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"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications

March 2008

Page 4-1

SECTION 4:

TROUBLESHOOTING

SECTION 4:

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

Troubleshooting ................................................................................................................... 4-3

General Troubleshooting Tips ............................................................................................ 4-3
Common Causes of Hydraulic System Malfunctions: ....................................................... 4-3

Hydraulic Pressure Adjustment Procedures ..................................................................... 4-9
Proportional Speed Adjustment.........................................................................................4-12
Controls and Switches ........................................................................................................4-14

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Summary of Contents for 3072RT

Page 1: ...T HD Serial Number Range 3072RT 9201000 Present 3772RT 3772RT HD 9301000 Present 1775 Park Stree t Suite 77 Selm a Calif ornia 9366 2 Phon e 559 891 2488 Fax 559 891 2493 1775 Park Stree t Suite 77 Se...

Page 2: ...ts list to identify Hole Plug Update illustration Engine Dual Fuel Update illustration Engine Dual Fuel Update parts list to identify new part numbers Update illustration Engine Diesel Update parts li...

Page 3: ...Machine Specifications V Primary Machine Components VII LUBRICATION VIII SECTION 1 HYDRAULIC SYSTEM 1 1 Hydraulic System General 1 2 Hydraulic Fluid 1 3 Hydraulic Fluid Reservoir 1 6 Hydraulic Pump 1...

Page 4: ...itches 2 10 Continuity Checks 2 11 SECTION 3 MECHANICAL COMPONENTS 3 1 Torque Specifications 3 2 Mechanical Components 3 3 Base Undercarriage 3 3 Raising the Machine 3 3 Tires 3 4 Drive Motors 3 5 Ste...

Page 5: ...on Causes of Hydraulic System Malfunctions 4 3 Hydraulic Pressure Adjustment Procedures 4 9 Proportional Speed Adjustment 4 12 Controls and Switches 4 14 SECTION 5 SCHEMATICS 5 1 Hydraulic Schematic 5...

Page 6: ...3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page iv Parts Sections SECTION 1 CONTROL BOXES SECTION 2 PLATFORM AND RAILS SECTION 3 SCISSORS SECTION 4 AXLES SECTION 5 HYDRAULICS SEC...

Page 7: ...MEC scissors lift always follow the proper operating and maintenance procedures Only trained authorized personnel should be allowed to operate or service this machine Service personnel should read an...

Page 8: ...OR S TO SERIOUS INJURY OR DEATH MEC s policies and procedures demonstrate our commitment to Quality and our relentless ongo ing efforts towards Continuous Improvement due to which product specificatio...

Page 9: ...hanical failure and resulting downtime is reduced to a minimum NEVER PERFORM SERVICE ON THE MACHINE WITH THE PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE BEAMS SCISSORS ASSEMBLY IN PLACE USING THE MAI...

Page 10: ...chine when the negative cable is installed a spark will occur This can cause damage to the electrical system battery explosion and personal injury Total System Engine coolant level must be checked onl...

Page 11: ...0 4 0 mph 91 psi 60 psi 60 psi 60 psi 2 722 lb 75 85 ft lb 2800 psi 2500 psi 1500 psi 23 GAL 15 GAL 12 Volts DC 40 Amp 26 sec 28 sec 28 sec 31 sec 28 sec 31 sec 45 24 2 40 21 5 40 21 5 Foam Filled 11...

Page 12: ...fications Page VI 3072RT 3772RT HD Front Front Platform Assembly Rollout Deck Lift Assembly Lift Assembly Power Module Upper Controls Maintenance Lock Maintenance Lock Control Module Outrigger Assembl...

Page 13: ...3 6 Hubs intro 6 Slide Block intro 6 Emergency Lowering 1 Hoses Cables 1 2 3 5 6 Outrigger Option 1 3 4 5 5 6 LPG Option 3 6 Power Module Engine 3 4 5 6 Hydraulic Pump 1 3 4 5 6 Hydraulic reservoir i...

Page 14: ...d Grease Lithium N L G 2 EP Purge Old Grease Fill To The Middle Of The Sight Gauge With Platform In The Stowed Position Mobile 424 Do not substitute with lower grade oils as pump damage may result Cha...

Page 15: ...RAULIC SYSTEM 1 1 Hydraulic System General 1 2 Hydraulic Fluid 1 3 Hydraulic Fluid Reservoir 1 6 Hydraulic Pump 1 7 Wheel Drive 1 7 Parking Brake and Towing Circuit 1 14 Emergency Systems And Procedur...

