Mec Titan Boom 40-S Service And Parts Manual
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Mec Titan Boom 40-S Service And Parts Manual

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SERVICE AND PARTS MANUAL
Titan Boom 40-S
Serial Number Range
Part # 92242
12400001 - Up
ART_3393
August 2012

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  • Page 1 SERVICE AND PARTS MANUAL Titan Boom 40-S Serial Number Range Part # 92242 12400001 - Up ART_3393 August 2012...
  • Page 2 Revision History Original Release Date: March 2011 Date Reason for Update 06/2011 New Release 08/2011 1st Revision Aerial Platform Sales Corp. 1401 S. Madera Avenue • Kerman, CA 93630 USA Ph: 1-800-387-4575 • E-mail: info@mecAWP.com Web: www.mecAWP.com...

  • Page 3: Table Of Contents

    Machine Specifications - Titan Boom 40-S ........
  • Page 4 Stabilizer Cylinders ........... . . 3-13 August 2012 “Titan Boom 40-S” Service and Parts Manual Page ii...
  • Page 5 Electrical Schematics - Optional Overload Sensing System ..... . . 5-13 “Titan Boom 40-S” Service and Parts Manual August 2012...
  • Page 6 Service Table of Contents August 2012 “Titan Boom 40-S” Service and Parts Manual Page iv...
  • Page 7 ONTENTS Machine Specifications - Titan Boom 40-S ......II MEC Operator Policy ..........III Safety Symbols .
  • Page 8 -40° F (-40° C) minimum; Range 122° F (50° C) maximum *Working Height adds 6 feet (2 m) to platform height. **Weight may increase with certain options or country standards. June 2011 “Titan Boom 40-S” Service and Parts Manual Page II...
  • Page 9 Any procedures not found within this manual must be evaluated by the individual to assure oneself that they are “proper and safe.” Your MEC Aerial Work Platform has been designed, built, and tested to provide many years of safe, dependable service. Only trained, authorized personnel should be allowed to operate or service the machine.

  • Page 10: Safety Symbols

    It may also be used to alert against unsafe practices. “Caution” without alert symbol indicates a situation which, if not avoided, may result in property damage. June 2011 “Titan Boom 40-S” Service and Parts Manual Page IV...

  • Page 11: General Safety Tips

    • Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as harmful as no lubrication. • Watch for makeshift “fixes” which can jeopardize safety as well as lead to more costly repair. “Titan Boom 40-S” Service and Parts Manual June 2011 Page V...
  • Page 12 • Remove the Maintenance Chock from the cylinder rod. • Store the Maintenance Chock in the tool storage compartment of the Engine Module. Figure 1-2: Maintenance Chock Installation Maintenance Chock Cylinder Proper Placement Of Maintenance Chock ART_3475 June 2011 “Titan Boom 40-S” Service and Parts Manual Page VI...

  • Page 13: Electrical System

    Immediately report to your supervisor any defect or malfunction. Any defect shall be repaired prior to continued use of the aerial work platform. Inspection and maintenance should be performed by qualified personnel familiar with the equipment. “Titan Boom 40-S” Service and Parts Manual June 2011 Page VII...

  • Page 14: Primary Machine Components

    Engine Module Cylinder Chassis Controls Module Battery Disconnect Switch Maintenance Chock Storage Compartment Stabilizer Fuel Tank Base Controls Hydraulic Tank *For Material Loading Only. Hydraulic Not For Personnel. Manifold ART_3389 June 2011 “Titan Boom 40-S” Service and Parts Manual Page VIII...
  • Page 15 85 - 90 115 - 122 950 - 1050 107 - 119 130 - 140 176 - 190 130 - 140 176 - 190 1300 - 1368 147 - 155 “Titan Boom 40-S” Service and Parts Manual June 2011 Page IX...

  • Page 16: Emergency Systems And Procedures

    • The lower controls switch must be reset or the machine will not operate. • The machine will operate from the lower controls if the upper controls switch is tripped. June 2011 “Titan Boom 40-S” Service and Parts Manual Page X...

  • Page 17: Emergency Lowering

    The Emergency Power Switch serves as an enable switch. It is not necessary to use the primary function enable switch. Figure 1-5: Emergency Power Switch Emergency Power Switch Emergency Power Switch Base Controls Emergency Lowering Switch Platform Controls ART_3525 “Titan Boom 40-S” Service and Parts Manual June 2011 Page XI...
  • Page 18 E F O R E R I V I N G • Remove the Brake Engage Cap and reinstall with the bump facing outward on all four (4) hubs. ART_2848 June 2011 “Titan Boom 40-S” Service and Parts Manual Page XII...

  • Page 19: Lift And Support The Machine

    2. Raise machine slightly and remove jack stands. 3. Lower the machine and remove the jack. 4. Tighten lug nuts to proper torque (refer to machine specifications). 5. Remove chocks. “Titan Boom 40-S” Service and Parts Manual June 2011 Page XIII...

  • Page 20: Transporting The Machine

    INCHING ONTO OR OFF OF A RANSPORT EHICLE MEC DOES NOT RECOMMEND UNASSISTED LOADING OR UNLOADING. ALWAYS ATTACH THE MACHINE TO A WINCH WHEN LOADING OR UNLOADING FROM A TRUCK OR TRAILER BY DRIVING. Refer to the Operator’s Manual for loading, unloading, driving and operating instruc- tions.
  • Page 21 Boom Lift System ..........1-42 “Titan Boom 40-S” Service and Parts Manual...
  • Page 22 Extend Cylinder Disassembly & Assembly ......1-53 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-2...
  • Page 23 Typical Cylinders, Exploded View ....... . . 1-50 “Titan Boom 40-S” Service and Parts Manual...

  • Page 24: Hydraulic System - General

    Reservoir Auxiliary Manifold Steer Cyl. Rear Axle Cyl. Wheel Motor Platform Level Cyl. Boom Extend Cyl. Boom Lift Cyl. Engine Charge Filter Drive Pump (piston-type) ART_3716 Functions Pump (gear-type) August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-4...

  • Page 25: Hydraulic Roadmap

    Return the wheels to center before switching to 2-wheel or 4-wheel mode. TABILIZER YSTEM Two hydraulic cylinders stabilize the machine in the fore-and-aft plane. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-5...
  • Page 26 -- O ENERATOR YSTEM PTIONAL If equipped, the generator is driven by a hydraulic motor which receives hydraulic fluid directly from the pressure port of the Functions Pump. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-6...

  • Page 27: Hydraulic Fluid

    E C O M M E N D A T I O N S MEC recommends only the use of the Mobile Fluid hydraulic fluids listed in the chart below, and each only in the operating temperatures listed in the chart. Do not substitute other fluids as pump damage may result, and use only the fluid appropriate to the ambient operating temperature.

  • Page 28: Hydraulic Fluid Reservoir

    Replace all filter elements every six (6) months or 500 hours. Extremely dirty conditions may require that the filter be replaced more often. BEWARE OF HOT FLUID. CONTACT WITH HOT FLUID MAY CAUSE SEVERE BURNS. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-8...

  • Page 29: Hydraulic Pumps

    Failure to open the ball valve on the Hydraulic Tank will result in damage to the pumps. DO NOT operate the Drive Pump until you have completed the "Drive Pump Start-Up Procedure" on page 1-11. Severe damage will occur. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-9...

  • Page 30: Drive Pump

    Charge Filter out to Func ons Manifold DA out to Func ons Manifold DB out to Func ons Manifold CP Case drain -- out to Tank ART_3718 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-10...
  • Page 31 Check for leaks at all line con- nections and listen for cavitation. Check for proper fluid level in reservoir. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-11...

  • Page 32: Functions Pump

    15. The pump is now ready for operation. RIVE ERVICE MEC does not recommend end-user maintenance or repair of the Sauer Danfoss hydraulic pump. Contact MEC or Sauer Danfoss for the nearest service provider. U N C T I O N S U M P The Functions Pump is a fixed-displacement gear pump.

  • Page 33: Hydraulic Manifolds

    3. Wash and dry each component and check for thread damage, torn or cracked O- rings, and proper operation. 4. Replace defective parts and O-rings. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-13...
  • Page 34 Failure to open the ball valve on the Hydraulic Tank will result in damage to the pumps. 5. Connect the battery. 6. Operate each hydraulic function and check for leaks and for proper operation. 7. Adjust valve pressures. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-14...
  • Page 35 Check Valve Solenoid Valve Load Sense Shuttle Check Valve EPFlow Regulator Solenoid Valve Solenoid Valve Crossport Steering Relief Valve Solenoid Valve Solenoid Valve Flow Regulator Flow Compensator Relief Valve ART_3720 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-15...
  • Page 36 Right Stabilizer Extend Telescope Proportional Brake Release Right Stabilizer Retract High Speed Drive Load Sense Dump Telescope Extend Steer Left Frame Level Left Frame Level Right Steer Right ART_3721 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-16...
  • Page 37 Y D R A U L I C A N I F O L D S Figure 1-7: Functions Manifold, Fitting Orientation ART_3722 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-17...
  • Page 38 Slide Forward Wire Connections Fitting +128 Orientation Flow Regulator Rotate Right EPFR2 +131 Level Up Slide Back Function +129 # printed on wire Rotate Left +130 Level Down ART_3723 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-18...
  • Page 39 A N I F O L D S Figure 1-9: Drive Manifold Flow Divider Pilot-Operated Valve PD1 Pilot-Operated Valve PD2 Flow Divider Oil Shuttle Valve Relief Valve Flow Divider Components Fitting Orientation ART_3724 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-19...

