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"3072ES / 3772ES / 3772ES HD" Service & Parts Manual

October 2008

Page 4-1

SECTION 4 ................................................................................................................................ 4-1

TROUBLESHOOTING ................................................................................... 4-1

General Troubleshooting Tips ........................................................................ 4-2
Electrical System Troubleshooting ............................................................... 4-4
EZ-Cal Scan Tool ............................................................................................. 4-8
EZ-Cal Adjustment ........................................................................................ 4-14
EZ-Cal Setup ................................................................................................. 4-16
EZ-Cal Diagnostics ....................................................................................... 4-17
EZ-Cal Outrigger Test Mode ........................................................................ 4-18
Retrieve Mode And Help Messages From The Ez-Cal ................................ 4-21
EZ-Cal HELP Messages ................................................................................ 4-24
Trouble Table ................................................................................................. 4-30
Hydraulic Pressure Adjustment Procedures .............................................. 4-35
Troubleshooting Battery Charger ................................................................ 4-38

SECTION 4

TROUBLESHOOTING

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Summary of Contents for 3072ES

Page 1: ...SERVICE AND PARTS MANUAL 3072ES 3772ES 3772ES HD October 2008 ART_2546 15 15 Serial Number Range 11211001 Present Part 91778 R1...

Page 2: ...ts Table of Contents All Update Table of Contents Section C C 2 Update illustration C 3 Update parts list C 4 Update illustration C 5 Update parts list C 6 Update illustration C 7 Update parts list C...

Page 3: ...achine Components Compartments VI Primary Machine Components Locator VII Specifications ANSI Models IX Specifications CE Models IX LUBRICATION X SECTION 1 HYDRAULICS 1 1 Hydraulic Fluid 1 2 Hydraulic...

Page 4: ...2 10 Lower Controls 2 10 Upper Controls 2 11 Alarms and Switches 2 12 Limit Switch 2 12 Continuity Checks 2 14 Motor Controller 2 16 SECTION 3 MECHANICAL COMPONENTS 3 1 Torque Specifications 3 2 Base...

Page 5: ...The Ez Cal 4 21 EZ Cal HELP Messages 4 24 Trouble Table 4 30 Hydraulic Pressure Adjustment Procedures 4 35 Troubleshooting Battery Charger 4 38 SECTION 5 SCHEMATICS 5 1 Hydraulic Schematic 5 2 Main H...

Page 6: ...ctober 2008 3072ES 3772ES 3772ES HD Service Parts Manual Page iv Parts Manual SECTION A CONTROL BOXES SECTION B PLATFORM AND RAILS SECTION C SCISSORS SECTION D AXLES SECTION E HYDRAULICS SECTION F BAS...

Page 7: ...roper operating and maintenance procedures Only trained authorized personnel should be allowed to operate or service this machine Service personnel should read and study the Operator s Manual and Serv...

Page 8: ...NJURY OR DEATH MEC s policies and procedures demonstrate our commitment to Quality and our relentless ongoing efforts towards Continuous Improvement due to which product specifications are subject to...

Page 9: ...al failure and resulting downtime is reduced to a minimum NEVER PERFORM SERVICE ONTHE MACHINE WITHTHE PLATFORM ELEVATEDWITHOUT FIRST BLOCKINGTHE SCISSOR ASSEMBLY USINGTHE MAINTENANCE LOCK Block the sc...

Page 10: ...the positive battery cable first If contact is made between the positive side of the battery and a metal surface on the machine when the negative cable is installed a spark will occur This can cause...

Page 11: ...Work Platform Extension Deck Guardrails Entry Ladder Limit Switch Outriggers option Scissor Assembly Beams Maintenance Lock Battery Compartment Pump Compartment Lift Cylinder Lift Cylinder Document Ca...

Page 12: ...or Alarm 12 Volt DC Battery 3772ES Emergency Lowering 3772ES Emergency Lowering Switch Battery Pack Eight 6 Volt DC Batteries Lower Controls Hydraulic Pump and Motor Hydraulic Reservoir Hydraulic Flui...

Page 13: ...5 C E F Wheels Tires intro 3 F Hubs intro 1 3 D F Slide Block intro 3 C Emergency Lowering 1 2 E F Hoses Cables 1 2 3 E F Outrigger Option 1 3 4 5 E F Power to Platform B F Power Module Battery Pack i...

Page 14: ...2 Amp 700 W Timed Shutoff 120 Volt AC 50 60 Hz 18 Amp 240 Volt AC 50 60 Hz 9 Amp 48 Volt DC 32 Amp 1500 W Timed Shutoff 8 h p 6 kW 3600 rpm Multi disc Dual Rear Wheel 48 Volts DC 36 0 ft 30 0 ft 54 in...

Page 15: ...ft 54 in 108 5 in 78 5 in 3 2 1 000 lb 400 lb 153 5 in 107 in 56 in 44 7 in 6 0 in 46 5 in 117 25 in 72 in 86 0 in 60 5 in 73 25 in 170 5 in 9 5 in 7868 lb 0 0 4 mph 0 3 0 mph 36 sec 28 sec 45 24 2 1...

Page 16: ...Purge old grease Lithium N L G 2 EP Purge old grease With platform in the stowed position fill to the middle of the sight gauge with ISO32 or equivalent Normal usage change EVERY SIX MONTHS or 500 HO...

Page 17: ...CS 1 1 Hydraulic Fluid 1 2 Hydraulic System components 1 4 Wheel Drive 1 4 Parking Brake and Towing Circuit 1 11 Emergency Systems And Procedures 1 12 Steering Circuit 1 13 Platform Lift Circuit 1 14...

Page 18: ...TO AVOID POTENTIAL HAZARDS TO HEALTH HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN DAMAGE EYES AND JUNE CAUSE SERIOUS INJURY OR BLINDNESS FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISI...

Page 19: ...hoses removed 8 Reinstall all hoses removed in the previous steps 9 Fill hydraulic reservoir with filtered fresh hydraulic fluid refer to Lubrication Chart 10 Loosen output hose fittings at pump to fl...

Page 20: ...re that the filter be replaced more often Hydraulic Pump Note Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure Refer to Section 3 for Remove and Replace instructions An electric mo...

Page 21: ...t coating of fluid to all new seals prior to installation Install the high pressure seal into the groove in the pilot of the housing 2 Place the shaft on a clean flat surface with the output end facin...

Page 22: ...eals prior to installation Motor Section Assembly 1 Install the drive link into the end of the shaft with the tapered end facing up Place the rear housing seal in the groove in the housing Place the d...

Page 23: ...t Washers 2 16 Thrust Bearing 17 Housing 18 Rear Housing Bearing 19 Drive Link 20 Divider Plate 21 Rotor Assembly 22 Manifold 23 Commutator Assembly 24 Endcover Piston 25 Piston Spring 26 Endcover 27...

Page 24: ...motor Remove the drive link from the motor and set aside 5 Clean all parts in an oil based solvent and dry using compressed air Assembly 1 Apply a light coating of fluid to all new seals prior to inst...

Page 25: ...screws and torque to 45 ft lbs 61 Nm 7 Install the drive link into the end of the shaft with the tapered end facing up Place the body seals in the grooves in both sides of the rotor Place the rotor on...

Page 26: ...k Stampings 2 20 Piston 21 Springs 25 22 Spacer Shims 1 3 23 Rear Housing 24 Capscrews 8 25 Drive Link Spacer 26 Drive Link 27 Rotor Assembly 28 Manifold 29 Commutator Assembly 30 Endcover Piston 31 P...

Page 27: ...vent machine from moving AFTER RELEASINGTHE BRAKES THERE IS NOTHINGTO STOP THE MACHINE STRAVEL MACHINEWILL ROLL FREELY ON SLOPES BE ON GUARD AGAINST RUNAWAY ART_2423 Hand Pump Release Valve To Reset B...

Page 28: ...controlled by a flow control orifice located under the pressure hose fitting on the lift cylinder manifold s Opening the down valve on the lift cylinder s allows hydraulic fluid to return to the reser...

Page 29: ...ther via a tie rod Steering is accomplished hydraulically using two 2 double acting cylinders and a 4 way 3 position solenoid operated hydraulic directional control cartridge valve Maximum steering pr...

Page 30: ...down holding valve The normally closed valve is 2 position 2 way solenoid operated and holds the platform in position by preventing hydraulic fluid from returning to the reservoir while the valve is...