Page 16: ...turns the hydraulic pump drains oil from the reser voir and pumps this fluid to the valve packages If no function is selected to perform the pump remains on standby and no fluid is pumped through the...

Page 17: ...ND THE PROPER METHODS FOR HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL HAZARDS TO HEALTH If mineral based hydraulic fluid is SPLASHED INTO THE EYES it must be WASHED OUT THOROUGHLY using abundant...

Page 18: ...6 months under normal operating conditions Every three 3 months in extremely dusty or dirty operating conditions The hydraulic fluid analysis must be done by a qualified laboratory Always provide the...

Page 19: ...d from the hydraulic reservoir 7 Reinstall all hoses removed in the previous steps 8 Fill hydraulic reservoir with filtered fresh hydraulic fluid refer to Lubrication Chart 9 Loosen output hose fittin...

Page 20: ...lter with a 10 micron filter element Check tank for signs of leakage every week Hydraulic Reservoir Assembly All machines are produced with a filter It is a 10 micron spin on bypassing filter When the...

Page 21: ...displacement The pump is not serviceable A faulty pump must be replaced WHEEL DRIVE Note Refer to Section 3 for Remove and Replace instructions There are four 4 hydraulic fixed displacement gear whee...

Page 22: ...an flat surface with the output end facing up Place the first thrust washer thrust bearing and second thrust washer over the shaft Using plastic installation sleeve place the shaft seal over the shaft...

Page 23: ...al in the groove in the housing Place the divider plate onto the housing Place body seals in grooves in both sides of the rotor Place the rotor onto the housing with the side of the rotor with chamfer...

Page 24: ...hrust 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...

Page 25: ...from the 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 oil to all new seals prior...

Page 26: ...ight 8 capscrews 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 th...

Page 27: ...Shaft Seal 5 Small Piston O Ring Seal 6 Small Piston Seal 7 Large Piston O Ring Seal 8 Large Piston Seal 9 O Ring Seal 10 Body Seals 3 11 Manifold Seal 12 Commutator Seal 13 O Ring Seal 14 Backup Sea...

Page 28: ...CHOCKED TO PREVENT MACHINE FROM MOVING Release Brakes Before Towing Push in the manual Brake Release valve located on the main manifold Using the hand pump on the manifold pump valve until pressure i...

Page 29: ...HE DECK EXTENSION Emergency Lowering 3072RT Emergency Down system is used to lower the platform in case of power or valve failure To lower the platform pull the red T handle located at the rear of the...

Page 30: ...e Adjustment Procedure Refer to Section 3 for Remove and Replace instructions Refer to Parts Section 5 for hose routing The steering system consists of the following components The wheel motor housing...

Page 31: ...ructions Refer to the Parts Manual Section 5 for parts list There are two 2 cylinders utilized in the steering system These cylinders are a double acting type which requires oil flow to operate the cy...

Page 32: ...ed by a hydraulic relief valve in the lift circuit Refer to Machine Specifications or the Hydraulic Schematic for proper setting Lift Cylinder Note Refer to Cylinder Repair 3072RT One 1 single acting...

Page 33: ...e Bearing Barbed Fitting Hose Clamp 3772RT LOWER LIFT CYLINDER WITH BEARINGS Electrically Operated Down Valve Return Hose 2 Barbed Straight Fittings and Hose Clamps Pressure Hose Pressure Sensor Tee F...

Page 34: ...rigger Stowed Switch UP Retract Coil Extend Coil Outrigger Retract Valve Outrigger Extend Valve Outrigger Pressure Switch DOWN OPTIONAL OUTRIGGERS Note Refer to Section 3 for detailed description and...

Page 35: ...er Barrel Head Piston Securing Nut Rod Head Seals Seals Piston Vent to Tank Return to Tank Barrel Pressure Piston Securing Nut Typical Single Acting Cylinder Removal Note Refer to Section 3 for Remove...

Page 36: ...the head 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...

Page 37: ...on sharp seal tool 3 Place a small amount of oil 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 in...

Page 38: ...o remove 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 surface...

Page 39: ...WHT DRIVE FORWARD 111 GRY RED PROPORTIONAL 333 PPL WHT RIGHT REAR B LIFT PORT PRESSURE PORT FROM PUMP RIGHT REAR A LEFT REAR B TO TANK LOAD SENSE TO PUMP RIGHT FRONT A LEFT FRONT B RIGHT REAR B LEFT R...

Page 40: ...March 2008 3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page 1 26...

