Mec 6092RT - CE Rough Terrain Scissor Lift Service And Parts Manual

SERVICE AND PARTS MANUAL

4069RT

ART_4480

Serial Number Range

13500001 - Up

Part # 93080

November 2013

Revision History

Original Release Date: November 2013

Date

November

2013

Reason for Update

New Release

Aerial Platform Sales Corp.

1401 S. Madera Avenue • Kerman, CA 93630 USA

877-632-5438 • 559-842-1500 • Fax: 559-842-1520

[email protected] • www.MECawp.com

93080 | 4069RT

Service Table of Contents

Introduction I Page

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II

MEC Operator Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV

General Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Primary Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Emergency Systems and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

Free-Wheel Configuration For Winching or Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI

Lift and Support the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII

Section 1: Hydraulic System Page

Hydraulic System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Roadmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

System Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hydraulic Pump Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Functions Manifold & Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Hydraulic Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Lift Vent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Rear Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Brake Release Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Drive Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

General Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Section 2: Electrical System Page

Electrical System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Battery Maintenance (in storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

“4069RT” Service and Parts Manual March 2014

Page i

Service Table of Contents

Battery Maintenance (in use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Lower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Upper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Alarms and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

GP400 Control Module Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

GP400 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Failure Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Information Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Section 3: Mechanical Components Page

Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Scissor Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Rear Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Front Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

DIESEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

DUAL FUEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Section 4: Troubleshooting Page

General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

EZ-Cal Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Optional Onboard EZ-Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

EZ-Cal Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

EZ-Cal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

EZ-Cal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Ez-Cal Retrieve Mode And Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

MODE Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

OTHER Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

March 2014

Page ii

“4069RT” Service and Parts Manual

Service Table of Contents

Section 5: Schematics Page

Hydraulic Schematics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

“4069RT” Service and Parts Manual March 2014

Page iii

N

O T E S

:

Service Table of Contents

March 2014

Page iv

“4069RT” Service and Parts Manual

INTRODUCTION

This manual consists of Service and Illustrated Parts sections.

The Service Section of this manual is designed to provide you, the customer, with the instructions needed to properly maintain the MEC self-propelled aerial work platform. When used in conjunction with the Illustrated Parts Section and the Operators Manual (provided separately), this manual will assist you in making necessary adjustments and repairs, and identifying and ordering the correct replacement parts.

All parts represented here are manufactured and supplied in accordance with MEC quality standards.

We recommend that you use genuine MEC parts to ensure proper operation and reliable performance.

To obtain maximum benefits from your MEC Aerial Work Platform, 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 and study the Operator’s, Service and

Parts Manuals in order to gain a thorough understanding of the unit prior to making any repairs.

C

ONTENTS

P

AGE

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

MEC Operator Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV

General Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI

Primary Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Emergency Systems and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

Free-Wheel Configuration For Winching or Towing . . . . . . . . . . . . . . . . . . . . . . XI

Lift and Support the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII

F

IGURES

P

AGE

Support Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

“4069RT” Service and Parts Manual March 2014

Page I

M

ACHINE

S

PECIFICATIONS

4069RT

Working Height*

Platform Height

Maximum Drive Height

Stowed Height Top Guardrail

Rails Folded

Platform Floor

Guardrail Height

Toeboard Height

Machine Weight** (Unloaded)

Lift Capacity Total

Platform

Sheet Material Rack

Deck Extension Capacity

Maximum Occupants

Length-Stowed (Overall)

Length-Stowed (Without Step)

Length-Stowed, with optional Outriggers

46 ft

40 ft

40 ft

95.5 in.

64 in.

51 in.

43.5 in.

6 in.

14 m

12 m

12 m

2.43 m

1.63 m

1.3 m

1.11 m

15 cm

11,000 lb

900 lb

600 lb

4,990 kg

410 kg

274 kg

300 lb 136 kg

1 Person / 250 lb (113 kg)

2

126 in.

125 in.

145 in.

3.2 m

3.18 m

3.64 m

Platform Length (Extended)

Platform Length (Retracted)

Width (Overall)

Platform Width (Outside)

Sheet Rack Width

Wheel Base

Turning Radius--Inside

Ground Clearance

Drive Speed (Proportional) Platform Stowed

Platform Elevated†

Gradability

Breakover Angle

Optional Outrigger Range Of Motion

Maximum Ground Pressure, Wheel

166 in.

118 in.

69 in.

59 in.

7 in.

94.5 in

79 in.

10 in

0-3.4 mph

0-.5 mph max.†

40%/21.8°

42%/23°

4.22 m

3 m

1.75 m

1.5 cm

18 cm

2.4 m

2 m

25 cm

0-5.5 km/h

0-.8 km/h max.†

10° side to side

Maximum Ground Pressure, Outrigger Pad

123 psi

56 psi

8.6 kg/cm

2

3.9 kg/cm

2

Maximum Wheel Load

Maximum Operating Wind Speed

Tire Size

Tire Pressure

Wheel Bolt Torque

Hydraulic Pressure

3540 lb

55 ft/lb

1605 kg

28 mph / 12.5 m/sec (45 km/h)

26" x 12" / 66 cm x 33 cm

55 psi

74.6 Nm

Drive System

Lift System

3500 psi/ 240 bar

3200 psi / 220 bar

14 gal / 53 liter Hydraulic Fluid Capacity

System Voltage

Fuel Capacity

Battery

12 Volt DC

15 gal/ 57 liter

Type 31 1000CCA

Engine

Diesel --

Kubota D1105 24.8 HP (18.8 kW) Tier 4

Dual Fuel --

Kubota DF752, 20HP (14.9 kW)

Meets applicable requirements of ANSI A92.6-2006.

*Working Height adds 6 feet (2 m) to platform height. **Weight may increase with certain options.

†Drive speed while elevated is inversely proportional to platform height; the higher the platform is, the lower the maximum elevated drive speed. The machine is driveable at full height.

March 2014

Page II

“4069RT” Service and Parts Manual

MEC O

PERATOR

P

OLICY

NOTE: The best method to protect yourself and others from injury or death is to use common sense. If you are unsure of any operation, don’t start until you are satisfied that it is safe to proceed and have discussed the situation with your supervisor.

Service personnel and machine operators must understand and comply with all warnings and instructional decals on the body of the machine, at the ground controls, and platform control console.

MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND

SPECIFICATIONS WITHOUT WRITTEN PERMISSION FROM MEC ARE STRICTLY

FORBIDDEN. A MODIFICATION MAY COMPROMISE THE SAFETY OF THE

MACHINE, SUBJECTING OPERATOR(S) TO SERIOUS INJURY 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 change without notice.

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.

MEC, as manufacturer, has no direct control over machine application and operation. Proper safety practices are the responsibility of the user and all operating personnel.

If there is a question on application and/or operation contact:

MEC Aerial Work Platform

1401 S. Madera Avenue

Kerman, CA 93630 USA

Ph: 1-800-387-4575 www.mecAWP.com

“4069RT” Service and Parts Manual March 2014

Page III

S

AFETY

S

YMBOLS

To help you recognize important safety information, we have identified warnings and instructions that directly impact on safety with the following signals:

“DANGER” INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF

NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME SITUATIONS.

“WARNING” INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF

NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.

“CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. 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.

March 2014

Page IV

“4069RT” Service and Parts Manual

G

ENERAL

S

AFETY

T

IPS

Regular inspection and conscientious maintenance is the key to efficient economical operation of your aerial work platform. It will help to assure that your equipment will perform satisfactorily with a minimum of service and repair.

The actual operating environment of the machine governs the inspection schedule. Correct lubrication is an essential part of the preventative maintenance to minimize wear on working parts and ensure against premature failure. By maintaining correct lubrication, the possibility of mechanical failure and resulting downtime is reduced to a minimum.

• Never leave hydraulic components or hoses open. They must be protected from contamination (including rain) at all times.

• Never open a hydraulic system when there are contaminants in the air.

• Always clean the surrounding area before opening hydraulic systems.

• 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.

M

A I N T E N A N C E

L

O C K

DEATH OR SERIOUS INJURY HAZARD!

NEVER PERFORM WORK OR INSPECTION ON THE MACHINE WITH THE

PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE SCISSOR ASSEMBLY

WITH THE MAINTENANCE LOCK.

Figure 1-1:

Support Platform

To set the Maintenance Lock, raise the platform enough to allow the Maintenance

Lock to rotate to vertical. Carefully lower the platform until the pin above rests securely on the Maintenance Lock.

ART_4283

“4069RT” Service and Parts Manual March 2014

Page V

H

Y D R A U L I C

S

Y S T E M

HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN,

DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND EVEN

DEATH.

CORRECT LEAKS IMMEDIATELY.

Hydraulic fluid leaks under pressure may not always be visible. Check for pin hole leaks with a piece of cardboard, not your hand.

E

L E C T R I C A L

S

Y S T E M

Prevent damage to battery and/or electrical system;

• Always disconnect the negative battery cable first.

• Always connect the positive battery cable first.

When the negative cable is installed, a spark will occur if contact is made between the positive side of the battery and a metal surface on the machine. This can cause damage to the electrical system, battery explosion, and personal injury.

T

O T A L

S

Y S T E M

FAILURE TO PERFORM PREVENTIVE MAINTENANCE AT RECOMMENDED

INTERVALS MAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT

THAT COULD RESULT IN INJURY OR DEATH OF THE OPERATOR.

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.

March 2014

Page VI

“4069RT” Service and Parts Manual

P

RIMAR Y

M

ACHINE

C

OMPONENTS

Figure 1-2:

Component Locations

Deck

Extension

Platform

Controls

Entry Gate

Platform

Lift Cylinders

Sheet

Materials

Rack

Maintenance

Lock

Air Filter

Engine

Entry Ladder

Fuel

Tank

Hydraulic

Pump

Battery

Disconnect

Switch

Lower Controls

Battery

Hydraulic Manifold

Hydraulic Tank

Chassis

Controls

Module

Module Covers removed for clarity

ART_4403

“4069RT” Service and Parts Manual March 2014

Page VII

T

ORQUE

S

PECIFICATIONS

F

ASTENERS

Use the following values to apply torque unless a specific torque value is called out for the part being used.

SAE GRADE

AMERICAN STANDARD CAP SCREWS

5 8

CAP SCREW

SIZE

- inches -

FT. LBS

MIN

TORQUE

MAX

Nm

MIN MAX

1/4 - 20 6.25

1/4 - 28

8

5/16 - 18

5/16 - 24

3/8 - 16

3/8 - 24

14

17.5

26

31

7/16 - 14

7/16 - 20

1/2 - 13

41

51

1/2 - 20

9/16 - 12

9/16 - 18

5/8 - 11

5/8 - 18

3/4 - 10

65

76

95

111

126

152

3/4 - 16

7/8 - 9

7/8 - 14

1 - 8

1 - 14

238

274

350

407

537

670

7.25

9

15

19

28

34

45

55

72

84

105

123

139

168

262

302

386

448

592

740

103

129

150

171

206

322

371

474

551

728

908

8.5

11

19

23

35

42

55.5

69

88

114

142

167

188

228

255

409

523

607

802

1003

10

12

20

26

38

46

61

74.5

97.5

FT. LBS

MIN

TORQUE

MAX

Nm

MIN MAX

35

41

55

68

86

102

8.25

10.5

18.5

23

365

466

543

716

894

127

148

168

203

318

140

164

185

224

350

402

515

597

790

987

37

45

60

75

96

112

9.5

12

20

25

172

200

228

275

431

495

631

736

970

1211

55.5

74.5

92

116

138

11

14

25

31

47.5

222

251

304

474

544

698

809

1070

1137

61

81

102

130

152

190

13

16

27

34

50

METRIC GRADE

METRIC CAP SCREWS

8.8

10.9

8.8

10.9

M6 X 1.00

M8 X 1.25

M10 X 1.50

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

CAP SCREW

SIZE

- millimete r s-

210

301

404

517

779

1066

8

20

35

62

103

158

FT. LBS

TORQUE

FT. LBS

TORQUE

Nm Nm

MIN MAX MIN MAX MIN MAX MIN MAX

130

172

247

332

423

637

6

16

29

52

85

872

8

21.5

39

70

115

176

233

335

450

573

863

1181

11

27

47

84

139

214

284

408

547

700

1055

1444

9

23

42

75

120

176

240

343

472

599

898

1224

11

27

52

91

146

216

294

426

576

732

1098

1496

12

31

57

102

163

238

325

465

639

812

1217

1658

15

36.5

70

123

198

293

398

577

780

992

1488

2027

Torque values apply to fasteneers as received from the supplier, dry or when lubricated with normal engine oil.

If special graphite grease, molydisulphide grease, or other extreme pressure lubricants are used, these torque values do not apply.

H

YDRAULIC

C

OMPONENTS

T

ORQUE

T

ABLE

NOTE: Always lubricate threads with clean hydraulic fluid prior to installation.

Use the following values to torque hydraulic components when a specific value is not available. Always check for torque values in the following places before relying on the

Hydraulic Components Torque Table:

• parts drawings and service instructions in this manual.

• packaging and instruction sheets provided with new parts.

• instruction manuals provided by the manufacturer of the component being serviced.

TYPE: SAE PORT SERIES

#4

#6

#8

#10

#12

#16

CARTRIDGE POPPET

FT. LBS Nm

N/A

N/A

25 - 30

35 - 40

85 - 90

130 - 140

N/A

N/A

31 - 41

47 - 54

115 - 122

176 - 190

FT. LBS

N/A

10 - 20

25 - 30

35 - 40

85 - 90

130 - 140

FITTINGS

Nm

N/A

14 - 27

34 - 41

47 - 54

115 - 122

176 - 190

FT. LBS

135 - 145

215 - 245

430 - 470

680 - 750

950 - 1050

1300 - 1368

HOSES

Nm

15 - 16

24 - 28

49 - 53

77 - 85

107 - 119

147 - 155

March 2014

Page VIII

“4069RT” Service and Parts Manual

E

MERGENCY

S

YSTEMS AND

P

ROCEDURES

IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED, HAVE

AN EXPERIENCED OPERATOR USE THE EMERGENCY LOWERING PROCEDURE

TO SAFELY LOWER THE PLATFORM.

DO NOT ATTEMPT TO CLIMB DOWN ELEVATING ASSEMBLY.

E

M E R G E N C Y

S

T O P

Figure 1-3:

Emergency Stop Buttons

The machine is equipped with an EMERGENCY STOP switch at the base controls and at the platform control box.

• Press the EMERGENCY STOP switch at any time to stop all machine functions.

• Turn switch

clockwise

to reset.

ART_3817

S

ELECTOR

S

WITCH SET TO

PLATFORM

• Either switch will stop all machine functions.

• Both switches must be reset or machine will not operate.

S

ELECTOR

S

WITCH IS SET TO

BASE

• The upper controls are locked out.

• The lower controls switch must be reset or the machine will not operate.

ART_3866

• The machine will not operate from the lower controls if the upper controls switch is tripped.

“4069RT” Service and Parts Manual March 2014

Page IX

E

M E R G E N C Y

L

O W E R I N G

IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED,

USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE

PLATFORM.

DO NOT CLIMB DOWN THE ELEVATING ASSEMBLY OR EXIT THE PLATFORM.

Figure 1-4:

Emergency Lowering

The Emergency Lowering

System is used to lower the platform in case of power failure.

To lower the platform, push down on the Emergency

Lowering Switch, located on the Base Control panel.

ART_4281

March 2014

Page X

“4069RT” Service and Parts Manual

F

R E E

- W

H E E L

C

O N F I G U R A T I O N

F

O R

W

I N C H I N G O R

T

O W I N G

RUNAWAY HAZARD!

AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP MACHINE

TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES.

ALWAYS CHOCK THE WHEELS BEFORE MANUALLY RELEASING THE BRAKES.

The machine can be winched or towed short distances at speeds not to exceed 5 MPH

(8 km/h). Before towing or winching the machine, it is necessary to release the brakes.

Reset the brakes after towing or winching.

Hand Pump

ART_4293

Release

Valve

D

ISENGAGE

B

RAKES BEFORE

T

OWING OR

W

INCHING

• Chock the wheels.

• Press and hold the Brake Release Valve, then slowly press the Hand Pump button on the

Functions Manifold repeatedly until the brakes release (normally 8-10 full pump strokes).

E

NGAGE

B

RAKES BEFORE

D

RIVING

The brakes reset automatically when the motor is started.

The brakes may be manually applied by pulling the Brake Release Valve out.

BE SURE THAT THE BRAKES ARE ENGAGED BEFORE REMOVING THE WHEEL

CHOCKS.

“4069RT” Service and Parts Manual March 2014

Page XI

L

IFT AND

S

UPPORT THE

M

ACHINE

DEATH OR SERIOUS PERSONAL INJURY MAY RESULT FROM THE USE OF

SUBSTANDARD LIFTING DEVICES AND/OR JACK STANDS. ENSURE THAT ALL

LIFTING DEVICES AND JACK STANDS ARE OF ADEQUATE CAPACITY AND IN

GOOD WORKING CONDITION BEFORE USE.

The following are needed to safely lift and support the machine;

• a jack with a lifting capacity of three (3) tons or more.

• jack stands with a rating of three (3) tons or more.

T

O RAISE THE 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. If wheel is to be removed, break loose but do not remove the lug bolts before raising the machine.

4. Position a jack at the end of the machine to be lifted, under a solid lifting point in the center of the frame.

5. Raise the machine and place two (2) suitable jack stands under solid support points at the outer ends of the frame.

6. Lower the machine to rest on the jack stands and inspect for stability.

T

O LOWER THE MACHINE

1. Tighten lug bolts to proper torque (refer to machine specifications).

2. Raise machine slightly and remove jack stands.

3. Lower the machine and remove the jack.

4. Remove chocks.

March 2014

Page XII

“4069RT” Service and Parts Manual

Section 1

C

ONTENTS

H

YDRAULIC

S

YSTEM

P

AGE

Hydraulic System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Roadmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

System Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hydraulic Pump Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Functions Manifold & Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Hydraulic Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Lift Vent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Rear Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Brake Release Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Drive Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

General Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

“4069RT” Service and Parts Manual March 2014

Page 1-1

F

IGURES

P

AGE

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hydraulic Pump Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Functions Manifold - Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Adjustable Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Lift Vent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Rear Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Brake Release Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Drive Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Typical Cylinders, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

March 2014

Page 1-2

“4069RT” Service and Parts Manual

H

Y D R A U L I C

S

Y S T E M

– G

E N E R A L

H

YDRAULIC

S

YSTEM

– G

ENERAL

The hydraulic integrated circuit, generally known as the valve-type manifold system is designed to control all or part of machine functions by integrating various hydraulic cartridge valves into a manifold to provide directional, pressure, flow, and load control.

The hydraulic system is a feedback, load-sensing type. Generally in this type of system, hydraulic fluid is provided by a variable displacement, pressure compensated, axial piston type pump which is directly coupled to the engine. As the engine turns, the hydraulic pump drains fluid from the reservoir and pumps this fluid to the Functions

Manifold.

If no function is in use, the pump remains on standby and no fluid is pumped to the manifold. Each function has a maximum pressure control limit set by pressure relief valve.

Figure 1-1:

Hydraulic System

Hydraulic

Reservoir

Functions

Manifold

Upper Lift

Cylinder

Lower Lift

Cylinder

Rear Wheel

Motor/Brake

Hydraulic

Pump

Front Wheel

Motor/ Brake

ART_4481

Outrigger

Cylinder x4

“4069RT” Service and Parts Manual

Steer

Cylinder

March 2014

Page 1-3

H

Y D R A U L I C

S

Y S T E M

– G

E N E R A L

H

Y D R A U L I C

R

O A D M A P

H

YDRAULIC

R

ESERVOIR

Hydraulic fluid is held in the reservoir for delivery to the various components and then returned to the reservoir. Returning hydraulic fluid is routed through a filter before entering the reservoir. The reservoir also serves as the oil cooling device.

P

UMP

The pump delivers hydraulic fluid under pressure to the Functions Manifold.

F

UNCTIONS

M

ANIFOLD

The Functions Manifold directs the hydraulic fluid to the hydraulically operated components and returns fluid to the reservoir through the use of electronically operated solenoid valves.

D

RIVE AND

B

RAKE

S

YSTEM

There are four (4) hydraulic gear wheel motors that provide power to all four wheels.

All wheel motors have integral spring-held brakes. The brakes are released by hydraulic pressure developed in the drive circuit when the drive functions is in use. A fixed orifice in the brake circuit controls the deceleration rate and initiates a smooth stop.

S

TEERING

S

YSTEM

Two (2) hydraulic cylinders control steering.

P

LATFORM

L

IFT

S

YSTEM

The machine is equipped with two (2) hydraulic lift cylinder.

O

UTRIGGER

S

YSTEM

On machines equipped with outriggers, four outrigger cylinders level the machine on uneven ground.

March 2014

Page 1-4

“4069RT” Service and Parts Manual

H

Y D R A U L I C

F

L U I D

H

YDRAULIC

F

LUID

H

A N D L I N G

P

R E C A U T I O N S

PERSONS IN REGULAR CONTACT WITH MINERAL-BASED HYDRAULIC

FLUID NEED TO BE AWARE OF THE IMPORTANCE OF THOROUGH

HYGIENE AND 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

QUANTITIES OF WATER. SEEK MEDICAL ATTENTION IF IRRITATION

PERSISTS.

HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN

SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY OR

BLINDNESS.

FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE.

BEWARE OF HOT FLUID. CONTACT WITH HOT FLUID MAY CAUSE

SEVERE BURNS.

F

L U I D

R

E C O M M E N D A T I O N S

Do not substitute lower grade fluids as pump damage may result.

ITEM SPECIFICATION FREQUENCY

Hydraulic Fluid

Normal ambient temperatures

Mobile Fluid DTE 10, DTE 13 M, or AW32

Ambient temperatures below 0° F (-18° C)

Chevron Rando Premium MV

Routine Maintenance

Check sight gauge level daily

Scheduled Maintenance

Change yearly or every 600 hours,

whichever occurs first

Do not substitute other fluids as pump damage may result.

Fill to the middle of the sight gauge with platform in the stowed position and outriggers retracted.

Hydraulic Filter Filter Element

(located inside Hydraulic Reservoir)

Scheduled Maintenance

Normal Conditions

Change every six months or 300 hours, whichever occurs first

Severe Conditions--very dusty, exceptionally hot or exceptionally cold conditions

Change every three months or 150 hours, whichever occurs first

S

Y S T E M

F

L U S H I N G

P

R O C E D U R E

Dispose of used hydraulic fluid in accordance with local regulations.

1. With platform fully down, drain the hydraulic fluid from hydraulic reservoir into a clean, empty container.

2. When the hydraulic reservoir is empty, remove the hoses.

3. Flush the hoses with clean hydraulic fluid.

“4069RT” Service and Parts Manual March 2014

Page 1-5

H

Y D R A U L I C

F

L U I D

4. Flush out the reservoir with hoses removed from the hydraulic reservoir.

5. Change the hydraulic fluid filter.

6. Reinstall all hoses removed in previous steps.

7. Fill hydraulic reservoir with filtered, fresh hydraulic fluid (refer to Lubrication Chart).

8. Loosen output hose fittings at pump to flood with hydraulic fluid. Tighten fittings.

9. Start up the machine. Briefly operate all functions. Two or three lift cycles may be necessary to purge all air from lift cylinder(s).

10. When the above procedures have been completed, fill hydraulic reservoir to full mark on sight gauge.

11. Check all leaks and correct as necessary. Machine is now ready to be placed back in operation.

NOTE: Avoid mixing petroleum and synthetic base fluids. It is not advisable to mix fluids of different brands or types, except as recommended.

March 2014

Page 1-6

“4069RT” Service and Parts Manual

H

Y D R A U L I C

F

L U I D

R

E S E R V O I R

H

YDRAULIC

F

LUID

R

ESER VOIR

The Hydraulic Fluid Reservoir consists of the reservoir, a filler cap with breather, a return filter assembly, a drain plug, a suction strainer and a sight gauge. Check the reservoir for signs of leakage weekly.

Check the level of the Hydraulic Fluid Reservoir with the platform fully lowered.

DO NOT overfill.

Figure 1-2:

Hydraulic Fluid Reservoir

Filter

Housing

Sight Gauge

Hydraulic

Reservoir

H

Y D R A U L I C

F

I L T E R

ART_4482

BEWARE OF HOT FLUID. CONTACT WITH HOT FLUID MAY CAUSE

SEVERE BURNS.

All machines are equipped with a bypassing filter where the hydraulic fluid returns to the tank (see Figure 1-2). When the filter is clogged, hydraulic flow bypasses the filter element. The filter element must be changed every six months or 300 hours. Extremely dirty conditions may require the filter to be replaced more often.

To replace:

• Unscrew the filter assembly cap, then remove the filter

• Place the new filter into position and press firmly into place

• Carefully thread the filter assembly cap, then hand-tighten only.

“4069RT” Service and Parts Manual March 2014

Page 1-7

H

Y D R A U L I C

P

U M P

H

YDRAULIC

P

UMP

• Clean all fittings before disconnecting hoses.

• Tag hoses for proper reassembly.

• Plug all openings to prevent contamination.

Figure 1-3:

Hydraulic Pump

An internal combustion engine drives a variable displacement axial piston pump.

R

EMOVE

1. Place a large container under the engine and pump to catch fluid that will be lost during pump replacement. Dispose of used fluid properly.

2. Tag and disconnect hydraulic hoses, and IMMEDI-

ATELY cap or cover

ART_4483 the openings to prevent contamination.

3. Remove the two bolts that hold the pump to the housing.

4. Remove the pump.

Hydraulic

Pump Unit

I

NSTALL

1. Install drive hub onto pump shaft. Torque bolt to 45 Ft. Lbs. (61 Nm).

2. Position the pump next to the housing. Turn the pump until the splines on the hub align allowing the pump to become flush with the housing.

3. Turn the pump until the bolt holes align with the mounting holes on the housing and install the bolts. Torque to 25-28 Ft. Lbs. (35-38 Nm).

4. Install the hydraulic hoses.

5. Check for leaks and check all hydraulic pressures.

March 2014

Page 1-8

“4069RT” Service and Parts Manual

H

Y D R A U L I C

P

U M P

H

Y D R A U L I C

P

U M P

S

E A L S

D

RIVE

S

HAFT

S

EAL

R

EPLACEMENT

Caution: Be careful not to damage the drive shaft when removing the old seal.

1. Remove the shaft key.

2. Remove the snap ring.

3. Remove the shaft seal.

• Check the surface of the shaft and the housing for imperfections.

4. Install new shaft seal.

• Cover the keyway portion of the drive shaft with tape to prevent damage to the seal during installation.

• Coat the shaft seal with grease.

• Seat the shaft seal with a seal setting tool.

5. Install the snap ring.

6. Install the shaft key.

H

YDRAULIC

P

UMP

R

EBUILD

Pump rebuild should be performed only by a qualified mechanic. Contact MEC

Technical Support before attempting to rebuild the pump.

“4069RT” Service and Parts Manual March 2014

Page 1-9

Snap Ring

Groove

Snap Ring

Shaft Seal

Drive shaft splines

Covered with tape

To protect seal during

Installation

Roller

Bearing

Bearing

Shaft Seal Installation

Case Drain

Port

Swash

Plate

Control

Piston

ART_3900

March 2014

Page 1-10

Suction Port

Minimum Flow

Adjustment

Pressure Port

Main Pressure

Adjustment

Standby Pressure

Adjustment

Rotary

Group

Retainer Ball

Seal Pins

Spring

Control

Piston

Guide

O-ring

Line Sense

Port

Allen

Head

Screws

Control

Valve

Min Flow

Stopper

Stop Nut

Cap Nut

“4069RT” Service and Parts Manual

H

Y D R A U L I C

P

U M P

Figure 1-4:

Hydraulic Pump Seals

Snap

Ring

Shaft

Seal

Housing

Bearing

Shell

Drive

Shaft

Retainer

Plate

Piston

Pistons

(9 total)

Piston

Spring

Piston

Cylinder

Piston Guide

Shim

Shim

Snap Ring

Bearing

Port

Body

Allen

Head

Screws

F

U N C T I O N S

M

A N I F O L D

& H

Y D R A U L I C

V

A L V E S

F

UNCTIONS

M

ANIFOLD

& H

YDRAULIC

V

ALVES

NOTE: Refer to

Parts Section E

.

Tag all components as they are removed to aid in reassembly.

H

YDRAULIC

M

ANIFOLD

R

EMOVAL

1. Disconnect the negative battery terminal.

2. Tag and disconnect the solenoid valve leads.

3. Tag and disconnect hydraulic hoses, and immediately cap the openings to prevent contamination.

4. Remove the mounting bolts from the manifold.

5. Remove the manifold.

D

ISASSEMBLY

1. Mark and remove the coils from solenoid valves.

2. Mark and remove valves.

3. Mark and remove fittings, plugs, springs, balls, and orifices.

C

LEANING AND

I

NSPECTION

1. Wash the manifold in cleaning solvent to 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 surfaces.

3. Wash and dry each component and check for thread damage, torn or cracked Orings, and proper operation.

4. Replace defective parts and O-rings.

A

SSEMBLY

NOTE: Lubricate all O-rings before installation to prevent damage to the O-ring. Seat balls in manifold block by lightly tapping on the ball with a brass drift punch.

1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Loctite #424 or equivalent thread locker on each screw-in orifice.

2. Install valves.

I

NSTALLATION

1. Mount the manifold assembly using the mounting bolts.

2. Connect hydraulic hoses (as previously tagged). Be certain to tighten hoses.

3. Connect solenoid leads (as previously tagged).

4. Connect the battery.

5. Operate each hydraulic function and check for proper operation and leaks.

6. Adjust valve pressures.

“4069RT” Service and Parts Manual March 2014

Page 1-11

F

U N C T I O N S

M

A N I F O L D

& H

Y D R A U L I C

V

A L V E S

M

ANIFOLD

& V

ALVE

D

IAGRAMS

See Section E of the Parts Section for component part numbers.

Figure 1-5:

Functions Manifold - Components

COIL #10

COIL # 8

CHECK VALVE - ANTI CAVITATION

CHECK VALVE - ANTI CAVITATION

CHECK VALVE - ANTI CAVITATION

HAND PUMP – BRAKE RELEASE

SOLENOID VALVE – HIGH SPEED

SOLENOID VALVE – HIGH TORQUE

SOLENOID VALVE – OUTRIGGER DIRECTIONAL

SOLENOID VALVE – REAR WHEEL BYPASS

SOLENOID VALVE – REAR WHEEL BYPASS

SOLENOID VALVE – STEER DIRECTIONAL

SOLENOID VALVE – PLATFORM LIFT

SOLENOID VALVE – REAR WHEEL BYPASS

FLOW DIVIDER VALVE – DRIVE MID & LOW

FLOW DIVIDER VALVE – DRIVE MID & LOW

MANUAL OP. VALVE – BRAKE EMR. RELEASE

SOLENOID VALVE – DRIVE FORWARD

SOLENOID VALVE – DRIVE REVERSE

PILOT OP. VALVE – MID SPEED

PILOT OP. VALVE – LOW SPEED

RELIEF VALVE – MAIN

RELIEF VALVE – PLATFORM LIFT

FLOW REGULATING VALVE- BRAKE APPLY

SHUTTLE VALVE – BRAKE RELEASE

ORIFICE – STEER SPEED CONTROL

ORIFICE – FLOW DIVDER BYPASS

ORIFICE – FLOW DIVDER BYPASS

ORIFICE – BYPASS CONTROL

PILOT OP. VALVE – HIGH TORQUE SHIFT

PILOT OP. VALVE – MID RANGE SHIFT

PILOT OP. VALVE – HIGH TORQUE SHIFT

COUNTERBALANCE VALVE – DRIVE

COUNTERBALANCE VALVE – DRIVE

Front

Of Machine

Left Side

Of Machine

Rear

Of Machine

Center

Of Machine

Functions Manifold

4069

March 2014

Page 1-12

“4069RT” Service and Parts Manual

ART_4471

H

YDRAULIC

P

RESSURE

A

DJUSTMENT

H

Y D R A U L I C

P

R E S S U R E

A

D J U S T M E N T

Do not operate pump with relief valve cap removed. Fluid will emit under pressure.