  • Page 40: Hydraulic Pressure Adjustment

    Port GLS Port GP2 Steering Cross-Port Traction Manifold Axle Float-- PR1 Relief--CR1, CR2 Oil Supply -- RV4 1500 PSI 103 bar Do not adjust Do not adjust Port GP2 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-20...

  • Page 41: Adjusting Relief Valves

    Do not operate pump with tamper proof cap removed. Fluid will emit under pressure. Figure 1-10: Adjustable Valves Location Functions Manifold PR1* Traction Manifold behind RV1 RV3* Adjustable Valve Gauge Port Do not adjust ART_3715 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-21...

  • Page 42: Adjustments

    • If pressure is LOW, adjust steering relief valve ¼ turn clockwise and recheck. • If pressure is HIGH, adjust steering relief valve ¼ turn counterclockwise and recheck. • Repeat until correct. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-22...
  • Page 43 • Steer the wheels fully left. Hold the switch 10 seconds. This is the read- ing for CR1. • If pressure is HIGH, adjust Valve CR2 1/8 turn counterclockwise and recheck. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-23...

  • Page 44: Drive Pump

    Flush the lines and refill the reservoir with the correct filtered hydraulic fluid. 7. Before re-installing the pump, test for leaks. 8. See "Drive Pump Start-Up Procedure" on page 1-11 for start-up instructions August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-24...

  • Page 45: Drive Pump/Drive Manifold Connections

    (17 Nm). 7. When you achieve the desired charge pressure setting, remove the gauges and plug the ports. Functions Manifold Drive Pump Charge Pressure Adjustment Screw & Locknut ART_3725 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-25...
  • Page 46 (M4 for M5, MB for MA) from those stated above since the pump is now stroking the other direction. 8. Remove all gauges and replace gauge port plugs. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-26...
  • Page 47 Manifold. These hoses allow fresh oil to pass into and out of the drive system. Figure 1-13: Drive Pump/Drive Manifold Connections Port 2SPD on Functions Manifold Drive Manifold Port L2 Drive Pump Engine Module Port A Port B ART_3743 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-27...
  • Page 48 Out to Suction Hydraulic Tank Manifold In from tank Out to Functions Pump Out to Drive Pump Suction Manifold Port L2 Drive Pump Functions Pump Suction Port Suction Port ART_3744 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-28...

  • Page 49: Drive Pump/Function Manifold Connections

    Port MB on the Drive Pump connects to Port DB on the Functions Manifold. Figure 1-15: Drive Pump/Function Manifold Connections h i d v a l Functions Manifold Drive Pump ART_3745 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-29...

  • Page 50: Charge Filter Circuit

    In from Port F Out to Port E Charge Filter Drive Pump Port E -- top In from Charge Filter Port F -- bottom Out to Charge Filter Engine Module ART_3746 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-30...
  • Page 51 Port T of the Functions Manifold moves return oil to the Hydraulic Tank. Figure 1-17: Drive Circuit Functions Manifold Functions Pump In from Port T Hydraulic Tank ART_3747 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-31...

  • Page 52: Hydraulic Functions

    D5 - A D2 - A D4 - B D8 - B Drive Manifold Wheel Motor D7 - A D1 - A 2 Places D3 - B D6 - B ART_3733 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-32...

  • Page 53: Wheel Motor Startup Procedure

    • Drained of fluid for any reason. Figure 1-19: Drive Motor Servo piston Bias spring Swashplate Output shaft Cylinder block Shaft seal Endcap Bearing Valve plate Slipper Piston ART_3579 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-33...
  • Page 54 11. Check the fluid level in the reservoir; add clean filtered fluid if necessary. 12. The motor is now ready for operation. EPAIR MEC does not recommend end-user maintenance or repair of the Sauer Danfoss drive motors. Contact MEC or Sauer Danfoss for the nearest service provider. August 2012 “Titan Boom 40-S”...

  • Page 55: High Speed Function

    Smaller displacement means the wheel motor requires less flow per rotation. See Figure 1-19, page 33. Figure 1-20: High Speed Hose Routing Functions Manifold High Speed Port Wheel Motor ART_3734 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-35...

  • Page 56: Brake Release Function

    Fluid passes through the Wheel Motor to the Gear Hub to release the brakes. Figure 1-21: Brake Release Hose Routing Functions Manifold Brake Release Port Wheel Motor ART_3735 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-36...

  • Page 57: Drive Case Drain Function

    The Drive Motor Case Drain hoses lead from the Case Drain Port on each wheel motor to the Hydraulic Tank located in the Controls Module. Figure 1-22: Drive Case Drain Hose Routing Hydraulic Tank Case Drain Port Wheel Motor ART_3736 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-37...

  • Page 58: Axle Lock Function

    Figure 1-23: Axle Lock Cylinders Functions Manifold P i l r t A r t A ART_3728 Front Axle Cylinder August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-38...

  • Page 59: Frame Level Function

    The rear axle is locked in place when the Frame Level Function is not in use. Figure 1-24: Frame Level Cylinders behind valve Functions Manifold P i l s s u P r e Pressure Pilot Pressure Pilot Rear Axle Cylinder ART_3729 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-39...
  • Page 60 Valve SV5. Figure 1-25: Steering Circuit Valve SVD2 Valve Functions Manifold Control Module Side Engine Module Steer Cylinders Side each axle ART_3730 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-40...

  • Page 61: Stabilizer System

    A pressure transducer mounted to each cylinder provides stabilizer pressure information to the GP400 Processor. Figure 1-26: Stabilizer Cylinders Functions Manifold ART_3731 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-41...

  • Page 62: Boom Lift System

    The counterbalance valve prevents retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve. Figure 1-27: Boom Lift Circuit Functions Manifold ART_3732 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-42...

  • Page 63: Boom Extend System

    Figure 1-28: Boom Extend Circuit behind valve behind valve Functions Manifold BR2 BE2 Boom Extend Cylinders ART_3737 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-43...

  • Page 64: Auxiliary Manifold Supply

    Platform Slide functions, and is supplied by hoses from the PFS and PFR ports of the Functions Manifold. Figure 1-29: Auxiliary Manifold Supply Circuit Functions Manifold Auxiliary Manifold ART_3737 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-44...

  • Page 65: Platform Level Function

    The Auxiliary Manifold provides directional control, while the Platform Level Control Valve provides proportional control. Figure 1-30: Platform Level Circuit Platform Level Cylinder Auxiliary Manifold ART_3739 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-45...

  • Page 66: Platform Rotate Function

    Platform Rotate Drive Unit to the rotate the platform. The Auxiliary Manifold valve provides directional control. Figure 1-31: Platform Rotate Circuit Auxiliary Manifold Platform Rotate Drive Unit ART_3740 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-46...

  • Page 67: Platform Slide Function

    Manifold flows to the Carriage Motor to the slide the platform. Pressure from the Carriage Motor’s check valve circuit releases the Carriage Brake while the carriage is in motion. Figure 1-32: Platform Rotate Circuit Carriage Brake Auxiliary Manifold Carriage Motor ART_3741 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-47...

  • Page 68: Emergency Power Function

    Figure 1-33: Emergency Power Circuit Out to Port S Hydraulic Tank Emergency Power Unit Functions Manifold ART_3742 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-48...

  • Page 69: Generator Option

    Functions Manifold Electrical Power Out to Junction Box Return -- To T in E-Down Suction Port at Tank Case Drain-- To T in Case Drain Port at Tank ART_3749 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-49...

  • Page 70: General Cylinder Repair

    1. Tag hoses for proper reassembly. 2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination. 3. Remove cylinder from the machine as described in Section 3. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-50...

  • Page 71: Preparation

    Scratches or pits deep enough to catch the fingernail are unacceptable; replace the cylinder. b. Polishing is a sign of uneven loading. Check for roundness. If a polished surface is not round within .007 in. (0.18 mm) replace the cylinder. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 1-51...

  • Page 72: Cylinder Assembly

    10. Cycle the cylinder using air to check for proper operation. NOTE: Keep all parts clean when working with hydraulic cylinders. Even one small piece of dirt or grit can damage the cylinder. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-52...
  • Page 73 3. Install cylinder manifold (with tube) into the cylinder, ensuring that the tube fits into the o-ring port in the center of the piston at the far end of the rod. “Titan Boom 40-S” Service and Parts Manual August 2012...
  • Page 74 7. Install the cylinder gland nut using a small amount of anti seize compound on the threads. Tighten sufficiently. Repeat procedure on other cylinder if necessary. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 1-54...
  • Page 75 Information Messages ........2-32 “Titan Boom 40-S” Service and Parts Manual...
  • Page 76 GP440 Module & VCCM Locations ....... . . 2-23 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-2...

  • Page 77: Electrical System - General

    The LED on the module should be ON. If the EZ-Cal has an error message, or if the LED is OFF or FLASHING, see Section 4 of this manual for assistance in troubleshooting. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-3...
  • Page 78 All electrical power is routed through the Master Disconnect switch located in the Control Module. The switch can be locked in the OFF position with a padlock to prevent unauthorized use. ART_2387 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-4...

  • Page 79: Batteries

    • drops to 40% at 0°F (-32°C) Table 2-1: Recommended Battery Charge Intervals If Stored At Recharge Below 40°F (4°C) Every week 40°-60°F (4°-15°C) Every 2 weeks Above 60°F (15°C) Every month “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-5...
  • Page 80 Table 2-2: Battery Specific Gravity and Voltage Specific Gravity Volts DC Each Cell Per Cell 6V Battery 12V Battery Fully Charged 1.280 2.10 6.30 12.60 Fully Discharged 1.130 1.75 5.19 10.50 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-6...
  • Page 81 3. Lift the battery from the compartment, put the battery aside and dispose of properly. O INSTALL A BATTERY 1. Position the battery in the compartment and secure with hold-down hardware. 2. Connect battery cables. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-7...