Page 41: ...ECTRICAL SYSTEM SECTION 2 ELECTRICAL SYSTEM 2 1 Electrical System General 2 2 Deutsch Connectors 2 3 Battery 2 4 Battery Preventative Maintenance 2 5 Battery Replacement 2 6 Alarms and Switches 2 7 Ti...

Page 42: ...except steering and drive Platform Control Station The platform control station will operate all functions including drive steer and lift lower Momen tary bidirectional rocker switch on the drive cont...

Page 43: ...r 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 rem...

Page 44: ...o operate the electrical circuits Battery Maintenance in storage Follow these procedures for maintenance of battery on a machine not in use Keep battery clean Electrolyte of batteries should be checke...

Page 45: ...will lead to 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...

Page 46: ...ine Always disconnect the negative battery cable first Remove bolts holding battery Lift the battery from the compartment Put the battery to the side and dispose of properly Prevent damage to battery...

Page 47: ...p immediately when depressed Turn the button clockwise to reset NOTE As a safety feature selecting and operating the base controls will override the platform controls except the platform emergency sto...

Page 48: ...the 90 corners and repeat this test procedure Tilt Alarm Sensor Adjustment Before attempting to adjust the alarm park the machine on a firm flat level surface Use of an inclinometer is recommended to...

Page 49: ...efer to the Section 5 for relay functions and interconnect Upper Control Power Relay Purpose Cuts power to Upper Controls when Lower Controls are selected Torque Speed Relay Purpose Disperses power to...

Page 50: ...portional circuit board to enable elevated drive speed OPTIONAL OUTRIGGERS SWITCHES If the machine is equipped with outriggers each of the four 4 outriggers has a Stowed Switch and a Pressure Switch O...

Page 51: ...85 terminal grounded apply voltage to 86 terminal connection Confirm normally closed 87A contacts are opening Continuity with 30 will be broken Confirm normally open 87 contacts are closing Continuity...

Page 52: ...March 2008 3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page 2 12...

Page 53: ...carriage 3 3 Raising the Machine 3 3 Tires 3 4 Drive Motors 3 5 Steer Cylinder 3 6 Hoses and Cables 3 7 Platform Removal 3 7 Lift Cylinder Removal and Installation 3 8 Scissor Beam Assembly 3 8 Engine...

Page 54: ...0 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 70 115 176 233 335 450 573 863 1181 11 27 47 84...

Page 55: ...support the machine a jack with a lifting capacity of two 2 tons or more jack stands with a rating of one 1 ton or more To raise the machine 1 Move machine to a firm level surface capable of supportin...

Page 56: ...e tires with the correct tires to maintain the rating of this equipment Changing Tires FOAM FILLED TIRES ARE EXTREMELY HEAVY CARE MUST BE TAKEN TO AVOID PERSONAL INJURY Always block the wheels before...

Page 57: ...ne see Raising the Machine 2 Remove the wheel and tire as sembly 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 Tu...

Page 58: ...e see Raising the Machine 1 Disconnect hydraulic hoses and cap them 2 Remove the nut and bolt holding the steer cylinder to the motor mounting bracket 3 Remove the pin and cotter pin holding the steer...

Page 59: ...damaged hose or cable 1 Tag hoses for proper reassembly 2 Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination 3 Torque hose fittings according to the Hydraulic Torque Specifica...

Page 60: ...lift cylinder s 3 Use a suitable lifting device to support the lift cylinder 4 Remove retaining pins and rod end pin 5 Lift the cylinder from the scissor assembly using a suitable lifting device CAUTI...

Page 61: ...ntainer to catch drained oil Remove the drain plug After oil has drained replace the drain plug 2 Remove the old filter and wipe the filter seal contact surface with a clean towel Coat the seal on the...

Page 62: ...ter Idle Speed Adjustment Diesel 1 Bring engine to operating temperature 2 Slow engine to complete idle 3 Adjust the Idle Stop Screw until the RPM is 950 Adjust slightly up or down to avoid vibrations...

Page 63: ...grasping the piston just ahead of the boot and pull to the fully retracted position 2 With the solenoid piston fully retracted measure the distance between the High Speed Stop Screw and the Throttle...

Page 64: ...l and tighten by hand 3 Fill engine with 10w 30 motor oil until the dipstick indicates FULL Capacity is 3 4 US quarts 3 25 l 4 Recheck dipstick after running engine Fill as necessary Fuel Filter Gasol...