Relief and counterbalance valves should be checked during routine maintenance to ensure proper machine. It is necessary to remove the hexhead relief valve cap from the relief valve if adjustment is needed. Replace the caps before operating the machine.

Table 1-1: Hydraulic Pressure Settings

Main Relief

RV1

Lift Relief

RV2

Drive

Counterbalance

CBV1, CBV2

3500 PSI

246 bar

3200 PSI

220 bar not adjustable

• Before attempting to check or adjust pressure relief valves, operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid.

• Insert a 0-5000 psi gauge into gauge adapter fitting at Port GP of the Functions Manifold.

“4069RT” Service and Parts Manual March 2014

Page 1-13

M

AIN

R

ELIEF

(RV1)

1. Attach a 0-5000 psi gauge to Port GP.

2. Place a 4 inch x 4 inch (10cm x 10cm) wood block in front of each wheel.

3. Set the Drive Mode to High Speed.

Using the Drive function, slowly push the control handle completely forward. Hold for 10 seconds.

4. If pressure is LOW, adjust main relief valve ¼ turn clockwise and recheck.

5. If pressure is HIGH, adjust main relief valve ¼ turn counterclockwise and recheck.

Repeat until the pressure is correct as listed in Table 1-1.

Main Relief

RV1

ART_4484

H

Y D R A U L I C

P

R E S S U R E

A

D J U S T M E N T

Figure 1-6:

Adjustable Valve Location

Gauge Port

GP

GP

Lift Relief

RV2

March 2014

Page 1-14

“4069RT” Service and Parts Manual

H

Y D R A U L I C

P

R E S S U R E

A

D J U S T M E N T

L

IFT

R

ELIEF

(RV2)

1. Attach a

0-5000 psi gauge to Port GP.

2. With no load on platform, use the Lift function to raise the platform completely.

3. Press and hold the Lift switch for 10 seconds to get an accurate reading on the pressure gauge.

4. If pressure is LOW, adjust lift relief valve ¼ turn clockwise and recheck.

5. If pressure is HIGH, adjust lift relief valve ¼ turn counterclockwise and recheck.

Repeat until the pressure is correct as listed in Table 1-1.

D

RIVE

C

OUNTERBALANCE

V

ALVES

(CBV1, CBV2)

The Drive Counterbalance Valves are not adjustable and should be replaced if they are determined to be malfunctioning.

“4069RT” Service and Parts Manual March 2014

Page 1-15

S

Y S T E M

D

E S C R I P T I O N S

S

YSTEM

D

ESCRIPTIONS

P

U M P

C

I R C U I T

Hydraulic fluid is pulled from the Hydraulic Tank to the suction port of the Hydraulic

Pump. Pressurized fluid leaves the pump and goes to Proportional Valve. From the

Proportional Valve, fluid goes to Port P of the Functions Manifold and to the Load

Sense port of the pump. Unused fluid is routed back to the tank through Port T of the

Functions Manifold. Pump case pressure drains back to the tank.

Figure 1-7:

Pump Circuit

ART_4590

March 2014

Page 1-16

“4069RT” Service and Parts Manual

P

T

S

Y S T E M

D

E S C R I P T I O N S

L

I F T

C

I R C U I T

Hydraulic fluid flows to the lift cylinders from Port LFT on the Functions Manifold and is returned to the to the manifold through the same hose.

Figure 1-8:

Lift Circuit

LFT

ART_4591

“4069RT” Service and Parts Manual March 2014

Page 1-17

S

Y S T E M

D

E S C R I P T I O N S

L

I F T

V

E N T

C

I R C U I T

Vent lines to both cylinders provide a path to the tank for unpressurized hydraulic fluid that has gone over the relief valves in the lift cylinders.

Figure 1-9:

Lift Vent Circuit

Later Machines with upper vent hose on upper cylinder.

Upper Lift

Cylinder

Lower Lift

Cylinder

ART_4592

March 2014

Page 1-18

“4069RT” Service and Parts Manual

S

Y S T E M

D

E S C R I P T I O N S

S

T E E R I N G

C

I R C U I T

Pressurized fluid is supplied to the Steer Cylinders from Ports STRA and STRB on the

Functions Manifold as shown below.

Figure 1-10:

Steering Circuit

STRA

STRB

ART_4593

Left Side

Front of

Machine

Right Side

“4069RT” Service and Parts Manual March 2014

Page 1-19

S

Y S T E M

D

E S C R I P T I O N S

F

R O N T

D

R I V E

C

I R C U I T

Pressurized fluid is supplied to the front drive motors as shown below.

Figure 1-11:

Front Drive Circuit

RFA

LFB

LFA

RFB

Right Front

A

B

March 2014

Page 1-20

B

ART_4594

A

Left Front

“4069RT” Service and Parts Manual

S

Y S T E M

D

E S C R I P T I O N S

R

E A R

D

R I V E

C

I R C U I T

Pressurized fluid is supplied to the rear drive motors as shown below.

Figure 1-12:

Rear Drive Circuit

Right Rear

A

B

B

A

Left Rear

LRA

LRB

RRA

RRB

ART_4595

“4069RT” Service and Parts Manual March 2014

Page 1-21

S

Y S T E M

D

E S C R I P T I O N S

B

R A K E

R

E L E A S E

C

I R C U I T

Pressure from Port BRK on the Functions Manifold provides pressure to the Brake

Release Circuit when the Drive function is enabled. When the Drive function is not enabled, fluid flows freely through it to Port T on the Functions Manifold, and from there returns to the tank.

Figure 1-13:

Brake Release Circuit

BRK

ART_4596

March 2014

Page 1-22

“4069RT” Service and Parts Manual

S

Y S T E M

D

E S C R I P T I O N S

D

R I V E

C

A S E

D

R A I N

C

I R C U I T

Hoses connect the Case Drain ports of each wheel motor route the fluid back to the tank at the center return port of the Hydraulic Reservoir.

Figure 1-14:

Drive Case Drain Circuit

D

“4069RT” Service and Parts Manual

ART_4597

March 2014

Page 1-23

S

Y S T E M

D

E S C R I P T I O N S

O

U T R I G G E R

C

I R C U I T

The Outriggers Cylinders are controlled by Ports ORA and ORB on the Functions

Manifold. Pressurized fluid from Port ORA extends the outrigger cylinders. Pressurized fluid from Port ORB retracts them.

Figure 1-15:

Outrigger Circuit

ORA circuit to Extend port

ORB circuit to Retract port

ORA circuit

ORB circuit

R

E

March 2014

Page 1-24

ORB ORA

ORB cir cuit ont cuit to

rear

ORA cir cuit to

fr ont

ORA cir cuit to rear

“4069RT” Service and Parts Manual

ART_4598

G

E N E R A L

C

Y L I N D E R

R

E P A I R

G

ENERAL

C

YLINDER

R

EPAIR

CYLINDERS ARE HEAVY. SUPPORT CYLINDERS BEFORE REMOVING

HARDWARE THAT SECURES THE CYLINDER TO THE MACHINE.

Figure 1-16:

Typical Cylinders, Exploded View

Rod

Seals

Seals

Piston

Return to Tank

Vent to Tank

Rod

Head

Piston Securing Nut

Typical Single Acting Cylinder

Seals

Barrel

Pressure

Seals

Piston

Piston Securing Nut

Pressure and

Return

Head

Seals

Typical Dual Acting Cylinder

Barrel

ART_2040

R

E M O V A L

NOTE: Refer to

Section 3

for Remove and Replace instructions, and the

Parts Manual

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 the machine as described in Section 3.

“4069RT” Service and Parts Manual March 2014

Page 1-25

G

E N E R A L

C

Y L I N D E R

R

E P A I R

P

R E P A R A T I O N

Take precautions to protect the rod surface. Guard against dirt or other foreign objects entering system.

1. Drain all fluid from cylinder.

2. Clean all dirt and grit from outside of cylinder.

3. Insert cylinder into vise.

C

Y L I N D E R

D

I S A S S E M B L Y

1. Remove the head from the cylinder body.

2. Remove the shaft assembly from the barrel, pulling in a straight line, so as not to scar the internal parts.

3. Insert shaft into a soft jawed vise so that the head and piston can be removed. Be sure the shaft and vise are both clean before using.

4. Loosen the set screw from the side of the piston. Using a piston removal tool, unscrew the piston from the rod. It may be necessary to heat the piston to 200° F

5. (93° C) to loosen the Loctite.

6. Remove all seals from the head and piston using a non-sharp seal tool. These tools are available from various seal suppliers.

7. Clean all fluid and debris off of the head, piston, shaft, collar and barrel using solvent, rags, and an air hose.

8. Inspect parts for scratches, pits or polishing. Check seal groves and sealing surfaces.

a. 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.

Assembly is reverse of disassembly. Lubricate all seals with clean hydraulic fluid before assembly. Use Loctite when securing the piston to the rod.

March 2014

Page 1-26

“4069RT” Service and Parts Manual

Section 2

E

LECTRICAL

S

YSTEM

C

ONTENTS

P

AGE

Electrical System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Battery Maintenance (in storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Battery Maintenance (in use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Lower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Upper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Alarms and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

GP400 Control Module Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

GP400 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Failure Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Information Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

“4069RT” Service and Parts Manual March 2014

Page 2-1

F

IGURES

P

AGE

Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Emergency Lowering Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Diagnostic LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Upper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

EZfit Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Outrigger Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Relay Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Toggle Switch, ON-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Toggle Switch, 1-Pole 2-Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Toggle Switch, 1-Pole 3-Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Toggle Switch, Momentary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Button Switch, Momentary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

EZ-Cal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

T

ABLES

P

AGE

Table 2-1: Recommended Battery Charge Intervals . . . . . . . . . . . . . . . . . . . . 2-5

Table 2-2: Battery Specific Gravity and Voltage . . . . . . . . . . . . . . . . . . . . . . . 2-6

March 2014

Page 2-2

“4069RT” Service and Parts Manual

E

L E C T R I C A L

S

Y S T E M

– G

E N E R A L

E

LECTRICAL

S

YSTEM

– G

ENERAL

The electrical control system consists of lower controls located on the machine base and upper controls located on the machine platform. The emergency lowering switch is also located on the lower controls, and is electrically operated.

L

OWER

C

ONTROLS

The lower controls operate the glow, start, emergency down, lift and lower functions.

U

PPER

C

ONTROLS

The upper controls operate all functions including drive, steer, lift, and lower, along with outrigger controls for machines equipped with outriggers. A momentary bi-directional rocker switch on the joystick provides the steering function. The joystick also has an enable bar switch that must be depressed to enable the Lift, Lower and Drive functions.The control system for operation of drive, steer, lift, and lower are electricover-hydraulic type. The drive and lift systems are proportional systems controlled by position and direction of the upper controls joystick.

E

MERGENCY

S

TOP

Figure 2-1:

Emergency Stop Switches

There are two red Emergency Stop switches: One located on the upper controls and one on the lower controls. Activation of either

Emergency Stop switch will immediately cut electrical power to all controls, thereby stopping all machine functions. Press the switch to stop all electrical power and turn the switch clockwise to reset.

When both Emergency Stop switches are “set”, the controls have electrical power and the machine will operate.

ART_3817

NOTE: Both switches must be set or the machine will not operate.

E

MERGENCY

L

OWERING

S

WITCH

IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED,

USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE

PLATFORM.

DO NOT CLIMB DOWN THE SCISSOR ASSEMBLY OR EXIT THE

PLATFORM.

Figure 2-2:

Emergency Lowering Switch

The Emergency Lowering

System is used to lower the platform in case of power failure.

To lower the platform, push down on the Emergency

Lowering Switch, located at the Lower Control Box.

ART_4281

“4069RT” Service and Parts Manual March 2014

Page 2-3

E

L E C T R I C A L

S

Y S T E M

– G

E N E R A L

D

IAGNOSTIC

LED

If the machine fails to operate, inspect the GP400

Module located inside the Lower Controls box. The LED located on the module should be ON. If the LED is OFF or FLASHING, refer to Section 4: Troubleshooting.

Figure 2-3:

Diagnostic LED

Lower Controls

GP400

Module

Terminal

Block

Module

ART_3093

Diagnostic LED

March 2014

Page 2-4

“4069RT” Service and Parts Manual

B

A T T E R I E S

B

ATTERIES

CHARGING BATTERIES CREATE EXPLOSIVE HYDROGEN GAS. KEEP

SPARKS, FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES.

ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH

BATTERIES.

BATTERY FLUID IS CORROSIVE. THOROUGHLY RINSE SPILLED FLUID

WITH CLEAN WATER.

REPLACE ONLY WITH MANUFACTURER-APPROVED BATTERIES.

BEFORE DISCONNECTING THE BATTERY NEGATIVE (–) LEAD, MAKE

SURE THAT ALL SWITCHES ARE OFF. IF ON, A SPARK WILL OCCUR

AT THE GROUND TERMINAL THAT COULD IGNITE HYDROGEN GAS.

Discharged batteries can freeze, causing damage to the battery and/or battery case. A broken battery case will allow electrolyte to leak out.

One 12V DC battery supplies the electrical power required to start the engine and operate the electrical circuits.

B

A T T E R Y

M

A I N T E N A N C E

(

I N S T O R A G E

)

Follow these procedures for maintenance of the battery on a machine that is not in use:

• Keep batteries clean. Electrolyte of batteries should be checked regularly and kept at proper level.

• Never stack one battery directly on top of another, as post or container damage may occur. If batteries are stored individually, place supporting boards between layers. Rotate stock so that the oldest batteries are used first.

• Batteries should be kept fully charged. A battery, while in storage, should be recharged to full charge at recommended intervals.

A

BATTERY FULLY

(100%)

CHARGED AT

80°F (26.6°C)

• drops to 65% at 32°F (0°C)

• drops to 40% at 0°F (-32°C)

Table 2-1: Recommended Battery Charge Intervals

If Stored At

Below 40°F (4°C)

40°-60°F (4°-15°C)

Above 60°F (15°C)

Recharge

Every week

Every 2 weeks

Every month

“4069RT” Service and Parts Manual March 2014

Page 2-5

B

A T T E R I E S

B

A T T E R Y

M

A I N T E N A N C E

(

I N U S E

)

Check batteries and surrounding area for signs of damage or corrosion.

Check battery terminals for:

•

Corrosion:

Regularly clean connections and apply a nonmetallic grease or protective spray to retard corrosion.

•

Loose connections:

Be sure all cable connections are tightly secured, and that good contact is made with terminals.

•

Broken or frayed cables:

Be sure all connections are good and that no loose or broken wires are exposed. Replace as necessary.

Check battery electrolyte level. Replenish the electrolyte, if necessary. Remove vent caps before filling, and USE ONLY DISTILLED WATER. DO NOT OVERFILL. Fill to level indicator (or ½ inch over the top of separators, if there is no level indicator). Fill after charging to prevent overflow of acid due to expansion. Do not use a hose to add water to batteries.

Allowing the electrolyte level to drop below the top of the separators will lead to shortened battery life.

Excessive water usage may indicate that a battery has been overcharged, has been subjected to excessively high temperatures, or is nearing the end of its service life.

B

ATTERY

P

REVENTATIVE

M

AINTENANCE

:

15 hours after battery has been charged, spot-check the specific gravity of two or more cells. A fully charged battery should indicate 1.28 specific gravity. If low readings are noted, check the following:

• Check terminals for corrosion, loose connections and broken or frayed cables.

• Check all cells with a hydrometer for variance in specific gravity. A variation of 0.03 points or more between cells is a cause for concern. Mark the low cells.

Recheck specific gravity of all cells after recharging. Wash the top of the battery, making sure all vents are in place. Do not allow cleaning water or other foreign matter to enter the cells. Use a solution of bicarbonate soda (5 tsp. of baking soda per quart of warm water) and water to wash the battery if there is an accumulation of acid.

Table 2-2: Battery Specific Gravity and Voltage

Fully Charged

Fully Discharged

Specific Gravity

Each Cell

1.280

1.130

Per Cell

2.10

1.75

Volts DC

12V Battery

12.60

10.50

March 2014

Page 2-6

“4069RT” Service and Parts Manual

B

A T T E R I E S

B

A T T E R Y

R

E P L A C E M E N T

To prevent damage to the battery and/or electrical system:

• Always disconnect the negative battery cable first.

• Always connect the positive battery cable first.

T

O REMOVE A BATTERY

;

1. Disconnect the negative battery cable, then the positive battery cable. Remove the battery hold-down hardware.

2. Lift the battery from the compartment, put the battery aside and dispose of properly.

T

O INSTALL A BATTERY

;

1. Position the battery in the compartment and secure with hold-down hardware.

2. Connect the positive battery cable, then the negative battery cable.

“4069RT” Service and Parts Manual March 2014

Page 2-7

C

ONTROLS

L

O W E R

C

O N T R O L S

1

2

3

4

C

O N T R O L S

Figure 2-4:

Lower Controls

10

9

5

6 7 8

ART_4399

CONTROL

1 Emergency Stop

Switch

2 Platform Lift

Button

3 Platform Lower

Button

4 Selector Switch

DESCRIPTION

Press the EMERGENCY STOP switch at any time to stop all machine functions.

Turn switch

clockwise

to reset.

Press this button to lift the platform.

Press this button to lower the platform.

5 Hour Meter

6 Glow

7 Emergency Down

Switch

PLATFORM Select to operate from the platform control panel.

BASE Select to operate from the base control panel.

OFF Select to stop operation from either control panel.

Indicates total elapsed time of machine operation.

Operate when starting in cold start conditions.

Move this switch down to lower the platform in the event of an emergency or power loss.

8 Circuit Breaker

9 Start Button

Trips when there is excessive electrical load. Push to reset.

Press to start engine. Release when engine starts.

10 Start Delay Light Prevents over-cranking of engine. When lit, starter is disabled. After approximately 35 seconds the light will go out and starter will operate.

March 2014

Page 2-8

“4069RT” Service and Parts Manual

U

P P E R

C

O N T R O L S

1

2

2*

3

11

12

13

9321

1

4

5

6

7

8

9

10

C

O N T R O L S

Figure 2-5:

Upper Controls

ART_4485

1

CONTROL

Speed/Torque

Selector Switch

2

Tilt Indicator Light

(amber)

Overload Indicator

Light (red)*

3 Lift/Drive Switch

DESCRIPTION

Move this switch to the up for high speed drive. Push this switch to down for high torque drive.

If illuminated, the machine is not level. Carefully lower the platform, then move the machine to a firm, level surface.

Platform overloaded when light is ON. An audible alarm will sound and all machine functions will stop.

Remove weight from the platform to restore function and continue.

Move this switch UP to enable the Lift function. Move this switch DOWN to enable the Drive function.

4

5

Emergency Stop

Switch

Start Switch

6 Glow

7 Generator (Option)

Press the EMERGENCY STOP switch at any time to stop all machine functions.

Turn switch

clockwise

to reset.

Turn to far right to start engine. Switch will return to RUN position for normal operation.

Turn to

OFF

to shut engine down.

Operate when starting in cold start conditions.

Starts and stops optional generator.

8 Horn Button (Option) Press to sound warning horn.

9

Drive Enable Indicator

(Outrigger Option)

Lamp ON

Lamp OFF

Outriggers are retracted and machine will drive.

Outriggers are extended and machine will not drive.

10

Extend/Retract

(Outrigger Option)

11 Steer Switch**

12

Control Handle**

13 Enable Bar

Push the toggle switch DOWN to extend the outriggers. Continue pushing down until the outriggers stop automatically. Push the toggle switch UP to retract the outriggers.

Using your thumb, press and hold the rocker switch to steer Left or Right.

DRIVE Proportionally controls Forward and Reverse travel.

LIFT Proportionally controls Lift and Lower functions.

Squeeze to enable DRIVE, STEER, and LIFT functions from the Joystick.

*Machines equipped with optional Overload Sensing System

**These controls operate only when the Enable Bar (#13) is depressed. The Enable Bar must be depressed before operating the function for correct control system safety sequence.

“4069RT” Service and Parts Manual March 2014

Page 2-9

A

L A R M S A N D

S

W I T C H E S

A

LARMS AND

S

WITCHES

M

OVEMENT

A

LARM

The Movement Alarm is activated as soon as the DOWN operation is activated from either control station. This is the default setting. If desired, the movement alarm setting can be modified to activate the alarm during other functions (refer to Section 4:

Troubleshooting).

THE MOVEMENT ALARM IS PROVIDED FOR YOUR PROTECTION, AND

PROTECTION OF PERSONS WORKING IN THE IMMEDIATE AREA.

DISABLING THIS IMPORTANT SAFETY DEVICE MAY RESULT IN SERIOUS

INJURY OR DEATH.

Arm Guard Cutout – On machines equipped with the optional Overload Sensing System, the automatic Arm Guard Cutout function will stop the platform when lowering at approximately 2.5 meter platform height and will sound a fast intermittent beeping alarm. Release the Lower button or control handle.

A three second delay is provided for the operator to verify that there are no hazardous conditions or personnel near the machine. Lowering may resume after these 3 seconds have elapsed when the Lower button is engaged.

L

EVEL

S

ENSOR

The Level Sensor is integrated into the GP400 Control Module.

Figure 2-6:

EZfit Angle Sensor

EZ

FIT

A

NGLE

S

ENSOR

The EZfit Angle Sensor provides platform elevation information to the GP400 control module. When the GP400 reads certain outputs from the angle sensor it will:

• enable or disable tilt sensor operation.

• reduce drive speed for elevated drive.

On machines equipped with the optional Overload

Sensing System, the

Angle Sensor works in conjunction with the

Pressure Transducer and a second redundant

Angle Sensor located beside the first.

EZFit

Two present on machines equipped with optional

Overload Sensing System

ART_4488

March 2014

Page 2-10

“4069RT” Service and Parts Manual

A

L A R M S A N D

S

W I T C H E S

Figure 2-7:

Pressure Transducer

L

IFT

P

RESSURE

T

RANSDUCER

The Lift Pressure

Transducer is used on machines equipped with the optional Overload

Sensing System. It provides lift cylinder pressure information to the

GP400 and works in conjunction with two EZfit Angle

Sensors.

Excessive pressure indicates platform overload.

When the GP400 reads a certain output from the pressure sensor it will:

Lift Pressure

Transducer

Only on machines equipped with optional

Overload Sensing System

• disable lift, lower and drive operation.

• sound audible alarms.

• turn ON the OVERLOAD light on the upper control panel.

Remove weight from the platform to restore function and continue.

ART_4489

“4069RT” Service and Parts Manual March 2014

Page 2-11

March 2014

Page 2-12

O

P

UTRIGGER

ROXIMITY

S

ENSOR

outriggers has a

On machines equipped with outriggers, each of the four

Proximity Sensor. Pressure from the outrigger cylinder lifts the cylinder slightly and moves this switch away from a tab on the Cover Weldment, indicating full deployment of the outrigger.

R

ELAYS

Relays are located on the engine inside the power module. These relays reduce the current flow through the GP400 Control Module.

Refer to the Section 5 for relay functions and interconnect.

S

TART

R

ELAY

Provides power to the starter solenoid.

T

HROTTLE

R

ELAY

Provides power to the electric throttle solenoid.

P

REHEAT

R

ELAY

Provides power to the diesel engine glow plugs.

ART_4491

A

L A R M S A N D

S

W I T C H E S

Figure 2-8:

Outrigger Proximity Sensor

Proximity

Switch

Cover

Weldment

Tab

Cover

Plate

ART_4490

Figure 2-9:

Relay Locations

Preheat

Start

Throttle

“4069RT” Service and Parts Manual

D

E U T S C H

C

O N N E C T O R S

D

EUTSCH

C

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.

Figure 2-10:

Deutsch Connectors

M

ALE

P

LUG

C

ONNECTOR

• Use the flat end of the Removal Tool or a flat blade screwdriver to pry the locking wedge from the connector, taking care not to damage the Sealing Gasket.

• Inspect and replace damaged parts.

• Replace or re-crimp wires and contacts.

F

EMALE

R

ECEPTACLE

C

ONNECTOR

• Use the notched end of the removal tool or a wire hook to pull the locking wedge from the connector

• Replace worn or damaged parts

• Replace or re-crimp wires and contacts.

L

OCKING

F

INGERS

• Remove the locking wedge as outlined above.

• Using the removal tool or a flat blade screwdriver, push the Locking Fingers aside to release the contact.

• Pull the wire and contact out of the connector.

H

EAVY

D

UTY

P

LUG

• Slide the removal tool along the wire to be replaced and push into the connector to release the contact.

• Pull the wire and contact out of the plug.

C

RIMPING

• Strip 1/4 in. (6 mm) insulation from the wire.

• Insert the contact into the crimping tool and insert the stripped wire into the contact making sure no wires are outside the contact barrel.

• Close the handles of the crimping tool, then release the handles to remove the crimped contact.

ART_2041

De u t s ch Co nn ecto r Field Kit

MEC pa r t # 84091

“4069RT” Service and Parts Manual March 2014

Page 2-13

C

O N T I N U I T Y

C

H E C K S

C

ONTINUITY

C

HECKS

S

ELECTOR

S

WITCH

– ON-OFF

• Disconnect wires.

• Connect first probe of ohm meter to

common

terminal.

• Connect second probe to any normally open terminal.

• With switch OFF (open) there should be no reading.

• With the switch ON (closed) there should be a low reading.

• Repeat for each normally open terminal.

No r mally

Ope n

ART_3153

Figure 2-11:

Selector Switch

Commo n

No r mally

Clo s ed

T

OGGLE

S

WITCH

– ON-OFF

• Disconnect wires.

• Connect first probe of ohm meter to

common

terminal.

• Connect second probe to normally open terminal.

• With the switch turned OFF there should be no reading.

• With the switch turned ON there should be a low resistance.

Figure 2-12:

Toggle Switch, ON-OFF

Not U s ed

Commo n

No r mally Ope n

ART_2562

Not U s ed

Commo n

No r mally Ope n

T

OGGLE

S

WITCH

– 1-P

OLE

2-P

OSITION

Figure 2-13:

Toggle Switch, 1-Pole 2-Position

• Disconnect wires.

• Connect first probe of ohm meter to

common

terminal.

No r mally Ope n

• Connect second probe to

top

normally open terminal.

• With toggle DOWN there should be no reading.

Commo n

No r mally Ope n

• With the toggle UP there should be a low resistance.

• Move second probe to

bottom

normally open terminal.

• With toggle UP there should be no reading.

• With the toggle DOWN there should be a low resistance.

No r mally Ope n

Commo n

ART_2563

No r mally Ope n

March 2014

Page 2-14

“4069RT” Service and Parts Manual

C

O N T I N U I T Y

C

H E C K S

T

OGGLE

S

WITCH

– 1-P

OLE

3-P

OSITION

Figure 2-14:

Toggle 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.

Top

• With the toggle UP or MIDDLE there should be a low resistance.

• Move second probe to

bottom

terminal.

Commo n

Bottom

• With the toggle DOWN or MIDDLE there should be a low resistance.

• Connect first probe of ohm meter to

top

terminal.

Top

Commo n

• Connect second probe of ohm meter to

bottom

terminal.

• With toggle in ANY POSITION there should be no reading.

ART_3152

Bottom

T

OGGLE

M

OMENTARY

S

WITCH

Figure 2-15:

Toggle Switch, Momentary

• Disconnect wires.

• Connect first probe of ohm meter to common terminal.

No r mally Ope n

Test top position

Commo n

No r mally Ope n

• Connect second probe to

top

normally open terminal.

• With the toggle in the neutral (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.

ART_2563

No r mally Ope n

Commo n

No r mally Ope n

Test bottom position

No r mally Ope n

Commo n

• Move second probe to

bottom

normally open terminal.

• With the toggle in the neutral (open) position there should be no reading.

• With the toggle DOWN (closed) there should be a low resistance.

• With the toggle UP (closed) there should be no reading.

• Repeat for both rows of two-row switch.

No r mally Ope n

Commo n

No r mally Ope n

ART_2564

No r mally Ope n

No r mally Ope n

Commo n

No r mally Ope n

“4069RT” Service and Parts Manual March 2014

Page 2-15

M

OMENTARY

B

UTTON

S

WITCH

• Disconnect wires.

• Connect one probe of ohm meter each terminal.

• With the button in the neutral (open) position there should be no reading.

• With the button pushed (closed) there should be a low resistance

C

O N T I N U I T Y

C

H E C K S

Figure 2-16:

Button Switch, Momentary

Commo n

No r mally Ope n

Commo n

ART_2565

No r mally Ope n

E

MERGENCY

S

TOP

B

UTTON

• Disconnect wires.

• Connect one probe of ohm meter each terminal.

• With the button PRESSED there should be no reading.

• With the button RESET there should be a low resistance.

Figure 2-17:

Emergency Stop Switch

1

1A

ART_2566

R

ELAY

• With the #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 with #30 will be made.

B−

85

Figure 2-18:

Relay Operation

RELAY DETAIL

( r elay e n e r gized)

30

87A

86

B+

87

ART_2330

March 2014

Page 2-16

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

GP400 C

ONTROL

M

ODULE

S

ETUP

L

O C A T I O N

• The GP400 Control Module processor is located in the lower control box.

• The Matrix Module is located in the upper control box.

Diagnostic information can be found in Section 4: Troubleshooting.

Wiring information can be found in Section 5: Schematics.

Figure 2-19:

Module Locations

Upper Controls Lower Controls

GP400

Control Module

Terminal

Block

Module

GP400

Matrix Module

ART_3156

Diagnostic LED

“4069RT” Service and Parts Manual March 2014

Page 2-17

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

G

E N E R A L

D

E S C R I P T I O N

The GP400 control module uses a variety of sensors to maintain proper and safe operation of the machine.

In the event the GP400 requires replacement, a calibration process must be performed before the machine can be operated. The GP400 will operate initially in an “assembly mode” to provide basic machine operation. However, it will divert to a failure mode if not properly calibrated within a few start-up cycles.

Machines may be equipped with an optional Onboard EZ-Cal, which is different in appearance but functions similarly to the hand-held type. See Section 4 of this manual for details.

Figure 2-20:

EZ-Cal Connection

Calibrator

MEC P/N 90888

GP400 Control Module

13 15 13 15 13 15 13 15 13 15

1 3 1 3 1 3 1 3 1 3

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS

To move back and forth between menu and sub-menu

LEFT/RIGHT BUTTONS

Select menus and setting to be adjusted

UP/DOWN BUTTONS

Adjust setting values

LED

10 12

1 3

Lower Controls

Terminal Block

Module

GP400 Module

Diagnostic LED

ART_3969

March 2014

Page 2-18

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

G P 4 0 0 C

A L I B R A T I O N

CALIBRATION OF THE GP400 MAY BE PERFORMED ONLY BY QUALIFIED,

TRAINED AND AUTHORIZED PERSONNEL.

READ ALL INSTRUCTIONS CLOSELY BEFORE ATTEMPTING EACH STEP

OF THE CALIBRATION PROCEDURE.

The EZ-Cal hand-held device (MEC part # 90888) is required to access the GP400 for troubleshooting and calibration.

The GP400 processor relies on sensors to monitor platform elevation at all times. These sensors send varied voltages to the GP400 that relate directly to their respective position.

The calibration process is the means by which the GP400 equates these voltages to actual platform elevation.

For example, the Angle Transducer, used to monitor platform elevation, varies its output between 1 and 4 volts through 140 degrees of rotation. During calibration the GP400 may learn that 1.8 volts (fictional number used for explanation) represents the fully stowed position and 3.6 volts represents the fully elevated position and therefore voltages between those figures relate to various heights in between.

All machines are calibrated at the factory and should not require calibration unless the

GP400 is replaced or displays a code that indicates the need to recalibrate.

Tilt Sensor Calibration is required on all machines regardless of installed options and must be performed first.

Height Calibration follows Tilt Sensor Calibration for machines not equipped with the

Optional Overload Sensing System and consists of only height calibration. Skip this procedure if your machine is equipped with the optional Overload Sensing System.

