Carriage; should be.00" (.76 mm) total clearance top-to-bottom and side-to-side August 0 Page - Titan Boom 60-S Service and Parts Manual

16 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION DRIVE No drive operation NOTE: Drive function on the Titan 60-S cuts out when the boom is extended beyond feet (. m). No drive with platform elevated NOTE: Drive function on the Titan 60-S cuts out when the boom is extended beyond feet (. m). Stabilizers not raised off of ground Stabilizer pressure sensor/s inoperative Planetary hub bypass engaged Return Boom to stowed position and raise stabilizers Check Stabilizer pressure sensors using EZ-Cal (see EZ-Cal I.D.# d, P8-5 and d, P8-8. Should should read 0.0 volts each. Check bypass plates located in the center of each planetary hub, should be convex - turn over. Drive Valve (on drive pump) not shifting Check drive output from GP00 (see EZ-Cal chart ID#s e, P5-7 and P5-8). Check connections at valve located on top of drive pump. Check drive valve for contamination. Brakes not releasing Check brake valve and brake pressure (see hydraulic diagram for location). Drive joystick output failure Check drive joystick output from GP00 (see d, P0-) check joystick enable trigger operation, Check wire connections. System interlock Check EZ-Cal HELP messages for interlock. Low pump stand-by pressure Check at main manifold port GCP, (See Hydraulics section of this manual). Should be 00 PSI ( bar) - Adjust standby pressure. Incorrectly adjusted or worn hydraulic drive pump Unit out of level Outriggers deployed Low pump stand-by pressure System interlock See Hydraulics section of this manual for pump adjustment, inspect or replace pump. Lower boom and operate on more level surfaces. Lower platform and retract outriggers. Check at main manifold port GCP, (See Hydraulics section of this manual). Should be 00 PSI ( bar) - Adjust standby pressure. Check EZ-Cal HELP messages for interlock. Slow drive with Platform in stowed position Poor Gradeability or Drive performance Drive in one direction only Slow speed enabled Low pump stand-by pressure FWD MAX, REV MAX setting incorrect Wheel motor not functioning correctly High Speed enabled Wheel motor not functioning correctly Planetary hub bypass engaged Low pump stand-by pressure Incorrectly adjusted or worn hydraulic drive pump Drive valve not energizing in one direction No output from GP00 Check speed switch in platform box; check -speed valve located on the main manifold (see Schematics section of this manual). Check at main manifold port GCP, (see Hydraulics section of this manual). Should be 00 PSI ( bar) - Adjust stand-by pressure. Reset drive speeds using EZ-Cal. Inspect wheel motors for damage or wear. Check Speed Switch. Inspect wheel motors for excessive bypass. Check bypass plates located in the center of each planetary hub, should be convex - turn over. Check at main manifold port GCP, (see Hydraulics section of this manual). Should be 00 PSI ( bar) - Adjust stand-by pressure. See Hydraulics section of this manual for pump adjustment; inspect or replace pump. Check volts to coil, check coil, check valve function (located on top of drive pump). Check switch position output from GP00 (see EZ-Cal ID# e, P5-7 and P5-8). Titan Boom 60-S Service and Parts Manual August 0 Page -