Page 31: ...ed Fitting Hose Clamp 3772 LOWER LIFT CYLINDER Down Valve and Solenoid Return Hose 2 Barbed Straight Fittings and Hose Clamps Pressure Hose Pressure Sensor Tee Fitting Orifice Vent Hose Barbed Elbow F...

Page 32: ...ifold The Optional outrigger manifold is located in the Control Module behind the Lower Control Box Cylinders Four 4 double acting type hydraulic cylinders ART_2554 PORT ORS OUTRIGGER MANIFOLD PORT OR...

Page 33: ...for a list of hardware specific to the cylinder being repaired 1 Tag hoses for proper reassembly 2 Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination 3 Remove cylinder from th...

Page 34: ...d and piston can be removed Be sure the shaft and vise are both clean before using 4 Remove nut at the end of the shaft and pull head and piston off of the rod 5 Remove all seals from the head and pis...

Page 35: ...3 Place a small amount of fluid on the inside seals of the head and reinstall it on the shaft by slipping head over the piston end of the shaft being very careful not to damage the inside seals 4 Plac...

Page 36: ...built up contaminants then blow out all passages with clean compressed air 2 Inspect the manifold for cracks thread damage and scoring where O rings seal against internal and external surfaces 3 Wash...

Page 37: ...LK HIGH TORQUE 313 YEL BLK HAND PUMP BRAKE RELEASE STEER RIGHT 107 ORG WHT HIGH SPEED 213 YEL WHT TO TANK RIGHT FRONT A LEFT FRONT B RIGHT REAR B LEFT REAR A LEFT FRONT A BRAKE PORT COUNTERBALANCE VAL...

Page 38: ...October 2008 3072ES 3772ES 3772ES HD Service Parts Manual Page 1 22...

Page 39: ...2 Diagnostic LED 2 2 Battery Charge Indicator 2 2 Master Disconnect Switch 2 2 Deutsch Connectors 2 3 Batteries 2 4 Battery Replacement 2 6 Battery Charger 2 7 Controls 2 10 Lower Controls 2 10 Upper...

Page 40: ...ed by position and direction of the upper controls joystick Emergency Lowering 3772ES The 3772ES utilizes a toggle switch and independent 12 Volts DC battery to open the down valve on the lift cylinde...

Page 41: ...or a wire hook to pull the locking wedge from the connector Replace worn or damaged parts Replace or re crimp wires and contacts Locking Fingers Remove the locking wedge as outlined above Using the r...

Page 42: ...tery Maintenance in storage Follow these procedures for maintenance of battery on a machine not in use Keep battery clean Electrolyte of wet lead acid type flooded batteries should be checked regularl...

Page 43: ...shortened battery life Excessive water usage can indicate that a battery has been overcharged has been subjected to excessively high temperatures or is nearing the end of its service life Battery Pre...

Page 44: ...ove a battery 1 Turn OFF the Master Disconnect switch 2 Disconnect the battery cables and remove battery hold down hardware 3 Lift the battery from the compartment put the battery aside and dispose of...

Page 45: ...hey will not be driven over stepped on tripped over or otherwise subjected to damage or stress Refer to the Operator s Manual for detailed charging instructions Refer to Section 4 Troubleshooting Refe...

Page 46: ...ht Loose or corroded wires and fittings will cause an output error 2 Keep the charger fins clean to improve cooling If fins are covered with debris the charger s over temperature protection system may...

Page 47: ...tery chargers working in line to provide 48 Volts DC to the battery pack ART_2374 HB1500 48 ALL LED S MUST BE OFF BEFORE CONNECTING TO AC POWER INDUSTRIAL BATTERY CHARGER FAULT STATUS HSB1500 48 AUTO...

Page 48: ...itch to set machine operation to the upper controls PLATFORM or the lower controls BASE When the switch is set to PLATFORM all lower controls functions are disabled with the exception of the Emergency...

Page 49: ...ith the Mode Select switch set to LIFT squeeze the Enable bar and pull back on the Joystick Lift speed is controlled by the amount that the Joystick is pulled Push forward on the Joystick to lower the...

Page 50: ...Emergency Lowering switch is used to lower the plat form in case of power or valve failure The switch receives power from a 12 Volts DC battery that is dedicated to the Emergency Lowering system and...

Page 51: ...HD Models Each of the four outriggers has a stowed switch Indicates full retraction of the outrigger cylinder Drive Function The machine will drive when the Outrigger Stowed switch on all four outrig...

Page 52: ...ggle Switch 1 Pole 3 Position Disconnect wires Connect first probe of ohm meter to common terminal Connect second probe of ohm meter to top terminal With the toggle UP or MIDDLE there should be a low...

Page 53: ...open position there should be no reading With the toggle UP closed there should be a low resistance With the toggle DOWN closed there should be no reading Test bottom position Move second probe to bot...

Page 54: ...d other probe to closed contact low resistance should be seen Move limit switch arm and no resistance should be seen Check Emergency Stop Button Disconnect wires Connect one probe of ohm meter each te...

Page 55: ...ercarriage 3 3 Hoses and Cables 3 3 Raising the Machine 3 4 Tires Wheels 3 5 Changing Tires Wheels 3 5 Drive Motors 3 6 Front Drive Motors 3 6 Rear Drive Motor with Brakes 3 6 Steer Cylinder 3 7 Platf...

Page 56: ...0 M12 X 1 75 M14 X 2 00 M16 X 2 50 M18 X 2 50 M20 X 2 50 M22 X 2 50 M24 X 3 00 M27 X 3 00 M3 X 3 00 6 16 29 52 85 130 172 247 332 423 637 872 8 20 35 62 103 158 210 301 404 517 779 1066 8 21 5 39 70 1...

Page 57: ...rackets Check for cylinder pins that turn in their mounting which will indicate sheared retaining pins HOSES AND CABLES Note Refer to Parts Section E for detailed hydraulic hose diagrams Inspect all h...

Page 58: ...he machine 1 Move machine to a firm level surface capable of supporting the weight of the machine 2 Chock tires on one end of machine and raise the other end of machine 3 Position a jack at the end of...

Page 59: ...RES ARE EXTREMELY HEAVY CARE MUST BE TAKEN TO AVOID PERSONAL INJURY Always block the wheels before raising the machine When a tire change is necessary follow these tips 1 While the machine is on the g...

Page 60: ...e Machine 2 Remove the wheel and tire assembly to access drive motor 3 Remove the hub from the drive motor shaft 4 Disconnect the cylinder end and tie rod from the motor housing 5 Turn the motor housi...

Page 61: ...hoses and cap them 3 Remove the nut and bolt holding the steer cylinder to the motor mounting bracket 4 Remove the pin and cotter pin holding the steer cylinder to the steer axle tie rod 5 Carefully...

Page 62: ...Remove any components that will obstruct the scissor slide path 4 Remove the bolts from both fixed blocks at the rear of the platform 5 Lift the rear of the platform until the fixed blocks are clear...

Page 63: ...Use a suitable lifting device to support the lift cylinder Attach the lifting device to the cylinder body Lifting by the rod end will cause the cylinder to extend 5 Remove the upper retaining plate c...

Page 64: ...Remove the bolts from the Limit Speed switch bracket and move the switch and bracket out of the way 6 Remove the stationary mounts 7 Carefully lift until the rear of the scissor assembly is clear 8 S...

Page 65: ...ndicator light will signal that the outriggers are fully retracted If the slope of the terrain is in excess of the outrigger s leveling capabilities the outrigger con trol system will continue to atte...

Page 66: ...October 2008 3072ES 3772ES 3772ES HD Service Parts Manual Page 3 12...

Page 67: ...tem Troubleshooting 4 4 EZ Cal Scan Tool 4 8 EZ Cal Adjustment 4 14 EZ Cal Setup 4 16 EZ Cal Diagnostics 4 17 EZ Cal Outrigger Test Mode 4 18 Retrieve Mode And Help Messages From The Ez Cal 4 21 EZ Ca...

Page 68: ...er is in the tripped OFF position Common Causes of Hydraulic System Malfunctions Hydraulic fluid level is too low Incompatible hydraulic fluids mixed destroying the additives and causing varnish build...

Page 69: ...RQUE 313 YEL BLK HAND PUMP BRAKE RELEASE STEER RIGHT 107 ORG WHT HIGH SPEED 213 YEL WHT TO TANK RIGHT FRONT A LEFT FRONT B RIGHT REAR B LEFT REAR A LEFT FRONT A BRAKE PORT COUNTERBALANCE VALVES PULL V...