Separate calibration is required of all machines outfitted with the optional Overload Sensing System. All steps in the Overload Sensing System calibration must be performed in the proper sequence before the GP400 will recognize complete and proper calibration.

Begin with the Tilt Sensor Calibration, then proceed to the Optional Overload Sensing

System Calibrations section.

If the calibration procedure is performed incorrectly or if there is a failure in one of the monitored circuits during the calibration, the GP400 will not allow the operator to continue with the calibration process. 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.

This and other procedures can only be performed using an EZ-Cal scan tool. If you do not have an EZ-Cal, please contact MEC to obtain one.

“4069RT” Service and Parts Manual March 2014

Page 2-19

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

Tilt Sensor Calibration

Correctly performing the following procedure will ensure that your machine will continue to auto-level correctly and operate safely.

The Tilt Sensor is located within the GP400 Control Module. It is used by the control system to monitor machine level status, and is used on machines equipped with outriggers for auto-leveling. Correctly performing the Tilt Sensor Calibration will ensure that the machine will operate safely and that the outriggers (if equipped) will continue to auto-deploy correctly.

1. Park machine on a flat level surface. Using a spirit level or framer’s level, check that the machine is absolutely level, both fore-and-aft and side-to-side.

2. Check the tire pressure (see Specifications in the Introduction section), and check that the tires are in good condition. If the machine is equipped with foam-filled tires, be sure that all tires are in good condition and that the tires are all the same size.

3. Open the lower control box and plug the EZ-cal into plug J-9 (4-pin connector) on the

GP400. The display should light up and read "HELP - PRESS ENTER. a. Press the right arrow to access "ACCESS LEVEL 3", press ENTER.

• The display reads CODE 0000 with the cursor flashing.

b. Press the Up and Right arrows to enter code 1775, Press Enter

• Display reads "ACCESS LEVEL 2" c. Right arrow to SETUPS, Press Enter

• Display reads ‘CHANGE DEFAULTS" d. Right arrow to TILT SETUPS, Press Enter

• Display reads "CALIBRATE LEVEL".

e. Press Enter

• Display reads "CALIBRATE LEVEL YES: ENTER NO: ESC" f. Press Enter

• Display reads "CALIBRATE LEVEL YES: ENTER NO: ESC" plus has actual tilt percentages.

g. Press Enter again.

• The percentage numbers should be 0.0 - 0.0 (or very close).

h. Level calibration is complete. Unplug the EZ-Cal or press ESC ESC ESC.

Height Calibration

Height calibration must be performed if the GP400 is replaced.

Skip this procedure if your machine is equipped with the optional

Overload Sensing System.

For this procedure it is not necessary to place any load in the platform.

1. Drive machine to a flat level surface, in area where it can reach full elevation.

2. Turn selector switch to Base controls.

3. Plug EZ-Cal into connector P9 on GP400 Control Module. EZ-Cal display reads

HELP: PRESS ENTER

4. Press right arrow to ACCESS LEVEL 3, Press Enter.

• Display reads CODE 0000

5. Press Up and Right Arrow to enter code 1775. Press Enter.

• Display reads ACCESS LEVEL 2.

6. Press Right Arrow to SETUPS, Press Enter.

• Display reads CHANGE DEFAULTS

March 2014

Page 2-20

“4069RT” Service and Parts Manual

7. Press Right Arrow to HEIGHT SETUPS, Press Enter.

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

• Display reads CALIBRATE HEIGHT

8. Press Enter.

• Display reads PLATFORM DOWN? Verify that platform is fully lowered.

9. Press Enter.

• Display reads PLEASE LIFT.

10. Hold lower controls switch in the up position until machine is fully elevated, then release switch.

• Display reads PLEASE LOWER.

11. Hold switch in down position until platform is in the fully lowered position. Release switch.

• Display reads FINISHED.

O

PTIONAL

O

VERLOAD

S

ENSING

S

YSTEM

C

ALIBRATIONS

Do not perform this procedure UNLESS your machine is equipped with the optional Overload Sensing System.

Optional Overload Sensing System

Platform Load Calibration

Perform the Tilt Sensor Calibration outlined at the beginning of this section (" Tilt

Sensor Calibration" on page 2-20).

Platform Load Calibration must be performed any time the GP400 is replaced or significant repairs are made to the elevating assembly.

During the calibration procedure the platform is fully raised and lowered three times:

• “DYNAMIC” calibration – fully loaded platform raised & lowered in one continuous movement.

DYNAMIC measurements are taken.

• “LOADED” calibration – fully loaded platform raised & lowered with stops to take measurements. STATIC measurements are taken.

• “EMPTY” calibration – unloaded platform raised & lowered with stops to take measurements.

STATIC measurements are taken.

The following procedure must be followed COMPLETELY to calibrate the optional Over-

load Sensing System. If any problem is detected, the procedure stops and an Error Message will display on the EZ-Cal. Explanations of each message and suggested corrections can be found in the section of this manual following the calibration procedure.

NOTE: If the calibration procedure is interrupted, completed phases do not need to be repeated. A “REDO” prompt will appear – answer “NO” if there is no reason to repeat the phase, or “YES” if the phase must be repeated (for example because the wrong platform load was used on the previous phase).

1. Drive machine to a flat, level surface where it can reach full elevation. Choose a place where the rated load can be placed in the platform and later removed without moving the machine.

2. Place the rated load in platform (see platform labels or serial plate). The load must be evenly distributed on the platform.

3. Turn selector switch to Base controls.

4. Plug EZ-Cal into connector P9 on GP400 Control Module. EZ-Cal display reads

HELP: PRESS ENTER

5. Press right arrow to ACCESS LEVEL 3, Press Enter.

• Display reads CODE 0000

“4069RT” Service and Parts Manual March 2014

Page 2-21

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

6. Press up and right arrow to enter code 1775, Press Enter.

• Display reads ACCESS LEVEL 2.

7. Press Right Arrow to SETUPS, Press Enter.

• Display reads CHANGE DEFAULTS

8. Press Right Arrow to LOAD SETUPS. Press Enter.

• Display reads CALIBRATE LOAD

9. Press Enter.

• Display reads PLATFORM DOWN? Verify that platform is fully lowered.

10. Press Enter.

• Display reads PLATFORM LOADED? Verify that rated load is evenly distributed in platform.

11. Press Enter.

• Display reads PLEASE LIFT.

12. Hold lower controls switch in the up position until machine is fully elevated, then release switch.

• Display reads PLEASE LOWER.

13. Hold switch in down position until platform is in the fully lowered position. Release switch.

• Display reads PLATFORM LOADED?

14. Ensure that the rated load is distributed evenly in the platform, then press Enter.

• Display reads PLEASE LIFT.

15. Hold lower controls switch in the up position until machine is fully elevated, then release switch.

• Display reads TOTAL DATA #XX, then PLEASE LOWER.

NOTE: The platform will rise incrementally during this phase on the calibration. Do not release the switch until fully elevated.

16. Hold switch in down position until platform is in the fully lowered position.

NOTE: The platform will lower incrementally during this phase on the calibration. Do not release the switch until fully lowered.

17. Release switch.

• Display reads TOTAL DATA #XX, then PLATFORM EMPTY?

18. Remove the load from the platform.

NOTE: If you must switch to platform controls to move the machine, steps 1.] through 7.] must be repeated. Steps

12.] through 20.] will generate the REDO prompt. Answer NO. If machine was not moved, proceed to step 22.].

March 2014

Page 2-22

19. Press Enter.

• Display reads PLEASE LIFT.

20. Hold lower controls switch in the up position until machine is fully elevated, then release switch.

• Display reads TOTAL DATA #XX, then PLEASE LOWER.

21. Hold switch in down position until platform is in the fully lowered position.

• Display reads TOTAL DATA #XX, then BUILDING TABLES, then CALDATE mm/dd/yy.

22. Enter current date using Up, Down and Right Arrows.

• Display reads FINISHED.

23. Disconnect EZ-Cal.

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

The Platform Overload Sensing System is now calibrated.

Optional Overload Sensing System

Height Calibration

For this procedure it is not necessary to place any load in the platform.

1. Drive machine to a flat, level surface where it can reach full elevation.

2. Turn selector switch to Base controls.

3. Plug EZ-Cal into connector P9 on GP400 Control Module.

• Display reads HELP: PRESS ENTER

4. Press right arrow to ACCESS LEVEL 3. Press Enter.

• Display reads CODE 0000

5. Press Up and Right Arrow to enter code 1775. Press Enter.

• Display reads ACCESS LEVEL 2.

6. Press Right Arrow to SETUPS. Press Enter.

• Display reads CHANGE DEFAULTS

7. Press Right Arrow to HEIGHT SETUPS. Press Enter.

• Display reads CALIBRATE HEIGHT

8. Press Enter.

• Display reads PLATFORM DOWN?

9. Verify that platform is fully lowered. Press Enter.

• Display reads PLEASE LIFT.

10. Hold lower controls switch in the up position until machine is fully elevated, then release switch.

• Display reads PLEASE LOWER.

11. Hold switch in down position until platform is in the fully lowered position. Release switch.

• Display reads FINISHED.

“4069RT” Service and Parts Manual March 2014

Page 2-23

C

ALIBRATION

P

ROBLEMS

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

F

A I L U R E

M

E S S A G E S

Various problems can be detected by the EZ-Cal that prevent successful calibration.

These problems are reported with a flashing message including an “F” code. The following descriptions are helpful in solving the problem. References in parentheses refer to electrical schematic points.

F01:CHECK HWFS

This message is given if the startup tests have not completed.

Check HELP message for more information.

F02:NOT GROUND MODE

This message is given if the base/platform selector switch is not in ground mode (P7-2 must be high). Calibration can only be carried out in ground mode.

F03:NOT STOPPED

This message is given if any function switch is closed. Check DIAGNOSTICS /

SWITCHES to see which function switch is closed.

F04:TILTED

This message is given if the machine is tilted. Calibration must be carried out with the machine level. If the machine is level, perform the Tilt Calibration procedure above.

F05:BAD HEIGHT

This message is given if the height sensor output (P8-2 and P8-6) is out of range at the start of calibration. The height sensor output must be between 1.0V and 4.0V. Check

DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem.

F06:CHECK ELEV

This message is given if the elevation switch (P7-5) is open at the start of calibration, when the operator has confirmed the “PLATFORM DOWN?” question.

If the platform is down, check the elevation switch wiring.

F08:CHECK ELEV

This message is given if the elevation switch (P7-5) is closed at the end of the DYNAMIC lift, when the platform should be fully raised.

This message would occur if the UP switch was accidentally opened near the start of the

DYNAMIC lift.

If the platform is fully raised, check the elevation switch wiring.

F09:BAD HEIGHT

This message is given if the height sensor output (P8-2 and P8-6) is out of range at the start of the DYNAMIC lift. The height sensor output must be between 1.0V and 4.0V.

Check DIAGNOSTICS / SENSORS to see the output. This is usually due to a wiring problem.

F10:BAD HEIGHT

This message is given if the height sensor output (P8-2 and P8-6) is out of range at the end of the DYNAMIC lift. The height sensor output must be between 1.0V and 4.0V. Check

DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem.

F11:NOT UP

This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP.

March 2014

Page 2-24

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

F12:TOO MANY

This message occurs if the DYNAMIC lift takes too long.

This message could occur if the UP switch was not released at the end of the dynamic lift.

F13:LOW HEIGHT RANGE

This message occurs at the end of the DYNAMIC lift if the height sensor output did not change sufficiently to give a reasonably accurate platform height estimate. DIAGNOS-

TICS / ANALOGS can be used to check the height sensor output (P8-2 and P8-6) when the platform is fully lowered and fully raised; a difference of at least 1V is to be expected.

This message could occur if the UP switch was accidentally opened too early (when the platform is not fully raised).

F14:BAD HEIGHT

This message occurs if the height sensor output (P8-2 and P8-6) is out of range during the DYNAMIC lift. The height sensor output must be between 1.0V and 4.0V. Check DIAG-

NOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem.

F15:CHECK ELEV

This message is given if the elevation switch (P7-5) is open when the platform has been fully lowered after the DYNAMIC lift.

This message would occur if the DOWN switch was accidentally opened before the platform was fully lowered.

If the platform is fully lowered, check the elevation switch.

F16:LOW ELEV.OPEN

This message is given if the elevation switch (P7-5) opened during lift at too low of a height (below 5%). Check CALIBRATIONS / HEIGHT CALS. The “ElevUp” value shows the recorded height where the switch opened.

F17:HIGH ELEV.OPEN

This message is given if the elevation switch (P7-5) opened during lift at a too high height

(above 25%).

Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch opened.

F18:LOW ELEV.CLOSE

This message is given if the elevation switch (P7-5) closed during lower at a too low height

(below 5%).

Check CALIBRATIONS / HEIGHT CALS; the “ElevDown” value shows the recorded height where the switch opened.

F19:HIGH ELEV.CLOSE

This message is given if the elevation switch (P7-5) closed during lower at a too high height (above 25%).

Check CALIBRATIONS / HEIGHT CALS; the “ElevUp” value shows the recorded height where the switch opened.

F20:HEIGHT<>0%

F21:HEIGHT<>0%

This message occurs if the platform height is not 0% after the platform has been fully lowered at the end of a calibration step. The platform must return to the same height each time it is fully lowered.

Check DIAGOSTICS / SYSTEM to check the height.

“4069RT” Service and Parts Manual March 2014

Page 2-25

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

F22:HEIGHT<>100%

F23:HEIGHT<>100%

This message occurs if the platform height is not 100% after the platform has been fully raised during a calibration step. The platform must return to the same height each time it is fully raised. Check DIAGNOSTICS / SYSTEM to check the height.

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.

F25:CHECK ELEV

F26:CHECK ELEV

This message indicates a problem with the elevation switch (P7-5) during the STATIC phases.

The switch is either staying closed to a higher height, or staying open to a lower height, than that recorded during the DYNAMIC phase.

F27:BAD HEIGHT

This message indicates a problem with the height sensor output (P8-2 and P8-6) during the STATIC calibration phases.

The height sensor output must be between 1.0V and 4.0V at all times.

Check DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem.

F30:BAD HEIGHTS

This message indicates that the recorded heights are not increasing during STATIC lift, or are not decreasing during STATIC lower.

This problem may be caused by repeatedly opening and closing the UP or DOWN switch during the STATIC phases.

F31:REJECT CURVE

The DYNAMIC pressure curve is unacceptable.

An initial pressure peak when the platform lifted cannot be found between 0% and 15% height.

Check for proper weight in the platform and check pressure sensor and lift cylinder hydraulics.

F32:REJECT CURVE

The DYNAMIC pressure curve is unacceptable.

There should be a lowest pressure about halfway through the lift (i.e.: near 50% height); the lowest pressure measured is at too low a height.

Check for proper weight in the platform and check pressure sensor and lift cylinder hydraulics.

F33:REJECT CURVE

The DYNAMIC pressure curve is unacceptable.

There should be a lowest pressure about halfway through the lift (i.e.: near 50% height); the lowest pressure measured is at too high a height.

Check for proper weight in the platform and check pressure sensor and lift cylinder hydraulics.

F34:REJECT CURVE

The DYNAMIC pressure curve is unacceptable.

March 2014

Page 2-26

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

There is not enough difference between the initial pressure peak and the minimum pressure.

Check for proper weight in the platform and check pressure sensor and lift cylinder hydraulics.

F40:REJECT DELTA

This message indicates that there is not enough difference between the loaded & empty pressure.

This message could occur if the platform were not properly loaded during the STATIC

LOADED phase, or if the platform were not properly empty during the STATIC EMPTY phase.

This message could also occur if the wrong pressure sensor was fitted (e.g.: a 5000psi sensor when a 3000psi one is needed).

Check CALIBRATIONS / HEIGHT CALS; the “Height” indicates the first height at which there was insufficient difference and the “Up” and “Down” values show the loaded pressure (first) and the difference between loaded and empty pressure (second).

F42:LOW PRESSURE

This message indicates that the pressure is too low (0.5V or less) when the elevation switch opens during the DYNAMIC lift.

This message would occur if the pressure sensor was disconnected, or if there were some other wiring error.

Check DIAGNOSTICS / SENSORS to check the pressure.

F43:HIGH PRESSURE

This message indicates that the pressure is too high (4.5V or more) when the elevation switch opens during the DYNAMIC lift.

This message would occur if the wrong pressure sensor was fitted, or if there were some other wiring error.

Check DIAGNOSTICS / SENSORS to check the pressure.

F44:LOW PRESSURE

This message indicates that the pressure is too low (0.5V or less) at a STATIC measurement point.

This message would occur if the pressure sensor was disconnected, or if there were some other wiring error.

Check DIAGNOSTICS / SENSORS to check the pressure.

F45:HIGH PRESSURE

This message indicates that the pressure is too high (4.5V or more) at a STATIC measurement point.

This message would occur if the wrong pressure sensor was fitted, or if there were some other wiring error.

Check DIAGNOSTICS / SENSORS to check the pressure.

F46:CHECK ELEV

This message indicates that the elevation switch opened more than once during the

DYNAMIC lift.

F47:CHECK ELEV

This message indicates that the elevation switch closed more than once during the

DYNAMIC lower.

“4069RT” Service and Parts Manual March 2014

Page 2-27

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

F48:BAD PRESSURE

This message is given if the pressure sensor output (P8-2 and P8-6) is out of range at the start of calibration.

The height 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.

F52:NOT CALIBRATED

This message is a catch-all code which indicates an improper calibration sequence or that one of the phases of calibration was not completed. The skipped phase must be completed or the calibration sequence must be passed through in proper sequence before this message will clear. Re-start the calibration sequence and proceed through each sequence in the specified order.

A “Redo” prompt will appear before each sequence. Answer “NO” if there is no reason to repeat or “YES” if the phase must be completed.

March 2014

Page 2-28

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

I

N F O R M A T I O N

M

E S S A G E S

During calibration the following messages will be displayed. They are informational prompts only and do not indicate a failure.

BUILDING TABLES

This message indicates that the STATIC measurements are being used to build calibration data - the process should take no more than 5s.

CALDATE:

This message is prompting for the date to be entered; it is stored to identify when the machine was calibrated.

The last calibrate date can be viewed in DIAGNOSTICS / LOG.

Press LEFT & RIGHT to select the flashing digits.

Press UP & DOWN to change the flashing digits.

Press ENTER when the entry is complete.

IMPORTANT: The date 00/00/00 is not allowed!

FINISHED

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).

GO UP MORE!

This message occurs if the UP switch is released during either STATIC lifting phase, when more measurements are needed (before the platform is fully raised).

LIFT EMPTY

This message is displayed during the STATIC empty phase while the platform is being raised to the next measurement height.

LIFT LOADED

This message is displayed during the STATIC loaded phase while the platform is being raised to the next measurement height.

LIFTING

This message is displayed during the DYNAMIC phase while the platform is being raised.

LOWER EMPTY

This message is displayed during the STATIC empty phase while the platform is being lowered to the next measurement height.

LOWER LOADED

This message is displayed during the STATIC loaded phase while the platform is being lowered to the next measurement height.

LOWERING

This message is displayed during the DYNAMIC phase while the platform is being lowered.

MEASURING #

This message is displayed when the platform is stopped during either STATIC phase, when the GP400 takes a measurement.

There will be a short delay while the machine is allowed to stabilize after movement is stopped.

“4069RT” Service and Parts Manual March 2014

Page 2-29

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

MUST GO DOWN!

This message occurs if the wrong switch is operated when the GP400 is waiting for the platform to be lowered.

MUST GO UP!

This message occurs if the wrong switch is operated when the GP400 is waiting for the platform to be raised.

PLATFORM DOWN?

This message is prompting for confirmation that the platform is fully lowered. If necessary the DOWN switch can be activated to lower the platform.

Press ENTER to confirm when the platform is fully lowered.

PLATFORM EMPTY?

This message is prompting for confirmation that the platform is completely empty.

Press ENTER to confirm when the platform is empty.

PLATFORM LOADED?

This message is prompting for confirmation that the platform is loaded to rated load:

1500 lbs (US/CSA), 680 Kgs (CE/AU). (100% of the load rating listed on the serial plate).

Press ENTER to confirm when the platform is loaded.

PLEASE LIFT …

This message is prompting for the platform to be raised.

The UP switch should be operated.

PLEASE LOWER …

This message is prompting for the platform to be lowered.

The DOWN switch should be operated.

PLEASE WAIT

This message indicates that the is busy; the delay will be short (no more than 5s).

REDO DYNAMIC:

This message is displayed if the DYNAMIC phase of load calibration has previously been completed.

Press ENTER when “NO” is displayed if there is no need to redo the DYNAMIC phase.

Press UP or DOWN to display “YES” then press ENTER if it is necessary to redo the

DYNAMIC phase.

If the previous DYNAMIC calibration was in error, or if the height or pressure sensor is replaced, it will be necessary to redo the DYNAMIC phase.

REDO EMPTY:

This message is displayed if the EMPTY phase of load calibration has previously been completed.

Press ENTER when “NO” is displayed if there is no need to redo the EMPTY phase.

Press UP or DOWN to display “YES” then press ENTER if it is necessary to redo the

EMPTY phase.

If the previous EMPTY calibration was in error, or if the pressure sensor is replaced, it will be necessary to redo the EMPTY phase.

REDO LOADED:

This message is displayed if the LOADED phase of load calibration has previously been completed.

March 2014

Page 2-30

“4069RT” Service and Parts Manual

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

Press ENTER when “NO” is displayed if there is no need to redo the LOADED phase.

Press UP or DOWN to display “YES” then press ENTER if it is necessary to redo the

LOADED phase.

If the previous LOADED calibration was in error, or if the pressure sensor is replaced, it will be necessary to redo the LOADED phase.

TOTAL DATA:

This message is displayed at the end of each phase, to confirm the number of measurements recorded by the GP400. No operator input is required during this process.

“4069RT” Service and Parts Manual March 2014

Page 2-31

N

O T E S

:

G P 4 0 0 C

O N T R O L

M

O D U L E

S

E T U P

C

A L I B R A T I O N

P

R O B L E M S

March 2014

Page 2-32

“4069RT” Service and Parts Manual

Section 3

M

ECHANICAL

C

OMPONENTS

C

ONTENTS

P

AGE

Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Scissor Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Rear Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Front Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

DIESEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

DUAL FUEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

“4069RT” Service and Parts Manual March 2014

Page 3-1

F

IGURES

P

AGE

Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Scissor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Scissor Assembly Removal, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Rear Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Diesel Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Diesel Engine Throttle Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

March 2014

Page 3-2

“4069RT” Service and Parts Manual

B

A S E

B

ASE

When steam cleaning the base/undercarriage, cover electrical components to prevent water penetration.

Steam clean the base as necessary, and inspect all welds and brackets. Check for cylinder pins that have turned in their mounting, which may indicate sheared retaining pins.

T

IRES AND

W

HEELS

Inspect for cuts, chunking, side-wall damage, or abnormal wear. ANY TIRE FAULTS

MUST BE CORRECTED before further machine operation. Refer to Parts sections for replacement tires.

FAILURE TO USE APPROVED PARTS MAY CAUSE DEATH OR SERIOUS

PERSONAL INJURY.

REPLACE TIRES WITH THE CORRECT TIRES TO MAINTAIN THE

RATING OF THE EQUIPMENT.

IF FOAM FILLED TIRES WERE FITTED AS ORIGINAL EQUIPMENT THEY

MUST BE REPLACED WITH EQUIVALENT SPECIFICATION TIRES AND

FOAM-FILL WEIGHT.

C

HANGING

T

IRES

Refer to “Lift and Support The Machine” in the Introduction Section of this manual for instructions and safety precautions.

Always block the wheels before lifting the machine.

1. Chock tires on the end of machine opposite the tire to be changed.

2. Lift the end of machine requiring a tire change and support with jackstands of adequate capacity.

3. Remove lug bolts and pull the wheel off. Note the position of the centering washers.

4. Install the replacement wheel.

5. While ensuring the correct positioning of the centering washers, install lug bolts and torque to 55 lb-ft. (75 Nm).

6. Remove the chocks.

“4069RT” Service and Parts Manual March 2014

Page 3-3

H

O S E S A N D

C

A B L E S

H

OSES AND

C

ABLES

NOTE: Refer to

Parts Section E

for detailed hydraulic hose diagrams.

Inspect all hoses and electrical cables for security and damage. Hoses and cables should be examined closely for rubbing and chafing.

Check all ties and clamps that keep hoses secure.

Check for leaks at fittings.

Replace any damaged hose or cable.

W

HEN DISASSEMBLING ANY HYDRAULIC COMPONENT

:

1. Clean the area of dirt and grease.

2. Tag hoses for proper reassembly.

3. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination.

4. Torque hose fittings according to the Hydraulic Torque Specification Table. See the

Introduction Section of this manual.

P

LATFORM

NOTE: Refer to Parts Section B for detailed parts list and illustration.

Remove all tools and materials from the platform before performing this procedure.

R

EMOVAL

1. Raise the platform and support it with the maintenance lock (see the Introduction

Section of this manual).

2. Connect an overhead crane to platform using appropriate slings. Arrange the rigging to avoid touching the guardrails and so that it runs between the toe board and the sheet materials rack. Apply slight lifting pressure.

3. Tag and disconnect all platform wires.

4. Remove the nuts from the two bolts on each side of the front of the platform (four nuts total). Press the bolts flush with the inner surface of the platform structure. It is not necessary to remove the bolts completely.

5. Remove any components that will obstruct the scissor slide path.

6. Remove the bolts from both fixed blocks at the rear of the platform.

7. Lift the rear of the platform until the fixed blocks are clear.

8. Slide the platform assembly backwards until the slide blocks clear the front of the platform.

THE PLATFORM MAY SHIFT SUDDENLY WHEN IT CLEARS THE SLIDE

BLOCKS.

9. Remove the platform assembly.

March 2014

Page 3-4

“4069RT” Service and Parts Manual

P

L A T F O R M

Installation

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to specifications listed in the Introduction Section of this manual.

Figure 3-1:

Platform Removal

Slide Block

Fixed

Block

ART_4492

“4069RT” Service and Parts Manual March 2014

Page 3-5

S

C I S S O R

S

T A C K

S

CISSOR

S

TACK

NOTE: Refer to Parts Section C for detailed parts list and illustration.

• Clean all fittings before disconnecting hoses.

• Tag hoses for proper reassembly.

• Plug all openings to prevent contamination.

Clean the beams once a year or more often if necessary and inspect the beams’ surfaces, especially welds and brackets.

Refer to “Lift and Support The Machine” in the Introduction section for instructions and safety precautions.

R

EMOVAL

1. Remove the platform and lower the scissor stack.

2. Raise and support the rear end of the machine. Remove the rear wheels.

3. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination.

4. Tag and disconnect all cables.

5. Immobilize the scissor assembly by wrapping a strap tightly around it.

6. Attach a suitable lifting device to the scissor assembly. Apply slight lifting pressure.

7. Remove the stationary pins at the rear end of the machine.

Figure 3-2:

Scissor Assembly Removal

Strap securing scissor assembly

March 2014

Page 3-6

ART_4493

Stationary Pin

“4069RT” Service and Parts Manual

S

C I S S O R

S

T A C K

8. Carefully lift until the rear of the scissor is clear.

9. Slide the scissor assembly toward the front until the slide blocks reach the end of slide channel, then lift the scissor assembly.

THE SCISSOR ASSEMBLY MAY SHIFT SUDDENLY UPON CLEARING THE

SLIDE CHANNEL.

Figure 3-3:

Scissor Assembly Removal, continued

Lift rear of scissor assembly, then slide

ART_4494

Installation

Clean all parts before installation. Replace worn or damaged parts with new parts.

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to specifications listed in the Introduction Section of this manual.

“4069RT” Service and Parts Manual March 2014

Page 3-7

L

I F T

C

Y L I N D E R S

L

IFT

C

YLINDERS

NOTE: Refer to Section 1 for seal replacement instructions.

Refer to Parts Section C and E for detailed parts list and illustration.

• Clean all fittings before disconnecting hoses.

• Tag hoses for proper reassembly.

• Plug all openings to prevent contamination.

The 4069 has two lift cylinders. This procedure covers removal of either cylinder without removing the entire scissor stack.

1. Raise the scissor arm assembly and support using the maintenance lock.

2. Remove the support beam.

• Remove the upper and lower retaining rings.

• Remove the upper and lower nylon washers.

3. Disconnect hoses, wires and cables from the lift cylinders.

4. Wrap a lift sling of adequate capacity completely around the barrel of the lift cylinder.

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 pin, cylinder mount pin, and two nylon washers.

6. Remove the lower retaining pin.

7. While supporting the cylinder, carefully remove the cylinder mount pin and two nylon washers.

THE CYLINDER MAY SHIFT SUDDENLY WHEN THE PIN IS REMOVED.

March 2014

Page 3-8

“4069RT” Service and Parts Manual

L

I F T

C

Y L I N D E R S

8. Lift the cylinder from the scissor assembly.

Installation

Clean all parts before installation. Replace worn or damaged parts with new parts.

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to specifications listed in the Introduction Section of this manual.

Figure 3-4:

Lift Cylinder

Cylinder

Mount Pin

Retaining

Pin

Nylon

Washer

Lift

Cylinder

Nylon

Washer

Support

Beam

Retaining

Ring

ART_4495

Nylon

Washer

“4069RT” Service and Parts Manual March 2014

Page 3-9

S

T E E R

C

Y L I N D E R S

S

TEER

C

YLINDERS

NOTE: Refer to Section 1 for seal replacement instructions.

Refer to Parts Section D and E for detailed parts list and illustration.

There are two double-acting steer cylinders on this machine. During operation, cylinder(s) should not leak, but a slight damping at the rod seal is acceptable. The pins and rod-end joints should be checked for wear.

• Clean all fittings before disconnecting hoses.

• Tag hoses for proper reassembly.

• Plug all openings to prevent contamination.

Refer to “Lift and Support The Machine” in the Introduction section for instructions and safety precautions.

Removal

1. Raise and support the machine.

2. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination.

Figure 3-5:

Steer Cylinder

3. Remove the tie rod.

4. Remove the shoulder bolt that secures the rod end of the cylinder to the steering yoke. Swing the steering yoke out of the way.

5. Remove the locking cotter pin from the clevis pin that secures the barrel end of the cylinder to the chassis.

6. Support the cylinder, then remove the pin. Remove the cylinder.

Tie Rod

Steer Cylinder

ART_4496

Installation

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to specifications listed in the Introduction Section of this manual.

• To purge air from cylinder, cycle the steering system fully left and right 4-5 times.

March 2014

Page 3-10

“4069RT” Service and Parts Manual

D

R I V E

M

O T O R S

D

RIVE

M

OTORS

NOTE: Refer to Section 1 for seal replacement instructions.

Refer to Parts Section D and E for detailed parts list and illustration.

There are four hydraulic drive motors on this machine. Repair or replace as necessary when damage or leaks occur.

• Clean all fittings before disconnecting hoses.

• Tag hoses for proper reassembly.

• Plug all openings immediately to prevent contamination.

Refer to “Lift and Support The Machine” in the Introduction section for instructions and safety precautions.

R

E A R

D

R I V E

M

O T O R S

Figure 3-6:

Rear Drive Motor

Removal

1. Raise and support the rear end of machine.

2. Raise the scissor arm assembly and support using the maintenance lock.

3. Remove the wheel and tire assembly.

4. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination.

5. Remove the bolts that attach the motor to the chassis.

Installation

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to 55 lb-ft (75Nm).

ART_4497

“4069RT” Service and Parts Manual March 2014

Page 3-11

F

R O N T

D

R I V E

M

O T O R S

Removal

1. Raise and support the machine.

2. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination.

3. Disconnect the steering tie bar and steer cylinder from the steering yoke.

4. Swing the steering yoke out to access the mounting bolts from behind.

5. Support the motor, then remove the bolts and carefully remove the drive motor from the steering yoke.

ART_4498

Installation

Installation is reverse of removal.

• Use Loctite 242 or equivalent on mounting bolts.