17 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION No High Speed Speed selector switch inoperative Check continuity through Speed Select switch with wires disconnected. -speed valve SV7 not functioning Check for volts and ground to valve; check for faulty valve spool; check switch position output from GP00 (See EZ-Cal ID# e, P5-9). Variable elevated speed Variable hydraulic oil temperature Out of the stowed position, each machine is set to drive 0m ( ft) in 0 seconds with the hydraulic oil at 50 C ( F), at a speed of. m/s (.7 mph). Through testing, this setting causes the speed to increase to 0m in 5 seconds [.0 m/s (.9 mph)] at an oil temperature of 0 C (68 F), and 0m in 8 seconds [.55 m/s (. mph)] at an oil temperature of 0 C ( F). Although colder ambient temperatures are likely, once the engine has started and hydraulic oil has been circulating, it very quickly reaches 0 C ( F) and therefore the elevated driving speed should not exceed.7 m/s (.57 mph). STEER No steer in either direction (-wheel steer mode) Stabilizers not raised off of ground Joystick rocker switch inoperative Steering valve inoperative Hoses connected incorrectly Steer Cross-Port Relief valve/s CR and CR set too low Return Boom to stowed position and raise stabilizers. Check continuity through micro-switch inside joystick handle using wires outside the handle. Check steering valve for power. Check for damage and contamination. check output from GP00 (see EZ-Cal ID # e, P5- and P5-). See Chapter -- Hydraulics for correct connection. Set steer relief valves to 500 PSI (0 bar) (see hydraulic diagram for relief valves location. Steer in one direction only Will steer but not fully, or slow steering Rear Wheel Steer operates uncommanded System interlock Steering Valve inoperative or stuck No power to steering coil System interlock Failure of one or both steering cylinder internal seals Steer Cross-Port Relief valve(s) set too low King pin(s) seizing in the bore Check EZ-Cal HELP messages for interlock. Inspect and/or replace Steering Valve. Check for power and ground in both directions; repair wiring; check output from GP00 (see EZ-Cal I.D. #S. f- right & f- left). Check EZ-Cal HELP messages for interlock. Check steering cylinder seals, replace. Set steer relief valves to 500 PSI (0 bar) (see hydraulic diagram for relief valves location. Disassemble and inspect, replace bushings. -wheel steer valve SVD not energizing Check wiring to valve. Check EZ-Cal ref. e, P- and P- for output. -wheel steer valve SVD not shifting Clean debris; Check for damage; Replace. Steer Cross-Port Relief valve CR defect Check, adjust, replace. Rear axle steer cylinders damaged or Check cylinders, repair, replace. internal seals leaking Steer select toggle switch failure Check toggle switch. -Wheel Steer Valve SVD not shifting Clean debris. Check for damage, replace. August 0 Page - Titan Boom 60-S Service and Parts Manual

18 TROUBLESHOOTING -- TROUBLESHOOTING CHART Table -: Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION Outrigger, Frame Leveling No Outrigger operation Note: Outrigger operation is disabled when the boom is elevated above 6% and when boom is extended more then ' (00mm). Frame level operates but frame is not level when cycle is complete System senses boom elevated to an angle above 6% System senses boom is extended beyond " (00mm) Unit on too extreme an angle side-to-side (chassis level must complete level cycle before outriggers deploy) Outrigger/Auto-level switch inoperative Return the boom to stowed position and try again. Check elevation status using the EZ-Cal (see I.D. # a0). Recalibration of Height may be necessary (see Calibration section for instruction). Also see EZ-CaI I.D # a7 for analog input from height sensor in %. Retract boom completely and try again. Check Boom Retract status using the EZ-Cal (see I.D.# A- ). Also see # C- GP00 digitals--go to P- for Retract Sensor output information. EZ-Cal Help message will read "LEVELING". Relocate machine to a more level surface. Check outrigger switch output (in the LOWER control box) using EZ-Cal; scan GP00 for switch inputs (see EZ-Cal I.D.# d)--go to P8- and P8-. Check outrigger switch in the UPPER control box using EZ-Cal, scan GP0 for switch inputs (see EZ-Cal I.D.# C- go to P-9 & P-0). Outrigger Valve SP or SP not energizing Check wiring to outrigger valve. Check for EZ-Cal message or flash code. Outrigger Valve SP or SP not shifting Clean debris; Check for damage; Replace. Frame Level Valve not functioning (chassis level must complete level cycle before outriggers deploy) Unit located on too extreme an angle sideto-side Lower control box loose Level sensor not properly calibrated (located inside the GP00). Located on function manifold. Inspect valve for power, inspect for damage, check output from GP00 (see EZ-Cal GP00 Outputs P-7 (left) and P-8 (right). Relocate unit to more level ground. Tighten four () lower control box mounting screws. See Calibration section for level sensor Calibration instructions. Titan Boom 60-S Service and Parts Manual August 0 Page -5

19 NOTES: TROUBLESHOOTING -- August 0 Page -6 Titan Boom 60-S Service and Parts Manual

20 Section 5 SCHEMATICS CONTENTS PAGE Hydraulic Schematics Electrical Schematics FIGURES PAGE Hydraulic Schematic, of Hydraulic Schematic, of Primary Functions Manifold, MA, of Primary Functions Manifold, MA, of Secondary Functions Manifold, MA Traction Manifold, MA Auxiliary Manifold, MA Electric Schematic, Lower Control Box Electric Schematic, Chassis Electric Schematic, Control Cable Electric Schematic, Upper Control Box Sensor Locations Titan Boom 60-S Service and Parts Manual August 0 Page 5-