  • Page 82: Controls

    O W E R O N T R O L S Figure 2-4: Lower Controls ART_3524 ALWAYS BE AWARE OF THE MACHINE’S POSITION AND OF YOUR SURROUNDINGS BEFORE ACTIVATING ANY CONTROL FUNCTION. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-8...
  • Page 83 When this red light is illuminated, the starter circuit is temporarily disabled. The starter circuit times out if Indicator the starter is run continuously for 10 seconds without the engine starting. The starter functions resets after 30 seconds. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-9...
  • Page 84 Speed/Torque Switch Move this switch to the left for high speed drive. Push this switch to the right for high torque drive. Horn Button Press to sound warning horn. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-10...
  • Page 85 To continue to rotate the platform, return the joystick to the neutral position, then push the joystick to rotate the platform in the desired direction. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-11...

  • Page 86: Sensors, Relays & Alarms

    Platform Beam the Platform Beam. These measure the angle of the beam both fore-and CAN-Tilt 153 aft and side-to-side. CAN-Tilt 151 ART_3752 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-12...
  • Page 87 5000 psi Pressure Pressure Transducer Transducer on machines equipped machines with optional Overload Sensing System with the optional Overload Sensing System. Pressure Transducer 5000 psi ART_3778 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-13...
  • Page 88 The boom Boom Extend 2 must be retracted to re-enable Proximity Sensor operation. Boom Extend 2 Proximity Sensor ART_3754 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-14...

  • Page 89: Cable Extension Transducer

    ABLE XTENSION RANSDUCER Figure 2-14: Cable Extension Transducer The Cable Extension Transducer Cable Extension measures boom extension on Transducer machines equipped with the optional Overload Sensing System. ART_3810 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-15...

  • Page 90: Engine Relays

    3kVA Generator, this relay controls the solenoid valve that turns the generator on and off. It also provides power to the exciter for the generator. Generator Relay ART_3765 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-16...
  • Page 91 • The All-Motion Alarm is optional and sounds at the Base Controls Box. • The Horn is activated by button from the Upper Controls Station and sounds from the Base Controls Box. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-17...

  • Page 92: Deutsch Connectors

    O N N E C T O R S EUTSCH ONNECTORS Deutsch connectors used on MEC equipment are designed so that individual parts may be replaced without replacing the entire component. Special tools and detailed instructions are provided in Deutsch Connector field kits, MEC part no. 84091.

  • Page 93: Selector Switch

    • Move second probe to bottom normally open terminal. • With toggle UP there should be no reading. Normally Open • With the toggle DOWN there should be a low resis- tance. Common Normally Open ART_2563 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-19...

  • Page 94: Toggle Switch, 1-Pole 3-Position

    Normally Open Normally Open • With the toggle UP (closed) there Common Common should be no reading. Normally Open Normally Open • Repeat for both rows of two-row switch. ART_2564 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-20...

  • Page 95: Emergency Stop Switch

    • Confirm normally closed (#87A) contacts are opening. Continuity with #30 will be broken. B− • Confirm normally open (#87) contacts are clos- SIGNAL SIGNAL ing. Continuity with #30 will be made. ART_2330 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-21...
  • Page 96 Lower Controls Box EZ Cal Onboard Scan Tool Matrix Module* GP400 Module EZ Cal Onboard Terminal Diagnostic Tool Block Module *Machines equipped with the optional Overload Sensing System ART_3758 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-22...
  • Page 97 An error message will display on the EZ-cal indicating the reason for the interruption. Additional details of these error messages can be found at the end of the calibration instructions. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-23...
  • Page 98 3. Extension Sensor Calibration 4. Load Calibration These and other procedures require the use of the onboard EZ-Cal Diagnostic Tool located inside the Lower Controls Box. If the EZ-Cal is missing please contact MEC Aerials parts department to purchase one. PRE-CALIBRATION SETUP Park the machine on an absolute flat and level surface free from overhead obstructions that will prevent full boom elevation.
  • Page 99 Use the up arrow and right arrow to enter the day's date. 7. Once the CAL DATE has been entered, calibration is complete. Press ESC 3 times and/or turn off the machine. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-25...
  • Page 100 Box door. Attached to the Lower Control Box Door is an EZ-Cal interface display which will be used to perform the calibration. 6. Power the Titan system up. The EZ-cal display will read HELP PRESS ENTER. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-26...
  • Page 101 ENTER. You should now see "FINISHED!" appear on the screen. The machine is now calibrated and ready to be used. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-27...
  • Page 102 DYNAMIC lift. The height sensor output must be between 1.0V and 4.0V. Check DIAG- NOSTICS / SYSTEM (2a-7) to see the output. This is usually due to a wiring problem. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-28...
  • Page 103 (The Titan has no elevation switch; check that the boom is fully retracted) F18:LOW ELEV.CLOSE This message is given if the elevation switch (P7-5) closed during lower at a too low height (below 5%). “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-29...
  • Page 104 F24:TOO MANY This message occurs if too many static measurements are taken during a calibration step. In the rare event that this occurs, please call MEC for assistance. F27:BAD HEIGHT This message indicates a problem with the height sensor output (P8-2) during the STATIC calibration phases.
  • Page 105 The sensor output must be between 0.5V and 4.5V. Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 2-31...
  • Page 106 This message confirms that calibration is complete and successful. GO DOWN MORE! This message occurs if the DOWN switch is released during either STATIC lowering phase, when more measurements are needed (before the platform is fully lowered). June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-32...
  • Page 107 This message is prompting for confirmation that the platform is loaded to rated load: For the Titan Boom 40-S, this is 3000 lbs (1360 kg) in the Load Zone, and 1000 lb (450kg) at the front of the platform (100% of the load rating listed on the serial plate).
  • Page 108 This message is displayed at the end of each phase, to confirm the number of measure- ments recorded by the GP400. No operator input is required during this process. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 2-34...
  • Page 109 Lubrication Points ..........3-39 “Titan Boom 40-S” Service and Parts Manual...
  • Page 110 Throttle Linkage ..........39 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-2...

  • Page 111: Mechanical Components

    5. Install the replacement wheel. 6. Install lug nuts and tighten. 7. Lower the machine. 8. Tighten lug nuts to proper torque (Refer to machine specifications). 9. Remove the chocks. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-3...
  • Page 112 Remove the Housing motor. ART_3760 Gear Hub 7. Support the gear hub, then remove the six bolts holding the gear hub to the motor/hub housing. Carefully remove the gear hub. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-4...
  • Page 113 RIVE OTORS MEC does not recommend end-user maintenance or repair of the Sauer Danfoss drive motors. Contact MEC or Sauer Danfoss for the nearest service provider. Lubrication • Change the oil after the first 100 hours of operation •...
  • Page 114 Figure 3-3: Gear Hub, Exploded View Seal kit parts Brake release parts ART_3569 1. Unscrew the plug and drain the oil into a container. Dispose of used oil properly. ART_3561 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-6...
  • Page 115 2. Remove the snap ring and cover. ART_3562 3. Pull out the pinion and the first stage reduction unit. ART_3563 4. Remove the securing screws and remove the planetary ring. ART_3564 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-7...
  • Page 116 8. Reassemble in reverse order, replacing seal kit and/or brake release kit components as you go. Use a light petroleum-based oil to lubricate parts and seals during reassembly. ART_3567 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-8...
  • Page 117 2. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent con- tamination. 3. Torque hose fittings according to the Hydraulic Torque Specification Table located in the Introduction section of this manual. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-9...

  • Page 118: Steer Cylinders

    7. Installation is reverse of removal. 8. To purge air from cylinder, cycle the steering system fully left and right 5-6 times. Figure 3-4: Steering Cylinder Installation Steer Cylinders Tie Rod ART_3761 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-10...

  • Page 119: Axle Cylinders

    7. Installation is reverse of removal. Apply one (1) Pin Retainer drop of Loctite® 242 or equivalent to the bolts Rear Axle shown; front axle similar. ART_3762 that secure the pin retainers. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-11...
  • Page 120 AND THE FRAME DURING THIS PROCEDURE. SERIOUS INJURY MAY OCCUR. 1. Start the engine. 2. Operate the Frame Tilt function and crack open the bleed fitting when the cylinder is retracting. Fluid will escape. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-12...

  • Page 121: Stabilizer Cylinders

    8. Unplug the electrical connection for the right Stabilizer Pressure Sensor. 9. Carefully remove stabilizer cylinder from chassis. Ensure that the hoses and sensor plug clear the access opening and will be extracted with the cylinder. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-13...
  • Page 122 Once finished, operate both stabilizers through 4-5 complete cycles to ensure all air is bled out of the cylinders and that there are no leaks. Remove and stow the Maintenance Chock. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-14...
  • Page 123 8. Apply slight lifting pressure. 9. Remove the socket-head bolts that secure the platform to the carriage. 10. Carefully lift the platform away from the Platform Rotate Drive Unit assembly. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-15...
  • Page 124 8. Re-install all cables that connect the platform to the boom. 9. Start the machine and perform the adjustment procedure for the Rotation Sensor (see Section 2 of this manual). June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-16...

  • Page 125: Platform Rotate Drive Unit

    M16-2.0 eyebolts into the threaded holes around the inner ring. Spacers NOTE: Unit is heavy--use a lifting device of adequate capacity to move. Keyed Shim Carriage Weldment ART_3772 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-17...