• Torque all bolts to 55 lb-ft (75Nm).

D

R I V E

M

O T O R S

Figure 3-7:

Front Drive Motor

March 2014

Page 3-12

“4069RT” Service and Parts Manual

L

UBRICATION

L

U B R I C A T I O N

Figure 3-8:

Lubrication Points

Hydraulic

Reservoir

Filter

Housing

Sight

Gauge

Controls Module

components removed

for clarity

ART_3816

Lubrication

No.

ITEM SPECIFICATION FREQUENCY

1 Hydraulic

Reservoir

Normal ambient temperatures

Mobile Fluid DTE 10, DTE 13 M, or AW32

Ambient temperatures below 0° F (-18° C)

Chevron Rando Premium MV

Routine Maintenance

Check sight gauge level daily

Scheduled Maintenance

Change yearly or every 600 hours,

whichever occurs first

Do not substitute other fluids as pump damage may result.

Fill to the middle of the sight gauge with platform in the stowed position and outriggers retracted.

2 Hydraulic Filter Filter Element

(located inside Hydraulic Reservoir)

Scheduled Maintenance

Normal Conditions

Change every six months or 300 hours, whichever occurs first

Severe Conditions--very dusty, exceptionally hot or exceptionally cold conditions

Change every three months or 150 hours, whichever occurs first

“4069RT” Service and Parts Manual March 2014

Page 3-13

D I E S E L E

N G I N E

M

A I N T E N A N C E

DIESEL E

NGINE

M

AINTENANCE

For complete service information consult the engine manual that came with the machine.

Always wear protective eye-wear when working with fuel and oil.

Engine should be OFF when replacing filter elements.

Figure 3-9:

Engine

O

IL AND

O

IL

F

ILTER

Dispose of used oil and filters properly.

1. Use a suitable container to catch drained oil. Place the end of the oil drain hose into the container and open the oil drain valve. After oil has drained, close the oil drain valve.

2. Remove the old filter and wipe the filter seal contact surface with a clean towel.

Coat the seal on the new filter with clean oil, then install and tighten by hand.

3. Fill engine with 10w-30 motor oil, API C/D or better, until the dipstick indicates FULL.

Capacity is 5.4 US quarts

(5,1 l). See Kubota engine manual for full oil specification.

4. Recheck dipstick after running engine. Fill as necessary.

A

IR

F

ILTER

E

LEMENT

1. Remove the wing-bolt

2. Remove old filter and replace with a new filter.

3. Replace and tighten the wing-bolt. Do not run the

engine with the air filter element removed.

Dipstick

Oil Filter

Oil Drain

Oil Fill Cap

Radiator Cap

ART_4602

Radiator

Drain Plug

March 2014

Page 3-14

“4069RT” Service and Parts Manual

D I E S E L E

N G I N E

M

A I N T E N A N C E

F

UEL

F

ILTER

The Fuel Filter is mounted beside the hydraulic pump at the rear of the engine.

Figure 3-10:

Diesel Engine Fuel Filter

Fuel Filter Bleed Screw

1. Turn OFF valve on bottom of fuel tank.

2. Place a suitable container beneath the fuel filter assembly to catch spilled fuel. Clean the filter area.

3. Turn filter cartridge ¼ counterclockwise remove. Wipe the filter seal contact surface with a clean towel and install a new filter.

4. Open valve at fuel tank and check for leaks.

5. Purge the air from the fuel system as follows;

• Fill fuel tank to the fullest extent. Open valve on bottom of fuel tank.

• Loosen bleed screw on top of fuel filter housing a few turns.

• Close the bleed screw when there are no more bubbles.

• Open the bleed screw on the fuel injector pump.

Use the lift pump hand lever to pump fuel to the injectors. Close the bleed screw when there are no more bubbles.

Fuel Filter

Housing

Fuel Filter

Cartridge

Water

Seperator

Fuel Injector

Pump

¼ Turn to Remove

Fuel Injector

Bleed Screw

Lift

Pump

NOTE: Do not attempt to start the engine until Step 5 has been performed.

ART_2782

Hand Lever

6. If fuel becomes contaminated with water, use the Water Separator Valve at the bottom of the fuel cartridge to drain water.

I

DLE

S

PEED

A

DJUSTMENT

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.

4. Hold the Idle Stop Screw while tightening the jam nut to prevent change in adjustment.

H

IGH

S

PEED

A

DJUSTMENT

IMPORTANT: – In order to prevent electrical system damage, check the Throttle Solenoid Adjustment after this procedure.

1. Bring engine to operating temperature.

2. Disconnect the Throttle Solenoid linkage at the clevis.

3. Manually pull the Throttle Lever until it contacts the High Speed Stop Screw.

4. Adjust the High Speed Stop Screw until the RPM is 3000 with the Throttle Lever against the High Speed Stop Screw.

5. Turn off the engine and reconnect the Throttle Solenoid linkage at the clevis.

“4069RT” Service and Parts Manual March 2014

Page 3-15

D I E S E L E

N G I N E

M

A I N T E N A N C E

6. Hold the High Speed Stop Screw while tightening the jam nut to prevent change in adjustment.

T

HROTTLE

S

OLENOID

A

DJUSTMENT

IMPORTANT: – This final adjustment must be made after all other throttle speed adjustments. The solenoid must be free to retract fully in order to turn OFF the High Amperage

Pull Circuit. Improper adjustment will result in solenoid failure and may damage the electrical system.

1. With the engine OFF, manually retract the solenoid by grasping the piston, just ahead of the boot, and pull to the fully retracted position.

NOTE: The solenoid must retract and extend smoothly. If movement is impaired it may be necessary to reposition the solenoid to improvement alignment.

2. With the solenoid piston fully retracted measure the distance between the High

Speed Stop Screw and the Throttle linkage using a .020 feeler gauge.

3. Adjust clearance at the Throttle Solenoid linkage only.

Do not adjust the High Speed Stop Screw.

• Disconnect the linkage at the clevis and turn the clevis to lengthen or shorten as necessary.

• Reconnect the clevis and measure again. Repeat until the measurement is correct.

Figure 3-11:

Diesel Engine Throttle Adjustments

High Speed

Stop Screw

.020

Throttle

Solenoid

Idle Stop

Screw

Throttle

Lever

Throttle

Solenoid

Piston

(Threaded Rod)

Clevis

Throttle

Solenoid

Adjustment

Throttle Link

ART_4002

March 2014

Page 3-16

“4069RT” Service and Parts Manual

D U A L F U E L E

N G I N E

M

A I N T E N A N C E

DUAL FUEL E

NGINE

M

AINTENANCE

For complete service information consult the engine manual that came with the machine.

Always wear protective eye-wear when working with fuel and oil.

Engine should be OFF when replacing filter elements.

O

IL AND

O

IL

F

ILTER

- D

UAL

F

UEL

Dispose of used oil and filters properly.

Figure 3-12:

Dual Fuel Engine - Oil and Fuel Filter

1. Use a suitable container to catch drained oil. Remove the drain plug. After oil has drained, replace the drain plug.

2. Remove the old filter. Coat the seal on the new filter with clean oil, then install 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.

F

UEL

F

ILTER

-

D

UAL

F

UEL

1. Turn OFF valve at fuel tank.

2. Loosen the hose clamps on the fuel lines and slide them away from the in-line fuel filter.

3. Remove the in-line fuel filter from the fuel lines.

4. Install a new in-line fuel filter.

• There is an arrow, indicating direction of flow, on the body of the in-line fuel filter. Make sure that the arrow points

from

the fuel tank and

to

the engine.

5. Reposition and tighten the hose clamps.

6. Open valve at fuel tank and check for leaks.

Air Filter

Canister

Fuel Filter

ART_4607

Throttle

Solenoid

Coolant

Recovery Tank

Oil Drain Access

Under Cabinet

Oil Dipstick

Oil Fill

Cap

Oil Filter

“4069RT” Service and Parts Manual March 2014

Page 3-17

March 2014

Page 3-18

D U A L F U E L E

N G I N E

M

A I N T E N A N C E

A

IR

F

ILTER

E

LEMENT

- D

UAL

F

UEL

1. Unlock the catches holding the filter canister cover.

2. Remove the wing-nut from the filter assembly and remove the filter element.

3. Inspect the canister for debris and clean as necessary.

4. Install a new filter element and tighten the wingnut.

5. Replace the canister cover and lock the catches.

E

NGINE

A

DJUSTMENT

- D

UAL

F

UEL

Figure 3-13:

Dual Fuel Engine Air Filter Element

ART_3204

Air Filter

Canister

Catch

Filter

Cover

Figure 3-14:

Dual Fuel Engine Adjustments

The following adjustment points are sealed by the factory and cannot be adjusted.

• Carburetor Pilot Screw

• LPG Main Pressure Adjustment Screw

• LPG Idle Pressure Adjustment Screw

• Distributor Ignition Timing Adjustment

Screw

Idle Adjustment Screw

Choke Adjustment Screw

C

HOKE

A

DJUSTMENT

- D

UAL

F

UEL

1. Loosen the Choke Adjustment

Screw until the linkage rod can move freely.

2. Manually retract 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.

Throttle Solenoid

4. Allow the choke plate to open slightly and tighten the Choke Adjustment Screw.

Throttle

Solenoid

Adjustment

Choke

Solenoid

Throttle

Linkage

ART_2067

5. Check Choke Solenoid operation to ensure that the choke plate travel does not prevent the Choke Solenoid from retracting fully.

“4069RT” Service and Parts Manual

D U A L F U E L E

N G I N E

M

A I N T E N A N C E

I

DLE

S

PEED

A

DJUSTMENT

- D

UAL

F

UEL

1. Bring the engine to operating temperature.

2. With the engine at idle, adjust the Throttle Stop Screw until the engine RPM is

1350±50.

H

IGH

S

PEED

A

DJUSTMENT

- D

UAL

F

UEL

1. Bring the engine to operating temperature.

2. Loosen the adjusting nuts on the Throttle Solenoid.

3. Have an assistant press the enable trigger on the Upper Controls joystick.

4. Adjust the nuts on the Throttle Solenoid Piston until the engine RPM is 3400±50.

5. Tighten the nuts to secure the adjustment.

“4069RT” Service and Parts Manual March 2014

Page 3-19

N

O T E S

:

D U A L F U E L E

N G I N E

M

A I N T E N A N C E

March 2014

Page 3-20

“4069RT” Service and Parts Manual

Section 4

T

ROUBLESHOOTING

C

ONTENTS

P

AGE

General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

EZ-Cal Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Optional Onboard EZ-Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

EZ-Cal Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

EZ-Cal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

EZ-Cal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Ez-Cal Retrieve Mode And Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

MODE Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

OTHER Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

F

IGURES

P

AGE

GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

EZ-Cal Scan Tool Connections - GP400 Module . . . . . . . . . . . . . . . . . . . . . . . 4-7

Onboard EZ-Cal Scan Tool & GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

EZ-Cal Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

EZ-Cal Display Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

EZ-Cal Flow Chart: Adjustments and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

EZ-Cal Flow Chart: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

“4069RT” Service and Parts Manual March 2014

Page 4-1

T

ABLES

P

AGE

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

March 2014

Page 4--2

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - G

E N E R A L

T

R O U B L E S H O O T I N G

T

I P S

G

ENERAL

T

ROUBLESHOOTING

T

IPS

H

YDRAULIC

F

LUID

P

UMP

The Hydraulic Drive Pump used in this model is a Variable Displacement, Axial Piston type pump. Proper adjustment is critical for normal operation of the machine. Refer to

Section 1 of this manual.

Common Causes of Electrical System Malfunctions:

• Battery connections are loose or corroded

• Battery is not fully charged.

• Emergency Stop buttons are pushed (OFF position).

• Circuit breaker is in the tripped (OFF position).

Common Causes of Hydraulic System Malfunctions:

• Hydraulic fluid level is too low.

• Mixed incompatible hydraulic fluids, destroying the additives and causing varnish build-up and sticking valves.

• Water in the hydraulic fluid due to damp climate.

• Improper hydraulic fluid. Viscosity too high in cold climates. Viscosity too low in warm climates.

• Hydraulic fluid contaminated with debris--filter change interval neglected, or debris introduced into the hydraulic system.

In machines equipped with the optional cold climate package, 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 with a lower grade fluid will result in pump failure. Refer to

Section 1 of this manual.

Contamination always causes failure in any hydraulic system. It is very important to be careful not to introduce any contamination into hydraulic system during the assembly procedures. Please make sure all ports and cavities of the manifold and cylinders are properly capped or plugged during maintenance activities.

“4069RT” Service and Parts Manual March 2014

Page 4-3

T

R O U B L E S H O O T I N G

- - E

L E C T R I C A L

S

Y S T E M

T

R O U B L E S H O O T I N G

E

LECTRICAL

S

YSTEM

T

ROUBLESHOOTING

The electronic control system used on this machine was designed for low maintenance and long trouble free operation. The system consists of two microprocessor based modules; The Matrix Module and the GP400 Processor. They communicate through a low voltage digital signal called Can-Bus communication.

To protect against part failure or incorrect plug connections, the modules are fully short circuit and reverse polarity protected. All electrical plug connections are waterproof to promote longer trouble free operation and to increase terminal life.

NEVER ATTEMPT TO SUPPLY BATTERY POWER, OR VOLTAGE HIGHER

THAN 12 VOLTS TO ANY PART OR MODULE IN THIS SYSTEM, AS

CATASTROPHIC FAILURE OF THE MODULES MAY RESULT.

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.

March 2014

Page 4-4

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

L E C T R I C A L

S

Y S T E M

T

R O U B L E S H O O T I N G

G P 4 0 0 M

O D U L E

The GP400 module is “the brains” of the system. It receives and processes a variety of inputs both from the machine and the operator, then controls all the operative functions of the machine. It also has a feature that allows the technician to access and monitor all functionality of the system, along with a technician-friendly series of fault messages that can be accessed through the use of the EZ-Cal scan tool. Flash codes are also provided in case an EZ-Cal scan tool is not available.

Such information can be used for preventative maintenance and troubleshooting should a problem arise. A comprehensive list of EZ-Cal accessible information can be found later in this section.

The GP400 operates on 12 volts DC and should never be probed or operated with voltage higher than 14 volts DC

Figure 4a-1:

GP400 Module

P4-1 — Choke/P r eheat

P4-2 — S ta r te r

P4-3 — n ot us ed

P4-4 — Th r ottle

P4-5 — F u el

P4-6 — F u el

P4-7 — Alt Excite r

P4-8 — Ig n itio n

P4-9 — n ot us ed

P4-10 — Rea r Wheel Bypa ss Valve

P4-11 — n ot us ed

P4-12 — P r opo r tio n al

P4-13 — n ot us ed

P4-14 — Dow n Valve 1

P4-15 — n ot us ed

P5-1 — Lift Valve

P5-2 — S tee r Right

P5-3 — S tee r Left

P5-4 — D r ive Fo r wa r d

P5-5 — D r ive Reve rs e

P5-6 — Ala r m

P5-7 — High To r q u e

P5-8 — High S peed

P5-9 — Ho ur Mete r

P5-10 — n ot us ed

P5-11 — n ot us ed

P5-12 — n ot us ed

P5-13 — n ot us ed

P5-14 — S ta r t I n hibit Wa rn

P5-15 — n ot us ed

OUTRIGGER VALVE S

P6-1 — Back Pitchi n g Valve

P6-2 — F r o n t Pitchi n g Valve

P6-3 — Right Pitchi n g Valve

P6-4 — Left Pitchi n g Valve

P6-5 — n ot us ed

P6-6 — n ot us ed

P6-7 — n ot us ed

P6-8 — n ot us ed

P6-9 — n ot us ed

P6-10 — n ot us ed

P6-11 — n ot us ed

P6-12 — n ot us ed

P6-13 — Axle Lock

P6-14 — n ot us ed

P6-15 — Ge n e r ato r

BA S E & LOWER CONTROL S

P7-1 — Valve Su pply

P7-2 — Ba s e S elected

P7-3 — UP - Ba s e

P7-4 — Platfo r m S elected

P7-5 — n ot us ed

P7-6 — n ot us ed

P7-7 — DOWN - Ba s e

P7-8 — n ot us ed

P7-9 — n ot us ed

P7-10 — Choke/P r eheat

P7-11 — n ot us ed

P7-12 — S ta r t

P7-13 — Oil P r e ssur e S witch

P7-14 — n ot us ed

P7-15 — n ot us ed

P1-1 — CAN BU S H

P1-2 — CAN BU S L

P1-3 — G r o un d

P2-1 — n ot us ed

P2-2 — n ot us ed

P2-3 — n ot us ed

13 15 13 15 13 15 13 15 13 15

1 3 1 3 1 3 1 3 1 3

10 12

P8-1 — Elevatio n T r a ns d u ce r

P8-2 — n ot us ed

P8-3 — n ot us ed

P8-4 — n ot us ed

P8-5 — CE Elevatio n

P8-6 — A n alog IN

P8-7 — n ot us ed

P8-8 — TBM A n alog IN

P8-9 — n ot us ed

P8-10 — n ot us ed

P8-11 — n ot us ed

P8-12 — n ot us ed

P8-13 — G r o un d

P8-14 — G r o un d

P8-15 — G r o un d

EZ-Cal

Connection

1 3

NOT U S ED

Diagnostic

LED ART_3185

“4069RT” Service and Parts Manual March 2014

Page 4-5

T

R O U B L E S H O O T I N G

- - E

L E C T R I C A L

S

Y S T E M

T

R O U B L E S H O O T I N G

M

A T R I X

M

O D U L E

The Matrix Module is the remote module located inside the upper control box. It received inputs from the operator and relays them to the GP400.

Figure 4a-2:

Matrix Module

P4-1 — n ot us ed

P4-2 — n ot us ed

P4-3 — n ot us ed

P4-4 — Level I n dicato r Lamp

P4-5 — Ala r m

P4-6 — D r iveE n abled Lamp (O u t r igge rs Optio n )

P4-7 — n ot us ed

P4-8 — n ot us ed

P4-9 — n ot us ed

Diagnostic

LED

P1-1 — 12 Volt s DC INPUT: Powe r u p

P1-2 — n ot us ed

P1-3 — CAN BU S H

P1-4 — G r o un d

P1-5 — n ot us ed

P1-6 — CAN BU S L

Matrix Module (inside Upper Control Box)

3

6

1

4

3

12

1

10

P2-1 — FORWARD / DOWN

P2-2 — REVER S E / UP

P2-3 — S TEER Left

P2-4 — S TEER Right

P2-5 — E n able Ba r

P2-6 — Pote n tiomete r

P2-7 — n ot us ed

P2-8 — n ot us ed

P2-9 — n ot us ed

P2-10 — Pote n tiomete r

P2-11 — Pote n tiomete r

P2-12 — S witch Su pply

P3-1 — High S peed

P3-2 — S witch Su pply

P3-3 — n ot us ed

P3-4 — DRIVE

P3-5 — LIFT

P3-6 — NOT U S ED

P3-7 — n ot us ed

P3-8 — n ot us ed

P3-9 — n ot us ed

P3-10 — UP S witch

P3-11 — DOWN S witch

P3-12 — n ot us ed

ART_3159

T

E R M I N A L

B

L O C K

M

O D U L E

( T B M )

Figure 4a-3:

Terminal Block Module (TBM)

There is a module inside the lower control box, called a TBM

(Terminal Block Module) that provides terminal point connections for both positive and ground circuits. A signal from the

Emergency Stop circuit activates a load-reduction relay within the

TBM that provides ample power to the B+ (positive) terminal strip.

This arrangement protects the system against voltage drop conditions that can be detrimental to the electrical system.

GROUND

(B−) Connection

PLATFORM Selected

BASE Selected

ANALOG (AMP)

COMMON B+

POSITIVE OUTPUT

(B+) Supply

To various circuits

ART_3186

March 2014

Page 4-6

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E Z - C

A L

S

C A N

T

O O L

EZ-C

AL

S

CAN

T

OOL

The EZ-Cal (MEC part # 90888; not part of the machine) is a hand-held scan tool that interfaces with the system to provide various information and adjustments. The EZ-cal receives its power from the GP400 when connected. The system must be powered up by closing the Battery disconnect switch and pulling both emergency stop switches. You must also select Base or Platform depending on the station you will operate from.

U

S I N G T H E

E Z -

C A L

S

C A N

T

O O L

To operate the EZ-cal, plug the cable into the 4-terminal receptacle P9 on the GP400 and power the system up.

• The EZ-Cal display will illuminate and read “HELP: PRESS ENTER”. From this point, use the right and left arrows to scroll through the base menus.

• Once the desired base menu is obtained (i.e.

ADJUSTMENTS

) press Enter to access sub menus.

• Use the right and left arrows to scroll through sub menus, press Enter again.

• The up/down arrows are used to change settings only.

• Press ESC to back up one level.

Figure 4a-4:

EZ-Cal Scan Tool Connections - GP400 Module

Calibrator

MEC P/N 90888

GP400 Control Module

15 13 15 13 15 13 15 13 15 13

1 3 1 3 1 3 1 3 1 3

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS

To move back and forth between menu and sub-menu

LEFT/RIGHT BUTTONS

Select menus and setting to be adjusted

UP/DOWN BUTTONS

Adjust setting values

GP400

Module

LED

10 12

10 12

1 3 1 3

Lower Controls

Terminal

Block

Module

Diagnostic LED

ART_3154

“4069RT” Service and Parts Manual March 2014

Page 4-7

T

R O U B L E S H O O T I N G

- - E Z - C

A L

S

C A N

T

O O L

O

P T I O N A L

O

N B O A R D

E Z - C

A L

To use and operate the onboard EZ-Cal, set the Base/Platform Key switch to Base or

Platform, then open the door to the Lower Controls Box. The onboard EZ-Cal scan tool provides the same functionality as the hand-held unit.

Figure 4-5:

Onboard EZ-Cal Scan Tool & GP400 Module

EZ Cal Onboard Scan Tool Typical Lower Controls Box

GP400 Module

Optional Onboard

Diagnostic Center

ART_4164

U

S I N G T H E

E Z - C

A L

S

C A N

T

O O L

Figure 4-6:

EZ-Cal Buttons

• Once, powered up, the EZ-Cal display will illuminate and read “HELP: PRESS

ENTER”. From this point, use the right and left arrows to scroll through the base menus.

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS

To move back and forth between menu and sub-menu

• Once the desired base menu is obtained (i.e.

ADJUSTMENTS

) press

Enter to access sub menus.

LEFT/RIGHT BUTTONS

Select menus and setting to be adjusted

UP/DOWN BUTTONS

Adjust setting values

• Use the right and left arrows to scroll through sub menus, then press Enter again to choose a sub menu.

ART_3710

• The up/down arrows are used to change settings only.

Press ESC to back up one level.

March 2014

Page 4-8

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - U

S I N G T H E

E Z - C

A L W I T H T H E

F

L O W

C

H A R T S

U

SING THE

EZ-C

AL WITH THE

F

LOW

C

HARTS

Use the EZ-cal Flow Charts as a guide to locate diagnostic information and make adjustments. Each box in the flow chart will have 3 bits of information.

Figure 4-7:

EZ-Cal Display Example

5C-2

UP MAX

75%

Identification Number

Personality

Default Setting

to match with information tables, this number will not appear on the EZ-Cal display

ART_3183

The IDENTIFIER (5c2): – Used to locate this specific personality in the informational charts. Here you can obtain specific information on the individual personalities.

The PERSONALITY (Up Max): – Identifies the individual personalities.

The DEFAULT SETTING: – The factory setting. If adjustments are made, they must be returned to default setting.

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.

F

L A S H

C

O D E S

Flash Codes, provided from the GP400 red LED, will also assist in the event an EZ-cal is not available. However, the EZ-cal yields considerably more relevant information.

Refer to "EZ-Cal HELP Messages" on page 4-16 for flash coded error messages.

“4069RT” Service and Parts Manual March 2014

Page 4-9

Adjustments & Setups

1

HELP

PRESS ENTER

ENTER

2

DIAGNOSTICS

ENTER

3

ACCESS LEVEL

ENTER

T

R O U B L E S H O O T I N G

- - U

S I N G T H E

E Z - C

A L W I T H T H E

F

L O W

C

H A R T S

Figure 4-8:

EZ-Cal Flow Chart: Adjustments and Setup

69 RT/IC SERIES

EZ-CAL MENU

RUN SYSTEM

TESTS

4

ADJUSTMENTS

ENTER

5

SETUPS

ENTER

EZ-Cal Flow Chart

Chart 1 of 2

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS

To move back and forth between

Menu and sub-menu

LEFT/RIGHT BUTTONS

Select menus and setting to be adjusted

UP/DOWN BUTTONS

Adjust setting values

NOT

FUNCTIONAL

ERROR

MESSAGE

ENTER

LOGGED

MESSAGES

PRESS RT & LT

ARROWS TO VIEW

PREVIOUS

ERRORS &

MESSAGES

2A

SYSTEM

2B

PLATFORM

2C

GROUND

2D

INPUTS

2E

ANALOGS

2F

OUTPUTS

2G

LOG

SEE

CHART

# 2

ACCESS LEVEL

2

FOR

CALIBRATIONS

ACCESS LEVEL

1

FOR

ADJUSTMENTS

5A

CHANGE

DEFAULTS

ENTER

5A-1

CUSTOMER

17= 4069RT

5A-2

MODEL

18= 4069RT US

19= 4069RT CE

5B

TILT

SETUPS

5B-1

ENTER

CALIBRATE LEVEL

SEE INSTRUCTIONS

5B-2

TILT SHUTDOWN

0= NEVER

5B-3

ELEVATED TILT

SHUTDOWN

1=LIFT & DRIVE

= DO NOT CHANGE

5C

HEIGHT

SETUPS

ENTER

5C-1

ELEVATION @

9%

5C-2

CALIBRATE HEIGHT

SEE INSTRUCTIONS

5C-3

MIN LIFT

1.0 SEC

5C-4

SAMPLES@

0.30 SEC

5C-5

TILT CORRECTION

1= X+

5C-6

SLOW DOWN

6%

5D

LOAD

SETUPS

ENTER

5D-1

CALIBRATE LOAD

SEE INSTRUCTIONS

5D-2

FAULTY LOAD

-100%

5D-3

DYNAMIC SCALE

.95

5D-4

DELAY UP

0.0 SEC

5D-5

DELAY DOWN

0.0 SEC

5E

INTERLOCKS

ENTER

5E-1

TRIGGER ONLY

10.0 SEC

5E-2

TRIGGER WAIT

0.5 SEC

5E-3

FUNCTION HOLD

0.2 SEC

5E-4

THROTTLE

DELAY

0.30 SEC

5E-5

STARTER DELAY

10.0 SEC

5E-6

BRAKE DELAY

0.0 SEC

4A

DRIVE

ENTER

4A-1

FWD MIN

23%

4A-2

FWD MAX

65%

4A-3

REV MIN

23%

4A-4

REV MAX

56%

4A-5

ACCEL

5.0 SEC

4A-6

DECEL

10.0 SEC

4A-7

STOP DECEL

9.0 SEC

4B

DRIVE

ELEVATED

4B-1

FWD MIN

23%

4B-2

FWD MID

35%

4B-3

FWD MAX

4%

4B-4

REV MIN

23%

4B-5

REV MID

32%

4B-6

REV MAX

45%

4B-7

ACCEL

10.0 SEC

4A-8

MAX HEIGHT

101%

4B-8

DECEL

0.5 SEC

4C

LIFT

4C-1

UP MIN

21%

4C-2

UP MAX

44%

4C-3

DOWN MIN

0%

4C-4

DOWN MAX

0%

4C-5

ACCEL

8 SEC

4C-6

DECEL

1.0

4C-7

MAX HEIGHT

98%

4C-8

ARM GUARD

4C-9

DELAY

BELOW ELEV

0.0 ANSI

2.0 SEC -CE

ENTER

4D

STEER

4D-1

SPEED

37%

ENTER

4D-2

SC +

1%

4D-3

SC X

25%

4D-4

ELEV DRIVE

COMP

2%

4D-5

EXCEL

0.2 SEC

4D-6

DECEL

0.2 SEC

4C-8a

TIME

0.0 ANSI

2.0 CE

4C-8b

@ HEIGHT

101% ANSI

9% CE

4E

DECK

4F

OUTRIGGERS

OPTIONAL

ENTER

4E-1

OUT MIN

20%

ENTER

4F-1

OUTRIGGERS

0= NO or

3= DRV RET

4E-2

OUT MAX

100%

4F-2

EXTEND

65%

4E-3

IN MIN

20%

4F-3

LEVEL

37%

4E-4

IN MAX

100%

4F-4

RETRACT

45%

4E-5

ACCEL

3.0 SEC

4F-5

DEBOUNCE

0.10 SEC

4E-6

DECEL

3.0 SEC

4F-6

INITIAL

0.0 SEC

4F-7

PRE- LEVEL

1.6 SEC

4F-8

TILT FILTER

4

4F-8

X TILT TARGET

0.1 DEG

4F-9

Y TILT TARGET

0.2 DEG

4F-10

TILT SLACK

0.3 DEG

4G

GROUND

MODE

ENTER

4G-1

UP

44%

4H

AIRTRAX

(NOT USED)

4H-1

HI MIN

ENTER

4G-2

DOWN

0%

4G-3

OUT

50%

4H-2

HI BREAK

4H-3

HIGH MAX

4J

TILT

4J-1

X TRIP

5.0°

ENTER

4J-2

Y TRIP

3.0°

4J-3

DELAY TRIP

2.0 SEC

4G-4

IN

50%

4G-5

ACCEL

8.0 SEC

4G-6

DECEL

1.0 SEC

4H-4

HI BREAK @

4H-5

LO MIN

4H-6

LO BREAK

4H-7

LO MAX

4J-5

DELAY CLEAR

0.5 SEC

4J-6

TILT #2

ENTER

4J-6a

@ HEIGHT

80%

4K-4

@ HEIGHT

8%

4K-5

SAFE DOWN

12%

4K-6

DELAY TRIP

1.5 SEC

4K-7

DELAY CLEAR

1.5 SEC

4K

OVERLOAD

4K-1

TRIP @

0% ANSI

110% CE

ENTER

4K-2

LAMP @

0%

4K-3

ALARM @

0%

4M

ALARMS

ENTER

4M-1

DRIVE

SELECT AS

NEEDED

4M-2

LIFT

2= DOWN +

SELECT AS

NEEDED

4M-3

TILT

1= WHEN

ELEVATED

4H-8

LO BREAK @

4J-6b

X TRIP 2

5.0 DEG

4J-6c

Y TRIP 2

0.5 DEG

4K-8

OVERLOAD 2

ENTER

4N

HEIGHTS

4N-1

ELEVATION@

9%

4N-2

MAX DRIVE

101%

4N-3

MAX LIFT

98%

4N-4

ARMGUARD

101% ANSI

9% CE

4N-5

OVERLOAD

0% ANSI

8% CE

4N-6

SAFE-DOWN

12%

4N-7

OVERLOAD 2

101%

4N-8

TILT 2

80%

4K-8a

@ HEIGHT

101%

4K-8b

SCALE

100%

4N-9

POTHOLE

101%

ART_4486

March 2014

Page 4-10

= DO NOT CHANGE

“4069RT” Service and Parts Manual

DIAGNOSTIC

Use in conjunction with

Diagnostic tables for

Thorough explanation

Of personalities and values

2A

SYSTEM

ENTER

2A-1

MODE

PRESS ENTER

FOR MESSAGES

2A-2

SUPPLY

ENTER

2A-8

TILTED

YES WHEN PAST 3

DEG.