21 NOTES: - August 0 Page 5- Titan Boom 60-S Service and Parts Manual

22 HYDRAULIC SCHEMATICS The following table applies to Figure 5- through Figure 5-7. H YDRAULIC SCHEMATICS - Callout Description Callout Description BR-BR Wheel Brakes (located in gear hubs) ORF Orifice -- Traction Manifold.05 BR5 Platform Slide Brake ORF5 Orifice -- Traction Manifold.090 CBV-CBV0 Counterbalance Valves ORF6 Orifice -- Traction Manifold.00 CR-CR Cross-Port Relief Valve P Pump -- Drive CV Check Valve -- Backflow Preventer P P Pump -- Primary Functions CV Check Valve -- Load Sense, Lift/Lower P Pump -- Secondary Functions CV Check Valve -- Load Sense, Ext./Retr. P Pump -- Auxiliary Power CV Check Valve -- Front Outrigger P5 Pump -- Auxiliary Power CV5 Check Valve -- Front Outrigger PD Pilot-Operated Valve CV6 Check Valve -- Rear Outrigger PD Pilot-Operated Valve CV7 Check Valve -- Rear Outrigger PD Pilot-Operated Valve CV8 Check Valve -- Steering PD Pilot-Operated Valve CV9 Check Valve -- Steering PD5 Pilot-Operated Valve CV0 Check Valve -- Backflow Preventer APU PR Pressure Reducing Valve CV Check Valve -- Secondary Functions Manif. PT Lift Cylinder Pressure Transducer CV Check Valve -- Aux Power PT Platform Level Cyl. Pressure Transducer CV Check Valve -- Platform Level PV Pilot Valve CV Check Valve -- Platform Rotate RV Relief Valve -- Extend CV5 Check Valve -- Platform Slide RV Relief Valve -- Auxiliary Power CYL Boom Lift Cylinder RV Relief Valve -- Low Flow CYL-CYL Boom Extend Cylinders RV Relief Valve -- Traction Manifold CYL5, CYL6 Front Outrigger Cylinders SF Solenoid Valve -- Boom Retract CYL7, CYL8 Rear Outrigger Cylinders SP Proportional Valve -- Boom Lift CYL9, CYL0 Steering Cylinders SP Proportional Valve -- Boom Extend CYL, CYL Rear Axle Cylinders SP Proportional Valve -- Front Outrigger CYL, CYL Front Axle Cylinders SP Proportional Valve -- Front Outrigger CYL5 Platform Level Cylinder SP5 Proportional Valve -- Rear Outrigger DC Steering Dual Check Valve SP6 Proportional Valve -- Rear Outrigger EM Electric Motor -- Auxiliary Power SP7 Proportional Valve -- Platform Level EP Flow Compensator -- Boom SP8 Proportional Valve -- Platform Rotate EP Flow Compensator -- Extend SP9 Proportional Valve -- Platform Slide EP Flow Compensator -- Auxiliary Manifold SV Solenoid Valve -- Load Sense Dump EPFR Flow Regulator SV Solenoid Valve -- Boom Ext. Regen. FD Flow Divider -- Traction Manifold SV Solenoid Valve -- Low Flow Dump FD Flow Divider -- Traction Manifold SV Solenoid Valve -- Rear Axle FD Flow Divider -- Traction Manifold SV5 Solenoid Valve -- Front Axle FL Filter -- Hydraulic Tank SV6 Solenoid Valve -- Brake FL Filter -- Charge SV7 Solenoid Valve -- -Speed HS Oil Shuttle Valve SV8 Solenoid Valve -- Boom Up/Down Pilot LS Load Sense Shuttle Valve SVD Directional Valve LS Load Sense Shuttle Valve SVD Directional Valve M-M Wheel Motors M5 Platform Rotate Motor M6 Platform Slide Motor MA Primary Functions Manifold Gauge Ports MA Secondary Functions Manifold GCP Gauge Port -- Charge Pressure MA Drive Manifold GD Gauge Port -- Drive Pressure MA Auxiliary Manifold GLS Gauge Port -- Load Sense ORF Orifice -- Steer.090 GLS Gauge Port -- Load Sense, Platform ORF Orifice -- Brake Apply.00 GP Gauge Port -- High Flow ORF Orifice -- Traction Manifold.05 GP Gauge Port -- Low Flow Titan Boom 60-S Service and Parts Manual August 0 Page 5-