Mec 3772RT-HD Service & Parts Manual
Mec 3772RT-HD is a machine designed for a variety of tasks, including construction, maintenance, and inspection, with a maximum platform height of nearly 40 feet and a maximum horizontal outreach of nearly 55 feet. It features a spacious platform and a 360-degree continuous rotation turntable for precise positioning. The Mec 3772RT-HD is also equipped with a powerful hydraulic system that provides smooth and precise operation, making it ideal for a variety of applications.
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SERVICE AND PARTS MANUAL
3072RT / 3772RT
3772RT HD
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Serial Number Range
3072RT: 9201000 - Present
3772RT / 3772RT HD: 9301000 - Present
Part # 91220 R1
March 2008
Revision History:
March 2008
Pages
Page V
Page VI
Reason for update
Introduction
Update Specifications Table
Update Illustration
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Service Section 2
Update illustration: Deutsch Connectors
Add illustrations and update text: Continuity Checks
Service Section 4
Update Step 3:Setting Counterbalance Valves
Service Section 5
Update text: Hydraulic Schematic - bold table heads
Update illustration: Hydraulic Schematic
Update illustration: Outrigger Electric Schematic
Update illustration: Generator Option Schematic
Parts Section 1
Update illustration: Base Control Box
Update parts list to identify key switch and related components
Parts Section 4
Update illustration: Rear Axle Assembly
Update parts list to identify valve shields and related components
Parts Section 6
Update illustration: Base Assembly
Update parts list to identify Power to Platform Bracket
Update illustration: Control Module
Update parts list to identify Hole Plug
Update illustration: Engine, Dual Fuel
Update illustration: Engine, Dual Fuel
Update parts list to identify new part numbers
Update illustration: Engine, Diesel
Update parts list to identify new part numbers
Update illustration: Engine, Diesel
Update parts list to identify new part numbers
New illustration: Harnesses
Update parts list to identify new part numbers
Update illustration: Outrigger Install
Update parts list to identify Power to Platform Bracket
New Illustration: Generator Option, Dual Fuel
Update parts list to identify new part numbers
New Illustration: Generator Option, Diesel
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Parts Section 7
Update illustration: 3072RT Sides
Update parts list
Update illustration: 3072RT Ends
Update parts list
Update illustration: 3772RT / 3772RT HD Sides
Update parts list
Update illustration: 3772RT / 3772RT HD Ends
Update parts list
Aerial Platform Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448
E-mail:[email protected] • Web:www.mecawp.com
Table of Contents
Service Sections
INTRODUCTION ............................................................................................... I
General Safety Tips ............................................................................................... III
Hydraulic System ............................................................................................... IV
Electrical System ................................................................................................ IV
Total System ....................................................................................................... IV
Machine Specifications .......................................................................................... V
Primary Machine Components ............................................................................ VII
LUBRICATION ...................................................................................................... VIII
SECTION 1:
HYDRAULIC SYSTEM ............................................................................. 1-1
Hydraulic System - General ................................................................................ 1-2
Hydraulic Fluid ..................................................................................................... 1-3
Hydraulic Fluid Reservoir ................................................................................... 1-6
Hydraulic Pump ................................................................................................... 1-7
Wheel Drive .......................................................................................................... 1-7
Parking Brake and Towing Circuit .................................................................... 1-14
Emergency Systems And Procedures ............................................................. 1-15
Steering Circuit .................................................................................................. 1-16
Platform Lift Circuit ........................................................................................... 1-18
Optional Outriggers ........................................................................................... 1-20
Cylinder Repair .................................................................................................. 1-21
Hydraulic Manifold............................................................................................. 1-24
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page i
Table of Contents
SECTION 2:
ELECTRICAL SYSTEM ........................................................................... 2-1
Electrical System - General ................................................................................ 2-2
Deutsch Connectors ............................................................................................ 2-3
Battery .................................................................................................................. 2-4
Battery Preventative Maintenance: ................................................................... 2-5
Battery Replacement ........................................................................................ 2-6
Alarms and Switches .......................................................................................... 2-7
Tilt Alarm .......................................................................................................... 2-8
Relays .............................................................................................................. 2-9
Limit Switch ....................................................................................................... 2-10
Optional Outriggers Switches .......................................................................... 2-10
Continuity Checks ............................................................................................. 2-11
SECTION 3:
MECHANICAL COMPONENTS ............................................................... 3-1
Torque Specifications ......................................................................................... 3-2
Mechanical Components .................................................................................... 3-3
Base/ Undercarriage ........................................................................................ 3-3
Raising the Machine ......................................................................................... 3-3
Tires ................................................................................................................. 3-4
Drive Motors ..................................................................................................... 3-5