Page 70: ...controlled modules the Matrix Module P600 Motor Control Module and the GP400 Processor The modules communicate through low voltage digital signal technology called CAN bus communication The modules a...

Page 71: ...d P2 9 not used P2 10 Potentiometer P2 11 Potentiometer P2 12 Switch Supply Matrix Module inside Upper Control Box 21 510 410 Serial Number 11211001 11211036 ART_2574 ART_2575 Matrix Module inside Upp...

Page 72: ...Selected P1 6 Output to EMERGENCY STOP Circuit for Module Activation P7 1 CAN BUS H P7 2 CAN BUS L P7 3 Ground P6 1 CAN BUS H P6 2 CAN BUS L P6 3 Ground P8 1 48 Volts DC INPUT P8 2 48 Volts DC INPUT...

Page 73: ...8 6 not used P8 7 not used P8 8 not used P8 9 not used P8 10 not used P8 11 not used P8 12 not used P8 13 Ground P8 14 not used P8 15 not used OUTRIGGER LIMIT SWITCHES P15 1 STOWED Rear Left P15 2 STO...

Page 74: ...the system up put the battery disconnect switch in the ON position reset the Base and the Platform emergency stop switches at the upper controls turn the key switch to ON at the lower controls select...

Page 75: ...r to HELP Menu on page 4 21 Scrolling Messages The EZ Cal will provide a scrolling message of the current error followed by a log of previous errors that may have occurred within recent operation Refe...

Page 76: ...RETRACT 55 LEVEL 35 DEBOUNCE 0 35 sec INITIAL 0 5 sec TILT FILTER 8 X TILT TARGET 0 2 Y TILT TARGET 0 2 TILT SLACK 0 3 DOWN 0 OUT 50 IN 50 ACCEL 1 0 sec DECEL 1 0 sec GROUND MODE TILT OVERLOAD DRIVE L...

Page 77: ...d past 1 2 ON retracted OFF extended past 1 2 ON retracted OFF extended past 1 2 ON retracted OFF extended past 1 2 ON weight on all 4 legs OFF 1 or more legs up P4 P5 1 P5 2 P5 3 P5 4 P5 5 P5 6 P5 7...

Page 78: ...VEL 35 DEBOUNCE 0 35 sec INITIAL 0 5 sec TILT FILTER 8 X TILT TARGET 0 2 Y TILT TARGET 0 2 TILT SLACK 0 3 DOWN 0 OUT 50 IN 50 ACCEL 1 0 sec DECEL 1 0 sec GROUND MODE TILT OVERLOAD DRIVE LIFT TILT 1 WH...

Page 79: ...powered up ON Valve activated ON Valve activated ON Valve activated ON Valve activated ON Valve activated ON Alarm activated ON Valve activated ON Valve activated ON Voltage OFF No Voltage ON Base Con...

Page 80: ...ght Speed Drive Compensation Drive Comp Elevated Accel Decel Not Used 5 100 5 100 1 5 sec 1 0 sec 101 Not Used 0 2 0 sec 5 23 5 23 1 5 sec 1 0 sec 5 60 0 not used 0 not used 1 2 sec 0 5 sec ANSI 101 C...

Page 81: ...E 12 0 ANSI 0 CE 74 Prevents drive when outrigger legs are down Test feature see outrigger section Maximum speed potential Extend speed after pads touch down Maximum speed potential Compensates for sw...

Page 82: ...CE procedure 1 0 sec 0 10 sec Disabled 10 CE procedure 100 95 10 0 sec 0 0 sec 0 2 sec Function shut down tilted when platform stowed Function shut down tilted when platform elevated CE Option only fo...

Page 83: ...2A 14c 2A 14d MODE Supply Valve Supply Motor Volts Motor 1 Temperature Tilt Tilted Y N Height Load Overloaded Y N Last Moved Elevated Y N Outrigger O R Retracted Y N O R Extended Y N O R Status O R T...

Page 84: ...nd valve in that leg The automatic stop indicates an operational pressureswitch If the pressure switch was not functional the outrigger leg would continue to extend and lift the machine until it reach...

Page 85: ...rm controls Platform Down limit switch ON platform down OFF platform elevated Down selected from base controls ON Down activated Not used Outrigger retracted L R ON retracted OFF extended beyond 1 2 O...

Page 86: ...ed Steer Left signal B ON valve activated Drive FWD signal B ON valve activated Drive Rev signal B ON valve activated Alarm signal B ON alarm activated High Torque signal B ON valve activated High Spe...

Page 87: ...ble How ever it is recommended to use an EZ Cal to diagnose problems and not rely on the LED The EZ Cal provides a much higher detail of information MODE Message Connect the EZ Cal see illustration Th...

Page 88: ...ger switch was closed at power on or closed for too long with no function selected check trigger switch FORWARD REVERSE A platform drive function is operating normally FORWARD LEFT FORWARD RIGHT REVER...

Page 89: ...D During descent the system is configured to stop movement to provide an armguard delay release and re select DOWN to continue lowering CE option only TOO HOT The EZLIFT heatsink has reached 75 c prev...

Page 90: ...powered down NOTE When using the LED to attempt diagnosis please note that a DUAL FLASH code is indicated The LED will flash on off a certain number of times pause off for a short delay then flash on...

Page 91: ...based decisions are active ADJUSTMENTS HEIGHT values set to between 1 and 100 then the height sensors must be calibrated Calibration procedures are accessible from the SETUPS HEIGHT SETUPS and SETUPS...

Page 92: ...ues Also check SETUPS TILT SETUPS TILT SHUTDOWN and ELEV TILT SHUTDOWN which determine what functions to prevent when the vehicle is tilted See chart 6 EZ Cal Setups for factory default values FUNCTIO...

Page 93: ...PERATURE Messages This section lists temperature HELP messages problems have been detected which are likely due to excessive dutycycling or poor heatsinking FAULT BAD INTERNALTEMPERATURE SENSOR Flash...

Page 94: ...e sensor is giving an out of range voltage below 0 5V or above 4 5V FAULT CHECK ELEVATION SWITCH Flash Code 6 3 The elevation switch is in disagreement with the height sensor s During calibration the...

Page 95: ...es The following are other HELP messages SOME BIG BAD PROBLEM Flash Code 9 9 This message should not occur FACTORY OVERRIDE Flash Code fast flashing When the controller is first shipped prior to initi...

Page 96: ...Joystick plug Check HELP or MODE message on EZ Cal continued TROUBLE TABLE The following chart is a guide to help the technician find the area of a problem In order to befefit from the information yo...

Page 97: ...e Check battery voltage Clean service and charge batteries Check HELP or MODE message on EZ Cal Maintenance Lock in maintenance position Lowering valve not energized Lowering valve not shifting Loweri...

Page 98: ...oning rear wheel bypass valve Wheel motors not functioning correctly Check Speed Torque switch on platform controls Check limit switch located on left rear of base Check limit switch input with EZ Cal...

Page 99: ...valve Check ground to valve Check for faulty valve spool Check or replace vavle Speed Torque switch inoperative Valve SV3 not functioning EP1 poppet valve not functioning No low speed high torque mode...

Page 100: ...heck pressure switches with outriggers retracted switches should be open First assure that the unit is level Use EZ cal Access level 2 SETUPS TILT to Calibrate Correct wiring refer to schematic diagra...

Page 101: ...Relief RV2 Steer Relief RV3 Main Relief RV4 Overpressure Relief LEFT SIDE FRONT LIFT CYLINDER MANIFOLD 3772 Gauge Port Test Port STEER 2000 PSI 137 9 bar 2000 PSI 137 9 bar 2000 PSI 137 9 bar MODEL 30...

Page 102: ...relief valve turn clockwise and recheck If pressure is HIGH adjust lift relief valve turn counterclockwise and recheck Repeat until correct Steering Relief RV2 Energize the steering to full left Hold...

Page 103: ...s 2 Turn the adjustment screw counterclockwise to the left until it reaches the internal stop and the screw will turn no further 3 Turn the adjustment screw clockwise to the right 2 turns 4 Tighten th...

Page 104: ...DUCE THE RISK OF ELECTRIC SHOCK ALWAYS DISCONNECT BOTH THE POWER SUPPLY CORD AND THE OUTPUT WIRES BEFORE ATTEMPTING MAINTENANCE THE CHARGER SURFACE CAN GET HOT WHILE OPERATING CONTACT WITH THE SKIN OR...