  • Page 126: Platform Carriage

    3. Clean all hydraulic fittings, then tag all hoses for proper reassembly. 4. Disconnect all hydraulic hoses. Immediately plug and cap all openings to prevent contamination. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-18...
  • Page 127 10. Installation is reverse of removal. Apply one (1) drop of Loctite 242 or equivalent to mounting bolts. See the Introduction section of this manual for proper torque specifi- cations. Perform the following Shim Procedure before returning the machine to service. IMPORTANT! “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-19...
  • Page 128 See the Introduction section of this manual for proper torque specifications. Motor/Brake Pinion Depth Adjustment 1. Turn Engine off and turn the Battery Disconnect Switch off. 2. Remove the Platform Slide Drive Unit cover. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-20...
  • Page 129 Step 6. 5. If no free play is observed, loosen all four bolts and add one more shim (MEC part #22195) on each side. Tighten all four bolts to proper torque and attempt to manually rotate the gears on both the motor and the brake.
  • Page 130 Platform 8. Position the overhead hoist over the Level Cylinder Platform lift cylinder and securely attach the sling. Apply slight lifting pressure. ART_3788 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-22...

  • Page 131: Extend Cylinder

    A sling of 6 feet (2 m) approximate length capable of lifting 2000 lbs (908 kg) is also necessary. Base Boom Sections Section Section Section Forward Middle Rear Pin Boss Pin Boss Pin Boss Cylinder Assembly ART_3789 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-23...
  • Page 132 8. Remove the hoses from the Mid Section extension cylinder. Access these hoses from the rear of the boom. Immediately plug and cap all openings to prevent contamina- tion. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-24...
  • Page 133 2. Secure a sling around the Rear Pin Boss and attach it to a second forklift or hoist with a short lead (1-2 foot [25-50 cm]). Remove the support. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-25...
  • Page 134 14. Raise boom slightly and remove boom support apparatus from the End Section. 15. Operate boom extend and retract through 5 complete cycles to purge air from the system. 16. Inspect for leaks and loose fasteners. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-26...

  • Page 135: Boom

    2. Slide the End Section of the boom out approximately 6 feet (2 m). Posi- tion an overhead hoist over the End Section and attach a sling. ART_3795 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-27...
  • Page 136 90%, use a second hoist or fork lift to support the end of the Mid Section that remains inside the boom. ART_3798 13. Carefully extract the boom Mid Sec- tion completely. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-28...
  • Page 137 Mid Section ART_3804 242 or equivalent per bolt. See the Introduction section of this manual for proper torque specifications. Insert the Mid Section into the Base Section of the boom. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-29...
  • Page 138 Apply one (1) drop of Loctite® ART_3806 242 or equivalent per bolt. See the Introduction section of this manual for proper torque specifications. Insert the Mid Section into the Base Section of the boom. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-30...
  • Page 139 Push the End Section into the Mid Section of the boom. Install the Extend Cylinder. Install the Platform Beam and Platform Level Cylinder. Install the Platform Carriage. Install the Platform. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-31...

  • Page 140: Boom Lift Cylinder

    (one at a time) just Cylinder Plate enough to release the pressure behind it. Retighten the counterbal- ART_3779 ance valves once the oil flow slows to just a drip. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-32...
  • Page 141 Boom Lift Cylinder Wood Block Placement Engine Module removed for clarity ART_3781 “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-33...
  • Page 142 Boom Lift Cylinder machine in preparation for pulling the cylinder from the rear of the machine. Wood Engine Module Blocks removed for clarity ART_3783 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-34...
  • Page 143 10. From the Lower Control station, lift the boom slightly and remove the boom support. 11. Operate the Boom Lift Function up and down through 3-4 cycles to purge air from the system. 12. Check for leaks and wipe up any residual oil. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-35...
  • Page 144 14. With the boom stowed, fill the hydraulic tank to the proper level using the clean fil- tered hydraulic oil of the type specified in Section 1 of this manual. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-36...

  • Page 145: Engine Maintenance

    3. Remove old filter and replace with a new Oil Dipstick filter. Fuel Filter 4. Replace the cap to the air filter canister. Oil Drain Access Under ART_3774 Engine Module “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-37...

  • Page 146: Fuel Filter

    NOTE: The engine will crank for up to 10 seconds before the starter is cut out for a mandatory 30-second starter cool- down cycle. A red light will illuminate on the Base Control Station during the cool-down cycle. June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-38...

  • Page 147: Throttle Adjustment

    E A R A D S Spread a thin even coat of with lithium-based grease on the areas where the slide pads rub -- top, bottom and sides of Platform Beam. “Titan Boom 40-S” Service and Parts Manual June 2011 Page 3-39...
  • Page 148 Apply spray lubricant to latches and hinges. Wipe off excess lubricant. N G I N E Apply spray lubricant to throttle solenoid linkage pivot points. See Figure 3-13 on page 3-39. ART_3802 June 2011 “Titan Boom 40-S” Service and Parts Manual Page 3-40...
  • Page 149 EZ-Cal Flow Chart: Diagnostic, Option ......4-15 “Titan Boom 40-S” Service and Parts Manual...
  • Page 150 Troubleshooting Chart ......... . . 4-29 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4--2...
  • Page 151 • Hydraulic fluid contaminated with debris - filter change interval neglected. NOTE: MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Use only the recommended hydraulic fluid. Substituting a lower grade fluid will cause the machine to operate incorrectly and may lead to pump and drive motor failure.
  • Page 152 USE OF HIGH PRESSURE WASHING EQUIPMENT DIRECTLY ON THE MODULES CAN FORCE WATER INTO SEALED CONNECTION AND CAN CAUSE A TEMPORARY SYSTEM SHUT-DOWN. HIGH PRESSURE WASHING WITHIN THE VICINITY OF THE MODULES IS HIGHLY DISCOURAGED. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-4...
  • Page 153 FRAME TILT RIGHT P15-3 PLATFORM LEVEL UP P15-4 CHOKE/GLOW PLUG IDLE ENABLE P15-5 P15-6 PLATFORM LEVEL DOWN Diagnostic PLATFORM ROTATE CW P15-7 P15-8 HI-SPEED ENABLE PLATFORM ROTATE CCW P15-9 ART_3707 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-5...
  • Page 154 P9-3 GROUND (B-)TO MODULE P8-15 B- GROUND P9-4 BOOM EXTENSION SWITCH LOWER P14-3 BOOM RETRACT SWITCH REAR P14-10 Diagnostic ART_3803 For machines equipped with the optional Overload Sensing System August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-6...
  • Page 155 DRIVE HALL EFFECT SUPPLY P10-6 DRIVE HALL EFFECT GROUND P10-7 STEER LEFT EZ-Cal Port P10-8 STEER RIGHT P10-11 DRIVE ENABLE SWITCH P10-12 STEER/DRIVE ENABLE SUPPLY GP440 Module (inside Upper Control Box) ART_3706 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-7...
  • Page 156 This arrangement protects the ANALOG (AMP) system against voltage drop COMMON B+ conditions that can be detrimental to the electrical system. POSITIVE OUTPUT (B+) Supply To various circuits ART_3186 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-8...
  • Page 157 Figure 4-6: Onboard EZ-Cal Scan Tool & GP400 Module EZ Cal Onboard Scan Tool Lower Controls Box Matrix Module* GP400 Module Terminal EZ Cal Block Module *Machines equipped with the optional ART_3708 Overload Sensing System “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-9...
  • Page 158 P P E R O N T R O L S 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: •...
  • Page 159 ACCESS LEVEL 1 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.
  • Page 160 1.5 SEC 4A-7F 1.40 4L-8 DECEL 4D-14 1.5 SEC DELAY CLEAR LIFT COMP T 1.5 SEC 4L-9 4D-15 DELAY DYNAMIC DELAY XXX = DO NOT CHANGE ART_3711 0.0 SEC -0.0 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-12...
  • Page 161 TILT (OVERLOAD CE MODELS) ACTUAL ONLY 12 VOLT SUPPLY 2A-18 P5-3 2B-12 TILT INDICATOR LAMP P5-4 ENGINE RPM INTERLOCK NOT USED P5-5 STABILIZER DOWN LAMP INFORMATION P5-8 STABILIZER LOW PRESS ALARM ART_3712 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-13...
  • Page 162 .3 SEC 4A-7F 1.40 4L-8 DECEL 4D-14 1.5 SEC LIFT COMP T DELAY CLEAR 1.0 SEC 4L-9 4D-15 DELAY XXX DELAY DYNAMIC ART_3808 = DO NOT CHANGE 0.0 SEC -0.0 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-14...
  • Page 163 AUTO FRAME YES or NO M4-2 TILT LIGHT ACTUAL LOW FUEL LIGHT M4-3 2A-18 2B-12 M4-4 START INHIBIT LIGHT ENGINE RPM M4-5 OVERLOAD LIGHT INTERLOCK NOT USED INFORMATION ART_3809 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-15...
  • Page 164 Maximum speed setting In Min Slowest speed threshold TELESCOPE In Max Maximum speed setting Accel 1.5 sec. Ramp up time to maximum Decel 0.7 sec. Ramp down time to stop August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-16...
  • Page 165 3.0 deg DO NOT CHANGE Y Trip 3.0 deg DO NOT CHANGE TILT Delay Trip 2.0 sec. DO NOT CHANGE Delay Clear 0.5 sec Time before clear out-of-level shutdown “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-17...
  • Page 166 DO NOT CHANGE Delay Dynamic 0.0 sec. DO NOT CHANGE Motion 0=NO Select alarm setting to indiv. requirement 1: When selects when tilt alarm sounds ALARMS Tilt Alarm Elevated August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-18...
  • Page 167 Amount of time starter will operate before 30 Starter Delay 10 Seconds sec cool down INTERLOCKS CE Drive DO NOT CHANGE Allows use of all enable triggers for any MultiTrigger function “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-19...
  • Page 168 Formula used for controlling platform auto-level 2A7f Platform UD Actual output controlling auto-level 2A7g F Abandon Platform angle point when auto-level is abandoned 2A7h Last Stable Last recorded height when stabilizers were set. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-20...
  • Page 169 Time that stabilizers auto-retract during initial drive. 2B10 AUTO PLT ud NOT USED 2B11 AUTO FRAME Actual state, direction and % frame level when Auto-leveling 2B12 INTERLOCK Information on interlocks (shut downs) “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-21...
  • Page 170 On - off output from fuel tank sensor 2D1e Level Sensor P8-8 Right Actual pressure indicated between 1.5 and 4.5 volts 2D1f Stabilizer Down Press Sensor P8-9 Valve Current NOT USED 2D1g Measurement August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-22...
  • Page 171 Display changes from OFF to On when power signal is sent displayed separately Cal Date Date entered after last calibration completed Software Software revision number Max Battery Maximum battery voltage recorded. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-23...
  • Page 172 • Chassis is tilted beyond pre-set maximum. Use auto-level feature to level chassis or re-posi- tion 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 GP400. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-24...
  • Page 173 DEFAULTS/CUSTOMER to correct. Changing customer or model will require access level 1 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 40-S” Service and Parts Manual August 2012 Page 4-25...
  • Page 174 CHECK PLATFORM SWITCHES_______________________ Flash Code 2/2 • 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 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-26...
  • Page 175 • Height 2 sensor output over 4.5 volts or under .5 volts. Check height 2 sensor output using the EZ-Cal (height 2 sensor on CE option only). Possible sensor failure or wire connection fail- ure. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-27...
  • Page 176 • This message should not occur on Titan models; check for incorrect GP 400 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 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-28...
  • Page 177 Check help messages using the EZ-Cal tool. Also check for machines with optional Overload Sensing joystick inputs (see 2b1 - 2b7 in diagnostic chart) System only System interlock Check EZ-Cal HELP messages for interlock “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-29...
  • Page 178 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 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-30...
  • Page 179 Emergency Down switch failure Check/replace switch. Lowering valve not shifting Clean debris; Check for damage; Replace. Battery discharged/No charge output Check battery voltage, alternator output (14.5 volts); Clean, service and charge battery. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-31...
  • Page 180 Battery discharged/No charge output Check battery voltage, alternator output (14.5 volts) Check GP400 for 4-4 flash code. System interlock Check EZ-Cal HELP messages for interlock. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-32...
  • Page 181 --Lower Controls -- see I.D. #2c-1, P15-3 (up) or 2c-1, manually P15-6 (down) --Upper Controls -- see I.D. #2c-2, P14-11 (up) or 2c2, P14-12 (down) System Interlock Check EZ-Cal HELP message for interlock . PLATFORM ROTATE “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-33...
  • Page 182 Inspect, clean or repair System interlock Check EZ-Cal HELP messages for interlock Shims too tight Check shim clearance of Platform Carriage; should be .030" (.762 mm) total clearance top-to-bottom and side-to-side August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-34...
  • Page 183 Drive valve not energizing in one direction Check 12 volts to coil, check coil, check valve function only (located on top of drive pump). No output from GP400 Check switch position output from GP400 (see EZ-Cal ID# 2e1, P5-7 and P5-8). “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-35...
  • Page 184 Check cylinders, repair, replace. internal seals leaking Rear Wheel Steer Steer select toggle switch failure Check toggle switch. operates uncommanded 4-Wheel Steer Valve SVD2 not shifting Clean debris. Check for damage, replace. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-36...
  • Page 185 Lower control box loose Tighten four (4) lower control box mounting screws. Level sensor not properly calibrated See Calibration section for level sensor Calibration (located inside the GP400). instructions. “Titan Boom 40-S” Service and Parts Manual August 2012 Page 4-37...
  • Page 186 R O U B L E S H O O T I N G O T E S August 2012 “Titan Boom 40-S” Service and Parts Manual Page 4-38...
  • Page 187 Sensor Locations ..........5-17 “Titan Boom 40-S” Service and Parts Manual...
  • Page 188 O T E S August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-2...