ENTER

2A-9

HEIGHT

ACTUAL IN %

2A-10

LOAD

OVERLOAD

PROTECTION ONLY

2A-11

OVERLOADED

YES or NO

2A-12

LAST MOVED

NOT USED

2A-13

ELEVATED

YES or NO

2A-14

OUTRIGGERS

EXTENDED

2A-15

OUTRIGGERS

RETRACTED

2A-16

OUTRIGGERS

STATUS

2A-17

OUTRIGGERS

AUTO-RETRACT

ENTER

2A-3

VALVE SUPPLY

ON/OFF

2A-4

MOTOR VOLTS

ACTUAL

2A-5

MOTOR AMPS

ACTUAL

2A-6

TEMPERATURE

OF P600

CONTROLLER

2A-7

TILT

2A-2A

SUPPLY

12 VOLTS DC

2A-2B

SUPPLY

CAP BANK

2A-7A

TILT FILTERED

NOT USED

2A-7B

TILT LOCAL

ACTUAL IN

DEGREES LEVEL

2A-8A

TILTED MORE

YES or NO

2B

PLATFORM

ENTER

2B-1

TRIGGER

ON/OFF

2B-2

DLD

ACTUAL

2B-3

JOYSTICK

ACTUAL DEG OF

MOVEMENT

2B-4

FWD / UP

FWD JOYSTCK

MOVEMENT

2B-5

REV / UP

REV JOYSTICK

MOVEMENT

2B-6

LEFT(STEER)

ON/OFF

2B-7

RIGHT (STEER)

ON/OFF

2C

GROUND

ENTER

2C-1

UP

ON/OFF

2C-2

DOWN

ON/OFF

2C-3

OUT

NOT USED

2C-4

IN

NOT USED

2D

INPUTS

ENTER

2D-1

P7-1

12 V SUPPLY

2D-2

P7-2

BASE SELECTED

P7-12

START SWITCH

2D-8

P7-13

OIL PRESSURE

SWITCH

2D-9

P15-5

O/R PRESSURE

SWITCH

2D-10

P15-6

O/R PRESSURE

SWITCH

2D-11

P15-7

O/R PRESSURE

SWITCH

2D-12

P15-8

O/R PRESSURE

SWITCH

2D-3

P7-3

UP

SELECTED

2D-4

P7-4

PLATFORM

SELECTED

2D-5

P7-7

DOWN SELECTED

2D-6

P7-10

PREHEAT SWITCH

2D-7

NOTE:

All other plug numbers that appear on the

EZ-cal but not listed here are not used on this model

2E

ANALOGS

ENTER

2E-1A

P8-2

ANGLE

TRANSDUCER 1

2E-1B

P8-5

ANGLE

TRANSDUCER 2

CE ONLY

2E-1C

P8-6

PRESSURE

TRANSDUCER

CE ONLY

2E-1D

P8-9

TBM IN

2E-2

MATRIX

ANALOGS

UPPER CONTROL

ENTER

2E-2A

M2-6

POTENTIOMETER

BOOM GP400

ALL CIRCUITS 12V ONLY

T

R O U B L E S H O O T I N G

- - U

S I N G T H E

E Z - C

A L W I T H T H E

F

L O W

C

H A R T S

Figure 4-9:

EZ-Cal Flow Chart: Diagnostics

69 SERIES RT/IC

EZ-CAL MENU

2

DIAGNOSTICS

ENTER

EZ-Cal Flow Chart

Chart 2 of 2

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONS

To move back and forth between

Menu and sub-menu

LEFT/RIGHT BUTTONS

Select menus and setting to be adjusted

UP/DOWN BUTTONS

Adjust setting values

2F

OUTPUTS

ENTER

2F-1

P4-1

PREHEAT/CHOKE

2F-2

P4-2

STARTER

2F-3

P4-3

REAR WHEEL

BYPASS VALVE

2F-4

P4-4

THROTTLE

2F-5

P4-6

FUEL SOLENOID

2F-6

P4-7

ALTERNATOR

EXCITE

2F-7

P4-8

IGNITION

2F-8

P4-10

REAR WHEEL

BYPASS VALVE

2F-9

P4-12

PROPORTIONAL

VALVE

2F-10

P4-14

DOWN VALVE

2F-11

P5-1

LIFT VALVE

2F-12

P5-2

STEER RIGHT

2F-13

P5-3

STEER LEFT

2F-14

P5-4

DRIVE FORWARD

2F-15

P5-5

DRIVE REVERSE

2F-16

P5-6

ALARM

2F-17

P5-7

HIGH TORQUE

2F-18

P5-8

HIGH SPEED

2F-19

P5-9

HOUR METER

2F-20

P5-10

OUTRIGGER

EXTEND VALVE

2F-21

P5-11

OUTRIGGER

RETRACT VALVE

2F-22

P5-14

START INHIBIT

WARNING LT

2F-23

P6-1

OUTRIGGER

R/F UP

2F-24

P6-2

OUTRIGGER

L/F UP

2F-25

P6-3

OUTRIGGER

R/R UP

2F-26

P6-4

OUTRIGGER

L/R UP

2F-27

P6-5

OUTRIGGER

R/F DOWN

2F-28

P6-6

OUTRIGGER

L/F DOWN

2F-29

P6-7

OUTRIGGER

R/R DOWN

2F-30

P6-8

AMBER BEACON

2F-31

P6-10

OUTRIGGER

L/R DOWN

2F-32

P6-15

A/C GENERATOR

2G

LOG

ENTER

2G-1

CALDATE

DATE OF

CALIBRATION

2G-2

SOFTWARE

SOFTWARE

VERSION NUMBER

2G-3

POWERED

ACCUMULATED

HRS ON GP400

2G-4

MAX BATTERY

HIGHEST BATT

VOLTAGE

ART_4487

“4069RT” Service and Parts Manual March 2014

Page 4-11

T

R O U B L E S H O O T I N G

- - E Z - C

A L

A

D J U S T M E N T S

EZ-C

AL

A

DJUSTMENTS

Refer to "Using the EZ-Cal Scan Tool" on page 4-8.

Adjustments are possible only in Access Level 1.

Before changing personalities, ensure that the Correct Customer and Model have been selected in the SETUPS menu. Any changes to settings will be lost when the model or customer is changed.

To reach ADJUSTMENTS, first access Level 1, then press --> for ADJUSTMENTS.

Press Enter, then press --> to scroll through the sub-menus.

Once the desired sub-menu is found, press Enter again, then --> to scroll through the personalities. Press the Up or Down arrows to change the personality. Press ESC to go back one or more levels to reach other sub-menus.

E Z - C

A L

S

E T U P

Only authorized personnel may have access to and may make changes to personalities.

The Setups Menu is where machine and model settings may be changed. It is also the location where calibrations are performed.

Refer to "Using the EZ-Cal Scan Tool" on page 4-8.

E Z - C

A L

D

I A G N O S T I C S

The EZ-Cal Diagnostics menu provides the ability to view and test individual circuits for irregularities. Whether diagnosing a failure or testing functions during preventative maintenance, the Diagnostics Menu provides a quick view at the inputs and outputs as registered by the GP400 Control Module in real time.

To reach DIAGNOSTICS menu from HELP;

• Press the right arrow and scroll to DIAGNOSTICS and press ENTER.

• Locate the desired sub menu and press ENTER.

• Press the right arrow to scroll through the test points.

NOTE: The ID number will not appear on the EZ-Cal display. It is shown in the

Diagnostics Menu

for reference only.

Press ESC to go back one level (necessary to change selection).

March 2014

Page 4-12

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

E

Z

-C

AL

R

ETRIEVE

M

ODE

A

ND

H

ELP

M

ESSAGES

NOTE:

It is important to understand that an error message will only be available if the red Diagnostic

LED is flashing. If the machine is not operating properly and the red Diagnostic LED is not flashing, the trouble may lie with something not monitored by the electronic control system, i.e. a switch, hydraulic valve or wiring damage.

There are two different menus that you can access for message retrieval; MODE and

HELP.

M O D E M

E N U

Allows the technician to see the current state of the controller interlocks with a short description. Go to, DIAGNOSTICS/SYSTEM/MODE (EZ-Cal Flow Chart 2, ID# 2a1).

Pressing ENTER a second time will provide additional information with certain messages.

H E L P M

E N U

Provides various HELP messages to identify failure modes.

Some error messages may also be identified by counting the number of times the red

LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible. However, the EZ-Cal provides a much higher level of diagnostic information. Do not rely on the LED alone.

MODE M

ESSAGE

• Connect the EZ-Cal (see illustration).

The display will read, “HELP: PRESS ENTER”.

• Press the Right Arrow once, then press ENTER twice.

• Refer to the following list of messages to better understand the nature of the message or fault.

• If the GP400 does not register a fault, the display will read EVERYTHING OK.

L

OGGED

M

ESSAGE

Pressing ENTER twice will provide the current message, followed by a log of previous operations and/or errors that occurred immediately prior, starting with most recent.

Press the Right and Left Arrows to view all logged messages.

Other helpful menus available include DIAGNOSTICS which allows the technician to monitor specific plug input/output information. Refer to EZ-Cal Flow Chart 2 –

Diagnostics.

M O D E M

E S S A G E S

The purpose of MODE is to indicate, in real time, the current state of the controller with a short description.

INITIALIZING

• The system is preparing to operate, immediately after power-on.

SHUTDOWN!

• The system cannot operate – for example both the PLATFORM & GROUND inputs are active together.

CHECK CANBUS

• The system cannot operate – CANBUS communications is not successful (for example wire damage to the platform)

“4069RT” Service and Parts Manual March 2014

Page 4-13

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

PLATFORM, GROUND

• The system is ready to operate, from the upper or lower controls as indicated (selected by the

Base/Platform selector switch)

GROUND UP, GROUND DOWN,

• A ground function is operating normally

GROUND UP LOCKED, GROUND DOWN LOCKED,

• A ground function is selected but not allowed (for example, the function switch was closed at power-on)

GROUND FAULTY

• Multiple ground function inputs are active at the same time

WAITING FOR TRIGGER

• A platform function is selected, but the joystick trigger switch is not closed (close the trigger switch to proceed)

TRIGGER CLOSED

• The joystick trigger switch is closed, but no function is selected (select a function to proceed)

TRIGGER LOCKED

• The joystick trigger 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), REVERSE (LEFT), REVERSE (RIGHT)

• A platform drive function is operating normally, with steer also active

STEER LEFT, STEER RIGHT

• A platform steer function is operating normally (without drive)

UP, DOWN

• A platform lift/lower function is operating normally

FORWARD LOCKED, REVERSE LOCKED

• A platform drive function is selected but not allowed (for example, the switch was closed at power-on)

LEFT LOCKED, RIGHT LOCKED

• A platform steer function is selected but not allowed (for example, the switch was closed at power-on)

UP LOCKED, DOWN LOCKED

• A platform lift/lower function is selected but not allowed (for example, the switch was closed at power-on)

CHECK DRIVE/LIFT

• Neither platform drive nor platform lift select is active, or both are active at the same time

CHECK JOYSTICK

• Both platform joystick directions are active at the same time

STEER FAULTY

• Both platform steer directions are active at the same time

March 2014

Page 4-14

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

EXTENDING LEGS

• Outrigger legs are extending normally

RETRACTING LEGS

• Outrigger legs are extending normally

OUTRIGGERS LOCKED

• An outrigger function is selected but not allowed (for example, the switch was closed at power-ON)

INTERLOCKED**

• An interlock shutdown is active, preventing one or more functions. The interlock can be due to many different causes …

**Press <ENTER> from the MODE display to see the precise cause of the interlock

(listed below) – press <ESC> from that display to return to the MODE display:

TEST MODE

• The system test mode is active – switch power off and on again to clear

TILTED

• The vehicle is tilted beyond limits, descend, then move vehicle to a more level location

TOO HIGH

• The vehicle platform is too high to allow some functions – descend first

TOO HOT

• The EZLIFT heatsink has reached 75ºc, preventing all functions except lowering. Functions will be allowed again when the heatsink cools to below 70ºc.

• The heatsink temperature can be viewed in the DIAGNOSTICS/SYSTEM/ TEMPERATURE display, ID # 2a5.

• The heatsink must be bolted to a significant metal panel of the vehicle, capable of dissipating heat to the environment.

UNCALIBRATED

• The height and/or pressure sensors have not been calibrated see CALIBRATION OF OVER-

LOAD SYSTEM

(CE option only)

.

• If machine is not equipped with Overload system, refer to SETUPS table and change those personalities that do not match the figure listed in the table.

EXTERNAL ALL, EXTERNAL DRIVE, EXTERNAL LIFT

• An external cutout input is preventing functions – determine the cause of the external cutout

(for example, a limit switch)

“4069RT” Service and Parts Manual March 2014

Page 4-15

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

E Z - C

A L

H E L P M

E S S A G E S

In addition to the MODE messages detailed above, the GP400 provides a HELP message to identify failure modes. Some error messages may also be identified by counting the number of times the red LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible. However, 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.

• Connect the EZ-Cal (see illustration).

The display will read, “HELP: PRESS ENTER”.

• Press Enter to display the current message.

• Refer to the following list of HELP messages to better understand the nature of the message or fault.

• If the GP400 does not register a fault, the display will read EVERYTHING OK.

Pressing ENTER twice will provide a scrolling message of the current message (if one exists) followed by a log of previous operations and/or errors that occurred immediately prior, starting with most recent. All messages are cleared whenever the system is

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/off a second certain number of times, followed by a much longer pause off. The sequence will then repeat.

I N F O R M A T I O N O N L Y M

E S S A G E S

The following are “information only” HELP messages which are not indicative of any possible problem – there is no LED flash code (the LED remains on steady):

STARTUP! _____________________________________________ (no flash code)

• The system has just been powered on and is carrying out some initialization steps prior to being ready to operate. If you select a function during this time, it may be locked out until you release then re-select it.

EVERYTHING OK _______________________________________ (no flash code)

• There is no problem with the system – it is ready to operate in platform mode when a function is selected.

NOTE:

If this is the HELP message when a function is selected, check for open-circuit switches or wiring.

GROUND MODE ACTIVE!

________________________________ (no flash code)

• There is no problem with the GP400 – it is ready to operate in ground mode when a function is selected.

CLOSE TRIGGER _______________________________________ (no flash code)

• A platform function is selected but the trigger switch is not closed.

VEHICLE TILTED _______________________________________ (no flash code)

• The vehicle is tilted beyond the limits, some functions may be prevented.

March 2014

Page 4-16

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

F U N C T I O N A C T I V E M

E S S A G E S

The following HELP messages indicate that there is no problem with the GP400 but that a function is active – the vehicle should be moving as requested by the operator.

DRIVING! _____________________________________________ (no flash code)

LIFTING! ______________________________________________ (no flash code)

LOWERING! ___________________________________________ (no flash code)

STEERING!

___________________________________________ (no flash code)

EXTENDING OUTRIGGERS! ______________________________ (no flash code)

RETRACTING OUTRIGGERS!

____________________________ (no flash code)

C A L I B R AT I O N M

E S S A G E S

The following are “calibration” HELP messages – until the machine is properly calibrated for height and/or pressure (as required), many functions will not be available.

NOT CALIBRATED ______________________________________ Flash Code: 1/1

FUNCTIONS LOCKED - NOT CALIBRATED __________________ Flash Code: 1/1

• The height and/or pressure sensors have not been calibrated and are required because of the setup of the GP400.

• Calibration procedures are accessible from the

SETUPS/HEIGHT SETUPS

and

SETUPS/LOAD

SETUPS

menus.

FAULT: CUSTOMER _____________________________________ Flash Code: 1/1

• The system must be configured to the customer requirements – with the EZ-Cal in SETUPS/

CHANGE DEFAULTS menu, scroll to the correct machine from this menu, the press Right

Arrow to select the appropriate model.

NOTE: Selecting the incorrect customer or model will cause the machine to operate incorrectly or go into fault mode.

“4069RT” Service and Parts Manual March 2014

Page 4-17

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

S H U T D O W N H

E L P

M

E S S A G E S

This section lists “shutdown” HELP messages – functions can be shut down to prevent them being used:

SHUTDOWN - CHECK EMS SWITCHES! ____________________ Flash Code: 2/1

• The Base/Platform selector switch position indicates the mode in which the system must operate if both are active together; the system does not know how to function

FUNCTIONS LOCKED - TEST MODE SELECTED _____________ Flash Code: 2/2

• Test mode is not accessible with this system. Switch power off/on to reset to normal operation

FUNCTIONS LOCKED - TOO HIGH _________________________ Flash Code: 2/2

• The platform is raised too high to allow some functions. Certain functions may not be allowed above certain elevations.

• Check operator’s manual or ADJUSTMENTS/HEIGHTS/MAX DRIVE and MAX LIFT to see if drive and/or lift is allowed at all heights.

FUNCTIONS LOCKED - TILTED ___________________________ Flash Code: 2/2

• The vehicle is tilted too much to allow some functions.

• Check operator’s manual or ADJUSTMENTS/TILT/Xtrip and Ytrip, which determine the maximum allowed vehicle tilt.

• Refer to EZ-Cal Flow Chart 1 – Adjustments and Setup.

FUNCTIONS LOCKED - EXTERNAL SHUTDOWN _____________ Flash Code: 2/2

• An external shutdown is preventing functions – check DIAGNOSTICS/SYSTEM/ MODE/INTER-

LOCK to see which external interlock is active.

CHECK GROUND INPUT SWITCHES! ______________________ Flash Code: 2/2

• There is a problem with the ground function select switches – more than one is active at the same time.

SELECT DRIVE/LIFT MODE! ______________________________ Flash Code: 2/2

• There is a problem with the platform drive/lift select switch – neither mode is selected.

CHECK DRIVE/LIFT SELECT SWITCH! _____________________ Flash Code: 2/2

• There is a problem with the platform drive/lift select switch – both modes are selected together.

CHECK JOYSTICK SWITCHES! ___________________________ Flash Code: 2/2

• There is a problem with the platform joystick switches – both directions are selected together.

RELEASE TRIGGER! ____________________________________ Flash Code: 2/2

• The trigger was closed at power-on, or closed for too long with no function selected.

RELEASE GROUND SWITCHES! __________________________ Flash Code: 2/2

• Ground function switches were closed at power-on.

RELEASE JOYSTICK SWITCHES! _________________________ Flash Code: 2/2

• Platform joystick switches were closed at power-on, or closed for too long without trigger switch (see

SETUPS/INTERLOCKS/TRIGGERwait

).

RELEASE OUTRIGGER SWITCHES! _______________________ Flash Code: 2/2

• Outrigger switches were closed at power-on.

March 2014

Page 4-18

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

W I R I N G M

E S S A G E S

The following are “wiring” HELP messages – problems have been detected which are likely due to vehicle wiring issues:

FAULT: ENERGIZED VALVE - CHECK P5 WIRING! ____________ Flash Code: 3/2

FAULT: VALVE FEEDBACK HIGH - CHECK VALVE WIRING! _____ Flash Code: 3/2

• There is a voltage on one or more valve outputs, when all outputs are off.

• Check each valve output to trace where the invalid supply is coming from.

FAULT: CAPBANK VOLTAGE TOO HIGH - CHECK LINE CONT! __ Flash Code: 3/3

• The voltage on the B+ stud of the controller (connected to an internal voltage stabilization capacitor bank) is too high when the line contactor is off. B+ stud voltage should be approximately 32 volts at idle.

• Check the line contactor tips are not welded, and check the power wiring for errors

.

FAULT: ENERGIZED LINE CONTACTOR - CHECK P5 WIRING! __ Flash Code: 3/4

• There is a voltage on the line contactor coil output, when it is off.

• Check wiring to the line contactor coil to trace where the invalid supply is coming from.

FAULT: MOTOR OVERLOAD! ______________________________ Flash Code: 3/5

• The power protection circuits in the controller have activated to protect from extreme overload.

• Check for short-circuit power wiring; check for a seized or shorted motor.

“4069RT” Service and Parts Manual March 2014

Page 4-19

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

S U P P LY M

E S S A G E S

The following are “supply” HELP messages – problems have been detected which are likely due to supply issues:

FAULT: LOW OIL PRESSURE! _____________________________ Flash Code: 4/1

• Engine oil pressure switch open after start sequence initiated. Engine stalled or unable to start.

FAULT: BAD INTERNAL 5V!_______________________________ Flash Code: 4/2

• The internal “5V slave” supply is out of range; if the fault remains, the controller may have to be replaced.

FAULT: BAD INTERNAL SLAVE! ___________________________ Flash Code: 4/2

• The internal “slave” is not operating correctly; if the fault remains, the controller may have to be replaced.

FAULT: BAD INTERNAL 12V!______________________________ Flash Code: 4/3

• The internal “12V” supply is out of range;

• 12V Supply is generated by the Motor control module and supplied to the GP400. Check for wiring errors between the two modules. If the fault remains, the Motor Controller may have to be replaced.

FAULT: BATTERY VOLTAGE TOO LOW! _____________________ Flash Code: 4/4

• The battery supply is too low – the batteries must be re-charged.

FAULT: BATTERY VOLTAGE TOO HIGH! ____________________ Flash Code: 4/4

• The battery supply is too high – check that the correct battery and charger are installed.

FAULT: BAD 5V SENSOR SUPPLY - CHECK P2-1 WIRING! _____ Flash Code: 4/5

• The “5V sensor” supply is out of range; this supply is available to power external 5V-powered sensors – check that is has not been overloaded or short-circuited to other wiring (CE models).

March 2014

Page 4-20

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - E

Z

- C

A L

R

E T R I E V E

M

O D E

A

N D

H

E L P

M

E S S A G E S

C A N B U S M

E S S A G E S

This section lists “CANBUS” HELP messages – problems have been detected with

CANBUS communications between different modules (of course, only applicable if more than one module is connected together via CANBUS):

FAULT: CANBUS! _______________________________________ Flash Code: 6/6

• There are problems with CANBUS communications between the different modules; messages expected from one or more module are not being received, or messages intended to one or more module cannot be transmitted.

• Check for open- and short- circuit problems with CANBUS wiring; ensure that the CANBUS is wired correctly pin-to-pin; ensure that the vehicle chassis is not erroneously shorted to the chassis (for example, due to insulator breakdown in the motor).

P O W E R W I R I N G M

E S S A G E S

The following are “power wiring” HELP messages – problems have been detected which are likely due to power wiring errors:

FAULT: CAPBANK VOLTAGE TOO LOW - CHECK STUD WIRING! Flash Code: 7/7

• The voltage on the B+ stud of the controller (connected to an internal voltage stabilization capacitor bank) is too low (a pre-charge circuit in the module normally applies approximately

32 volts to the capacitor bank and B+ stud).

• Check the 300 amp fuse, line contactor or power wiring for errors. Also check DC motor for internal grounding. Possible motor controller failure.

O T H E R M

E S S A G E S

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 initial calibration, it is configured in a special “factory override” state. In this state, none of the normal shutdowns or interlocks will occur – the vehicle can be freely lifted/lowered and driven irrespective of any calibration needs, vehicle tilt, etc.

• As soon as an EZ-Cal is connected to the controller, the factory override state is ended.

• If calibration does not occur, then the factory override state will recur if the EZ-Cal is disconnected and power is switched off/on.

IMPORTANT: – Never use a vehicle in factory override; this state is ONLY intended for use during manufacture! While factory override is active, the LED is rapidly flashed on/off.

“4069RT” Service and Parts Manual March 2014

Page 4-21

T

R O U B L E S H O O T I N G

- - T

R O U B L E S H O O T I N G

C

H A R T

T

ROUBLESHOOTING

C

HART

The following chart is a guide to help the technician find the area of a problem. In order to benefit from the information, you are advised to fully assess the symptoms by operating all machine functions. There may be some functions that operate while others may not.

Record this information and proceed down the left-hand column until you find the failure scenario that best fits the problem. Refer to the information provided to the right for possible causes and remedies. This unit contains a Microprocessor based control system which contains various safety features designed to protect itself and the operator in the event of a failure.

The EZ-Cal scan tool will provide the technician with detailed information related to the failure. It is strongly recommended that the technician use the EZ-Cal to read any

displayed messages before proceeding to use this Troubleshooting chart.

Information on the use of the EZ-cal tool plus helpful Flow Charts and graphs can be found earlier in this troubleshooting section. Please read and familiarize yourself with all of the information provided in the troubleshooting section before attempting to diagnose or repair the machine.

Table 4-1: Troubleshooting Chart

PROBLEM

General Power Issue

No operation from

Upper or Lower control station

Functions from Lower

Controls but not from

Upper Controls

POSSIBLE CAUSE

Main Battery Switch turned OFF

Emergency Stop Switch pushed or Ignition

Switch turned OFF

Battery discharged or faulty cables

Circuit Breaker Tripped

Damaged Upper Control Box harness

Blown supply fuse

Other fault in system monitored by GP400

Interlock Switch (Joystick)

Lift/Lower

Platform will not raise

Excessive weight on platform

Lift Relief Valve out of adjustment

Lift Valve not energized

Lowering valve stuck open

(located at base of lift cylinder

Level sensor out of level

(platform elevated above 10')

Main system pressure inadequate

Battery discharged - no charge output

System interruption

REMEDY/SOLUTION

Located left of Lower Control Box

Upper or lower E-Stop will cut all power, as will the Ignition

Switch in the Upper Control Box

Will receive 4-4 or 7-7 flash on GP400.

Clean, service and charge battery - repair cables

Located in Lower Control Box Panel

Look for short circuit and/or damage in wiring or high amperage draw at valve coils or engine actuators.

Inspect the harnesses and harness plugs for damage or broken wires - May receive 6-6 flash code on GP-400 (CAN bus) or no power at all

Locate source of short circuit. Inspect/replace fuse located just below Main Battery Switch

Check HELP message on EZ-cal or check Flash Code for error

Check power to red wire (power to switch) and power to purple wire (power out of switch) at the joystick plug

Reduce weight to within platform capacity

Adjust Relief Valve to rated platform capacity

Check wiring to lift valve

Check for EZ-cal message or flash code

Check and remove contamination from valve

Reposition machine to firm level surface

Check level sensor function using EZ-cal

Check pump output pressure

Check battery voltage, alternator output (14.5 volts)

Clean, service and charge battery

Check HELP messages using EZ-cal

March 2014

Page 4-22

“4069RT” Service and Parts Manual

T

R O U B L E S H O O T I N G

- - T

R O U B L E S H O O T I N G

C

H A R T

Table 4-1: Troubleshooting Chart

PROBLEM

Platform will not lower or lowers slowly

POSSIBLE CAUSE REMEDY/SOLUTION

Maintenance lock in maintenance position Return maintenance lock to the stowed position

Lowering valve not energized Check wiring to lowering valve located on Lift Cylinder

Lowering valve not shifting

Lowering orifice/s plugged

Clean debris, check for damage, replace

Clean orifice/s located inside hose fitting on lift cylinder

System interruption

Down valve on lift cylinder inoperative

Check HELP messages using EZ-cal

Check lift valve coil

Lowers but not completely

Emergency lowering not working

Lowering valve not shifting

Lowering orifice plugged

Clean debris, check for damage, replace

Clean orifice/s located inside hose fitting on the lift cylinder

Valve coil failed on cylinder Test (6-8 ohms), replace

Drive

No drive function

Lift/Drive select switch not in Drive position or not operational

Drive valve not shifting

Proportional Valve not shifting

Select Drive position (upper control box), Check switch

Check switch position from GP400 with EZ-cal

DLD

Check connections at valve

Check Drive Valve for contamination

Check Drive output from GP400 (

Check connections at valve

Check Proportional valve for contamination

Check proportional output from GP400

No drive elevated

Slow drive with platform stowed

Poor gradeability or drive performance

Drive in one direction only

Drive system shut down (interlock)

Unit out of level

System Interruption (interlock)

High torque enabled

Malfunctioning rear wheel bypass valve

Wheel motors not functioning correctly

High or mid speed enabled

Batteries discharged

Wheel motors not functioning correctly

Malfunctioning rear wheel bypass valve

Malfunctioning series parallel valves

Check HELP and MODE message on EZ-Cal

Lower and operate Auto-level

Check HELP messages using EZ-Cal

Check Speed/Torque switch on upper controls

Located on rear wheel motors only

Check electrical by disconnecting valves

Check function by replacing valves

Inspect wheel motors for excessive bypass

Check Speed/Torque switch on upper controls

Check battery voltage with multi-meter or EZ-Cal

Clean, service, charge batteries

Inspect wheel motors for excessive bypass

Located on rear wheels only

Check electrical by disconnecting valves

Check function by replacing valves

Located on top of main hydraulic manifold

Remove and inspect

See Hydraulics section for pump adjustment

Inspect or replace pump

Incorrectly adjusted or worn hydraulic pump

Drive valve not energized in one direction Check 12 volts to appropriate coil

Check coil

Check valve function

Counterbalance valve CBV1 or CBV2 not functioning correctly

Swap counterbalance valves to see if functioning direction changes

No output from GP400 Check switch position output from GP400

“4069RT” Service and Parts Manual March 2014

Page 4-23

T

R O U B L E S H O O T I N G

- - T

R O U B L E S H O O T I N G

C

H A R T

Table 4-1: Troubleshooting Chart

PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION

No low speed

(high torque mode)

Speed/Torque switch inoperative

Valve SV3 not functioning

No Mid Speed

No High Speed

EP1 poppet valve not functioning

SV3 or SV4 powered and/or shifted

Check or replace valve (see hyd schematic for location)

These valves should not have 12 volts

In mid-speed, check valve function

Speed/Torque selector switch malfunction Terminals 1 or 3 are common with terminal 2 when switch is in mid position

Speed/Torque selector switch inoperative Check continuity through Speed Select switch with wires disconnected terminals 2 & 3

Valve not functioning Check voltage and ground to valve

Check for faulty valve spool

Check switch position output from GP400

EP2 poppet valve not functioning

No Speed Selection

Limit switch not functioning

Check or replace valve

Check limit switch located on left rear of base

Check limit switch input with EZ-Cal

Steer

No steer in either direction

Check continuity through Speed Select switch with wires disconnected terminals 2 & 1

Check for 12 volts and ground to valve

Check for faulty valve spool

Check switch position output from GP400

(See EZ-cal ID# 2f-17)

Steers in one direction only

Steers, but not fully, or steers slowly

Lift/Drive selector switch in the Lift position

Joystick rocker switch inoperative

Steering valve inoperative

System Interruption

Hoses connected incorrectly

Pressure relief valve set too low

Steering valve inoperative or stuck

No power to steering coil

Switch must be in Drive position for steer operation

Check continuity through rocker switch on green and yellow wires (right & left) with blue wire (input).

Check steering valve for power or damage

Check switch position output from GP400

Check HELP messages using EZ-Cal

See hydraulic section for proper connection

Set steer relief valve to 2000 p.s.i.

Inspect – replace steering valve

Check for power and ground in both directions.

Repair wiring

Check switch position output from GP400

System Interruption Check HELP and MODE message on EZ-Cal

One or both steering cylinder seals failed Check steering cylinder seals – replace

Outriggers deploy unevenly and/or unit will not level

King pin/s seizing in the bore

Unit on excessive angle

Outrigger extend valve sticking

Proximity switch failed open or closed

Tilt sensor not properly calibrated

Damage to one or more outrigger legs

Outrigger hoses connected incorrectly

Pressure relief valve set too low

Disassemble and inspect

Repair

Replace bushings

Relocate machine to more level ground.

Inspect/replace deploy valve found at each outrigger cylinder.

Check proximity switches. Switches should be closed with outriggers retracted.

Recalibrate Level (see instructions in Section 2 of this manual).

Inspect and replace as needed.

See Section 1 of this manual for hose routing detail.

Set main relief valve RV1 to 3500PSI.