Page 105: ...ctions 1 Charger does not turn ON or no yellow LED 2 Red FAULT LED is ON or BLINKING 3 Batteries do not fully charge 4 The AC supply circuit breaker is tripped or fuse is blown If the problem is not l...

Page 106: ...t is removed the charger restarts automatically Possible Causes Batteries are extremely discharged unplug for 30 seconds then plug charger back in to restart and complete charging Electrolyte is low i...

Page 107: ...aker or fuse is blown 6 GEL LED is ON If the problem is not listed above refer the problem to a qualified service agent for additional trouble shooting procedures Note Over 1 2 of all battery chargers...

Page 108: ...Output connection error Check the AC input voltage The charger is indicating the AC voltage is too low or too high This is an unusual problem and would most likely occur with a very poorly regulated e...

Page 109: ...wn A defective circuit breaker or fuse overloaded circuit or a charger problem can cause this condition Check battery condition following the battery supplier s instructions Check for dead cells or re...

Page 110: ...October 2008 3072ES 3772ES 3772ES HD Service Parts Manual Page 4 44...

Page 111: ...5 4 Main Relief Hydraulic Manifold 5 5 Optional Outriggers Hydraulic Manifold 5 5 Electric System 5 6 Electric Schematics Upper Controls Early Models 5 6 Electric Schematics Upper Controls Current Mo...

Page 112: ...10 Micron Cylinder Steering Optional Outriggers Components Outrigger Cylinder Solenoid Valve Poppet N C Solenoid Valve Poppet N C Spool Valve 4 way 3 Position Callout MA1 SVD1 SV1 SV2 SV3 SV4 RV1 RV2...

Page 113: ...ER 3772 ONLY MA 3 067 3072 ONLY LOWER LIFT CYLINDER MAIN RELIEF STEERING LIFT CYLINDER 035 CL1 2500 PSI 3000 PSI 2000 PSI CL2 025 CL1 T B ORB ORLS ORR ORS ORA OPTIONAL OUTRIGGERS RV4 SV6 SV5 CYL5 CYL5...

Page 114: ...LFT P RFB LRB RRA GP PLG4 PLG4 OPL6 PLG4 OPL5 PLG4 PLG4 PLG6 CBV1 CBV2 PLG6 OPL2 PLG4 PLG4 PLG4 PLG4 PLG4 PLG4 SVD1 FD1 EP1 LS2 PLG4 LS1 CV1 CV2 LS3 PD1 PD2 PD3 FD2 EP1 HP1 EC1 SV1 CL2 RV1 RV2 SV3 CL1...

Page 115: ...Parts Manual October 2008 Page 5 5 Main Relief Hydraulic Manifold Optional Outriggers Hydraulic Manifold ART_2583 BOTTOM RIGHT LEFT FRONT RV3 ART_2584 BOTTOM RIGHT LEFT FRONT ORA ORLS ORS ORB ORR PLG...

Page 116: ...ER LEFT STEER RIGHT ENABLE BAR POTENTIOMETER not used not used not used POTENTIOMETER POTENTIOMETER SWITCH SUPPLY HIGH SPEED SWITCH SUPPLY not used LEVEL INDICATOR LAMP ALARM DRIVE ENABLE LAMP O R not...

Page 117: ...ER POTENTIOMETER SWITCH SUPPLY HIGH SPEED SWITCH SUPPLY not used DRIVE LIFT not used not used not used not used O R UP SWITCH O R DOWN SWITCH not used P4 1 P4 2 P4 3 P4 4 P4 5 P4 6 P4 7 P4 8 P4 9 not...

Page 118: ...DOWN SWITCH P8 15 GROUND GROUND GROUND ANALOG IN ANALOG IN P15 1 P15 2 P15 3 P15 4 P15 5 P15 6 P15 7 P15 8 P15 10 P15 11 STOWED LEFT REAR STOWED RIGHT REAR STOWED RIGHT FRONT STOWED LEFT FRONT LOAD S...

Page 119: ...Connection P6 P5 To Pump Motor To Battery Disconnect Switch To Battery Ground B B Diagnostic LED 1 3 1 3 1 3 1 4 1 2 P1 1 12 Volts DC OUTPUT P1 2 12 Volts DC OUTPUT P1 3 12 Volts DC OUTPUT P1 4 BASE S...

Page 120: ...t used P6 13 not used P6 14 not used P6 15 not used BASE LOWER CONTROLS P7 1 Valve Supply P7 2 Base Selected P7 3 UP Base P7 4 Platform Selected P7 5 Limit Switch P7 6 not used P7 7 DOWN Base P7 8 not...

Page 121: ...2 11 Potentiometer P2 12 Switch Supply Matrix Module inside Upper Control Box 21 510 410 Serial Number 11211001 11211036 ART_2574 ART_2575 Matrix Module inside Upper Control Box 21 510 411 Serial Numb...

Page 122: ...October 2008 3072ES 3772ES 3772ES HD Service Parts Manual Page 5 12...

Page 123: ...n Installation B 13 Power to Platform Airline to Platform B 15 Lanyard Attachment CE Standard ANSI Option B 17 Section C Scissors Page Scissor Assembly 3072RT Up to Serial 11211099 C 3 Scissor Assembl...

Page 124: ...Hoses Pump and Return E 15 Hydraulic Hoses Outrigger HD Models E 17 Lift Cylinder 3072 E 19 Lift Cylinder Lower 3772 E 21 Lift Cylinder Upper 3772 E 23 Steering Cylinder E 25 Outrigger Cylinder E 27...

Page 125: ...72ES 3772ES 3772ES HD Service and Parts Manual SECTION A CONTROLS CONTENTS PAGE Upper Controls ANSI Models A 3 Upper Controls CE Models A 5 Upper Control Box Cover Assembly A 7 Upper Control Joystick...

Page 126: ...68 301 57 57 301 OUTRIGGER FIXED CABLE REMOVABLE CABLE 6 13 38 SPEED TORQUE LIFT DRIVE GRN WHT YEL WHT JUMPER GRY JUMPER PPL BLU RED PNK WHT RED BLU YEL No Connection ORG RED YEL WHT WHT RED WHT RED B...

Page 127: ...re Harness Section F 7 REF 1 Cable Removable see Wire Harness Section F Fixed and Removable Control Box ANSI 8 16242 1 Weldment Control Box 9 13865 1 Bracket Control Box Holder 10 6350 0 5 FT Tape Foa...

Page 128: ...VABLE CABLE 6 13 38 SPEED TORQUE LIFT DRIVE GRN WHT YEL WHT JUMPER GRY JUMPER PPL BLU RED PNK WHT RED BLU YEL No Connection ORG RED YEL WHT WHT RED WHT RED BLK WHT RED ORG BLK PNK WHT WHT WHT YEL WHT...

Page 129: ...arm Overload Warning 6 16242 1 Weldment Control Box 7 13865 1 Bracket Control Box Holder 8 6350 0 5 FT Tape Foam 9 HDW5724 1 Screw 5 16 18 10 13864 1 Bracket Control Box Holder 11 HDW8294 1 Washer Fla...

Page 130: ...3072ES 3772ES 3772ES HD Service and Parts Manual ART_2220 R1 Control Box Cover Assembly ES Machines Reference ART_13868 1 2 4 5 6 29 28 7 8 9 11 13 15 19 20 22 21 24 25 32 26 27 31 23 16 17 18 10 12...

Page 131: ...763 1 Spacer Step 11 13402 1 Gear Large 12 HDW8531 2 Washer Flat 13 HDW7881 1 Washer Bevel 14 3782 1 Cam Directional 15 13403 1 Plate Bottom 16 6917 1 Clamp Cable 1 4 17 7818 1 Bearing Bronze Flanged...

Page 132: ...October 2008 Page A 8 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2221 R1 Control Arm Joystick Reference ART_188 3 4 9 10 2 1 6 11 8 5 7...

Page 133: ...TCH ACTUATOR SERVICE ONLY 3 HDW8455 4 SCREW 6 1 2 LG SERVICE ONLY 4 8752 1 GRIP TOP HALF SERVICE ONLY 5 8751 1 GRIP BOTTOM HALF SERVICE ONLY 6 13638 1 CONTROL ARM WITHOUT WIRE 7 8748 1 TRIGGER SERVICE...