  • Page 189: Hydraulic Schematics

    Gauge Port -- High Flow Motor -- Platform Rotate Gauge Port -- Low Flow Functions Manifold Gauge Port -- Charge Pressure Traction Manifold Gauge Port -- Drive Pressure Auxiliary Manifold “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-3...
  • Page 190 C H E M A T I C S Figure 5-1: Hydraulic Schematic, 1 of 2 *Lift cylinder and platform level cylinder pressure transducers only on machines equipped with the optional Overload Sensing System. August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-4...
  • Page 191 Y D R A U L I C C H E M A T I C S Figure 5-2: Hydraulic Schematic, 2 of 2 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-5...
  • Page 192 Y D R A U L I C C H E M A T I C S Figure 5-3: Function Manifold, MA1 SVD1 SVD2 PLG4 EPFR1 TITAN BOOM 40-S FUNCTIONS MANIFOLD ART_3697 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-6...

  • Page 193: Drive Manifold, Ma2

    Y D R A U L I C C H E M A T I C S Figure 5-4: Drive Manifold, MA2 ORF2 ORF3 ORF5 ORF4 Titan Bom 40-S DRIVE MANIFOLD ART_3698 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-7...

  • Page 194: Auxiliary Manifold, Ma3

    Y D R A U L I C C H E M A T I C S Figure 5-5: Auxiliary Manifold, MA3 EPFR2 Titan Boom 40-S AUXILLARY MANIFOLD ART_3699 August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-8...

  • Page 195: Electric Schematic, Lower Control Box, Standard

    A C H I N E LECTRICAL CHEMATICS TANDARD ACHINE Figure 5-6: Electric Schematic, Lower Control Box, Standard Machines TITAN BOOM 40-S ELECTRICAL SCHEMATICS PAGE 1 (LOWER CONTROL BOX) 22551 REV-0 GP400 MICROPROCESSOR (414) CAN BUS H (413) TO MAIN...

  • Page 196: Electrical Schematics - Standard Machine

    C H E M A T I C S T A N D A R D A C H I N E Figure 5-7: Electric Schematic, Chassis, Standard Machines August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-10...

  • Page 197: Electric Schematic, Control Cable, Standard

    C H E M A T I C S T A N D A R D A C H I N E Figure 5-8: Electric Schematic, Control Cable, Standard Machines “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-11...

  • Page 198: Electric Schematic, Upper Control Box, All

    HORN (383) BOOM ENABLE ENGINE START/STOP (419) (450) CAN BUS HI P12-1 HI SPEED CAN BUS LO P12-2 (515) (420) EMERGENCY STOP (73) (415) STEER MODE 2WHL/4WHL/CRAB (387) (388) August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-12...

  • Page 199: Electrical Schematics - Optional Overload Sensing System

    BOOM RET PROX SWITCH REAR (280) TERMINAL BLOCK MODULE (TBM) (36) START INHIBIT (74) (405) OVER (515) (16) LOAD (117) (15) DIAGNOSTIC DISPLAY (15) (405) (415) (00) (00) (15) (15) “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-13...

  • Page 200: Electric Schematic, Chassis, Option

    P T I O N A L V E R L O A D E N S I N G Y S T E M Figure 5-11: Electric Schematic, Chassis, Optional Overload Sensing System August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-14...

  • Page 201: Electric Schematic, Control Cable, Option

    P T I O N A L V E R L O A D E N S I N G Y S T E M Figure 5-12: Electric Schematic, Control Cable, Optional Overload Sensing System “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-15...