Page 65: ...tract the Choke Solenoid Piston until it stops 3 While holding the solenoid fully retracted close the choke plate until it stops in the fully closed position 4 Allow the choke plate to open slightly a...

Page 66: ...eveling capabilities the outrigger control system will continue to attempt to level and the engine will not return to idle In this case if the platform remains outside of the pre described tilt sensor...

Page 67: ...usted UP DOWN BUTTONS Adjust setting values GP106 Outrigger Control Module Calibrator MEC P N 90888 Connects to P1 Outriggers Relay Outrigger Calibration Before attempting the calibration procedure mo...

Page 68: ...o level ground b Plug EZ Cal into connector P1 on the control module Display reads HELP PRESS ENTER c Press right arrow to ACCESS LEVEL 3 Press Enter Display reads CODE 0000 d Press up and right arrow...

Page 69: ...Ensure that the GP106 is correctly installed if it is wrongly oriented its integral tilt sensor will be unable to measure vehicle tilt correctly CHECK OUTRIGGERS SUPPLY P4 9 An auto level or auto retr...

Page 70: ...fault with the stable output of the GP106 a short to the supply has been detected Check wiring from pin P2 8 LED flash code 4 This indicates that the outriggers cannot be operated because the machine...

Page 71: ...Page 4 1 SECTION 4 TROUBLESHOOTING SECTION 4 TROUBLESHOOTING 4 1 Troubleshooting 4 3 General Troubleshooting Tips 4 3 Common Causes of Hydraulic System Malfunctions 4 3 Hydraulic Pressure Adjustment...

Page 72: ...K HIGH TORQUE 313 YEL BLK HAND PUMP BRAKE RELEASE STEER RIGHT 107 ORG WHT HIGH SPEED 213 YEL WHT TO TANK LOAD SENSE TO PUMP RIGHT FRONT A LEFT FRONT B RIGHT REAR B LEFT REAR A LEFT FRONT A BRAKE PORT...

Page 73: ...emergency stop button is released UP OUT position Check that the hydraulic fluid is at the correct level Check that the circuit breaker is in the ON position not tripped Common Causes of Hydraulic Sys...

Page 74: ...ergized Lowering valve SV 5 stuck open located at base of lift cylinder CYL 1 Level Sensor out of level platform elevated above 6 Main system pressure inadequate Proportional control out of adjustment...

Page 75: ...al Controller Adjustment in this section Check Drive Enable light raise outriggers Check enable light on Platform Controls box Check outrigger switches located on top of each outrigger jack for contin...

Page 76: ...al valve SP 1 Check replace valve EC1 Check voltage and ground to valve Check for faulty SV2 valve Check power on wire 25A on switch Check switch in Joystick handle Check for internal leakage repair C...

Page 77: ...ing engine crank Check fuel pump operation No Engine start Starter operates continued Diesel Engine Starter inoperative No Engine start Starter operates Engine starts but dies when starter disengaged...

Page 78: ...perating glow plugs Power on these wires should 12 volts on ORG BLU wire 224 Check for 12 volts at glow plugs while operating glow plugs end Trouble Table Dual Fuel Engine LP Starter inoperative No En...

Page 79: ...000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no 8434 MODEL 3072RT 3772RT MAIN 2800 PSI 193 bar 2800 PSI 193 bar LIFT 2500 PSI 172 4 bar 2500 PSI...

Page 80: ...am nut and install the acorn nut 6 Check the gauge reading again to ensure the setting did not change 7 Turn the Standby adjustment screw counterclockwise until the gauge reads 550 PSI 38bar Tighten t...

Page 81: ...verpressure valves are located on each of the lift cylinder valve blocks on the 3772RT model only Proper valve adjustment is not possible by the consumer Considering their importance to the safe opera...

Page 82: ...urse measured at 20 feet 6 meters long Ensure there are no obstructions preventing a straight travel over the distance of the course including leading up to and away from the course Try not to steer w...

Page 83: ...point While holding the Joystick in that position adjust the THRESH trim pot until the platform does NOT lift Once adjusted slight additional reverse motion of the Joystick should result in very slow...

Page 84: ...Gasoline Propane Dual Fuel Platform Chassis Engine Stop Red Throttle Green Lower Green Raise Green Engine Start Stop Power Relay Lift Drive Speed Torque Emergency Stop Choke Glow Plug Generator Optio...