Page 134: ...OP PUSH FOR EMERGENCY STOP TWIST TO RESET 15 Emergency Stop Hour Meter Charge Indicator Circuit Breaker Emergency Stop N C Hour Meter Charge Indicator Circuit Breaker Platform Base Platform Base N C P...

Page 135: ...ower Controls ITEM PART NO QTY DESCRIPTION 1 9549 1 Switch 3 position Keyed 2 91533 2 Switch Button Green 3 91534 1 Switch Button Red 4 91744 1 Charge Indicator 5 7909 1 Hour Meter 6 7235 1 Circuit Br...

Page 136: ...October 2008 Page A 12 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 137: ...ND RAILS CONTENTS PAGE Platform Assembly B 3 Rollout Lock Pin Assembly B 5 Roller Assembly B 7 Entry Chain ANSI Models B 9 Swing Gate CE Standard ANSI Option B 11 Control Cable Horn Installation B 13...

Page 138: ...October 2008 Page B 2 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2094 Platform and Rails 5 4 6 1 2 3 7 8 24 9 23 29 26 27 30 25 22 27 24 20 28 19 21 17 16 10 31 12 11 15 14 13 18...

Page 139: ...10 16177 1 Front Rail Weldment 11 8909 1 Manual Enclosure 12 HDW5723 8 Screw 20 LG 13 HDW8294 4 Flat Washer 328 ID 1 000 OD 100 THK 14 HDW8267 4 Nut 20 15 14415 2 Bracket Extension Stop 16 HDW5724 20...

Page 140: ...October 2008 Page B 4 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2133 Roll out Deck Lock Pin Assembly 5 4 8 3 6 1 7 8 9...

Page 141: ...EF Reference only Rollout Lock Pin Assembly ITEM PART NO QTY DESCRIPTION 1 13737 1 Pin Extension Lock 2 7184 3 7 FT Cable Coated And Rolled 3 8814 2 Sleeve Aluminum Oval 4 14344 1 Handle 5 HDW8303 1 S...

Page 142: ...October 2008 Page B 6 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2095 Roll out Deck Roller Reference ART_687 4 5 3 2 1...

Page 143: ...uired INCL Included with assembly NS Not a Stock item REF Reference only Roller Assembly ITEM PART NO QTY DESCRIPTION 1 5918 1 Retaining Ring Heavy Duty 1IN 2 HDW8370 1 Washer Flat 1 015 ID 1 375 OD 0...

Page 144: ...October 2008 Page B 8 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2096 Entry Chain Reference ART_13850 1 2 3...

Page 145: ...S HD Service and Parts Manual as req as required INCL Included with assembly NS Not a Stock item REF Reference only Entry Chain ANSI Models ITEM PART NO QTY DESCRIPTION 1 13846 1 Chain 2 5239 2 S hook...

Page 146: ...October 2008 Page B 10 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2097 Gate 1 5 2 3 4 16 17 7 10 11 9 13 5 12 15 14 6 8 7...

Page 147: ...40006 1 Rod Latch Lever Rear Gate 4 HDW6434 1 Screw 3 8 16 2 LG 5 8187 2 Bearing Nyliner 5 8 ID 5 8 LG 6 40014 1 Mounting Bracket Upper 7 HDW8294 6 Washer 328 ID 1 OD 100 THK 8 HDW8486 4 Screw 5 16 1...

Page 148: ...October 2008 Page B 12 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2591 R1 Control Cable Installation 1 3 3 2 3 9 8 6 7 4 10 5...

Page 149: ...ION 1 9716 1 HORN 12 48V option 2 HDW5217 2 WASHER FLAT 343 ID 688 OD 063 THK 3 HDW6455 5 SCREW 20 LG GR 5 4 5863 2 GROMMET 1 5 ID 1 75 OD 187 THK 5 14604 1 COVER TERMINAL STRIP 6 6964 1 CLAMP CABLE 1...

Page 150: ...October 2008 Page B 14 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2099 Power to Platform 11 12 13 7 8 9 4 1 5 3 6 10 2...

Page 151: ...Screw 20 LG 5 HDW8267 2 LOCKNUT 20 6 5381 1 Receptacle Duplex 7 8208 1 Conduit 3 8 Flexible 8 8209 1 Ferrule 3 8 9 8479 1 Bushing ID 10 8833 1 Connector Outlet Box 3 8 Conduit 11 16221 1 Bracket 12 H...

Page 152: ...October 2008 Page B 16 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2100 Lanyard Anchorage Points 1 4 3 5 2...

Page 153: ...mbly NS Not a Stock item REF Reference only Lanyard Attachment CE Standard ANSI Option ITEM PART NO QTY DESCRIPTION 14583 Lanyard Attachment Kit 1 HDW6433 10 Screw 3 8 16 1 LG GR 5 2 HDW8268 10 Nut 3...

Page 154: ...October 2008 Page B 18 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 155: ...or Assembly 3772RT Up to Serial 11211099 C 5 Scissor Assembly 3072RT Serial 11211100 UP C 7 Scissor Assembly 3072RT Serial 11211100 UP continued C 9 Scissor Assembly 3772RT Serial 11211100 UP C 11 Sci...

Page 156: ...rvice and Parts Manual ART_2592 R1 Scissor Assembly 3072 Early Style 250 313 313 250 250 313 313 250 1 3 4 5 6 7 11 12 13 17 18 19 20 7 21 22 27 35 28 30 34 26 27 25 31 32 33 29 10 23 24 9 36 8 6a 2 D...

Page 157: ...455 4 Screw 20 LG 13 14537 2 Pin Cylinder Mount 14 15 16 17 6701 10 Ring Retaining 2 18 9587 2 Wear Pad Slide Block Bottom 19 90235 2 Wear Pad Angle Slide Block Top 20 40306 2 Slide Pvt Lwr Cast Machi...

Page 158: ...rts Manual ART_2593 R1 Scissor Assembly 3772 Early Style 188 188 375 375 375 375 188 250 188 250 1 3 4 5 6 7 11 12 13 14 17 17 18 15 16 19 30 20 23 41 21 22 35 38 40 34 26 25 31 32 28 39 29 33 27 10 2...

Page 159: ...2 28DU32 17 5432 4 Grease Fitting 18 9587 2 Wear pad Slide block Bottom 19 16286 1 Beam 6 6 188 6669 2 Bearing 2 0 2 0 32DU32 20 40106 1 Beam 6 6 375 6669 2 Bearing 2 0 2 0 32DU32 21 16284 1 Beam 6 6...

Page 160: ...72ES 3772ES 3772ES HD Service and Parts Manual ART_2594 Scissor Assembly Beams Install 3072RT 3072ES Sheet 1 of 2 250 313 313 250 313 313 250 250 12 11 13 13 13 13 11 11 11 11 11 11 11 11 12 12 12 12...

Page 161: ...1 40448 1 Beam 6x8x 250 TS w pins 2 17070 1 Beam 6x8x 313 w pins 3 40081 1 Beam 6x8x 313 w pins 4 17071 1 Beam 6x8x 250 BF w pins 5 40447 1 Beam 6x8x 250 TF w Bearings 6 17067 1 Beam 6x6x 312 bored 7...

Page 162: ...3772ES HD Service and Parts Manual ART_2595 R1 Scissor Assembly Cylinder Install 3072RT 3072ES Sheet 2 of 2 12 19 11 24 35 36 30 34 31 32 33 14 16 11 26 20 24 14 19 23 21 22 25 24 13 29 27 28 12 17 1...

Page 163: ...G 18 14537 2 PIN CYLINDER MOUNT 19 HDW8899 2 Retaining Clip 20 40459 2 LOWER PIVOT MACHINED CASTING 21 HDW8457 6 LOCKNUT 13 GR B 22 HDW6491 6 Washer Flat 562 ID 1 375 OD 109 THK 23 HDW8284 6 SCREW 13...

Page 164: ...D Service and Parts Manual ART_2596 R1 Scissor Assembly Cylinder Install 3772RT 3772ES Sheet 1 of 2 188 188 375 375 375 375 188 250 188 250 14 13 15 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 14 14...

Page 165: ...17017 1 Beam Weldment 6x6x 250 3 17015 1 Beam Weldment 6x6x 188 4 16292 1 Beam Weldment 6x6x 375 5 17011 1 Beam Weldment 6x6x 375 6 17018 1 Beam Weldment 6x6x 188 7 16288 1 Beam Weldment 6x6x 250 8 1...