  • Page 202: Electric Schematic, Upper Control Box, All

    HORN (383) BOOM ENABLE ENGINE START/STOP (419) (450) CAN BUS HI P12-1 HI SPEED CAN BUS LO P12-2 (515) (420) EMERGENCY STOP (73) (415) STEER MODE 2WHL/4WHL/CRAB (387) (388) August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-16...
  • Page 203 BOOM RETRACT 2X PRESSURE TRANSDUCER STABILIZER CYLINDER PRESSURE *Only in machines equipped with Optional Overload Sensing System **Two (2) present on machines equipped with Optional Overload Sensing System ART_3705 “Titan Boom 40-S” Service and Parts Manual August 2012 Page 5-17...
  • Page 204 P T I O N A L V E R L O A D E N S I N G Y S T E M O T E S August 2012 “Titan Boom 40-S” Service and Parts Manual Page 5-18...
  • Page 205 Nut, M8 Nylock 19131 Puck 50016 Bolt, HHCS M8 x 55 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page B-29...
  • Page 206 Optional 14-Ft. Platform Left Side Rail Assembly, Optional 14ft. Platform TITAN BOOM 40-S ART_4190 June 2011 “Titan Boom 40-S” Parts Section Page B-30...
  • Page 207 Nut, M8 Nylock 19131 Puck 50016 Bolt, HHCS M8 x 55 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page B-31...
  • Page 208 Optional 14-Ft. Platform Sliding Gate Assemblies, Optional 14ft. Platform TITAN BOOM 40-S ART_4191 June 2011 “Titan Boom 40-S” Parts Section Page B-32...
  • Page 209 Nut, M10 Nylock 50294 Bolt, HHCS M6 x 45 22719 Gate Striker • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page B-33...
  • Page 210 Deck components removed for clarity. It is only necessary to remove the central Load Zone plate to access these parts. Platform/Cantilever Assembly TITAN BOOM 40-S ART_3627 June 2011 “Titan Boom 40-S” Parts Section Page B-34...
  • Page 211 Rotation Sensor Assembly -- See page 37 50263 Bolt, SHCS M16-2.00 x 110 50261 Washer, M16 Hardened • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page B-35...
  • Page 212 Rotational Sensor Assembly TITAN BOOM 40-S ART_3613 June 2011 “Titan Boom 40-S” Parts Section Page B-36...
  • Page 213 Cotter Pin, 1/16” x 0.75” 50326 Bolt, SHCS #10-32 X 0.5” • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page B-37...
  • Page 214 OTES June 2011 “Titan Boom 40-S” Parts Section Page B-38...
  • Page 215 Axle/Chassis Assembly ..........D-7 “Titan Boom 40-S” Parts Section...
  • Page 216 10 27 11 20 21 FRONT AXLE ASSEMBLY TITAN BOOM 40-S ART_3601 June 2011 “Titan Boom 40-S” Parts Section Page D-2...
  • Page 217 Bolt, CARB M8 x 20 50048 Nut, M8 Nylock 91953 P-Clip • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page D-3...
  • Page 218 20 21 REAR AXLE ASSEMBLY TITAN BOOM 40-S ART_3602 June 2011 “Titan Boom 40-S” Parts Section Page D-4...
  • Page 219 Bolt, CARB M8 x 20 50048 Nut, M8 Nylock 91953 P-Clip • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page D-5...
  • Page 220 Axle/Chassis Assembly TITAN BOOM 40-S ART_3623 June 2011 “Titan Boom 40-S” Parts Section Page D-6...
  • Page 221 50266 Lug nut, 5/8-18 91898 Tire/Wheel Assembly, Foam Filled, Right Hand • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page D-7...
  • Page 222 OTES June 2011 “Titan Boom 40-S” Parts Section Page D-8...
  • Page 223 Lift Cylinder Circuit ..........E-65 “Titan Boom 40-S” Parts Section...
  • Page 224 Platform Circuit ..........E-85 June 2011 “Titan Boom 40-S” Parts Section Page E-2...
  • Page 225 OTES • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-3...

  • Page 226: Hydraulic Components -- Chassis

    Hydraulic Components -- Chassis TITAN BOOM 40-S ART_3650 June 2011 “Titan Boom 40-S” Parts Section Page E-4...
  • Page 227 Hydraulic Fluid Tank Component Fittings not show or listed on this page. • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-5...
  • Page 228 Hydraulic Components -- Boom & Platform TITAN BOOM 40-S ART_3651 June 2011 “Titan Boom 40-S” Parts Section Page E-6...
  • Page 229 Carriage Slide Motor (see “Carriage Motor & Brake” on Page E-43) 92018 Platform Rotate Drive Unit • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-7...
  • Page 230 F ro n t O f M a c h in e 2SPD R e a r O f M a c h in e Functions Manifold Fittings TITAN BOOM 40-S ART_3638 June 2011 “Titan Boom 40-S” Parts Section Page E-8...
  • Page 231 50820 Fitting, MFFOR-MB-6-4 50858 Fitting, MFFOR-MB-MFFORT-4 50974 Fitting, Test Port, TPO-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-9...
  • Page 232 27 27 Functions Manifold Valves & Coils TITAN BOOM 40-S ART_3639 June 2011 “Titan Boom 40-S” Parts Section Page E-10...
  • Page 233 Valve, Flow-Reducing 92588 Valve, Flow-Reducing 92475 Orifice 91143 Coil 92589 Coil • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-11...
  • Page 234 12 behind plug behind plug Traction Manifold TITAN BOOM 40-S ART_3652 June 2011 “Titan Boom 40-S” Parts Section Page E-12...
  • Page 235 Orifice Plug, .090" 91017 Orifice Plug, .040" 92608 Orifice Plug, .052" • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-13...
  • Page 236 Auxilliary Manifold TITAN BOOM 40-S ART_3653 June 2011 “Titan Boom 40-S” Parts Section Page E-14...
  • Page 237 Check Valve Disk 92399 Check Valve Disk 92669 Valve Flow Regulator • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-15...
  • Page 238 Suction Manifold TITAN BOOM 40-S ART_3655 June 2011 “Titan Boom 40-S” Parts Section Page E-16...
  • Page 239 Suction Manifold 50966 Fitting, MB-MJ90-24-24 50967 Fitting, MB-MJ-20-20 50765 Fitting, MB-MJ-16-16 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-17...

  • Page 240: Hydraulic Pumps

    Hydraulic Pumps TITAN BOOM 40-S ART_3644 June 2011 “Titan Boom 40-S” Parts Section Page E-18...
  • Page 241 50843 Fitting, MFFOR-MB90-12-12 50841 Fitting, MFFOR-MB-8-8 50787 Fitting, MB-MJ90-16-20 17971 O-Ring • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-19...

  • Page 242: Charge Filter Assembly

    Charge Filter Assembly TITAN BOOM 40-S ART_3656 June 2011 “Titan Boom 40-S” Parts Section Page E-20...
  • Page 243 Charge Filter Assembly, , without fittings 92169 Filter Element 50849 Fitting, MFFOR-MB90-8-12 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-21...
  • Page 244 OPTION -- High Pressure Filters TITAN BOOM 40-S ART_4192 June 2011 “Titan Boom 40-S” Parts Section Page E-22...

  • Page 245: Option -- High Pressure Filter Assembly

    Filter Element, Short, 10GPM 92832 Guage, Filter Minder 50838 Fitting, MB-MFFOR-12-8 50849 Fitting, MB-MFFOR90-12-8 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-23...

  • Page 246: Emergency Power Unit Assembly

    Emergency Power Unit Assembly TITAN BOOM 40-S ART_3657 June 2011 “Titan Boom 40-S” Parts Section Page E-24...
  • Page 247 Emergency Power Unit 90997 Motor 90998 Pump 50847 Fitting, MFFOR-MB90-6-8 50848 Fitting, MFFOR-MB90-8-10 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-25...

  • Page 248: Wheel Motor Assembly

    Case Drain Port High Speed Port Brake Release Port Wheel Motor Assembly TITAN BOOM 40-S ART_3658 June 2011 “Titan Boom 40-S” Parts Section Page E-26...
  • Page 249 Fitting, MFFOR-MB-4-4 50671 Fitting, MFFOR-FFORX90-04-04 50656 Fitting, MFFOR-MB90-04-06 92166 O-Ring 92042 O-Ring • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-27...

  • Page 250: Hydraulic Tank Assembly

    Serial ~ #12400061 Serial #12400062 ~ Hydraulic Tank Assembly TITAN BOOM 40-S ART_3671 June 2011 “Titan Boom 40-S” Parts Section Page E-28...
  • Page 251 Breather Assembly 92355 Suction Strainer, .5” NPT 92356 Suction Strainer, 1.5” NPT • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-29...
  • Page 252 Control Module Side Engine Module Side Same each axle Steer Cylinders TITAN BOOM 40-S ART_3659 June 2011 “Titan Boom 40-S” Parts Section Page E-30...

  • Page 253: Steer Cylinder

    Steer Cylinder, without fittings 92616 Seal Kit 50858 Fitting, MFFOR-MB-MFFORT-4 50673 Fitting, MFFOR-MB90-04-04 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-31...
  • Page 254 Axle Lock Cylinders TITAN BOOM 40-S ART_3660 June 2011 “Titan Boom 40-S” Parts Section Page E-32...

  • Page 255: Axle Lock Cylinder

    50846 Fitting, MFFOR-MB90-4-6 50673 Fitting, MFFOR-MB90-4-4 92622 Valve, Counterbalance 7217 Bearing • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-33...
  • Page 256 Stabilizer Cylinders TITAN BOOM 40-S ART_3661 June 2011 “Titan Boom 40-S” Parts Section Page E-34...

  • Page 257: Stabilizer Cylinder

    Valve, Counterbalance, 3600 psi 92019 Valve, Counterbalance, 1000 psi 7217 Bearing 92629 Bearing, Spherical • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-35...

  • Page 258: Lift Cylinder

    Lift Cylinder TITAN BOOM 40-S ART_3662 June 2011 “Titan Boom 40-S” Parts Section Page E-36...
  • Page 259 92646 Pressure Transducer -- Optional Overload Sensing System Only 92630 Bearing • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-37...

  • Page 260: Extend Cylinder

    Extend CB Valve Retract CB Valve Extend Cylinder TITAN BOOM 40-S ART_3663 June 2011 “Titan Boom 40-S” Parts Section Page E-38...
  • Page 261 Fitting, MFFOR-MB45-06-06 50819 Fitting, MFFOR-MB45-8-8 92625 Valve, Counterbalance 92626 Valve, Counterbalance • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-39...

  • Page 262: Platform Level Cylinder

    Extend CB Valve Retract CB Valve Platform Level Cylinder TITAN BOOM 40-S ART_3664 June 2011 “Titan Boom 40-S” Parts Section Page E-40...
  • Page 263 92646 Pressure Transducer -- Optional Overload Sensing System Only 92631 Bearing • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-41...