Page 85: ...2008 Page 5 1 SECTION 5 SCHEMATICS SECTION 5 SCHEMATICS 5 1 Hydraulic Schematic 5 2 Main Hydraulic Manifold 5 4 Optional Outriggers Hydraulic Manifold 5 5 Electric Schematics 5 6 Circuit Board 5 8 Con...

Page 86: ...Pressure Compensated Return Filter 10 Micron Cylinder Steering Optional Outriggers Components Outrigger Cylinder Solenoid Valve Poppet N C Solenoid Valve Poppet N C Spool Valve 4Way 3 Position Callou...

Page 87: ...IFT CYLINDER 3772RT ONLY MA 3 073 3072RT ONLY LOWER LIFT CYLINDER STEERING LIFT CYLINDER RV4 SV6 SV5 SV7 SV7 SV8 SV8 CYL5 CYL5 CYL5 CYL5 SV7 SV7 SV8 SV8 SV9 CYL3 ORF4 ORF3 RV4 RV3 RV3 CV1 CV2 SV2 SV1...

Page 88: ...PLG4 OPL6 PLG4 OPL5 PLG4 PLG4 PLG6 CBV1 CBV2 PLG6 OPL6 PLG4 PLG4 PLG4 PLG4 PLG4 SVD1 FD1 EP1 LS2 PLG4 LS1 CV1 CV2 LS3 PD1 PD2 PD3 FD2 EP1 HP1 EC1 SV1 CL2 SP1 CL3 RV1 RV2 SV3 CL1 MP1 OD1 SV4 CL1 SV2 C...

Page 89: ...72RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications March 2008 Page 5 5 Optional Outriggers Hydraulic Manifold BOTTOM RIGHT LEFT FRONT ORA ORLS ORS ORB ORR PLG4 PLG10 CAV1 CV1 SV1 CL1 CL1 C...

Page 90: ...March 2008 3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page 5 6 A B C D ELECTRIC SCHEMATICS...

Page 91: ...3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications March 2008 Page 5 7 A A B C C TILT SENSOR MAIN HARNESS ANSI...

Page 92: ...3772RT HD Service Parts Manual ANSI Specifications Page 5 8 Circuit Board The Circuit Bard schematic is broken into two pages for clarity The cable connections are shown on this page Match the number...

Page 93: ...3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications March 2008 Page 5 9...

Page 94: ...BLK 3 RED PLUG NUMBERS FORWARD DOWN S3 S1 ROCKER STEER L R ENABLE REVERSE UP PPL BLU YEL GRN 3A 31 32 31 BLU BLK 3 PPL 8 GRN 7 ORG 25 GRN WHT 101A RED 38 PNK WHT 104 BLU RED 15 BLK 6 ORG BLK 3 PPL 25...

Page 95: ...EVERSE UP PPL BLU YEL GRN 3A 31 32 31 BLU BLK 3 PPL 8 GRN 7 ORG 25 GRN WHT 101A RED 38 PNK WHT 104 BLU RED WHT ORG GRN BLK 15 BLK 6 ORG BLK 3 PPL GRY 57 RED BLU 301 EXTEND RETRACT PNK WHT 69 YEL 68 GR...

Page 96: ...March 2008 3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page 5 12...

Page 97: ...3772RT 3772RT HD Service Parts Manual ANSI Specifications March 2008 Page 5 13 CONTROL MODULE POWER MODULE ENGINE RUN SOLENOID 10 GA RED 00 12 GA RED 00 14 GA RED 00 BATTERY CABLE BLK BATTERY CABLE RE...

Page 98: ...h 2008 3072RT 3772RT 3772RT HD Service Parts Manual ANSI Specifications Page 5 14 CONTROL MODULE POWER MODULE BATTERY CABLE BLK BATTERY CABLE RED LIQUID PROPANE GASOLINE 10 GA RED 00 14 GA RED 00 RED...

Page 99: ...INAL S17 B VCC1 ALARM TERMINAL THROTTLE SWITCH TERMINAL 4 PCB TERMINAL S5 LOWER CONTROL BOX RED WHT 201 ORG BLU 125 BLK ORG 125 BLK ORG 125 1 2 3 4 PPL PPL LR RR RF LF PPL LF BRN BLK 60 BLK 15 BLK 15...

Page 100: ...WHT RED UPPER CONTROLS EXISTING UPPER CONTROL CABLE GENERATOR TOGGLE SWITCH ALT N O N C N C N C ORG BLK BLK BLK BLK ORG ORG ORG ORG GRN ORG GRN ORG GRN ORG BLK INTERMEDIATE HARNESS RED WHT POWER MODUL...

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