Page 166: ...772ES 3772ES HD Service and Parts Manual ART_2597 R1 Scissor Assembly Cylinder Install 3772RT 3772ES Sheet 2 of 2 38 39 40 33 37 34 35 36 29 27 32 30 31 17 15 18 14 14 13 13 13 13 14 13 19 19 20 20 21...

Page 167: ...37 4 PIN CYLINDER MOUNT 22 HDW8899 4 Retaining Clip 23 40459 2 LOWER PIVOT MACHINED CASTING 24 HDW8457 6 LOCKNUT 13 GR B 25 HDW6491 6 Washer Flat 562 ID 1 375 OD 109 THK 26 HDW8284 6 SCREW 13 2 LG GR...

Page 168: ...October 2008 Page C 14 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2598 R1 Limit Switch Installation 1 1 5 4 3 6 2 7...

Page 169: ...ith assembly NS Not a Stock item REF Reference only Limit Switch Installation ITEM PART NO QTY DESCRIPTION 1 HDW8273 4 Screw 20 1 LG GR 8 2 HDW8267 2 NUT 20 3 13838 1 BRKT LIMIT SWITCH 4 90996 1 LIMIT...

Page 170: ...October 2008 Page C 16 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2745 Scissor Guards 3072RT 3072ES CE MODELS 3 4 5 5 3 2 1...

Page 171: ...ed INCL Included with assembly NS Not a Stock item REF Reference only Scissor Guards 3072ES CE Models ITEM PART NO QTY DESCRIPTION 1 16323 1 Front Panel Scissor Guard 2 16324 1 Rear Panel Scissor Guar...

Page 172: ...October 2008 Page C 18 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2744 Scissor Guards 3772RT 3772ES CE MODELS 3 4 2 1...

Page 173: ...s required INCL Included with assembly NS Not a Stock item REF Reference only Scissor Guards 3772ES CE Models ITEM PART NO QTY DESCRIPTION 1 16350 1 Front Panel Scissor Guard 2 16353 2 Rear Panel Scis...

Page 174: ...October 2008 Page C 20 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 175: ...October 2008 Page D 1 3072ES 3772ES 3772ES HD Service and Parts Manual SECTION D AXLES CONTENTS PAGE Rear Axle Assembly D 3 Front Axle Assembly D 5 Wheel Motor Rear D 7 Wheel Motor Front D 9...

Page 176: ...2008 Page D 2 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2599 X72 Rear Axle 15 13 14 12 11 10 2 9 21 3 19 20 2 1 22 4 16 17 18 Drive Ports Hydraulic Wheel Motor with Brake A B Case Drain Bra...

Page 177: ...Hub 12 91165 1 Wheel tire Assy RH 10 PLY PNEUMATIC ANSI standard 91167 1 Wheel tire Assy RH 10 PLY FOAM ANSI option CE standard 91166 1 Wheel tire Assy LH 10 PLY PNEUMATIC ANSI standard 91168 1 Wheel...

Page 178: ...72ES 3772ES 3772ES HD Service and Parts Manual ART_2600 X72 Front Axle 26 8 25 21 20 25 8 18 17 14 23 22 5 3 2 1 28 19 19 11 11 9 18a 16 13 12 18a 11 9 6 7 4 11 25 8 24 29 30 Drive Ports Hydraulic Whe...

Page 179: ...50 LG GR 8 Socket Head 14 7300P 2 Motor Wheel Hyd 15 90765 8 Hose Protection Not Shown 16 40464 1 Mount Wheel Motor LH FRONT cast 40463 40308 1 Mount Wheel Motor RH FRONT cast 40367 17 HDW6633 2 Nut...

Page 180: ...ring 4 3 2 Front Housing 1 DT710 BRAKE MOTOR COMPONENTS Shaft Key 1f 1h Piston Capscrews 8 Shaft Nut Spacer Shims 1 3 Shaft Bearing Shaft Bearing 1c 1j Piston Spring Assembly Bolts 7 1m 1l 1k Drive Li...

Page 181: ...1319 Wheel Motor W brake 1 9781 Seal Kit 1a 1 Dust Seal 1b 1 Metal Backup Shim 1c 1 Backup Seal 1d 1 Shaft Seal 1e 1 Small Piston O ring Seal 1f 1 Small Piston Seal 1g 1 Large Piston O ring Seal 1h 1...

Page 182: ...Assembly Endcover Piston Spring Rotor Assembly Divider Plate Endcover Piston Commutator Assembly Drive Link Manifold Rear Housing Bearing Shaft Housing Shaft Key Thrust Washers 2 Thrust Bearing 1 5 B...

Page 183: ...tem REF Reference only Wheel Motor Front ITEM PART NO QTY DESCRIPTION 7300P MOTOR WHEEL HYD PAINTED 1 90592 SEAL KIT 1a 1 DUST SEAL 1b 1 HIGH PRESSURE SEAL 1c 1 METAL BACKUP SHIM 1d 1 TEFLON BACK UP S...

Page 184: ...October 2008 Page D 10 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 185: ...E 5 Main Relief Manifold Assembly E 7 Manifold Outrigger HD Models E 9 Hydraulic Hoses Axles E 11 Hydraulic Hoses Steering Brake Release and Axle Return E 13 Hydraulic Hoses Pump and Return E 15 Hydra...

Page 186: ...Page E 2 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2702 X72ES Manifold Assembly Sheet 1 of 2 FRONT LEFT BACK RIGHT 10 18 13 9 15 11 19 19 17 26 20 1 16 12 4 24 14 23 17 22 21 18 2 1 14 7 1...

Page 187: ...49 1 Valve Relief Lift 10 91150 1 Valve relief Steer 11 91151 3 Valve Piloted Spool 4 way 3 position 12 91152 2 Valve Piloted Poppet 13 91153 1 Valve Load Shuttle Check 14 91154 2 Valve Load Shuttle C...

Page 188: ...October 2008 Page E 4 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2703 X72ES Manifold Assembly Hardware Sheet 2 of 2 28 28 29 29 31 30 38 32 34 35 37 36 33 29 FRONT LEFT BACK RIGHT...

Page 189: ...w 90 Male O Ring Male MB MJ90 8 8 30 HDW91334 1 Fitting Orifice 1 16 31 HDW8877 1 ELBOW 90 Male O ring Male MB MJ90 4 4 32 HDW91081 1 ELBOW 90 Male O ring Male MB MJ90LL 4 4 33 HDW91244 1 ELBOW 90 Mal...

Page 190: ...October 2008 Page E 6 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2704 Main Relief Manifold 3072ES 3772ES 3772ES HD 1 2...

Page 191: ...72ES 3772ES HD Service and Parts Manual as req as required INCL Included with assembly NS Not a Stock item REF Reference only Main Relief Manifold Assembly ITEM PART NO QTY DESCRIPTION 1 91657 1 Main...

Page 192: ...d Parts Manual ART_2705 Outrigger Manifold Installation 3772ES HD TO MAIN MANIFOLD ORS TO OUTRIGGERS CYLINDERS TO OUTRIGGERS CYLINDERS TO MAIN MANIFOLD ORR ORA MAIN MANIFOLD ORR ORS ORB OUTRIGGER RETR...

Page 193: ...ith assembly NS Not a Stock item REF Reference only Manifold Outrigger HD Models ITEM PART NO QTY DESCRIPTION 1 91721 1 Manifold Assembly 2 HDW7601 3 Elbow 90 Male 3 8 O ring Male 3 8 JIC 3 HDW8881 1...

Page 194: ...072ES 3772ES 3772ES HD Service and Parts Manual ART_2706 Hose Kit Axles 3072ES 3772ES 3772ES HD Sheet 1 of 4 CONTROL MODULE POWER MODULE HD Models OUTRIGGERS HD Models OUTRIGGERS BACK RIGHT FRONT LEFT...

Page 195: ...NO QTY DESCRIPTION 1 91263 4 Hose Assy 37 8M3K 8FJX 8FJX90S 37 2 9389 2 Hose Assy 44 8M3K 8FJX 8FJX 3 9386 1 Hose Assy 68 8M3K 8FJX 8FJX 68 4 91261 1 Hose Assy 61 8M3K 8FJX 8FJX 5 91258 1 Hose Assy 5...

Page 196: ...ervice and Parts Manual ART_2707 Hose Kit Steering Motor Case Drain Brake 3072ES 3772ES 3772ES HD Sheet 2 of 4 CONTROL MODULE POWER MODULE HD Models OUTRIGGERS HD Models OUTRIGGERS FRONT LEFT BACK RIG...