  • Page 264: Carriage Motor & Brake

    Carriage Brake Carriage Motor ~ serial #12400044 serial #12400045 ~ #12400076 serial #12400077 ~ Carriage Motor & Brake TITAN BOOM 40-S ART_3665 June 2011 “Titan Boom 40-S” Parts Section Page E-42...
  • Page 265 Fitting, MBSPPOR-MJ-4-4 50986 Fitting, MB-MJ90-04-06 HDW90952 Fitting, MB-10 Plug 50986 Fitting, MB-MJ90-04-06 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-43...

  • Page 266: Platform Rotate Drive Unit

    Platform Rotate Drive Unit TITAN BOOM 40-S ART_3666 June 2011 “Titan Boom 40-S” Parts Section Page E-44...
  • Page 267 QTY DESCRIPTION 92018 Platform Rotate motor, without fittings 50665 Fitting, MB-MJ90-04-04 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-45...

  • Page 268: Drive Circuit

    D2 - A D4 - B D8 - B Drive Manifold D7 - A D1 - A Wheel Motor D3 - B D6 - B Drive Circuit TITAN BOOM 40-S ART_3667 June 2011 “Titan Boom 40-S” Parts Section Page E-46...
  • Page 269 Hose Assy, 1/2" x 43.5", 8G-10FFORX-8G8FFORX 50867 Fitting, MMFOR-MMFORH-8 Bulkhead Adapter • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-47...
  • Page 270 To Port 2SPD on Functions Manifold Engine Module Traction Manifold Port L2 Piston Pump Port A Port B Drive Pump/Drive Manifold Circuit TITAN BOOM 40-S ART_3678 June 2011 “Titan Boom 40-S” Parts Section Page E-48...

  • Page 271: Drive Pump/Traction Manifold Circuit

    Hose Assy, Port DRN to Port L2 on Drive Pump 50975 Fitting, MFFOR-MFFOR-FFORX-08 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-49...

  • Page 272: High Speed Circuit

    Functions Manifold High Speed Port Wheel Motor High Speed Circuit TITAN BOOM 40-S ART_3668 June 2011 “Titan Boom 40-S” Parts Section Page E-50...
  • Page 273 Hose Assy, 1/4" x 18", 4G4FFORX-4G4FFORX90L 52048 Hose Assy, 1/4" x 90", 4G4FFORX-4G4FFORX 50878 Fitting, MFFORT-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-51...

  • Page 274: Brake Circuit

    Brake Release Port Wheel Motor Brake Circuit TITAN BOOM 40-S ART_3669 June 2011 “Titan Boom 40-S” Parts Section Page E-52...
  • Page 275 Hose Assy, 1/4" x 17", 4G4FFORX-4G4FFORX 52047 Hose Assy, 1/4" x 112", 4G4FFORX-4G4FFORX 50878 Fitting, MFFORT-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-53...

  • Page 276: Drive Case Drain Circuit

    Hydraulic Tank Case Drain Port Wheel Motor Drive Case Drain Circuit TITAN BOOM 40-S ART_3670 June 2011 “Titan Boom 40-S” Parts Section Page E-54...
  • Page 277 Hose Assy, 3/8" x 38", 6G6FJX-6G6FJX 52053 Hose Assy, 3/8" x 42", 6G6FJX-6G8FJX90 50879 Fitting, MFFORT-6 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-55...

  • Page 278: Rear Axle Cylinder Circuit

    Functions Manifold P i l s s u P r e Pressure Pilot Pilot Pressure Rear Axle Cylinder Rear Axle Cylinder Circuit TITAN BOOM 40-S ART_3672 June 2011 “Titan Boom 40-S” Parts Section Page E-56...
  • Page 279 Hose Assy, 1/4" x 119", 4G4FFORX-4G4FFORX 52002 Hose Assy, 1/4" x 87", 4G4FFORX-4G4FFORX 50878 Fitting, MFFORT-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-57...

  • Page 280: Front Axle Cylinder Circuit

    AS AP Functions Manifold P i l r t A r t A Front Axle Cylinder Front Axle Cylinder Circuit TITAN BOOM 40-S ART_3673 June 2011 “Titan Boom 40-S” Parts Section Page E-58...
  • Page 281 Hose Assy, 1/4" x 31", 4G4FFORX-4G4FFORX90S 52004 Hose Assy, 1/4" x 29", 4G4FFORX-4G4FFORX90L 50878 Fitting, MFFORT-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-59...

  • Page 282: Stabilizer Circuit

    Functions Manifold Stabilizer Cylinder Stabilizer Circuit TITAN BOOM 40-S ART_3674 June 2011 “Titan Boom 40-S” Parts Section Page E-60...
  • Page 283 Hose Assy, 3/8" x 94", 6G6FFORX-6G6FFORX90 50964 Fitting, MMFOR-MMFORH90-6 Bulkhead Adapter 50963 Fitting, MMFOR-MMFORH90-4 Bulkhead Adapter • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-61...
  • Page 284 Functions Manifold Control Module Side Engine Module Steer Cylinders Side each axle Steer Circuit TITAN BOOM 40-S ART_3675 June 2011 “Titan Boom 40-S” Parts Section Page E-62...

  • Page 285: Steer Cylinder Circuit

    Hose Assy, 1/4" x 90", 4G4FFORX-4G4FFORX45 52026 Hose Assy, 1/4" x 38", 4G4FFORX-4G4FFORX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-63...
  • Page 286 Functions Manifold Boom Lift Cylinder Lift Circuit TITAN BOOM 40-S ART_3683 June 2011 “Titan Boom 40-S” Parts Section Page E-64...

  • Page 287: Lift Cylinder Circuit

    Hose Assy, 3/8" x 120" 6G6FFORX-6G6FFORX90 52017 Hose Assy, 1/2" x 120" 8G8FFORX-8G8FFORX45 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-65...
  • Page 288 Functions Manifold BR2 BE2 Boom Extend Cylinders Extend Circuit TITAN BOOM 40-S ART_3684 June 2011 “Titan Boom 40-S” Parts Section Page E-66...

  • Page 289: Extend Cylinder Circuit

    Hose Assy, 1/2" x 684" 8G8FFORX-8G8FFORX45 52016 Hose Assy, 3/8" x 684" 6G6FFORX-6G6FFORX90 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-67...
  • Page 290 Out to gear pump Out to piston pump Suction Manifold Port L2 Piston Pump-- Drive Gear Pump-- Functions Suction Port Suction Port Suction/Piston Pump Case Drain Circuit TITAN BOOM 40-S ART_3677 June 2011 “Titan Boom 40-S” Parts Section Page E-68...

  • Page 291: Suction/ Piston Pump Case Drain Circuit

    Hose Assy, 1" x 35" 16GS16FJX-16GS16FJX 52036 Hose Assy, 1.25" x 31" 20G20FJX-20G20FJX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-69...
  • Page 292 Functions Manifold Gear Pump In from Port T Hydraulic Tank Gear Pump/Functions Manifold & Functions Manifold Return Hoses TITAN BOOM 40-S ART_3681 June 2011 “Titan Boom 40-S” Parts Section Page E-70...

  • Page 293: Gear Pump To Functions Manifold Pressure

    Hose Assy, 3/8" x 185" 6G6FFORX-6G8FFORX 52054 Hose Assy, 3/4" x 24", 12G12FFORX-12G12FFORX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-71...
  • Page 294 Functions Manifold Piston Pump Charge Pressure Circuit TITAN BOOM 40-S ART_3680 June 2011 “Titan Boom 40-S” Parts Section Page E-72...

  • Page 295: Charge Pressure & Drive Signal Hoses

    Hose Assy, 1/4" x 185" 4G4FFORX-4G4FFORX 52030 Hose Assy, 1/4" x 195" 4G4FFORX-4G4FFORX90L • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-73...

  • Page 296: Charge Filter Circuit

    Out to Port E Charge Filter Piston Pump Engine Module Port E -- top In from Charge Filter Port F -- bottom Out to Charge Filter Charge Filter Circuit TITAN BOOM 40-S ART_3679 June 2011 “Titan Boom 40-S” Parts Section Page E-74...
  • Page 297 PART NO. QTY DESCRIPTION 52032 Hose Assy, 1/2" x 35", 8G8FJX-8G8FJX90 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-75...

  • Page 298: Emergency Power Unit Hoses

    Out to Port S Hydraulic Tank Emergency Power Unit Functions Manifold Emergency Power Unit Hoses TITAN BOOM 40-S ART_3682 June 2011 “Titan Boom 40-S” Parts Section Page E-76...
  • Page 299 Hose Assy, 1/2" x 28", 8G8FJX-8G8FFORX 52038 Hose Assy, 3/8" x 26", 6G6FFORX-6G6FFORX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-77...
  • Page 300 Functions Manifold Auxiliary Manifold Functions Manifold/Auxilary Manifold Hoses TITAN BOOM 40-S ART_3685 June 2011 “Titan Boom 40-S” Parts Section Page E-78...

  • Page 301: Functions Manifold/Auxiliary Manifold Hoses

    PART NO. QTY DESCRIPTION 52019 Hose Assy, 3/8" x 666", 6G6FFORX-6G6FFORX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-79...
  • Page 302 Platform Level Cylinder Auxiliary Manifold Platform Level Circuit TITAN BOOM 40-S ART_3686 June 2011 “Titan Boom 40-S” Parts Section Page E-80...

  • Page 303: Platform Level Circuit

    Hose Assy, 3/8" x 12", 6G6FFORX-6G6FFORX 52042 Hose Assy, 3/8" x 26", 6G6FFORX-6G6FFORX90S • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-81...