March 2014

Page 4-24

“4069RT” Service and Parts Manual

Section 5

S

CHEMATICS

C

ONTENTS

P

AGE

Hydraulic Schematics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

F

IGURES

P

AGE

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Functions Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Electrical Schematic, 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Electrical Schematic, 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Electrical Schematic, 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

“4069RT” Service and Parts Manual March 2014

Page 5-1

H

Y D R A U L I C

S

C H E M A T I C S

T

A B L E

-

H

YDRAULIC

S

CHEMATICS

T

ABLE

Callout Description

MLR

MP1

MRF

MRR

ORF1

ORF3

EP1

EP2

FD1

FD2

FR1

HLS1

HP1

MLF

CBV1, CBV2

Counterbalance Valve, Drive

CV1

Check Valve

CV2

CV4

Check Valve

Check Valve

CYL1

CYL2

Cylinder, Upper Lift

Cylinder, Lower Lift

CYL3-CYL4

Cylinder, Steer

CYL5-8

Cylinder, Outrigger

Pilot Operated Valve, Mid Speed

Pilot Operated Valve, Low Speed

Flow Divider, Drive Mid & Low

Flow Divider, Drive Mid & Low

Flow Regulator Valve, Brake Apply

Shuttle Valve, Brake Release

Hand Pump, Brake Release

Motor, Left Front

Motor, Left Rear

Manual Operated Valve, Brake Release

Motor, Right Front

Motor, Right Rear

Orifice, Steer Speed .063

Orifice, Flow Divider Bypass.025

Callout Description

ORF4

ORF5

P1

PD1

PD2

PD3

RV1

RV2

Orifice, Flow Divider Bypass.025

Orifice, Bypass Control .060

Pump

Pilot Operated Valve, High Torque Shift

Pilot Operated Valve, Mid Range Shift

Pilot Operated Valve, High Torque Shift

Relief Valve, Main

Relief Valve, Lift

SP1

SV1

Proportional Solenoid Valve

Solenoid Valve, High Speed

SV10-SV17

Solenoid Valve, Outrigger

SV18

Solenoid Valve, Down Valve, Upper Lift Cyl

SV2

SV3

SV4

SV5

Solenoid Valve, High Torque

Solenoid Valve, Outrigger Directional

Solenoid Valve, Rear Wheel Bypass

Solenoid Valve, Rear Wheel Bypass

SV6

SV7

SV8

SV9

SVCL1

SVCL2

Solenoid Valve, Steer Directional

Solenoid Valve, Platform Lift

Solenoid Valve, Rear Wheel Bypass

Solenoid Valve, Down Valve, Lower Lift Cyl

Solenoid Valve, Drive Forward

Solenoid Valve, Drive Reverse

March 2014

Page 5-2

“4069RT” Service and Parts Manual

H

YDRAULIC

S

CHEMATIC

H

Y D R A U L I C

S

C H E M A T I C

-

Figure 5-1:

Hydraulic Schematic

OUTRIGGERS

SV10 SV11

SV18

ø.047

UPPER

LIFT CYLINDER

SV9

ø.073

LOWER

LIFT CYLINDER

LEFT SIDE

STEER CYLINDER

RIGHT SIDE

STEER CYLINDER

LEFT FRONT

WHEEL MOTOR/BRAKE

RIGHT REAR

WHEEL MOTOR/BRAKE

RIGHT FRONT

WHEEL MOTOR/BRAKE

LEFT REAR

WHEEL MOTOR/BRAKE

SV12

SV13

SV14 SV15

LF

A

B

RR

B A

RF

B A

LR

A B

SV16 SV17

RV3

2500 PSI

P1

Hydraulic Schematic

4069 RT

“4069RT” Service and Parts Manual

ART_4467

March 2014

Page 5-3

H

Y D R A U L I C

S

C H E M A T I C

-

Figure 5-2:

Functions Manifold

COIL #10

COIL # 8

CHECK VALVE - ANTI CAVITATION

CHECK VALVE - ANTI CAVITATION

CHECK VALVE - ANTI CAVITATION

HAND PUMP – BRAKE RELEASE

SOLENOID VALVE – HIGH SPEED

SOLENOID VALVE – HIGH TORQUE

SOLENOID VALVE – OUTRIGGER DIRECTIONAL

SOLENOID VALVE – REAR WHEEL BYPASS

SOLENOID VALVE – REAR WHEEL BYPASS

SOLENOID VALVE – STEER DIRECTIONAL

SOLENOID VALVE – PLATFORM LIFT

SOLENOID VALVE – REAR WHEEL BYPASS

FLOW DIVIDER VALVE – DRIVE MID & LOW

FLOW DIVIDER VALVE – DRIVE MID & LOW

MANUAL OP. VALVE – BRAKE EMR. RELEASE

SOLENOID VALVE – DRIVE FORWARD

SOLENOID VALVE – DRIVE REVERSE

PILOT OP. VALVE – MID SPEED

PILOT OP. VALVE – LOW SPEED

RELIEF VALVE – MAIN

RELIEF VALVE – PLATFORM LIFT

FLOW REGULATING VALVE- BRAKE APPLY

SHUTTLE VALVE – BRAKE RELEASE

ORIFICE – STEER SPEED CONTROL

ORIFICE – FLOW DIVDER BYPASS

ORIFICE – FLOW DIVDER BYPASS

ORIFICE – BYPASS CONTROL

PILOT OP. VALVE – HIGH TORQUE SHIFT

PILOT OP. VALVE – MID RANGE SHIFT

PILOT OP. VALVE – HIGH TORQUE SHIFT

COUNTERBALANCE VALVE – DRIVE

COUNTERBALANCE VALVE – DRIVE

Front

Of Machine

Left Side

Of Machine

Rear

Of Machine

Center

Of Machine

Functions Manifold

4069

March 2014

Page 5-4

“4069RT” Service and Parts Manual

ART_4471

N

O T E S

:

H

Y D R A U L I C

S

C H E M A T I C

-

“4069RT” Service and Parts Manual March 2014

Page 5-5

E

LECTRICAL

S

CHEMATICS

*3

0,&52352&(6625

$//&,5&8,76921/<

3

&$1%86/2

*5281'

3

3

3

&+2.(35(+($7

67$57(5

REAR WHEEL BYPASS VAL

3

3

3

7+5277/(

)8(/

$/7(51$725(;&,7(5

,*1,7,21

3

3

3

3

5($5:+((/%<3$669$/ 3

3523257,21$/9$/9(

'2:19$/9(

3

3

3

/,)79$/9(

67((55,*+7

67((5/()7

'5,9()25:$5'

'5,9(5(9(56(

$/$50

+,*+72548(

+,*+63(('

+2850(7(5

2875,*(;7(1'9$/

2875,*5(75$&79$/

3

3

3

3

3

3

3

3

3

3

3

67$57,1+,%,7:$51,1* 3

3

5)2875,**(583

/)2875,**(583

552875,**(583

/52875,**(583

5)2875,**(5'2:1

/)2875,**(5'2:1

3

3

3

3

3

3

552875,**(5'2:1 3

%($&21&(63(&3

/52875,**(5'2:1 3

$;/()/2$7&2,/

$&*(1(5$725

3

3

3

9$/9(6833/<

%$6(6(/(&7('

836:,7&+

3/$7)2506(/(&7('

'2:16:,7&+

&+2.(35(+($76:,7&+

67$576:,7&+

2,/35(6685(6:,7&+

3

3

3

3

3

3

3

3

3

(/(9$7,2175$16'8&(5

&((/(9$7,21

35(6685(75$16'8&(5

7%0$1$/2*,1

*5281'

*5281'

*5281'

3

3

3

3

3

3

3

3

35(6685(6:,7&+,1387

35(6685(6:,7&+,1387

3

3

35(6685(6:,7&+,1387

35(6685(6:,7&+,1387

3

3

15

15

15

43

407

42

117

204

107

108

111

110

37

313

213

411

168

169

36

63

61

65

67

62

60

64

106

66

225

414

413

412

124

120

126

125

16

19

417

14

5

201

405

406

404

409

24

282

21

56

56

56

56

7(50,1$/%/2&.

02'8/(7%0

%

404

405

117

00

%෥

37

$/$50

/2:(5&21752/%2;

5

'2:1',2'(

$66(0%/<

105

LOWER CONTROL

BOX DOOR

%$6(3/$7)250

6(/(&7

83

'2:1

24

*/2:

282

67$57

(0(5*(1&<

'2:1

105 (6723

$

%5($.(5

+2850(7(5

67$57',6$%/(

411

36

E

L E C T R I C A L

S

C H E M A T I C S

-

Figure 5-3:

Electrical Schematic, 1 of 4

J1

126

DEUTSCH

70 PIN

J2

00

15

1

2

3

4

DEUTSCH

4 PIN

Electrical Schematic, 1 of 4

4069RT

March 2014

Page 5-6

“4069RT” Service and Parts Manual

ART_4468

E

L E C T R I C A L

S

C H E M A T I C S

-

Figure 5-4:

Electrical Schematic, 2 of 4

J1

126

106

0$,10$1,)2/'

REAR WHL BYPASS

REAR WHL BYPASS

LIFT

STEER RT

STEER LT

FORWARD

REVERSE

TORQUE

SPEED

OUTRIGGER EXT

OUTRIGGER RET

REAR WHL BYPASS

GROUND

BUSS 1

PROPORTIONAL

J6

168

169

15

15

65

67

61

63

62

60

64

66

DEUTSCH

12 PIN

43

42

407

1

15

105

J5

15

DEUTSCH

12 PIN

ANSI BEACON

A

B

C

CE BEACON

1

2

3

1

2

3

1

2

3

DOWN VALVES

1

2

1

2

BEACON CONNECTION

PIN A. FOR ANSI

PIN B. FOR CE

ANGLE

TRANSDUCER

HEIGH 1

PRESSURE

TRANSDUCER

(CE ONLY)

ANGLE

TRANSDUCER

HEIGHT 2

(CE ONLY)

A

B

C

A

B

C

J7

1

1

1

1

1

1

1

1

A

B

C

OUTRIGGER

CYLINDERS

RF DOWN

RF UP

RR DOWN

RR UP

LR DOWN

LR UP

LF DOWN

LF UP

A

B

C

(BLU)

(BRN)

2

2

2

2

2

2

2

2

LR

(BLK)

RR

RF

LF

78 15

DEUTSCH

6 PIN

OUTRIGGER

SWITCHES

120

124

125

19

J3

225

16

21

DEUTSCH

12 PIN

TO ENGINE

PAGE 4 OF 4

J4

DEUTSCH

6 PIN

TO UPPER

CONTROL BOX

DEUTSCH

70 PIN

J2

1

2

3

4

DEUTSCH

4 PIN

Electrical Schematic, 2 of 4

4069RT

$

0$,1%$77(5<

',6&211(&7

6:,7&+

%$77(5<

92/76

(1*,1(

*5281'

“4069RT” Service and Parts Manual

ART_4469

March 2014

Page 5-7

E

L E C T R I C A L

S

C H E M A T I C S

-

Figure 5-5:

Electrical Schematic, 3 of 4

TO MAIN HARNESS

J4

DEUTSCH

6 PIN

JX

%51

%/8

25*

%/.

%$5(

5('

YEL

DEUTSCH

6 PIN

+251 C D E F G

H

UPPER CONTROL BOX (REVERSE)

IGN/START

GP400 MATRIX MODULE

21 510 411

12 VOLT + INPUT

P1

CAN BUS H

GROUND

CAN BUS L

P1-2

P1-3

P1-4

P1-6

P2

FWD/UP

REV/DOWN

LEFT STEER

RIGHT STEER

ENABLE BAR

P2-1

P2-2

P2-3

P2-4

P2-5

POTENTIOMETER

POTENTIOMETER

P2-6

P2-10

POTENTIOMETER

SWITCH POWER

P2-11

P2-12

POTENTOMETER

EMERG

STOP

3

ENABLE

4

3

RIGHT

4

3

LEFT

4

3

REV/UP

4

3

FWD/DWN

4

3

HORN

4

SWITCH COMMON

P3-1

SWITCH COMMON

START

DRIVE

P3-2

P3-3

P3-4

P3

LIFT

GLOW PLUG

OUTRIGGER UP

P3-5

P3-6

P3-10

OUTRIGGER DOWN

P3-11

TILT IND. LAMP

P4

TILT ALARM

DRIVE ENABLE

P4-4

P4-5

P4-6

LIFT/

DRIVE

TILT IND LIGHT

SPEED

7,/7

$/$50

GLOW

PLUG/

CHOKE

OUT

RIGGERS

DRIVE

ENABLE

Electrical Schematic, 3 of 4

4069RT

March 2014

Page 5-8

“4069RT” Service and Parts Manual

ART_4470

E

L E C T R I C A L

S

C H E M A T I C S

-

Figure 5-6:

Electrical Schematic, 4 of 4

',(6(/(1*,1(

5 5

120

124

125

19

J3

225

16

21

DEUTSCH

12 PIN

PULL

HOLD

FUEL

67$57(5

OUT

67 %

7+5277/(

2,/

35(6685(

$/7(51$725

( %

$

$

TO MAIN BATTERY DISCONNECT SWITCH

*/2:

*/2:

*/2:

¼”

SPADE

5

5

*(1(5$725

237,21

*(1(5$725

$

&

(

7+5277/(

.,&.

DIESEL ENGINE and optional Generator

DUAL FUEL ENGINE and optional Generator

'8$/)8(/(1*,1(

5 5

J3

120

124

125

19

23

22

225

16

21

DEUTSCH

12 PIN

COIL

67$57(5

7+5277/(

67

%

&+2.(

3523$1(

2,/

35(6685(

*$6

$/7(51$725

( %

$

$

¼”

SPADE

TO MAIN BATTERY DISCONNECT SWITCH

5

*(1(5$725

237,21

*(1(5$725

$

&

(

7+5277/(

.,&.

Electrical Schematic, 4 of 4

4069RT

ART_4603

“4069RT” Service and Parts Manual March 2014

Page 5-9

N

O T E S

:

E

L E C T R I C A L

S

C H E M A T I C S

-

March 2014

Page 5-10

“4069RT” Service and Parts Manual

Parts Table of Contents

Section A: Controls Page

Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Upper Control Box Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Upper Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Base Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Option -- Onboard Diagnostic Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Section B: Platform Page

Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Main Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Deck Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

OPTION -- GSE Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

OPTION -- GSE Deck Extension, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

OPTION -- GSE Deck Extension, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

OPTION -- GSE Main Platform, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15

OPTION -- GSE Main Platform, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17

OPTION -- Material Clamps/Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19

Section C: Scissor Assembly Page

Scissor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Section D: Wheel Assemblies Page

Wheels & Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Wheel Motors & Steering Yoke Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7

“4069RT” Parts Section March 2014

Page i

Parts Table of Contents

Section E: Hydraulics Page

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Functions Manifold, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Functions Manifold, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11

Wheel Motor/Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15

Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17

OPTION -- Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-19

Hoses -- Pump & Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-21

Hoses -- Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-23

Hoses -- Lift Cylinder Drain, Current Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-25

Hoses -- Lift Cylinder Drain, Early Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-27

Hoses -- Steer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-29

Hoses -- Drive Circuit, Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-31

Hoses -- Drive Circuit, Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-33

Hoses -- Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-35

Hoses -- Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-37

Hoses -- Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-39

Section F: Base Page

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Engine Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Diesel Engine, 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

Diesel Engine, 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9

Diesel Engine, 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

Dual Fuel Engine, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Dual Fuel Engine, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15

Dual Fuel LP Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17

Counterweight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19

Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21

OPTION -- Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Wiring Harness Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-24

Section G: Decals, ANSI Models Page

Decals, ANSI Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

Section H: Decals, CE Models Page

Decals, CE Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3

Decals, GSE Diesel Option, CE Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7

March 2014

Page ii

“4069RT” Parts Section

S

ECTION

A

C

ONTROLS

C

ONTENTS

P

AGE

Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Upper Control Box Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Upper Control Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Base Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Option -- Onboard Diagnostic Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

“4069RT” Parts Section March 2014

Page A-1

Optional Overload

System only

4

3

2

1

15

5 6*

7

8

9

*Std Machine

-- Amber Lens

Optional Overload System

-- Red Lens

10

5

12

13

14

Optional Outriggers only

16

17

18

19

20

21

Optional GSE

Lighting only

5

ART_4086

March 2014

Page A-2

4069RT

22

23

“4069RT” Parts Section

Upper Controls

11

12

13

14

15

7

8

9

10

20

21

22

23

16

17

18

19

Platform Controls

ITEM

2

3

--

1

4

5

--

--

--

--

--

--

6

PART NO.

91619

5630

--

8044

90789

5694

16242

13865

6350

HDW5724

13864

50350

8826

REF

REF

89058

89059

89060

89061

89079

89080

89083

HDW90803

HDW90879

91663

7553

6234

9184

9183

9188

9179

6905

7800

QTY DESCRIPTION

-A ss y, Uppe r Co n t r ol Box - RT - AN S I - No Optio ns

-A ss y, Uppe r Co n t r ol Box - RT - AN S I - With O u t r igge rs

-A ss y, Uppe r Co n t r ol Box - RT - AN S I - With Ho rn

-A ss y, Uppe r Co n t r ol Box - RT - AN S I - With O u t r igge rs + Ho rn

-A ss y, Uppe r Co n t r ol Box - RT - CE - No Optio ns

-A ss y, Uppe r Co n t r ol Box - RT - CE - With O u t r igge rs

-A ss y, Uppe r Co n t r ol Box - RT - CE - G S E -

2 N u t

2 S c r ew

1 Mat r ix Mod u le

1

Optional Overload Sensing System --

Ala r m, Ove r load Wa rn i n g

1 S witch, Toggle, 2-Po s itio n

1

Std. Machine --

Le ns , Ambe r , Tilt I n dicato r

1

Optional Overload Sensing System --

Le ns , Red, Ove r load I n dicato r

1 Light, Bayo n et, 14 Volt

1 S ocket, I n dicato r Light

1 S witch, Toggle, 3-Po s itio n

1 S witch, Eme r ge n cy S top

1 S witch, S ta r t

1 S witch, 2-Po s itio n Mome n ta r y

---

1 S witch, Ho rn B u tto n (Optio n )

1 LED, G r ee n , D r ive E n abled (o u t r igge r -eq u ipped machi n e s )

1 S witch, Toggle (o u t r igge r -eq u ipped machi n e s )

1 Weldme n t, Co n t r ol Box

1 B r acket, Co n t r ol Box Holde r

0.5 FT Tape, Foam

1 S c r ew, 5/16–18

1 B r acket, Co n t r ol Box Holde r

1 Wa s he r , Flat

1 Th u mb S c r ew, 5/16–18, Flowe r

1 Ha rn e ss , Removable ( S ee Wi r e Ha rn e ss , S ectio n F)

1 Cable, Removable ( S ee Wi r e Ha rn e ss , S ectio n F)

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page A-3

1

3

4

2

29

28

5

6

8

30

7

9

11

10

12

13

27

14

15

16

17

18

19

20

26

25

24

31

TO CONTROL BOX

ART_2220 R3

March 2014

Page A-4

Reference: ART_13868

32

“4069RT” Parts Section

Control Box Cover Assembly

PART NO.

8696

3765

3766

7819

8435

91824

REF

5736

50139

--

--

--

50191

3764

83076

92199

3772

7875

7882

HDW3768

1008348

50155

13502

3763

13402

HDW8531

HDW7881

3782

13403

6917

7818

HDW3771

Upper Control Box Cover Assembly

ITEM

30

31

32

26

27

28

29

19

20

21

22

23

24

25

15

16

17

18

11

12

13

14

7

8

9

10

3

4

5

6

1

2

QTY DESCRIPTION

1 Co n t r ol Box Cove r A ss embly

1 Joy s tick A ss embly

1 Cove r

1 Ga s ket

1 O-Ri n g

1 Wa s he r , Flat

1 Pi n , Hold Dow n

1 S c r ew, 6–32 x 1/2 i n ch

1 B r acket, Ce n te r i n g

1 S pace r , S tep

1 Gea r , la r ge

2 Wa s he r , Flat

1 Wa s he r , Bevel

1 Cam, Di r ectio n al

1 Plate, Bottom

1 Clamp, Cable, 1/4 i n ch

1 Bea r i n g, B r o n ze, Fla n ged

1 Wa s he r , Flat

1 Ri n g, Retai n i n g, 1/2 i n ch

4 S c r ew, 4-40 x 5/8 i n ch

---

---

---

12 S c r ew, 10–32 x 1/2 i n ch

2 Plate, S pace r

2 S witch, Limit, Mic r o V7

2 Plate, S t r ap

1 Plate, Top

1 Bea r i n g, B r o n ze, Fla n ged

1 S p r i n g, Joy s tick Ce n te r i n g

1 Pote n tiomete r A ss embly

1 Wi r e Ha rn e ss , ( s ee Wi r e Ha rn e ss , S ectio n F)

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page A-5

3

4

1

2

8

11

9

11

5

7

14

13

Connect Purple and Blue wires together at #13

12

Purple

Blue

10

ART_2221 R1

Reference: ART_188

March 2014

Page A-6

“4069RT” Parts Section

6

Control Arm (Joystick)

Upper Control Joystick

ITEM

13

14

--

9

10

11

12

7

8

5

6

1

2

3

4

--

--

PART NO.

92199

8630

8750

8453

HDW8455

8752

8751

13638

8748

8456

8447

8753

8448

91839

92194

92198

8761

QTY DESCRIPTION

-Joy s tick A ss embly

-Joy s tick A ss embly witho u t Co n t r ol A r m (#6)

1 Pi n

1 S witch Act u ato r

4 S c r ew

1 G r ip, Top Half

1 G r ip, Bottom Half

1 Co n t r ol A r m witho u t wi r e

1 T r igge r

1 Rocke r Boot

1 S witch S epa r ato r

1 Motio n S witch, OFF-ON

2 S witch

3 Amp S ocket

1 P us h Co nn ecto r , 3/16"

1 Adapte r , 2-to-1

-S witch A ss embly ( n ot s how n ) -- i n cl u de s item #9, item #11 (x2), wi r e a n d co nn ecto rs

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page A-7

Lift (Green) 2

Lower (Green) 2

Platform / Base

Selector Switch

1

25

22 x2

23 x2

24

GP400 10

11 x4

12 x4

Connector 13

14 x2

15 x2

Hour Meter

4

Platform / Base - N.O.

16 x2

17

Lower - N.O.

16

17

Raise - N.O. 16

17

ART_4464

March 2014

Page A-8

4069RT

15

3

Emergency Stop

4

Hour Meter

5

6

Preheat (Black)

2

Start (Green)

7

Circuit Breaker

8

9

Emergency Lower

Toggle Switch

18

Alarm

19

20 TBM

11 x2

12 x2

21

14 x2

15 x2

8

Emergency Lower

Toggle Switch

7

Circuit Breaker

16

Start - N.O.

17

5

30 Sec Delay (Red)

3

Emergency Stop

(complete switch)

16

Preheat - N.O.

17

Base Controls

“4069RT” Parts Section

Base Controls

ITEM

14

15

16

17

10

11

12

13

8

9

6

7

2

3

4

5

--

1

18

19

20

21

22

23

PART NO.

91659

50229

50230

91887

50233

50231

8082

90714

REF

9549

91667

7800

91704

92254

91957

7235

5630

1313

91711

17082

91838

91290

92016C

91921

QTY DESCRIPTION

-Ha rn e ss -- S ee S ectio n F

1 S witch, 3-Po s itio n , Keyed

3 S witch, B u tto n , G r ee n

1 S witch, Eme r ge n cy S top

1 Ho ur Mete r

1 Light, Red

1 S witch, B u tto n , Black

1 Ci r c u it B r eake r

1 S witch, Toggle, 1 Pole 2 Po s itio n , Eme r ge n cy Dow n

1 S witch G u a r d

1 S y s tem Co n t r olle r , GP400

6 S c r ew, 10-24 x 1.00

6 N u t, 10-24 Nylock

1 De u t s ch Co nn ecto r , DRC 12 70P

6 S c r ew, 8-32 x 1.00

6 N u t, 8-32 Nylock

6 Co n tact Block, N. O.

6 Co n tact Ba s e

1 Ala r m, 107dB

1 B r acket, Ala r m Mo un t

1 Te r mi n al Block Mod u le (TBM)

1 De u t s ch Co nn ectio n , DT14-4P-L012

1 Co n t r ol Box

1 La n ya r d

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page A-9

2 1

3 x2

ART_4465

March 2014

Page A-10

4069

4 x2

OPTION -- Onboard Diagnostic Center

“4069RT” Parts Section

Option -- Onboard Diagnostic Center

ITEM

1

2

3

4

PART NO.

92003

92741

26571

50422

50047

QTY DESCRIPTION

1 O n boa r d Diag n o s tic Ce n te r

1 O n boa r d Diag n o s tic Ce n te r , OLED Di s play fo r A r ctic Optio n

1 B r acket, O n boa r d Diag n o s tic s Ce n te r

2 S c r ew, B u tto n Head Cap M6 x 18

2 N u t, M6 Nylock

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page A-11

N

OTES

:

March 2014

Page A-12

“4069RT” Parts Section

S

ECTION

B

P

LATFORM

C

ONTENTS

P

AGE

Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Main Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Deck Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

OPTION -- GSE Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

OPTION -- GSE Deck Extension, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

OPTION -- GSE Deck Extension, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13

OPTION -- GSE Main Platform, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15

OPTION -- GSE Main Platform, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17

OPTION -- Material Clamps/Pipe Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19

“4069RT” Parts Section March 2014

Page B-1

2

1

4 5

3

ART_4459

March 2014

Page B-2

4069

“4069RT” Parts Section

Platform Assembly

ITEM

3

--

--

--

1

2

4

5

Platform Assembly

PART NO.

89016

89015

89009

26382

50361

50048

50040

50050

QTY DESCRIPTION

1 Mai n Platfo r m A ss embly

1 Deck Exte ns io n A ss embly

1 S heet Mate r ial s Rack

1 Rolle r

1 Bolt, Rolle r , M8 x 140

1 N u t, Rolle r , M8 Nylock

6 Bolt, M12 x 35

6 N u t, M12 Nylock

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-3

9

10

11

12

13

14

9

15

3 4

5

1

2

ART_4461

March 2014

Page B-4

4069

16

At each rail base

6

7 8

“4069RT” Parts Section

Main Platform

Main Platform

ITEM

9

10

11

12

7

8

5

6

13

--

14

15

16

--

3

4

1

2

PART NO.

21386

21373

21389

50512

50398

87125

26564

50030

50048

26566

21391

91888

19239

26342

26347

92836

21390

50182

QTY DESCRIPTION

2 S ide Rail

1 Mai n Platfo r m Weldme n t, witho u t deck plate

1 Mai n Platfo r m Deck Plate

2 Bolt, 5/8 x 3.25

2 N u t, 5/8 Nylock

2 Rolle r

1 Lock Plate

5 Bolt, M8 x 20

5 N u t, M8 Nylock

2 Co rn e r B r ace

1 Right S ide Rea r Rail

2 Hi n ge

4 Back u p Plate

1 Pe rs o nn el Gate, witho u t toe boa r d

1 Gate Toe Boa r d

1 Gate Latch

1 Left S ide Rea r Rail

10 S p r i n g Clip

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-5

1

2 3

At each rail base

11

12

4

5

6

ART_4460

March 2014

Page B-6

4069

7 3

8

9

10

13

14

15 16 15

17

22

23

18 19 20

21

“4069RT” Parts Section

Deck Extension

Deck Extension

ITEM

--

13

14

15

9

10

11

12

7

8

5

6

3

4

--

--

1

2

16

17

18

19

20

21

22

23

PART NO.

26433

26352

50182

21374

21466

50048

50397

26239

26348

50020

50049

50028

50000

50047

21394

8909

50022

26560

26326

92866

50418

50004

87125

50398

87124

26450

QTY DESCRIPTION

1 Right S ide Rail Weldme n t

3 Bolt, M10 x 50

5 N u t, M10 Nylock

4 Bolt, M6 x 20

4 Wa s he r , M6 s td.

4 N u t, M6 Nylock

1 F r o n t Rail Weldme n t

1 Ma nu al Box

2 Bolt, M10 x 70

1 Exte ns io n Ha n dle

1 Exte ns io n Relea s e Ba r

1 Left S ide Rail Weldme n t

4 S p r i n g Clip

1 Deck Exte ns io n Weldme n t, witho u t deck plate

1 Deck Exte ns io n Deck Plate

4 N u t, M8 Nylock

2 Bolt, 5/8 x 4.5

2 Deck Relea s e G u ide

1 Deck Relea s e Weldme n t

2 S p r i n g

4 Ca rr iage Bolt, M8 x 25

2 Wa s he r M16 S td.

2 Rolle r

2 N u t, 5/8 Nylock

2 Rolle r

2 Pi n

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-7

2

1

ART_4454

4069

March 2014

Page B-8

“4069RT” Parts Section

OPTION -- GSE Platform

OPTION -- GSE Platform

ITEM

--

1

2

PART NO.

21618

21617

21615

QTY DESCRIPTION

-Platfo r m, 4069 G S E Optio n

1 Deck Exte ns io n

1 Mai n Platfo r m

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-9

1

1a

2

2a

3 x4

4

ART_4455

March 2014

Page B-10

4069

7

8

5

6

9

10

11

12

13

14 x4

15

7

8

5

16

OPTION -- GSE Deck Extension, 1 of 2

“4069RT” Parts Section

OPTION -- GSE Deck Extension, 1 of 2

ITEM

13

14

15

16

9

10

11

12

7

8

5

6

1

1a

2

2a

3

4

PART NO.

93450

93400

21609

93399

21576

93359

21520

21511

21575

21510

21577

21512

21578

21521

21507

21513

21505

21506

QTY DESCRIPTION

1 Right S ide Top T r ay

1 Wea r Pad, La r ge, Right S ide Top

1 Right F r o n t Top T r ay

1 Wea r Pad, Top F r o n t Right

1 Left F r o n t Top T r ay

8 F r o n t Beam

2 F r o n t Wea r Pad, S mall

1 Wea r Pad, Top F r o n t Left

4 Wea r Pad, Bottom la r ge

4 Wea r Pad s , Bottom S mall

2 R u bbe r Cap

2 Pi n

2 S lide T u be

2 P u ll Pi n

1 Left S ide Top T r ay

4 T-Ha n dle

8 S ide Beam

1 Wea r Pad, La r ge, Left S ide Top

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-11

1

2

3

4

5

6

7

8

9

10

ART_4456

March 2014

Page B-12

4069

11

12

13

14

15

16 at each guardrail section at each guardrail section

16

17

OPTION -- GSE Deck Extension, 2 of 2

“4069RT” Parts Section

OPTION -- GSE Deck Extension, 2 of 2

ITEM

15

16

17

--

11

12

13

14

7

8

9

10

3

4

5

6

1

2

PART NO.

21599

21598

93249

21611

21613

21505

21541

21583

87126

21480

26450

87124

92213

21561

93374

26239

21564

92866

QTY DESCRIPTION

2 Rolle r

2 S lide T u be

2 Pi n

2 Rolle r

2 Hi n ge

1 Doo r

1 S q u a r e U-Bolt

2 Deck Relea s e G u ide

1 Relea s e Weldme n t

1 S p r i n g

1 Foam B u mpe r

1 B u mpe r Weldme n t

2 T u bi n g Clip

2 S lidi n g Rail, O u te r

2 S lidi n g Rail, I nn e r

4 Wea r Pad G u ide Rail

1 Deck Exte ns io n Weldme n t, witho u t deck plate

1 Deck Plate

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-13

2

1

4

5

6 x4

7

8

ART_4457

March 2014

Page B-14

4069

3

9

OPTION -- GSE Main Platform, 1 of 2

“4069RT” Parts Section

OPTION -- GSE Main Platform, 1 of 2

ITEM

7

8

9

3

4

5

6

1

2

PART NO.

21573

21508

93359

21574

21507

21509

21519

21505

21506

QTY DESCRIPTION

3 Right S ide Top T r ay

3 Wea r Pad, La r ge, Right S ide Top

6 T-Ha n dle

3 Left S ide Top T r ay

6 Wea r Pad, S mall Top

3 Wea r Pad, La r ge, Left S ide Top

24 G u a r d Rail Beam

6 Wea r Pad, Bottom La r ge

6 Wea r Pad, Bottom S mall

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-15

x4

4

5

1

2

3

6

3

8

11

13

17

16

15

14

18

19

9

19

20

19

21

12

22

ART_4458

March 2014

Page B-16

4069

10

15

23

24

OPTION -- GSE Main Platform, 2 of 2

“4069RT” Parts Section

OPTION -- GSE Main Platform, 2 of 2

PART NO.