Page 197: ...ake Release and Axle Return continued ITEM PART NO QTY DESCRIPTION 11 6458 as req Hose Return Line Cut to length 12 9227 1 Hose Assy 83 4G1 4FJX 4FJX90S 13 91256 1 Hose Assy 42 4G1 4FJX 4FJX90S 14 912...

Page 198: ...GGERS HD Models OUTRIGGERS BACK RIGHT FRONT LEFT LEFT FRONT 29 3772 Upper Cyl Return 3772 ONLY 3772 ONLY 3772 ONLY 3772 ONLY NOTE Main Manifold to Lift Cylinder Lift Cyl Return 30 11 11 19 20 21 11 28...

Page 199: ...Length 19 91466 1 TEE 20 91468 1 Reducer 21 9920 1 TEE 22 90315 1 Hose Assy 23 91698 1 Hose Assy 24 91247 6 FT Hose Assy 12LOLA bulk 25 HDW91246 2 Fitting Female JIC Male Hose Barb 26 91265 1 Hose As...

Page 200: ...72ES HD Service and Parts Manual ART_2709 Hose Kit Outriggers 3072ES 3772ES 3772ES HD Sheet 4 of 4 CONTROL MODULE POWER MODULE HD Models OUTRIGGERS HD Models OUTRIGGERS BACK RIGHT FRONT LEFT 34 36 35...

Page 201: ...lic Hoses Outrigger HD Models ITEM PART NO QTY DESCRIPTION 32 91346 4 Hose Assy 35 4G1 4FJX 4FJX90 S 33 91347 4 Hose Assy 58 4G1 4FJX 4FJX90 S 34 HDW7391 2 Tee Male 3 8 jic 35 HDW9557 4 Tee Male JIC 3...

Page 202: ...arts Manual ART_2710 3072 Lift Cylinder Rod Wiper Rod Rod Seal Static Seal Seal Retainer Seal Kit Piston Wear Ring Piston Seal Wear Ring Barrel Wear Ring 3 4 5 5 5 5 6 7 16 15 8 9 11 12 14 1 2 91020 L...

Page 203: ...985 1 Hose Assembly 3 8 3 HDW7601 1 Fitting Elbow Adaptor 4 91804 1 Orifice 0 042 5 6669 4 Bearing 2 ID 2 LG 6 91051 1 Valve 2 Way N C Cable Attach 7 91141 1 Coil 12 Volt Deutsch 8 HDW6727 1 Fitting P...

Page 204: ...s Manual ART_2711 3772 Lower Lift Cylinder 91314 LIFT CYLINDER WITH BEARINGS Rod Wiper Rod Rod Seal Seal Retainer Static Seal Seal Kit Piston Piston Seal Barrel Wear Ring Wear Ring 3 4 5 5 5 5 6 16 17...

Page 205: ...Fitting Elbow 90 37JIC 37 O ring 4 91804 1 Orifice 0 042 5 90993 4 Bearing Bronze 2 ID 2 LG 6 91462 1 Valve 2 Way N C Poppet Dual Coil 7 8 HDW6727 1 Fitting Pipe 90 Male Barb 9 HDW8152 2 Screw 20 LG...

Page 206: ...2ES HD Service and Parts Manual ART_2712 3772 Upper Lift Cylinder 91315 LIFT CYLINDER WITH BEARINGS 3 4 5 5 5 5 6 16 8 9 11 15 12 14 1 2 TO LIFT M ANIFO LD TO RESERVO IR Rod Wiper Rod Rod Seal Seal Re...

Page 207: ...7 1 Hose Assembly Lift Cylinder 3 8 370 3 HDW7601 1 Fitting Elbow Adaptor 4 91805 1 Orifice 0 067 5 90993 4 Bearing Bronze 2 ID 2 LG 6 91462 1 Valve 2 Way N C Dual Coil 7 8 HDW6727 1 Fitting Pipe 90 M...

Page 208: ...008 Page E 24 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2713 X72 Steering Cylinder 91019 Steering Cylinder PISTON PISTON SEAL WEAR RING STATIC SEAL ROD SEAL ROD WIPER SEAL KIT SEAL RETAINER...

Page 209: ...CL Included with assembly NS Not a Stock item REF Reference only Steering Cylinder ITEM PART NO QTY DESCRIPTION 91019 2 Steering Cylinder 1 HDW8881 1 Adapter Male O Ring Male JIC 2 HDW8876 1 Adapter M...

Page 210: ...08 Page E 26 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2714 Outrigger Cylinder 91278 Cylinder Assembly 9 10 11 8 2 1 7 6 5 4 PISTON STATIC SEAL ROD SEAL ROD WIPER PISTON SEAL WEAR RING SEAL...

Page 211: ...nder ITEM PART NO QTY DESCRIPTION 1 91278 4 Cylinder Outrigger 2 91281 1 Switch Outrigger Pressure N O 3 4 10907 1 Washer Actuator 5 HDW8476 1 Nut Jam 20 6 HDW9761 1 Screw Socket Head 20 2 7 91277 1 S...

Page 212: ...October 2008 Page E 28 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 213: ...e and Parts Manual SECTION F BASE CONTENTS PAGE Base Assembly F 3 Ballast Counterweight Installation F 5 Modules Installation F 7 Control Module F 9 Control Module continued F 11 Power Module F 13 Wir...

Page 214: ...October 2008 Page F 2 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2715 Base Assembly 3072 3772 1 6 7 7 7 2 9 3 4 4 5 10 8 9 9...

Page 215: ...ence only Base Assembly ITEM PART NO QTY DESCRIPTION 1 40159 1 Base Weldment 2 16160 1 Ladder Weldment 3072RT Standard 16293 Ladder Weldment 3772RT Standard 3 16206 1 Cover Slider Pan 4 14993 2 Suppor...

Page 216: ...October 2008 Page F 4 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2716 Ballast 3072 3772 3072 3772 7 3 9 6 3 5 3 4 1 2 8 7 3 9 6 3 5 3 4 1 2 8...

Page 217: ...ght Installation ITEM PART NO QTY DESCRIPTION 1 40159 1 Base Weldment 2 HDW8457 8 Nut Lock 13 GR 5 3 HDW13195 8 Washer Flat 515 ID 1 512 OD 098 THK 4 40590 1 Bar Ballast Weight 5 16736 2 Bar Counterwe...

Page 218: ...October 2008 Page F 6 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2717 Modules Installation 3072ES 3772ES 3 8 1 4 7 7 10 10 2 5 6...

Page 219: ...PTION 1 16985 1 Door Weldment Control Module 16984 1 Door Weldment Power Module Not Shown 2 8386 4 Latch Trigger 3 84077 1 Weldment Power Module 4 16165 1 Cover Hose Tray LH 3072RT 16313 1 Cover Hose...

Page 220: ...Page F 8 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2718 Control Module 3072ES 3772ES 1 35 2 3 4 26 27 28 29 31 21 32 33 34 5 6 7 8 9 15 41 37 34 16 17 18 19 20 23 24 25 22 12 11 13 40 14 38...

Page 221: ...JIC 9 HDW9200 1 Plug NPT 10 9367 1 Filler Strainer 11 16229 1 Bracket Battery Disconnect 12 8841 1 Switch Battery Disconnect 13 91659 1 System Controller GP400 14 91658 1 Motor Controller 15 91709 1...

Page 222: ...Page F 10 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2718 Control Module 3072ES 3772ES 1 35 2 3 4 26 27 28 29 31 21 32 33 34 5 6 7 8 9 15 41 37 34 16 17 18 19 20 23 24 25 22 12 11 13 40 14 3...

Page 223: ...ot a Stock item REF Reference only Control Module continued ITEM PART NO QTY DESCRIPTION 31 5904 2 Bolt 32 HDW6433 4 Screw 3 8 1 33 8273 4 Screw 20 1 34 HDW8267 4 Nut 20 35 91673 1 Pump 10CC 36 HDW912...

Page 224: ...October 2008 Page F 12 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2719 Power Module 3072ES 3772ES 14 15 4 3 16 17 9 7 8 10 5 13 12 1 18 11 6 18 17 2...

Page 225: ...Module 3 40826 1 Channel Battery Module 4 14896 4 Block Slide Door 5 25429 2 Pad 6 40620 2 Spacer Insulator 1 59 LG 7 16983 1 Battery Holddown 8 2987 2 Holddown Rod 9 6110 2 Wingnut 10 91641 8 Batter...