  • Page 304: Platform Rotate Circuit

    Auxiliary Manifold Platform Rotate Drive Unit Platform Rotate Circuit TITAN BOOM 40-S ART_3687 June 2011 “Titan Boom 40-S” Parts Section Page E-82...
  • Page 305 ITEM PART NO. QTY DESCRIPTION 52039 Hose Assy,1/4" x 257", 4G4FFORX-4G6FJX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-83...
  • Page 306 Carriage Brake Auxiliary Manifold Carriage Motor Carriage Slide Circuit TITAN BOOM 40-S ART_3688 June 2011 “Titan Boom 40-S” Parts Section Page E-84...

  • Page 307: Platform Circuit

    Hose Assy, 1/4" x 13", 4G4FFORX-4G4FFORX Serial #124000045-#12400059 50607 Hose Assy, 1/4" x 13", 4G4FJX-4G4FJX • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page E-85...
  • Page 308 OTES June 2011 “Titan Boom 40-S” Parts Section Page E-86...
  • Page 309 OPTION -- 3kVA Generator ........F-33 “Titan Boom 40-S” Parts Section...

  • Page 310: Module Installation

    Module Installation TITAN BOOM 40-S ART_3633 June 2011 “Titan Boom 40-S” Parts Section Page F-2...
  • Page 311 Block 50006 Washer, M10 Nordlock 50033 Bolt, HHCS M10 x 25 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-3...
  • Page 312 Control Module, 1 of 3 TITAN BOOM 40-S ART_3624 June 2011 “Titan Boom 40-S” Parts Section Page F-4...
  • Page 313 Bolt, HHCS M10 x 20 50006 Washer, M10 Nordlock 50049 Nut, M10 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-5...
  • Page 314 Control Module, 2 of 3 TITAN BOOM 40-S ART_3625 June 2011 “Titan Boom 40-S” Parts Section Page F-6...
  • Page 315 Emergency Power Unit -- See Section E 50049 Nut, M10 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-7...
  • Page 316 Control Module, 3 of 3 TITAN BOOM 40-S ART_3626 June 2011 “Titan Boom 40-S” Parts Section Page F-8...
  • Page 317 50028 Bolt, HHCS M6 x 20 90749 Plug 92033 Buss, 12-Terminal • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-9...
  • Page 318 Engine Module, 1 of 4 TITAN BOOM 40-S ART_3628 June 2011 “Titan Boom 40-S” Parts Section Page F-10...

  • Page 319: Engine Module, Drawing 1

    Bolt, HHCS M10 x 20 50006 Washer, M10 Nordlock 50049 Nut, M10 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-11...
  • Page 320 9 10 22 23 x3--sides and top bottom Engine Module, 2 of 4 TITAN BOOM 40-S ART_3629 June 2011 “Titan Boom 40-S” Parts Section Page F-12...
  • Page 321 Nut, M6 Nylock 50219 Bolt, HHCS 3/8-16 x .75 50006 Washer, M10 Nordlock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-13...
  • Page 322 22 23 32 33 37 18 38 33 Engine Module, 3 of 4 TITAN BOOM 40-S ART_3630 June 2011 “Titan Boom 40-S” Parts Section Page F-14...
  • Page 323 Bolt, HHCS 1/2 x 1.5” 50127 Bolt, SHCS M10 x 30 17971 O-Ring • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-15...
  • Page 324 20 21 22 Throttle Linkage Components 25 26 27 26 28 29 28 Engine Module, 4 of 4 TITAN BOOM 40-S ART_3631 June 2011 “Titan Boom 40-S” Parts Section Page F-16...

  • Page 325: Engine Module, Drawing 2

    50047 Nut, M6 Nylock 91591 Hose Mount 18257 Bar, Radiator Mount • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-17...

  • Page 326: Exhaust Components

    Exhaust Components TITAN BOOM 40-S ART_3632 June 2011 “Titan Boom 40-S” Parts Section Page F-18...
  • Page 327 Exhaust Pipe 50031 Bolt, HHCS M8 x 25 50048 Nut, M8 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-19...
  • Page 328 Chassis Components, 1 of 3 TITAN BOOM 40-S ART_3634 June 2011 “Titan Boom 40-S” Parts Section Page F-20...

  • Page 329: Chassis Components, Drawing 1 Of 3

    Bottom Pan 50006 Washer, M10 Nordlock 50034 Bolt, HHCS M10 x 30 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-21...
  • Page 330 Chassis Components, 2 of 3 TITAN BOOM 40-S ART_3635 June 2011 “Titan Boom 40-S” Parts Section Page F-22...
  • Page 331 Bolt, HHCS M8 x 15 50001 Washer, M8 Std. 22512 Hose Guard • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-23...
  • Page 332 Chassis Components, 3 of 3 TITAN BOOM 40-S ART_3636 June 2011 “Titan Boom 40-S” Parts Section Page F-24...
  • Page 333 92535 Trim Lock 22615 Pivot Guard -- CE option package only • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-25...
  • Page 334 Stabilizer Installation TITAN BOOM 40-S ART_3640 June 2011 “Titan Boom 40-S” Parts Section Page F-26...

  • Page 335: Stabilizer Components

    Washer, M12 Nordlock 22207 18152 Pin Retainer Stabilizer Cylinder -- See Section E • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-27...
  • Page 336 50 Amp Disconnect Auto-Reset Switch Breaker Lower Control Box Engine Engine Relays CAN-Tilt Angle Sensor To Rear Of Boom To Top of Boom Wiring Harness -- Chassis TITAN BOOM 40-S ART_3641 June 2011 “Titan Boom 40-S” Parts Section Page F-28...

  • Page 337: Wiring Harness -- Chassis

    Cable, Red 2-Gauge, 103” 55003 Cable, Red 2-Gauge, 130” 55004 Cable, Red 2-Gauge, 30” • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-29...
  • Page 338 Upper Control Box Auxilliary Manifold Valve Current Control Module (VCCM) Wiring Harness -- Boom & Platform TITAN BOOM 40-S ART_3642 June 2011 “Titan Boom 40-S” Parts Section Page F-30...

  • Page 339: Wiring Harness -- Boom & Platform

    85 ft. Cable, Power To Platform (not shown; follows path similar to Item #1) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-31...
  • Page 340 Power Out to Junction Box Return -- To T in E-Down Suction Port at Tank Case Drain-- To T in Case Drain Port at Tank 3kW Generator Option TITAN BOOM 40-S ART_3694 June 2011 “Titan Boom 40-S” Parts Section Page F-32...

  • Page 341: Option -- 3Kva Generator

    Plug, 30A 110V Female (not shown; attached to #16 and plugs into Power To Platform 92496 connection) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “Titan Boom 40-S” Parts Section June 2011 Page F-33...
  • Page 342 OTES June 2011 “Titan Boom 40-S” Parts Section Page F-34...
  • Page 343 Decals, Titan Boom 40-S ANSI ........
  • Page 344 Inside both sides of gate inside of gate only both sides of platform both sides of gate inside of gate only both sides of cylinder inside module between tie-down straps ART_3390 March 2011 “Titan Boom 40-S” Parts Section Page G-2...
  • Page 345 Decals, Titan Boom 40-S ANSI ITEM PART NO. QTY DESCRIPTION 92050 Decal, MEC TITAN BOOM, Boom 92049 Decal, MEC TITAN BOOM, Toeboard 92051 Decal, MEC TITAN BOOM, Module 92054 Decal, Patents Pending 92044 Decal, Platform Controls 92056 Decal, Instructions 92233...
  • Page 346 92114 22474 -- Paint Stencil for Load Zone 92236 4 places - not a decal 92542 11026730 4 Places 22484 -- Metal Plates on Pallet Stops 2 places 11026730 90751 ART_3391 March 2011 “Titan Boom 40-S” Parts Section Page G-4...
  • Page 347 Decals, Titan Boom 40-S CE ........
  • Page 348 Chock both sides of platform each both sides of gate side inside of gate only both sides of cylinder inside module between tie-down straps each side each side ART_3521 each side March 2011 “Titan Boom 40-S” Parts Section Page H-2...
  • Page 349 Decals, Titan Boom 40-S CE ITEM PART NO. QTY DESCRIPTION 92050 Decal, MEC TITAN BOOM, Boom 92049 Decal, MEC TITAN BOOM, Toeboard 92051 Decal, MEC TITAN BOOM, Module 92054 Decal, Patents Pending 92044 Decal, Platform Controls 92056 Decal, Instructions 92233...
  • Page 350 OVERHEAD POWER LINES ON POLES OVERHEAD POWER LINES ON TOWERS NO GO ZONE NO GO ZONE FOR THE PLATFORM OR PERSON IN THE PLATFORM FOR THE PLATFORM OR PERSON IN THE PLATFORM 9910 ART_3520 91325 March 2011 “Titan Boom 40-S” Parts Section Page H-4...
  • Page 351 Service Parts Order Form Fax to 559-263-9631 Please fill out completely Date: ______________________________ Ordered By: _________________________ Account: ___________________________ Your Fax No.: _______________________ Bill to: _____________________________ Ship to: ____________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ Ship VIA___________________________ Purchase Order Number ______________ **Fed Ex shipments require Fed Ex account number **All orders MUST have a Purchase Order Number Part Number...
  • Page 352 OTES...
  • Page 353 MEC Aerial Platform Sales Corp’s then current flat rate, provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp. and is found upon inspection by MEC Aerial Platform Sales Corp. to be defective in material and/or workmanship.
  • Page 354 Aerial Platform Sales Corp. 1401 S. Madera Avenue • Kerman, CA 93630 USA Ph: 1-800-387-4575 • 1-559-842-1510 • FAX 1-559-842-1520 E-mail:info@mecAWP.com • Web:www.mecAWP.com Speed Level™ is a trademark of MEC.

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