21585

--

8909

21580

21579

92302

50375

50047

21593

21595

21599

91888

21594

21598

--

87125

21587

21588

50000

50262

50294

21586

21589

92251

ITEM

15

16

17

18

11

12

13

14

19

20

21

22

23

24

7

8

9

10

3

4

5

6

1

2

QTY DESCRIPTION

2 B u mpe r , Lo n g

2 B u mpe r Weldme n t

3 B u mpe r , S ho r t

4 Hi n ge

1 Gate Po s t

1 B u mpe r Weldme n t

---

2 Rolle r

1 Right S ide Gate A ss embly

1 Left S ide Gate A ss embly

1 Gate Weldme n t, Right

---

1 Ma nu al s Box

1 Gate S toppe r , Right

2 Gate Latch B r acket

1 Gate Latch, Right

4 Bolt, M6 x 30 B u tto n Head

16 N u t, M6 Nylock

28 Wa s he r , M6 S td.

8 Bolt, M6 x 50

4 Bolt, M6 x 45

2 Gate Toe Boa r d

1 Gate S toppe r , Left

1 Gate Latch, Left

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-17

3

1

4

2

5

8

7

6

ART_4462

March 2014

Page B-18

4069

Pipe Rack

Configuration

Material Clamp

Configuration

OPTION -- Material Clamp/Pipe Rack

“4069RT” Parts Section

OPTION -- Material Clamps/Pipe Racks

NOTE: Material Clamps/Pipe Racks may be used only on the standard platform equipped with the Sheet Material Rack. DO NOT use on the optional GSE platform. See the Operator’s Manual for use instructions.

ITEM

6

7

4

5

8

2

3

--

1

PART NO.

26458

26459

26415

92840

50182

50401

92852

92863

92942

QTY DESCRIPTION

-Mate r ial Clamp/ Pipe Rack -- s old i n pai rs

1 Top Weldme n t

1 S lidi n g T u be Weldme n t

1 Wea r S t r ip

1 S p r i n g Clip

2 S p r i n g Clip

1 Wea r S t r ip

1 Wea r S t r ip

1 Cap

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page B-19

N

OTES

:

March 2014

Page B-20

“4069RT” Parts Section

S

ECTION

C

S

CISSOR

A

SSEMBLY

C

ONTENTS

P

AGE

Scissor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

“4069RT” Parts Section March 2014

Page C-1

12

11

27

4 places

At end of top beam pins

2

11

12

1

ART_4429

March 2014

Page C-2

4069

14

7

9

3

5

13

4

26

15 places

At end of all beam pins

6

25 places

Between all pivoting parts

15

16 places

Upward-facing sides of beams

8

16

17

18

10

4 places

Each end of both cylinders

19

20

21

28 19 20

23

24

25

2 places

Each side of forward end of base section

22

Elevating Assembly

“4069RT” Parts Section

ITEM

1

2

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

19

20

21

22

23

24

25

26

27

Scissor Assembly

PART NO.

HDW13175

25429

50236

18152

21472

9587

7160

40301

90235

30407

26449

21413

21412

21422

21288

REF

REF

21467

6701

21420

21557

21421

21558

21419

21418

21416

21417

21414

21415

QTY DESCRIPTION

1

Standard Machine --

S ci ss o r Beam

1

GSE Spec/Centered Platform Machine --

S ci ss o r Beam

1

Standard Machine --

S ci ss o r Beam

1

GSE Spec/Centered Platform Machine --

S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

1 S ci ss o r Beam

4 Cyli n de r Mo un t Weldme n t

2 Beam Su ppo r t Weldme n t

1 Uppe r Lift Cyli n de r -- S ee S ectio n E

1 Lowe r Lift Cyli n de r -- S ee S ectio n E

1 Mai n te n a n ce Lock

15 Retai n i n g Ri n g

25 Wa s he r , Nylo n

16 R u bbe r S pace r

4 Bolt, M12 x 40

4 Pi n Retai n e r

4 Cyli n de r Pi n

2 Lowe r S lide Pad

2 Bea r i n g

2 S lide Ca s ti n g

2 Uppe r S lide Pad

1 Pi n

4 Platfo r m Block

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page C-3

N

OTES

:

March 2014

Page C-4

“4069RT” Parts Section

S

ECTION

D

W

HEEL

A

SSEMBLIES

C

ONTENTS

P

AGE

Wheels & Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Wheel Motors & Steering Yoke Components . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7

“4069RT” Parts Section March 2014

Page D-1

1

ART_4431

March 2014

Page D-2

4069

2

3

4

5

“4069RT” Parts Section

Tires/Wheels

--

3

--

--

4

5

Wheels & Hubs

ITEM

1

2

PART NO.

21450

21452

21454

21456

21451

21453

21455

21457

91181

92803

21403

92977

50006

50127

QTY DESCRIPTION

2 RightS ide Wheel/Ti r e A ss embly, P n e u matic

2 RightS ide Wheel/Ti r e A ss embly, Foam-Filled*

2 RightS ide Wheel/Ti r e A ss embly, No n -Ma r ki n g, P n e u matic

2 RightS ide Wheel/Ti r e A ss embly, No n -Ma r ki n g, Foam-Filled*

2 LeftS ide Wheel/Ti r e A ss embly, P n e u matic

2 LeftS ide Wheel/Ti r e A ss embly, Foam-Filled*

2 LeftS ide Wheel/Ti r e A ss embly, No n -Ma r ki n g, P n e u matic

2 LeftS ide Wheel/Ti r e A ss embly, No n -Ma r ki n g, Foam-Filled*

-Ti r e O n ly, Black

-Ti r e O n ly, No n -Ma r ki n g

-Rim O n ly, 4069

32 Wa s he r , S elf-Alig n i n g

32 Wa s he r , M10 No r dlock

32 L u g Bolt, M10 x 30 S ocket Head

*USE ONLY FOAM-FILLED FOR CE AND GSE-SPEC MACHINES.

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page D-3

1

2

3

4

5

11

12

13

14

6

4

16

15

7

8

9

10

8

ART_4428

March 2014

Page D-4

4069

Wheel Motors & Steering Components

“4069RT” Parts Section

Wheel Motors & Steering Yoke Components

ITEM

11

12

13

14

15

16

7

8

9

10

3

4

5

6

1

2

PART NO.

21353

21344

50033

50006

26057

50439

21345

92360

REF

92341

50048

92787

21354

50031

50001

50025

QTY DESCRIPTION

1 Ho s e G u a r d, Right S ide

1 S tee r i n g Yoke, Right S ide

4 Bolt, M10 x 25

36 Wa s he r , M10 No r dlock

4 Ki n g Pi n Weldme n t

32 Bolt, M10 x 50 S ocket Head

1 S tee r i n g Yoke, Left S ide

4 Bea r i n g

4 Moto r /H u b A ss embly -- S ee S ectio n E

2 Th rus t Wa s he r

2 N u t, M8 Nylock

2 P-Clamp

1 Ho s e G u a r d, Left S ide

4 Bolt, M8 x 25

4 Wa s he r , M8 S td

2 Bolt, M8 Ca rr iage

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page D-5

ART_4430

March 2014

Page D-6

4069

7

8

1

2

3

4

5

6

9

“4069RT” Parts Section

Steering Components

Steering Components

ITEM

7

8

9

3

4

5

6

1

2

PART NO.

50433

93044

21337

17491

REF

21344

17492

21345

QTY DESCRIPTION

2 S ho u lde r Bolt, M16 Th r ead S ocket Head, M20 x 60 S ho u lde r

2 B r o n ze Bea r i n g

1 Tie Rod

2 Clevi s Pi n

2 S ho u lde r Bolt, 3/4" th r ead, 1 x 4 s ho u lde r

2 S tee r i n g Cyli n de r A ss embly -- S ee S ectio n E

1 S tee r i n g Yoke, Right S ide

2 Pi n Clip

1 S tee r i n g Yoke, Left S ide

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page D-7

N

OTES

:

March 2014

Page D-8

“4069RT” Parts Section

S

ECTION

E

H

YDRAULICS

C

ONTENTS

P

AGE

Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Functions Manifold, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Functions Manifold, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11

Wheel Motor/Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15

Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17

OPTION -- Outrigger Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-19

Hoses -- Pump & Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-21

Hoses -- Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-23

Hoses -- Lift Cylinder Drain, Current Machines . . . . . . . . . . . . . . . . . . . . . . . . E-25

Hoses -- Lift Cylinder Drain, Early Machines . . . . . . . . . . . . . . . . . . . . . . . . . E-27

Hoses -- Steer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-29

Hoses -- Drive Circuit, Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-31

Hoses -- Drive Circuit, Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-33

Hoses -- Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-35

Hoses -- Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-37

Hoses -- Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-39

“4069RT” Parts Section March 2014

Page E-1

9

3

4

1

5

6

8

7

Machines equipped with optional Outriggers

4069RT

ART_4463

March 2014

Page E-2

“4069RT” Parts Section

Hydraulic Components

Hydraulic Components

ITEM

7

8

9

3

4

5

6

1

2

PART NO.

89013

93145

21273

21272

92974

91160

21398

93031

93280

QTY DESCRIPTION

1 Hyd r a u lic Re s e r voi r

1 F un ctio ns Ma n ifold

1 Uppe r Lift Cyli n de r

1 Lowe r Lift Cyli n de r

4 Wheel Moto r /B r ake U n it

1 Hyd r a u lic P u mp

2 S tee r Cyli n de r

4 Optio n -- O u t r igge r Cyli n de r

1 P r opo r tio n al Valve

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-3

1

GP

RF

A

LFB

LF

A

RFB

BRK

ORB

ORA

8

7

2

3

4

5

6

LRB

RRA

LRA

RRB

5

ART_4476

March 2014

Page E-4

4069

9

10

LFT

P

11

T

STRAS

TRB

4

“4069RT” Parts Section

12

Functions Manifold, 1 of 2

Functions Manifold, 1 of 2

ITEM

7

8

9

10

3

4

5

6

1

2

11

12

PART NO.

93145

HDW7971

50950

50850

50853

50673

50809

50832

50838

50835

51004

50858

QTY DESCRIPTION

1 F un ctio ns Ma n ifold A ss embly, witho u t fitti n g s

1 Fitti n g, Male Di s co nn ect 1/4 n pt

1 Fitti n g, MB-MP-4-4

4 Fitti n g, MB-MFFOR90-8-8

4 Fitti n g, MB-MFFOR90LL-8-8

1 Fitti n g, MB-MFFOR90-4-4

2 Fitti n g, MFFOR-MFFOR-FFORX-4

2 Fitti n g, MB-MFFOR-6-4

1 Fitti n g, MB-MFFOR-12-8

1 Fitti n g, MB-MFFOR-6-6

1 Fitti n g, MB-HB90-12-16

2 Fitti n g, MB-MFFOR-MFFORT-4

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-5

6 7 8

6 9

2 10

2

1

3

4

5

2 2 11

12

2

13

2 11

LFB

LF

A

BRK

ORB

ORA

2 10

GP

RFB

1

2 3

5

16

15

2 14

17 beneath plug

18

19

20

ART_4478

March 2014

Page E-6

4069

LRB

RRA

LRA

RRB

18 beneath plug

17

6 9

LFT

P

T

21

20

STRAS

TRB

23

22 beneath plug

Functions Manifold, 2 of 2

“4069RT” Parts Section

Functions Manifold, 2 of 2

ITEM PART NO.

14

15

16

17

10

11

12

13

8

9

6

7

2

3

4

5

--

1

18

19

20

21

22

23

93496

91008

91015

93497

91145

91009

91012

93494

93145

91151

91143

93502

91152

91477

92173

91464

93501

91147

93500

93493

93503

93499

93495

93498

QTY DESCRIPTION

-F un ctio ns Ma n ifold A ss embly, witho u t fitti n g s

3 Pilot-Ope r ated Valve

9 Coil

2 S ole n oid Valve, Rea r Wheel Bypa ss

2 Pilot-Ope r ated Valve

2 Check Valve

3 Coil

1 S ole n oid Valve, Rea r Wheel Bypa ss

1 O r ifice Di s c, .060

2 S ole n oid Valve, High To r q u e/High S peed

2 S ole n oid Valve, D r ive

2 S ole n oid Valve, O u t r igge r & S tee r i n g Di r ectio n al

1 Ha n d P u mp

1 Relief Valve

1 S ole n oid Valve, Lift

1 Relief Valve

1 Ma nu al B r ake Relea s e Valve

2 Flow Divide r

2 O r ifice Pl u g, .025

1 Check Valve

2 Co un te r bala n ce Valve

1 S h u ttle Valve

1 O r ifice Pl u g, .063

1 Flow Reg u lato r

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-7

4

5

6

7

1

2

3

Early Machines

ART_4477

March 2014

Page E-8

4069

8

9

10

Later Machines

11

8

“4069RT” Parts Section

Hydraulic Reservoir

Hydraulic Reservoir

8

9

10

11

ITEM PART NO.

6

7

--

2

3

4

5

--

1

89013

21355

9370

51006

92335

50034

50002

92565

92924

50664

92569

51004

HDW6727

QTY DESCRIPTION

-Hyd r a u lic Re s e r voi r , Complete a s s how n

1 Ta n k Weldme n t

1 S ight Ga u ge

1 Pl u g, 3/8 NPT

1 Cap

4 Bolt, M10 x 30

4 Wa s he r , M10 s td.

1 Filte r A ss embly

-Filte r Eleme n t

3

Early Machines --

Fitti n g, MP-MJ-4-4

2

Later Machines --

Fitti n g, MP-MJ-4-4

1 Su ctio n S t r ai n e r

1 Fitti n g, MB-HB90-12-16

1 Fitti n g, 1/4 NPT, 5/16 Ba r b

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-9

2

3

4

5

1

6

7

ART_4479

March 2014

Page E-10

4069RT

“4069RT” Parts Section

Hydraulic Pump

Hydraulic Pump

ITEM PART NO.

3

4

1

2

5

6

7

91160

91163

91162

50790

50665

91161

51012

QTY DESCRIPTION

1 Hyd r a u lic P u mp

2 P r e ssur e Fitti n g, FL-MJ90-12-12

1 Fla n ge Kit, P r e ssur e (i n cl u de s bolt s )

1 Fitti n g, MB-MJ90-6-6

1 Fitti n g, MB-MJ90-4-4

1 Fla n ge Kit, Su ctio n (i n cl u de s bolt s )

1 Su ctio n Fitti n g, FL-MJ90-16-16

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-11

Right Rear

Right Front

Left Rear

Left Front

ART_4475

March 2014

Page E-12

4069

1

2

2

4* 3

“4069RT” Parts Section

*Item #4 on front wheel motors only.

Rear wheel motors have two of Item #3

Wheel Motor/Brake Units

Wheel Motor/Brake Unit

ITEM

3

4

1

2

PART NO.

93233

51118

50837

50980

QTY DESCRIPTION

4 Wheel Moto r /B r ake U n it

4 Fitti n g, MFFOR-MB S PP-04-02

6 Fitti n g, MB-MFFOR-10-8

2 Fitti n g, MB-MFFOR90-10-8

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-13

1

2

4 5

6

3

ART_4473

March 2014

Page E-14

4069

4 5

6

3

“4069RT” Parts Section

Lift Cylinders

Lift Cylinders -- Old Style

ITEM

2

--

3

4

1

--

5

6

PART NO.

21273

93613

21272

93614

50790

91464

93615

90969

QTY DESCRIPTION

1 Uppe r Lift Cyli n de r -- Old S tyle

-S eal Kit

1 Lowe r Lift Cyli n de r -- Old S tyle

-S eal Kit

2 Fitti n g, MB-MJ90-6-6

2 Valve

2 Coil

2 Valve, Relief

Lift Cylinders -- New Style

2

--

1

--

3

4

5

6

93519

93642

93518

93643

50790

91464

93615

90969

1 Uppe r Lift Cyli n de r -- New S tyle

-S eal Kit

1 Lowe r Lift Cyli n de r -- New S tyle

-S eal Kit

2 Fitti n g, MB-MJ90-6-6

2 Valve

2 Coil

2 Valve, Relief

Examine the collar at the rod end of the cylinder to determine whether your machine is equipped with

Old Style or New Style cylinders

• Old Style cylinders have a 3-inch (7.5 cm) collar.

• New Style cylinders have a 1-inch (2.5 cm) collar.

Old Style

Cylinder

New Style

Cylinder

3 inch

7.5 cm

1 inch

2.5 cm

IMPORTANT -- Both cylinders must be changed out if an Old Style cylinder requires replacement.

DO NOT pair a New Style cylinder with and Old Style cylinder.

ART_4601

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-15

1

2

3

ART_4472

March 2014

Page E-16

4069

“4069RT” Parts Section

Steer Cylinders

Steer Cylinders

ITEM

2

3

1

--

PART NO.

21398

93616

50831

50675

QTY DESCRIPTION

2 S tee r Cyli n de r

-S eal Kit

2 Fitti n g, MB-MFFOR-4-4

2 Fitti n g, MB-MFFOR45-4-4

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-17

1

ART_4474

March 2014

Page E-18

4069

3 4

2

“4069RT” Parts Section

OPTION -- Outrigger Cylinders

OPTION -- Outrigger Cylinders

ITEM PART NO.

2

3

1

--

4

93031

93617

50832

91464

93615

QTY DESCRIPTION

4 O u t r igge r Cyli n de r

-S eal Kit

8 MB-MFFORT-6-4

8 Valve

8 Coil

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-19

ART_4554

March 2014

Page E-20

4069RT

4

5

6

7

8

9

10

3

1

2

“4069RT” Parts Section

P

T

Pump & Manifold

ITEM

8

9

6

7

10

3

4

--

5

1

2

Hoses -- Pump & Manifold

PART

NUMBER

52484

52477

52483

93280

93618

50980

50837

50811

52476

52478

52475

QTY. DESCRIPTION

1

1

1

1

--

1

Ho

Ho

Ho

P

P r r s s s y, 1/4 x 82 i e, 1” P opo opo

Fitti e, 1” P e A n r r ss tio tio n n r r emoflex x 75 n emoflex x 44 al Valve Ma ch, 04G-04FFORX-04G-04FFORX90 n ifold i al Valve & Coil g, MB-MFFOR90-10-08 n cl u di n g Valve & Coil

S

HOSE NAME

S

PP-CD

MF-T-R

1 Fitti n g, MFFOR-MB-8-10

1 Fitti n g, MFFOR-FFORX-MFFOR-8

1 Ho s e A ss y, 1/2 x 18 i n ch, 08G-08FFORX -08G-08FFORX90L

1 Ho s e A ss y, 1/4 x 60 i n ch, 04G-04FFORX-04G-06FFORX

PV-MMP

L S

1 Ho s e A ss y, 1/2 x 64 i n ch, 08G-08FFORX -08G-12FJX90 S PP-PV

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-21

LFT

ART_4546

March 2014

Page E-22

4069

1

2

3

“4069RT” Parts Section

Lift Circuit

Hoses -- Lift Circuit

ITEM

1

2

3

PART

NUMBER

52450

50902

52451

QTY. DESCRIPTION

1

1

1

Ho

Fitti

Ho s s e A n g, MJ-MJ-FXT-6 e A ss ss y, 3/8 x 26'9" i n y, 3/8 x 161.5" i ch, 06G-06FJX - 06G-06FJX90 n ch, 06G-06FJX -06G-06FFORX90L

HOSE NAME

UPPER LIFT

LWR LIFT

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-23

1

2

Upper Lift

Cylinder

5

6

5

7

8

Later Machines with upper vent hose on upper cylinder.

8

6

5

7

8

3

4

5

Lower Lift

Cylinder

ART_4547

March 2014

Page E-24

4069

Lift Cylinder Drain, Current Machines

“4069RT” Parts Section

Hoses -- Lift Cylinder Drain, Current Machines

3

4

5

6

1

2

7

8

ITEM

PART

NUMBER

QTY. DESCRIPTION

50959

50959

HDW91249

50959 a a a s s s r r

1 r eq Ho eq Ho s s

Fitti eq Ho s e, 5/16” F e, 5/16” F n u u el Li el Li g, 5/16” Ba e, 5/16” F u r n n e e bed Tee el Li n e

HDW90945 2/4 Fitti n g, 5/16” Nipple

50905 1/2 Fitti n g, MJ-MJ-MPT-5-5-4

50959

HDW6727 a s r eq Ho s e, 5/16” F u el Li n e

2 Fitti n g, 5/16 Ba r bed 90

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-25

1

2

Upper Lift

Cylinder

6

3

4

5

6

Lower Lift

Cylinder

6

ART_4555

March 2014

Page E-26

4069

“4069RT” Parts Section

Lift Cylinder Drain, Early Machines

Hoses -- Lift Cylinder Drain, Early Machines

ITEM

3

4

5

6

1

2

PART

NUMBER

52479

52481

50892

51130

52480

50664

QTY. DESCRIPTION

1 Ho s e A ss y, 04G-04FJX-04G-04FJX, 322 i n che s

1 Ho s e A ss y, 04G-04FJX-04G-04FFORX90 S , 198 i n che s

1 Fitti n g, MJ-FJX-MJT-4-4-4

1 Fitti n g, MJ-MJ-MPT-4-4-4

1 Ho s e A ss y, 04G-04FJX- 04G-04FJX45, 49.5 i n che s

3 Fitti n g, MJ-MP90-4-4

HOSE NAME

UPPER VENT

LOWER VENT

JUMP VENT

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-27

STRA

STRB

ART_4545

March 2014

Page E-28

4069

Left Side

Front of

Machine

Right Side

1

2

3

4

“4069RT” Parts Section

Steer Circuit

Hoses -- Steer Circuit

ITEM

3

4

1

2

PART

NUMBER

52466

52460

52467

52459

QTY. DESCRIPTION

1

1

1

1

Ho

Ho

Ho

Ho s s s s e A e A e A e A ss ss ss ss y, 1/4 x 61.5 i y, 1/4 x 60.5 i y, 1/4 x 67 i n n n y, 1/4 x 67.25 i ch, 04G-04FFORX-04G-04FFORX90 ch, 04G-04FFORX-4G-4FFORX 45 ch, 04G-04FFORX-04G-04FFORX90 n

S ch, 04G-04FFORX-4G-4FFORX 45

S

HOSE NAME

S TL A

S TL B

S TR-B

S TR A

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-29

RFA

LFB

LFA

RFB

Right Front

A

B

1

2 x4

3

4

6

7

5

1

A

Left Front

B

ART_4548

March 2014

Page E-30

4069

“4069RT” Parts Section

Drive Circuit -- Front Wheels

ITEM

3

4

1

2

5

6

7

Hoses -- Drive Circuit, Front Wheels

PART

NUMBER

52444

52445

51112

52448

52443

52447

52446

QTY. DESCRIPTION

2

1

4

2

1

1

1

Ho

Ho

Fitti

Ho

Ho

Ho

Ho s s s s s s e A e A n g, MFFOR-MB45-8-8 B e A e A e A e A ss ss ss ss ss ss y, 1/2 x 36 i y, 1/2 x 33 i y, 1/2 x 80 i n n n y, 1/2 x 31.5 i y, 1/2 x 55.5 i y, 1/2 x 55.5 i ch, 08G-08FFORX -08G-08FFORX90 ch, 08G-08FFORX -08G-08FFORX90 ch, 08G-08FFORX -08G-08FFORX n n n u lkhead ch, 08G-08FFORX -08G-08FFORX

S

S ch, 08G-08FFORX -08G-08FFORX90 ch, 08G-08FFORX -08G-08FFORX45

S

S

HOSE NAME

D-LF-B-BH/RF-A-BH

D-RF-B-BH

D-RF-B-MF

D-LF-A-BH

D-LF-A-MF

D-LF-B-MF

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-31

Right Rear

A

B

B

A

Left Rear

ART_4549

March 2014

Page E-32

4069

LRA

LRB

RRA

RRB

1 2 3

“4069RT” Parts Section

Drive Circuit -- Rear Wheels

Hoses -- Drive Circuit, Rear Wheels

ITEM

1

2

3

PART

NUMBER

52442

52440

52441

QTY. DESCRIPTION

2

1

1

Ho

Ho

Ho s s s e A e A e A ss ss ss y, 1/2 x 90 i y, 1/2 x 66 i y, 1/2 x 67 i n n n ch, 08G-08FFORX -08G-08FFORX90 ch, 08G-08FFORX -08G-08FFORX90 ch, 08G-08FFORX -08G-08FFORX90

S

S

S

HOSE NAME

D-RR-A/B

D-LR-A

D-LR-B

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-33

BRK

1

2

3

4

2

5

6

7

8

ART_4550

March 2014

Page E-34

4069

“4069RT” Parts Section

Brake Circuit

ITEM

3

4

5

6

1

2

7

8

Hoses -- Brake Circuit

PART

NUMBER

52462

50878

52464

52461

50864

52468

52463

52465

QTY. DESCRIPTION

1

2

1

1

1

1

1

1

Ho

Fitti

Ho

Ho

Fitti

Ho

Ho

Ho s s s s s s e A n n g, MFFORT-4 e A e A g, MFFOR-MFFOR-FFORX-4 e A e A e A ss ss ss ss ss ss y, 1/4 x 79 i y, 1/4 x 45 i y, 1/4 x 30 i n n y, 1/4 x 73.5 i n y, 1/4 x 48.5 i y, 1/4 x 22 i n ch, 04G-04FFORX-4G-4FFORX 45 ch, 04G-04FFORX-4G-4FFORX 45 n ch, 04G-04FFORX-04G-04FFORX90 n ch, 04G-04FFORX-4G-4FFORX 45 ch, 04G-04FFORX-4G-4FFORX 45 ch, 04G-04FFORX-4G-4FFORX 45

S

HOSE NAME

RF-BRK

RR-BRK

LF-BRK

R-BRK-CRO SS

LR-BRK

MF-T-BRK

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-35

D

ART_4551

March 2014

Page E-36

4069

1

2

3

4

2

5

6

7

8

“4069RT” Parts Section

Case Drain Circuit

ITEM

3

4

5

6

1

2

7

8

Hoses -- Case Drain Circuit

PART

NUMBER

52454

50878

52455

52452

50864

52469

52453

52470

QTY. DESCRIPTION

1 Ho s e A ss y, 1/4 x 84.5 i n ch, 04G-04FFORX-04G-04FFORX

2 Fitti n g, MFFORT-4

1

1

Ho

Ho s s e A e A ss ss y, 1/4 x 39 i y, 1/4 x 65 i n n ch, 04G-04FFORX-04G-04FFORX ch, 04G-04FFORX-04G-04FFORX

HOSE NAME

RF-CD

RR-CD

LF-CD

1 Fitti n g, MFFOR-MFFOR-FFORX-4

1 Ho s e A ss y, 1/4 x 44 i n ch, 04G-04FFORX-04G-04FFORX90

1 Ho s e A ss y, 1/4 x 59 i n ch, 04G-04FFORX-04G-04FFORX

S T-CD

LR-CD

1 Ho s e A ss y, 1/4 x 18.25 i n ch, 04G-04FFORX-04G-04FFORX90 S TNK-CD

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-37

R

E

ORA circuit to Extend port

ORB circuit to Retract port

1 2

3

4

ORA circuit

ORB circuit

5

4

7 6

ART_4552

March 2014

Page E-38

4069

5

3

ORB ORA

x3

9

4

4

10

11

ORB cir

cir cuit ont

ORB to fr cui t to rear cuit to

rear

ORA cir cui t to fr ont

ORA cir

8

12

13

OPTION -- Outrigger Circuit

“4069RT” Parts Section

ITEM

7

8

9

10

3

4

5

6

1

2

11

12

13

Hoses -- Outrigger Circuit

PART

NUMBER

52474

52458

52472

52456

52471

52457

52473

50809

51074

51137

93288

51127

QTY. DESCRIPTION HOSE NAME

2 Ho s e A ss y, 1/4 x 43.75 i n ch, 04G-04FFORX-04G-04FFORX90 S ORR-R-A/B

2 Ho s e A ss y, 1/4 x 17.5 i n ch, 04G-04FFORX-04G-04FFORX ORR-L-A/B

1 Ho s e A ss y, 1/4 x 59 i n ch, 04G-04FFORX-04G-04FFORX90 S

2 Ho s e A ss y, 1/4 x 86 i n ch, 04G-04FFORX-04G-04FFORX

1 Ho s e A ss y, 1/4 x 61.25 i n ch, 04G-04FFORX-04G-04FFORX90 S ORR-B

2 Ho s e A ss y, 1/4 x 20.5 i n ch, 04G-04FFORX-04G-04FFORX ORF-L-A/B

2

1

Ho

Ho s s e A e A ss ss y, 1/4 x 40 i y, 1/4 x 6 i n n ch, 04G-04FFORX-04G-04FFORX90 ch, 04G-04FFORX-04G-04FFORX90

3 Fitti n g, MFFOR-FFORX-MFFOR-4

1 Fitti n g, FFORX-MB90-4-4

1 Fitti n g, MB-FB-6-4

1 Relief Valve A ss embly

1 Fitti n g, MB-MFFOR-6-4

S

S

ORR-A

ORF-B/A

ORF-R-A/B

OR RET

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page E-39

N

OTES

:

March 2014

Page E-40

“4069RT” Parts Section

S

ECTION

F

B

ASE

C

ONTENTS

P

AGE

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Engine Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

Diesel Engine, 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

Diesel Engine, 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9

Diesel Engine, 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

Dual Fuel Engine, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Dual Fuel Engine, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-15

Dual Fuel LP Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-17

Counterweight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19

Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21

OPTION -- Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Wiring Harness Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-24

“4069RT” Parts Section March 2014

Page F-1

ART_4432

March 2014

Page F-2

4069RT

1

2 3 4

5

6

9

10

11

7

8

“4069RT” Parts Section

12

13

14

Control Module

Control Module

ITEM

7

8

9

10

3

4

5

6

1

2

--

11

12

13

14

PART NO.

91539

21462

19271

REF

8386

21333

REF

REF

21496

22563

HDW6110

17966

14896

8841

90749

QTY DESCRIPTION

1 Ala r m

1 B r ace

1 B r acket

1 Lowe r Co n t r ol s -- S ee S ectio n A

1 Doo r Latch

1 Co n t r ol s Mod u le Doo r

1 Hyd r a u lic Ta n k -- S ee S ectio n E

1 F un ctio ns Ma n ifold -- S ee S ectio n E

1 Batte r y Hold-Dow n

2 J-Bolt

2 Wi n g N u t

1 Batte r y

1 Doo r S lide Block

1 S witch, Batte r y C u toff

1 Pl u g, Powe r To Platfo r m

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-3

3

5 x3

4 x3

2

1

ART_4447

March 2014

Page F-4

4069RT

“4069RT” Parts Section

Engine Module, 1 of 2

Engine Module

ITEM

2

3

4

5

1

--

PART NO.

91023

91091

21492

21493

92103

92400

QTY DESCRIPTION

1 F u el Ta n k

-Fille r Cap

1 B r acket

1 Relay Mo un t

3 Relay Ba s e

3 Relay

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-5

DIESEL MODELS

1

2

3

4

3

2

5

8

9

12

10

11

13

14 x3

15 x2

16 x9

ART_4448

March 2014

Page F-6

4069RT

“4069RT” Parts Section

Diesel Engine, 1 of 3

ITEM

9

10

11

12

8

--

6

7

13

14

15

16

3

4

5

1

2

Diesel Engine, 1 of 3

PART NO.

21364

21491

93267

92965

21363

--

--

91111

8667

21495

7545

16207

16210

16209

7736

QTY DESCRIPTION

1 Exha us t T u be

2 Mo un ti n g B r acket

2 U-Bolt

1 M u ffle r

1 Exha us t Weldme n t, Die s el

---

---

1 Ai r Filte r A ss embly

-Ai r Filte r Eleme n t

1 Elbow

1 I n take T u be

1 Elbow

3 Ho s e Clamp

1 Th r ottle S ole n oid Plate

3 S pace r Plate

2 Mo un ti n g Plate

8 E n gi n e Mo un t

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-7

DIESEL MODELS

11

1

10

9

8

2

7

6

5

3

4

ART_4449

March 2014

Page F-8

4069RT

15

14

“4069RT” Parts Section

Diesel Engine, 2 of 3

Diesel Engine, 2 of 3

ITEM

10

11

12

13

8

9

6

7

14

15

3

4

5

1

2

PART NO.