Page 226: ...LE D HOLD SWITCH IN DES IRED DIR ECT ION AUTOMATIC OUTRIGGERS RET RACT EXT END 9134 9 7156 UPPER CONTROLS Underside of Platform To Master Disconnect Switch Diode To Chassis Ground BATTERY PACK Master...

Page 227: ...der Down Valve 3772ES Control Module to Lift Cylinder 5 91672 1 Harness Lower Controls Inside Control Module 6 91759 1 Cable Battery to Master Disconnect 7 91760 1 Cable Chassis Ground 8 6208 8 Cable...

Page 228: ...October 2008 Page F 16 3072ES 3772ES 3772ES HD Service and Parts Manual ART_2720 Outrigger Installation 3772RT HD 3772 ES HD 2 3 2 3 15 4 10 10 7 7 5 7 14 14 16 20 19 17 21 18 11 9 7 5 6 7 1 8 12 13...

Page 229: ...Outer Outrigger 5 HDW7052 8 Screw 13 3 LG 6 HDW8498 4 Screw 13 4 7 HDW8457 20 Nut 13 8 16258 1 Ladder 3072RT W Outriggers 16294 1 Ladder 3772RT W Outriggers 9 16278 1 Weldment Outrigger Mount Front 10...

Page 230: ...October 2008 Page F 18 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 231: ...er 2008 Page G 1 3072ES 3772ES 3772ES HD Service and Parts Manual SECTION G DECALS CONTENTS PAGE Decals ANSI Models G 3 Decals ANSI Models continued G 5 Decals CE Models G 9 Decals CE Models continued...

Page 232: ...RUCTIONS DO NOT EXCEED MAXIMUM PLATFORM OR EXTENSION LOAD LIMIT CAPACITY LOAD TO BE UNIFORMLY DISTRIBUTED PLACE LOAD NEAR CENTER OF PLATFORM WHEN POSSIBLE DO NOT DRIVE ON SIDE SLOPE IF OVER 25 14 DO N...

Page 233: ...Wind Rating 10 90730 1 Decal Warning Sheet Loading 11 91155 2 Decal Capacity 1000 LB 3072ES 3772ES HD 12 91322 2 Decal Capacity 750 LB 3772ES 13 9932 1 Decal Platform Capacity Small 3072ES 14 90269 1...

Page 234: ...PLATFORM BASE PUSH FOR EMERGENCY STOP TWIST TO RESET MEC AERIAL PLATFORM SALES CORP 1775 PARK STREET SUITE 77 SELMA CA 93662 USA MFG DATE XX XX MAX PLATFORM CAPACITY INCLUDING PERSONS XXX LBS XXX kg...

Page 235: ...1 Decal Emergency Lowering Switch 3772ES 32 8867 1 Tag Warning 33 90826 1 Decal Battery Charge Indicator 34 8502 4 Decal Tire Inflation 35 8519 4 Decal Warning Tire Replacement 36 91083 1 Decal Emerge...

Page 236: ...als Front and Control Side 3072ES 3772ES 3772ES HD 1 51 5 25 25 OPTION ANSI Models Sheet 3 of 4 13 14 3072ES 3772ES HD 3772ES 36 36 24 35 36 35 34 27 29 40 37 40 30 16 16 32 28 31 47 33 26 36 18 45 46...

Page 237: ...er Side 3072ES 3772ES 3772ES HD ANSI Models Sheet 4 of 4 37 36 38 39 6 5 4 21 22 2 3 7 18 23 23 23 23 19 24 24 11 12 8 11 12 15 9 10 39 48 20 20 20 35 38 HD MODELS HD MODELS 3072ES STANDARD MODELS 307...

Page 238: ...NIFORMLY DISTRIBUTED PLACE LOAD NEAR CENTER OF PLATFORM WHEN POSSIBLE DO NOT DRIVE ON SIDE SLOPE IF OVER 25 14 DO NOT DRIVE UP OR DOWN A GRADE THAT IS GREATER THAN THE GRADEABILITY SPECIFICATIONS FOR...

Page 239: ...anel 9 90721 1 Decal Danger Electric Tipover Wind Rating 10 90730 1 Decal Warning Sheet Loading 11 91385 2 Decal Capacity 1000 LB 3072ES 3772ES HD 12 91384 2 Decal Capacity 750 LB 3772ES 13 91388 1 No...

Page 240: ...OISTURE MAY CAUSE DAMAGE AND OR ERRATIC OPERATION WARNING 7156 LOCATE CONTROL BOX HERE FOR NORMAL OPERATION OF THIS UNIT 7155 91349 EUR 90930 MAX 2500 lbs 1135 kg 91386 MAX 2980 lbs 1352 kg 91387 MEC...

Page 241: ...l Load 3772ES 32 90918EUR 2 Decal Emergency Lowering Switch 3772ES 33 8867 1 Tag Warning 34 90826 1 Decal Battery Charge Indicator 35 8519 4 Decal Warning Tire Replacement 36 91084 1 decal emergency l...

Page 242: ...ART_2752 R1 Decals Front and Control Side 3072ES 3772ES 3772ES HD 1 51 5 30 31 37 CE Models Sheet 3 of 4 23 23 24 29 23 35 27 29 40 37 6 32 39 39 33 28 32 47 34 26 23 43 45 46 5 2 3 4 42 44 24 24 24 H...

Page 243: ...ar and Power Side 3072ES 3772ES 3772ES HD CE Models Sheet 4 of 4 37 36 38 39 6 5 4 21 22 2 3 7 18 23 23 23 23 19 24 24 11 12 8 11 12 15 9 10 39 48 20 20 20 35 38 HD MODELS HD MODELS 3072ES STANDARD MO...

Page 244: ...October 2008 Page G 14 3072ES 3772ES 3772ES HD Service and Parts Manual NOTES...

Page 245: ...F 7 16176 B 3 16177 B 3 16196 B 3 16202 B 3 16206 F 3 16221 B 15 16222 B 3 16224 B 3 16226 F 9 16229 F 9 16242 A 3 A 5 16258 F 17 16278 F 17 16279 F 17 16282 C 5 C 13 16283 C 3 C 5 16284 C 5 16285 C...

Page 246: ...6669 C 3 C 5 C 9 C 13 E 19 6701 C 3 C 5 C 7 C 9 C 11 C 13 6714 F 9 6727 F 9 6823 B 3 B 11 6873 G 5 G 11 6905 A 3 A 5 6917 A 7 6947 B 13 6964 B 13 7048 B 3 7055 B 11 7155 G 5 G 11 7156 G 5 G 11 7160 C...

Page 247: ...B 15 90873 A 5 90898 F 13 90918 G 5 90918EUR G 11 90919 G 11 90930 G 11 90969 E 21 E 23 90985 E 15 E 19 90987 E 23 90988 E 21 90990 D 5 E 25 90993 E 21 E 23 90996 C 15 91012 E 3 91015 E 3 91019 D 5 E...

Page 248: ...1728 G 11 91729 G 11 91730 G 11 91740 G 3 G 9 91744 A 11 91745 F 9 91748 F 9 91756 F 15 91757 F 15 91758 F 15 91759 F 15 91760 F 15 91761 F 15 91762 A 3 A 5 91780 F 15 9179 A 5 91804 E 19 E 21 91805 E...

Page 249: ...B 3 B 5 B 15 C 3 C 5 C 9 C 13 HDW8370 B 7 HDW8399 A 7 HDW8455 A 9 HDW8457 B 3 C 3 C 5 C 9 C 13 D 5 F 3 F 5 F 17 HDW8476 E 27 HDW8482 C 15 F 9 HDW8486 B 11 HDW8498 F 17 HDW8501 B 15 HDW8513 B 5 HDW853...

Page 250: ...3072ES 3772ES 3772ES HD Service and Parts Manual October 2008 Part Number Index Part Number Page Part Number Page...

Page 251: ..._________________ ___________________________________ ___________________________________ Purchase Order Number ______________ All orders MUST have a Purchase Order Number Ship VIA____________________...

Page 252: ...NOTES...

Page 253: ...on 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 Plat...

Page 254: ...1775 Park Street Suite 77 Selma CA 93662 USA Ph 1 800 387 4575 559 891 2488 Fax 559 891 2448 E mail info mecawp com Web www mecawp com Aerial Platform Sales Corp...

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