91160

91112

91130

91572

23990

50027

50031

23991

50048

50474

91113

--

--

16345

91429

QTY DESCRIPTION

1 P u mp

1 Bell Ho us i n g

1 H u b

1 Co u ple r

1 Plate

2 Bolt, M6 x 10

1 Bolt, M8 x 25

1 B r acket, Exha us t

2 N u t, M8 Nylock

2 Bolt, M8 x 20 Ca rr iage

1 Radiato r

---

---

2 B r acket, Radiato r Mo un t

1 E n gi n e, K u bota D1105

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-9

1

2

3

4

18

8

5

6

7

DIESEL MODELS

ART_4450

March 2014

Page F-10

4069RT

9

10

19

10

11

12

13

14

15 16 17

20

“4069RT” Parts Section

Diesel Engine, 3 of 3

PART NO.

93620

91175

HDW91187

90227

8665

92486

8413

91630

93621

91124

93619

91589

HDW91231

91117

16347

HDW5217

HDW91590

HDW5290

9832

91114

91116

91123

Diesel Engine, 3 of 3

ITEM

14

15

16

17

10

11

12

13

18

19

20

--

8

9

6

7

--

3

4

5

1

2

QTY DESCRIPTION

1 Belt

1 Oil P r e ssur e S witch

1 Fitti n g, 1/8” NPT MF -- betwee n Oil P r e ssur e S witch a n d e n gi n e

1 Alte rn ato r

1 Oil Filte r

1 Exha us t Ma n ifold

1 S ta r te r

1 Ri n g Gea r

1 Oil Fill Cap

1 F u el S ole n oid

1 F u el P u mp

1 Th r ottle S ole n oid

1 Jam N u t, 1/2-28

1 Yoke

2 Th r ottle Li n k

1 Wa s he r , 5/16 S td.

1 Clevi s Pi n , 5/16 x 1

1 Cotte r Pi n , 1/8 x 1

3 Glow Pl u g

1 F u el Ret urn Check Valve

1 F u el Filte r A ss embly

-F u el Filte r Eleme n t

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-11

2 3 4

5

16

6 7

8 9 10 11

12 13

14

15

Coil

DUAL FUEL MODELS

17

18 19 20 21

22

23

24

1

27

20 32 33

25

26

28 29 30

25

ART_4604

March 2014

Page F-12

34 35

36

37

“4069RT” Parts Section

Dual Fuel Engine, 1 of 2

Dual Fuel Engine, 1 of 2

ITEM

30

31

32

33

26

27

28

29

34

35

36

37

19

20

21

22

23

24

25

15

16

17

18

11

12

13

14

7

8

9

10

3

4

5

6

1

2

PART NO.

6458

21020

91177

20204

9498

9502

20212

HDW91283

9252

91160

91130

91573

--

91133

91617

HDW6433

91129

91765

91766

91125

7406

HDW6894

91132

91197

9833

50015

91198

91232

HDW9247

HDW91231

50028

50047

91119

91375

50048

7788

8514

QTY DESCRIPTION

1 E n gi n e, K u bota DF752

1 Ho s e A ss embly, LP

1 Elbow, 90° B r a ss

1 Valve, lockoff

10 i n LP Ho s e, ½"

1 LPG Reg u lato r

2 S c r ew, M8 x 50

60 IN Radiato r Ho s e, 3/8"

6 Ho s e Clamp, #8

1 S c r ew, Cap S ocket Head, ¼–28 × 1.0"

2 Jam N u t, ¼–28

6 S c r ew, M6 x 20

6 N u t, M6 Nylock

1 S ole n oid, Th r ottle

1 Relay, Th r ottle

2 N u t, M8 Nylock

5 Ho s e Clamp, 5/16

1 F u el Filte r a s r eq Ho s e, F u el, 5/16

1 B r acket, Compo n e n t s

1 F u el P u mp

1 S pace r

1 Choke Li n kage

1 Choke S ole n oid

1 Choke B r acket

1 S c r ew, M6–1.0 × 25

1 Th r ottle Li n kage

1 hyd r a u lic P u mp

1 H u b

-Co u ple r , O u te r

---

1 Ca r b ur eto r Fla n ge

1 Ca r b ur eto r A ss embly

2 S c r ew, 3/8-16 × 1"

1 KTR Ho us i n g Kit, DF752 -- I n cl u de s Item #30

1 Ri n g Gea r

1 Flywheel

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-13

DUAL FUEL MODELS

1

2

3

4

3

2

5

ART_4605

March 2014

Page F-14

6

7

8 9

10

11

12

13

14

13

15

16

“4069RT” Parts Section

Dual Fuel Engine, 2 of 2

Dual Fuel Engine, 2 of 2

ITEM PART NO.

11

12

13

14

15

16

7

8

9

10

3

4

5

6

1

2

21364

21491

93267

92965

21635

8472

90227

91175

HDW91187

8516

8365

91799

7545

91340

91136

91188

QTY DESCRIPTION

1 Exha us t T u be

2 Mo un ti n g B r acket

2 U-Bolt

1 M u ffle r

1 Exha us t Weldme n t, D u al D u el

1 Radiato r

1 Alte rn ato r , 40 AMP

1 Oil P r e ssur e S witch

1 Fitti n g, 1/8 NPT, M-F

1 Oil Filte r

1 S ta r te r

1 B r eathe r Cap

2 Ho s e Clamp

1 Ho s e, 2.00" I.D. Flex

1 Ai r Filte r Eleme n t

1 I n take Ho s e

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-15

DUAL FUEL MODELS

2

1

3

4

5

4

6

7

8

9

ART_4606

March 2014

Page F-16

4069RT

“4069RT” Parts Section

Dual Fuel LP Tank

Dual Fuel LP Tank

ITEM

7

8

9

3

4

5

6

1

2

PART NO.

6859

6860

6868

HDW6894

6890

6938

6861

HDW6727

7406

QTY DESCRIPTION

1 LP Ta n k

2 B r acket, Ta n k Mo un t

1 Q u ick Di s co nn ect

2 Elbow, B r a ss , NPT to S AE 45°

1 Ho s e A ss embly, 30”

1 Relief Valve

1 B u lkhead Filte r

1 Elbow, B r a ss NPT to S AE 90

1 Ho s e A ss embly, 90”

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-17

1

2 3 4 x6 x6

5 x6

2 3 4

ART_4451

March 2014

Page F-18

4069RT

Not used on machines equipped with optional outriggers.

“4069RT” Parts Section

Counterweight Assembly

Counterweight Assembly

ITEM PART NO.

3

4

1

2

5

21494

50250

50417

50054

15140*

QTY DESCRIPTION

1 Balla s t Plate

6/12 Bolt, M12 x 110

6/12 Wa s he r , S q u a r e, 5/8 x 3/16 x 2

6/12 N u t, M12 Nylock

6 Balla s t Plate

*Not used on machines equipped with optional outriggers.

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-19

1

2 3 4 x4

Standard Machines without Outriggers

Machines with optional GSE Platforms

5

2 3 4 x4

March 2014

Page F-20

ART_4453

4069

“4069RT” Parts Section

Ladders

Ladders

ITEM PART NO.

3

4

1

2

5

21338

50250

50003

50050

21533

QTY DESCRIPTION

1 Ladde r Weldme n t, S ta n da r d

4 Bolt, M12 x 50

4 Wa s he r , M12 S td

4 N u t, M12 Nylock

1 Ladde r Weldme n t, G S E Optio n

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-21

2

1

Each Outrigger

ART_4452

4069

March 2014

Page F-22

3 4

5

6

7

8

9 10 x4

11

12

13

14

15

16

17

18

19

OPTION -- Outriggers

“4069RT” Parts Section

OPTION -- Outriggers

ITEM PART NO.

15

16

17

18

19

11

12

13

14

7

8

9

10

3

4

5

6

1

2

REF

92934

HDW8457

20998

50074

HDW5920

HDW9219

21477

HDW91395

21428

21429

50416

50001

21444

21436

50415

50446

50003

50050

QTY DESCRIPTION

1 F r o n t O u t r igge r Weldme n t

1 Rea r O u t r igge r Weldme n t

16 Bolt, M8 x 25 B u tto n Head

16 Wa s he r , M8 S td.

4 O u t r igge r Cove r Weldme n t

4 O u t r igge r Cove r Plate

8 Bolt, M8 x 20 B u tto n Head

16 Bolt, M12 x 120 S ocket Head

16 Wa s he r , M12 S td

16 N u t, M12 Nylock

-O u t r igge r Cyli n de r -- S ee S ectio n E

4 P r oximity S e ns o r

4 N u t, 1/2 Nylock

4 O u t r igge r Pivot B r acket

4 Bolt, 1/2 x 3.5

4 Cotte r pi n , .120 x 1.00

4 Wa s he r , 5/8 S td.

4 O u t r igge r Foot Pad

4 Clevi s Pi n , 5/8 x 5

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page F-23

4

5

6

7

ITEM

1

2

3

Wiring Harness Components

Harness plug designations (J#) and components listed in parentheses correspond to locations listed on the

Electrical Schematics. See Section 5 of the Service portion of this manual.

8

9

10

11

PART NO.

21629

--

21630

92222

92136

21623

91780

91761

9441

93251

21633

21631

91293

QTY DESCRIPTION

1 Ha rn e ss , Lowe r Co n t r ol Box I n te r io r (I n te r io r of Lowe r Co n t r ol Box, J1, J2)

---

1 Ha rn e ss , Mai n Cha ss i s (J1, J3, J4, J5, J6, J7, F un ctio ns Ma n ifold)

1 Ha rn e ss ,

Diesel Engine

1 Ha rn e ss ,

Dual Fuel Engine

1 Ha rn e ss , Comm un icatio n Cable (J4, J8)

1 Ha rn e ss , Platfo r m (J8, J9)

1 Ha rn e ss , Uppe r Co n t r ol Box I n te r io r

71 ft.

Cable, Powe r To Platfo r m (Pl u g at r ea r of Co n t r ol s Mod u le, O u tlet at platfo r m)

Thi s le n gth al s o us ed to powe r platfo r m wo r k light s

75 ft. Cable, Powe r To Platfo r m, A r ctic (Pl u g at r ea r of Co n t r ol s Mod u le, O u tlet at platfo r m)

1 Elevati n g A ss embly Ha rn e ss (J5, T r a ns d u ce rs , Dow n valve s )

1 OPTION -- O u t r igge r Ha rn e ss (J6, J7, O u t r igge rs )

1 Ha rn e ss , Joy s tick

March 2014

Page F-24

“4069RT” Parts Section

S

ECTION

G

D

ECALS

, ANSI M

ODELS

C

ONTENTS

P

AGE

Decals, ANSI Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

“4069RT” Parts Section March 2014

Page G-1

3 4 5 6

10

11

12

13

37 Option

7

8

9

14

18

5

15

1

2

15

16

17

38

Optional Material Clamps/

Pipe Racks

21

9

22

2

1

20

17

29

28

24

41

2

19

9

20

17

8

27

40

26

25 each side

41

24

1

23 inside

32

36

35

Optional Outriggers x4 Lanyard Attachments x6

42

24

41

15

17 each side

25

1

24 41

34 inside

33 inside

ART_4406

16

15

9

30

31

39

March 2014

Page G-2

“4069RT” Parts Section

Decals, ANSI Specification

ITEM PART NO.

QTY DESCRIPTION

1

2

7

8

9

10

5

6

3

4

15

16

17

18

11

12*

13

14

19

23

24

25

26

20

21

22

31

32*

33

34

27

28

29

30*

35

36

37

38

93209

93210

92416

92547

90730

90721

93059

90722

8911

6948

91850

90729

7156

93211

91730

92848

7982

8503

9910

90739

90719

93412

93051

90717

8779

90726

90725

11026730

90751

92767

--

9052

91930

90268

91975

92089

6873

9465

8605

8606

7155

4

4

3

3

1

1

2

1

1

1

6

1

1

1

1

2

4

2

4

1

1

1

5

Decal, 4069RT White

Decal, 4069RT G

Decal, Web

Decal, Web

Decal, Da

Decal, Wa

Decal, Ma

Decal, C

Decal, Co

Decal, F

Decal, Uppe

Decal, O r

Decal, Pipe Rack

Decal, Wa

Decal, Keep Clea

Decal, Pi o u n n n t rn rus n r t

Decal, Mate igge rn t s s

Decal, Platfo ge

Decal, Platfo nu h r ch r i r i r r n n

Decal, Made i r

Decal, LPG -- D

Co n g r u ol Ha

U n

S r r t t

S ay ite White ite G r ay m Wa n r r

A

Decal, MEC Oval, G rn dle ol r s ipe i ay n

Decal, MEC Oval, White g m Capacity g al I ns ide al F u el O n ly ial Rack Capacity

1 Decal, Mai n te n a n ce Lock

1 Decal, Batte r y Explo s io n Haza r d

1

4

4

1

1

--

1

1

1

1

1

1

4

6

1

1

Decal, Batte

Decal, Ti

Decal,

--

S

Decal, B

Decal, Hyd

Decal, C r rus

Decal, La

Decal, La r e

Decal, Die r e n n s s

Decal, Powe

Decal, Batte

Decal, Lowe

Decal, Platfo r r r el a h ya ya r r

Decal, Locate r r r y Weight

Decal, Tie Dow u n

To Platfo ial Plate y Di

Co s n t co r nn ol s r m ect m Capacity ake Relea d Poi d Wa s lic Oil n e t rn i n g

S mall

39

40

41

90732

92054

1

1

Decal, Powe

Decal, Pate n r t wa s s

Pe h n di n g

42

8502

92119

4

1

Decal, I n flate Ti

Decal, Relay s r e s

* Su b s tit u te the followi n g fo r machi n e s eq u ipped with optio n al D u al F u el E n gi n e:

12 91158 1 Decal, Uppe r Co n t r ol s , D u al F u el

30

32

92414

6872

1 Decal, Lowe r Co n t r ol s , D u al F u el

1 Decal, Ga s oli n e O n ly

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly • N S : Not a S tock item

“4069RT” Parts Section

• REF: Refe r e n ce o n ly

March 2014

Page G-3

1

93209 (white), 93210 (dark gray)

4 Places

2

92416 (white), 92547 (dark gray)

3 Places

6

90722

3

90730

7

8911

8

8911

6948 --

Dual Fuel Only

WARNING

L.P.G.

9

91850

6 Places

10

90729

4

90721

11

7156

12*

93211

5

93059

2 Places

WARNING

MAXIMUM PLATFORM CAPACITY - EVENLY DISTRIBUTED

EXTENSION RETRACTED

600 LBS

272 kg

EXTENSION EXTENDED

350 LBS

159 kg

250 LBS

113 kg

SIDE LOAD

100 LBS

444 N

1 PERSON

2 PERSONS

93059

13

91730 (Option)

91730

93211

14

92848 (Option)

2 Places

15

7982

4 Places

6948

16

8503

2 Places

17

9910

4 Places

18

90739

20

93051

5 Places

19

90719 (white)

93020 (dark gray)

21

90717

22

8779

23

90726

9910

24

90725

4 Places

WARNING

REPLACE TIRES WITH MANUFACTURER’S

EQUIPMENT ONLY.

FAILURE TO USE MANUFACTURER’S

TIRES MAY CAUSE MACHINE INSTABILITY.

REFER TO SERVICE AND PARTS MANUAL

FOR REPLACEMENT PART NUMBER.

90725

25

11026730

4 Places

26

90751

27

92767

MEC Aerial Work Platform Sales Corp.

Kerman, CA 93630

MATERIAL RACK CAPACITY

250 LBS

113 KG

MAX. SIDE LOAD

XXXX PSI

XXX bar

92767

28 not used

30*

91930

29

9052

31

90268

11026730

34

6873

35

9465 (Option)

4 Places

DANGER

STAND CLEAR

OUTRIGGER CONTACT

WILL CAUSE SERIOUS

CRUSHING INJURY

9465

36

8605

6 Places

37

8606 (option)

38

7155

39

90732

WARNING

DO NOT POWERWASH OR

SPRAY ELECTRONIC

COMPONENTS OR

CONNECTORS.

MOISTURE MAY CAUSE

DAMAGE AND/OR

ERRATIC OPERATION

90732

40

92054

Multiple Patents

Pending

92054

41

42

8502

4 Places

INFLATE TO TIRE

MANUFACTURER'S MAX.

SPECIFICATIONS

OR SEE

SERVICE MANUAL

8502

92119

START

RELAY

THROTTLE

RELAY

GLOW/

CHOKE

RELAY

92119

12

91158

32*

91975

33

92089

*Substitute the following for machines equipped with optional Dual Fuel Engine:

30

92414

PUSH FOR EMERGENCY

STOP

RAISE

LOWER

PLATFORM

OFF

BASE

TWIST TO RESET

CHOKE

START DELAY

START

PROPANE

GASOLINE

EMERGENCY

LOWERING

15 AMP

BREAKER

92414

32

6872

GASOLINE

ONLY

6872

ART_4405

March 2014

Page G-4

“4069RT” Parts Section

S

ECTION

H

D

ECALS

, CE M

ODELS

C

ONTENTS

P

AGE

Decals, CE Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3

Decals, GSE Diesel Option, CE Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7

“4069RT” Parts Section March 2014

Page H-1

47 3 4 5 6

7

9

37

41

Australia Only

14

10

11

12

13

18

5

1

2

15

16

17

38

Optional Material Clamps/

Pipe Racks

15

2

44 inside lip

1

20

17

29

28

24

43

21

2 at each corner

46

9

22

2

19

9 inside lip

44

20

17

27

40

26

25 each side

43

24

1

23 inside

35

45

Optional Outriggers x4 Lanyard Attachments x6

32

36

42

24

43

15

17 each side

25

1

24 43

34 inside

33 inside

ART_4409

16

15

9

30

31

39

March 2014

Page H-2

“4069RT” Parts Section

Decals, CE Specification

ITEM

1

PART NO.

9910

90739

90719

93412

93051

90717

8779

90726

90725

11026730

90751

92768

--

9052

91930

90268

91975

92089

6873

9465

8605

8606

7155

90732

92054

91325

91850

90729

7156

93215

91730

92848

7982

8503

93209

93210

92416

92547

90730

90721

93204

90722

8911

--

92119

93186

92769

93188

7982

• a s r eq: a s r eq u i r ed

2

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

19

32

33

34

35

28

29

30

31

24

25

26

27

20

21

22

23

36

37

38

39

40

41

42

43

44

45

46

QTY DESCRIPTION

4 Decal, 4069RT White

4 Decal, 4069RT G r ay

3 Decal, Web s ite White

3 Decal, Web s ite G r ay

1 Decal, Platfo r m Wa rn i n g

1 Decal, Da n ge r

2 Decal, Platfo r m Capacity

1 Decal, Wa rn i n g

1 Decal, Ma nu al I ns ide

---

6 Decal, C rus h

1 Decal, Co n t r ol Ha n dle

1 Decal, F r o n t

1 Decal, Uppe r Co n t r ol s

1 Decal, O u t r igge r

2 Decal, Pipe Rack

4 Decal, Wa rn i n g S t r ipe

2 Decal, Keep Clea r

4 Decal, Pi n ch

1 Decal, Made i n U S A

1 Decal, MEC Oval, White

1 Decal, MEC Oval, G r ay

5 Decal, Mate r ial Rack Capacity

1 Decal, Mai n te n a n ce Lock

1

Decal, Batte r y Explo s io n Haza r d

1 Decal, Batte r y Weight

4 Decal, Ti r e s

4 Decal, Tie Dow n

1 Decal, Powe r To Platfo r m

1 Decal, S e r ial Plate

---

1 Decal, Batte r y Di s co nn ect

1 Decal, Lowe r Co n t r ol s

1 Decal, Platfo r m Capacity S mall

1 Decal, Die s el

1 Decal, B r ake Relea s e

1 Decal, Hyd r a u lic Oil

4 Decal, C rus h

6 Decal, La n ya r d Poi n t

1 Decal, La n ya r d Wa rn i n g

1 Decal, Locate

1 Decal, Powe r wa s h

1 Decal, Pate n t s Pe n di n g

1 Decal, Da n ge r Elect r ical (A us t r alia o n ly)

1 Decal, Relay s

4 Decal, Wheel Load

2 Decal, No S tep

4 Decal, O u t r igge r Load

4 Decal, Wa rn i n g S t r ipe (c u t s ho r t to fit po s itio ns s how n )

• INCL: I n cl u ded with a ss embly • N S : Not a S tock item

“4069RT” Parts Section

• REF: Refe r e n ce o n ly

March 2014

Page H-3

1

93209 (white), 93210 (dark gray)

4 Places

2

92416 (white), 92547 (dark gray)

3 Places

6

90722

3

90730

7

8911

8911

9

91850

6 Places

10

90729

8 not used

11

4

90721

7156

12

93215

5

93204

2 Places

13

91730 (Option)

91730

14

92848 (Option)

2 Places

15

7982

4 Places

16

8503

2 Places

17

9910

4 Places

9910

18

90739

20

93051

5 Places

19

90719 (white)

93412 (dark gray)

21

90717

22

8779

23

90726

24

90725

4 Places

WARNING

REPLACE TIRES WITH MANUFACTURER’S

EQUIPMENT ONLY.

FAILURE TO USE MANUFACTURER’S

TIRES MAY CAUSE MACHINE INSTABILITY.

REFER TO SERVICE AND PARTS MANUAL

FOR REPLACEMENT PART NUMBER.

90725

25

11026730

4 Places

26

90751

28 not used

27

92768

MEC AERIAL WORK PLATFORMS

UNIT J, GREENFIELD BUSINESS PARK

MATERIAL RACK CAPACITY

113 KG

MAX. SIDE LOAD

400 N

MAX. INCLINATION

XXX° SIDE

5° IN-LINE

36 Volt DC

12.5 m/s

MANUFACTURED BY MEC AERIAL WORK PLATFORMS, 1401 S. MADERA AVE, KERMAN, CA 93630 USA

220 bar

92768

29

9052

11026730

34

6873

35

9465 (Option)

4 Places

DANGER

STAND CLEAR

OUTRIGGER CONTACT

WILL CAUSE SERIOUS

CRUSHING INJURY

9465

36

8605

6 Places

37

8606 (option)

ART_4408

38

7155

39

90732

WARNING

DO NOT POWERWASH OR

SPRAY ELECTRONIC

COMPONENTS OR

CONNECTORS.

MOISTURE MAY CAUSE

DAMAGE AND/OR

ERRATIC OPERATION

90732

42

92119

START

RELAY

THROTTLE

RELAY

GLOW/

CHOKE

RELAY

92119

43

93186

4 Places

40

92054

Multiple Patents

Pending

92054

44

92769

2 Places

41

91325 Australia only

DANGER r

THIS MACHINE IS NOT INSULATED!!! DEATH OR SERIOUS INJURY will esult om contact with o r r ance f om any elect ically cha ged conducto r .

MINIMUM CLEARANCES FROM POWER LINES

CLEARANCES FOR OPERATING ELEVATING WORK PLATFORMS NEAR

POWER LINES WHILE IN OPERATING MODE

OVERHEAD POWER LINES ON POLES OVERHEAD POWER LINES ON TOWERS

RE

SPOTTER

AND

WITHIN 3M EACH SIDE

AND

SEE SPECIAL PROVISIONS

OPEN

AREA

6.4M

BETWEEN

3-6.4M

OUTSIDE OF

POWER

LINES

OF

POWER

LINES

3M

3M

3M

SPOTTER

RE

BETWEEN

3-6.4M

OF

POWER

OPEN

AREA

OUTSIDE

6.4M

LINES

OF

POWER

LINES

RE

SPOTTER

Q UIRED

AND

WITHIN 3M EACH SIDE

AND

SEE SPECIAL PROVISIONS

RE

SPOTTER

OPEN

AREA

8-10M

BETWEEN

8-10M

OUTSIDE OF

POWER

LINES

OF

POWER

LINES

8M

8M

8M

BETWEEN

8-10M

OF

POWER

OPEN

AREA

OUTSIDE

8-10M

LINES

OF

POWER

LINES

91325

45

93188 (optional)

4 Places

30

91930

31

90268

46

7982 cut short to fit

4 Places

47

91388

32

91975

33

92089

Optional Centered

Platform

5

93573

2 Places

31

90577

Option omits items

#14, #20, #44

March 2014

Page H-4

“4069RT” Parts Section

N

OTES

:

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page H-5

10

11

12

13

19

18

5

40

15

28

24

31

21

17

23

33

27

42* inside

42*

*Cut off word “Inside” and discard for these

ART_4409 two locations if using 93368

23

33

1

37

29

1

2

5

35

9

16

17

36

9

42

2 at each corner

35

14

7

4

6

5

41

38

39

1

2

2

9

17

15

16

17

23

33 each side

27

9

23 33 25

1

22

34

8

37

30 inside

10 locations-one on each guardrail section

3

32

6 locations

March 2014

Page H-6

“4069RT” Parts Section

Decals, GSE Diesel Option, CE Specification

PART NO.

93412

93051

90751

91930

90725

92768

6873

--

11026730

92054

92119

92089

9052

8605

93186

7156

93215

93214

7155

7982

8503

9910

90739

93403

92547

93370

90721

93361

90722

8911

93404

91850

90729

90732

7982

93368

93369

93401

93402

93367

93186

92769

93188

7982

ITEM

30

31

32

33

26

27

28

29

19

20

21

22

23

24

25

15

16

17

18

11

12

13

14

7

8

9

10

3

4

5

6

1

2

38

39

40

43

34

35

36

37

44

45

46

QTY DESCRIPTION

4 Decal, 4069G S E G r ay

3 Decal, Web s ite G r ay

10 Decal, G u a r d r ail Pi ns

1 Decal, Da n ge r

2 Decal, Platfo r m Capacity 4069G S E

1 Decal, Wa rn i n g

1 Decal, Ma nu al I ns ide

1 Decal, Platfo r m Capacity S mall

6 Decal, C rus h

1 Decal, Co n t r ol Ha n dle

1 Decal, F r o n t

1 Decal, Uppe r Co n t r ol s

1 Decal, Light s

1 Decal, Locate

4 Decal, Wa rn i n g S t r ipe

2 Decal, Keep Clea r

4 Decal, Pi n ch

1 Decal, Made i n U S A

1 Decal, MEC Oval, G r ay

5 Decal, Mate r ial Rack Capacity

1 Decal, Powe r To Platfo r m

1 Decal, Lowe r Co n t r ol s

4 Decal, Ti r e s

1 Decal, S e r ial Plate

1 Decal, Hyd r a u lic Oil

---

4 Decal, Tie Dow n

1 Decal, Pate n t s Pe n di n g

1 Decal, Relay s

1 Decal, B r ake Relea s e

1 Decal, Batte r y Di s co nn ect

6 Decal, La n ya r d Poi n t

4 Decal, Wheel Load

1 Decal, Powe r wa s h

4 Decal, Wa rn i n g S t r ipe (c u t s ho r t to fit po s itio ns s how n )

3 Decal, Ga s Oil O n ly

2 Decal, E n gi n ee r i n g

1 Decal, Max Wi n d S peed

1 Decal, Ha rn e ss e s

1 Decal, G S E U s e O n ly

4 Decal, Wheel Load

2 Decal, No S tep

4 Decal, O u t r igge r Load

4 Decal, Wa rn i n g S t r ipe (c u t s ho r t to fit po s itio ns s how n )

• a s r eq: a s r eq u i r ed • INCL: I n cl u ded with a ss embly

“4069RT” Parts Section

• N S : Not a S tock item • REF: Refe r e n ce o n ly

March 2014

Page H-7

1

93403

4 Places

2

92547 (dark gray)

3 Places

6

90722

3 93370

10 places

4

90721

5

93361

3 Places

7

8911

8911

9

91850

6 Places

10

90729

8

93404

11

7156

12

93215

13

93214

14

7155

15

7982

4 Places

16

8503

2 Places

27

11026730

4 Places

30

92089

11026730

28

92054

Multiple Patents

Pending

92054

29

92119

START

RELAY

THROTTLE

RELAY

GLOW/

CHOKE

RELAY

92119

31

9052

41

91388

17

9910

4 Places

18

90739

9910

19

20

21

93412

90717

90751

22

91930

24

25

92768

UNIT J, GREENFIELD BUSINESS PARK

FLINTSHIRE CH8 7HJ UK

MATERIAL RACK CAPACITY

113 KG

MAX. SIDE LOAD

400 N

MAX. INCLINATION

5° IN-LINE

36 Volt DC

12.5 m/s

MANUFACTURED BY MEC AERIAL WORK PLATFORMS, 1401 S. MADERA AVE, KERMAN, CA 93630 USA

220 bar

92768

6873

23

90725

4 Places

WARNING

REPLACE TIRES WITH MANUFACTURER’S

EQUIPMENT ONLY.

FAILURE TO USE MANUFACTURER’S

TIRES MAY CAUSE MACHINE INSTABILITY.

REFER TO SERVICE AND PARTS MANUAL

FOR REPLACEMENT PART NUMBER.

90725

26 not used

32

8605

6 Places

33

93186

4 Places

35

7982 cut short to fit

4 Places

38 93401 -- 1 place

36 not used

39 93402 -- 1 place

34

90732

WARNING

DO NOT POWERWASH OR

SPRAY ELECTRONIC

COMPONENTS OR

CONNECTORS.

MOISTURE MAY CAUSE

DAMAGE AND/OR

ERRATIC OPERATION

90732

37 93369 -- 2 places

40 93367 -- 1 place

42

91975 -- 3 Places

OR

93368* -- 3 places

ART_4421

*Cut off “INSIDE” for two locations inside Control Module if using 93368.

March 2014

Page H-8

“4069RT” Parts Section

7Service Parts Order Form

Fax to 559-263-9631

Please fill out completely

Date: ______________________________

Account: ___________________________

Bill to: _____________________________

___________________________________

___________________________________

___________________________________

Purchase Order Number ______________

**All orders MUST have a Purchase Order Number

Part Number Description

Ordered By: _________________________

Your Fax No.: _______________________

Ship to: ____________________________

___________________________________

___________________________________

___________________________________

Ship VIA___________________________

**Fed Ex shipments require Fed Ex account number

Quantity Price

All back ordered parts will be shipped when available via the same ship method as original order unless noted below:

Ship complete order only - no back orders

Ship all available parts and contact customer on disposition of back ordered parts

other (please specify)

___________________________________________________________________

N

OTES

:

Limited Owner Warranty

MEC Aerial Platform Sales Corp. warrants its equipment to the original purchaser against defects in material and/or workmanship under normal use and service for one (1) year from date of registered sale or date the unit left the factory if not registered. MEC Aerial Platform Sales Corp. further warrants the structural weldments of the main frame and scissor arms to be free from defects in material or workmanship for five (5) years from date of registered sale or date unit left the factory if not registered. Excluded from such warranty is the battery(s) which carries a ninety (90) day warranty from described purchase date. Warranty claims within such warranty period shall be limited to repair or replacement, MEC Aerial Platform Sales Corp’s option, of the defective part in question and labor to perform the necessary repair or replacement based 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 Platform Sales Corp. to be defective in material and/or workmanship. MEC Aerial Platform Sales Corp. shall not be liable for any consequential, incidental or contingent damages whatsoever. Use of other than factory authorized parts; misuse, improper maintenance, or modification of the equipment voids this warranty. The foregoing warranty is exclusive and in lieu of all other warranties, express or implied. All such other warranties, including implied warranties of merchantability and of fitness for a particular purpose, are hereby excluded. No Dealer, Sales Representative, or other person purporting to act on behalf of MEC Aerial Platform Sales Corp. is authorized to alter the terms of this warranty, or in any manner assume on behalf of MEC Aerial Platform Sales Corp. any liability or obligation which exceeds

MEC Aerial Platform Sales Corp’s obligations under this warranty.

Aerial Platform Sales Corp.

1401 S. Madera Avenue • Kerman, CA 93630 USA

877-632-5438 • 559-842-1500 • Fax: 559-842-1520 [email protected] • www.MECawp.com