Steer Cylinder .................................................................................................. 3-6
Hoses and Cables ............................................................................................ 3-7
Platform Removal ............................................................................................. 3-7
Lift Cylinder Removal and Installation .............................................................. 3-8
Scissor Beam Assembly ................................................................................... 3-8
Engine Maintenance ............................................................................................ 3-9
Diesel Engine ................................................................................................... 3-9
Gasoline and Dual Fuel Engine ...................................................................... 3-12
Outrigger Function ............................................................................................ 3-14
Outrigger Calibration ...................................................................................... 3-15
GP106 Outrigger Control Module Troubleshooting ......................................... 3-17
Outrigger Module GP106 LED Flash Codes .................................................. 3-18
March 2008
Page ii
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Table of Contents
SECTION 4:
TROUBLESHOOTING ............................................................................. 4-1
Troubleshooting ................................................................................................... 4-3
General Troubleshooting Tips ........................................................................... 4-3
Common Causes of Hydraulic System Malfunctions: ....................................... 4-3
Hydraulic Pressure Adjustment Procedures ..................................................... 4-9
Proportional Speed Adjustment ....................................................................... 4-12
Controls and Switches ...................................................................................... 4-14
SECTION 5:
SCHEMATICS .......................................................................................... 5-1
Hydraulic Schematic ........................................................................................... 5-2
Main Hydraulic Manifold ................................................................................... 5-4
Optional Outriggers Hydraulic Manifold ............................................................ 5-5
Electric Schematics ............................................................................................. 5-6
Circuit Board .................................................................................................... 5-8
Controls .......................................................................................................... 5-10
Engine ............................................................................................................ 5-13
Optional Outriggers ........................................................................................ 5-15
Optional Generator ......................................................................................... 5-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page iii
Table of Contents
Parts Sections
SECTION 1: CONTROL BOXES
SECTION 2: PLATFORM AND RAILS
SECTION 3: SCISSORS
SECTION 4: AXLES
SECTION 5: HYDRAULICS
SECTION 6: BASE
SECTION 7: DECALS
March 2008
Page iv
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
INTRODUCTION
This manual consists of Service and Parts illustrations 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 scissors lift. When used in conjunction with the illustrated parts section and the Operators Manual (provided separately), this manual will assist you in making necessary adjustments, repairs, identifying, and ordering the correct replacement parts.
All parts represented here are manufactured and supplied in accordance with MEC’s quality standards.
We recommend that you use Genuine MEC parts to insure proper OPERATION and reliable
PERFORMANCE.
To obtain maximum benefits from your MEC scissors lift, always follow the proper operating and maintenance procedures. Only trained authorized personnel should be allowed to operate or service this machine. Service personnel should read and study the Operator’s, Service and Parts
Manuals in order to gain a thorough understanding of the unit prior to making any repairs.
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” IS USED FOR PROPERTY-DAMAGE ONLY
ACCIDENTS.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page I
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 Scissors Lift 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:
Aerial Platform Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448 www.mecawp.com
March 2008
Page II
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
GENERAL SAFETY TIPS
Regular inspection and conscientious maintenance is the key to efficient economical operation of your scissors lift. 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 PERFORM SERVICE ON THE MACHINE (WITH THE
PLATFORM ELEVATED) WITHOUT FIRST BLOCKING THE BEAMS
(SCISSORS) ASSEMBLY IN PLACE USING THE MAINTENANCE
LOCK!
Maintenance Lock In Position
•
Block scissors assembly using Maintenance Lock if machine is in the elevated/extended position.
•
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.
3072RT
3772RT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page III
Hydraulic System
HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND
BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY,
BLINDNESS, AND EVEN DEATH.
CORRECT LEAKS IMMEDIATELY.
Hydraulicfluid leaks under pressure may not always be visible.
Check for pin hole leaks with a piece of cardboard, not your hand.
Electrical System
Prevent damage to battery and/or electrical system;
• Always disconnect the negative battery cable first.
• Always connect the positive battery cable first.
If contact is made between the positive side of the battery and a metal surface on the machine when the negative cable is installed a spark will occur. This can cause damage to the electrical system, battery explosion, and personal injury.
Total System
Engine coolant level must be checked only after engine has cooled.
If radiator cap is removed while the coolant is at normal operating temperature, pressure within the coolant system will force hot liquid out through the filler opening and possibly cause severe scalding.
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 scissors lift.
Inspection and maintenance should be performed by qualified personnel familiar with the equipment.
March 2008
Page IV
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
MACHINE SPECIFICATIONS
Workin g Hei g ht*
Platform Hei g ht
S towed Hei g ht
Platform Entry Hei g ht
Rail s Up
Rail s Folded Down
Maximum Number of Occupant s
Lift Capacity (Evenly Di s tributed)
Roll-out Deck Capacity
Platform Dimen s ion s
With Roll-Out Deck Extended
With Roll-Out Deck Retracted
Deck Width
Guardrail Hei g ht
Toeboard Hei g ht
Roll-out Deck Len g th
Overall Len g th
Overall Width
Wheel Ba s e
Wheel Track
Turnin g Radiu s In s ide
Out s ide
Ground Clearance
Machine Wei g ht** (Unloaded) (Approx.)
Drive S y s tem (Proportional)
Drive S peed (Platform Elevated)
Drive S peed (Platform Lowered)
158 in
110 in
60 in
43.5 in
6.0 in
48 in
117.25 ft
72 in
86.0 in
60.5 in
73.25 in
14 ft 2.5 in
9.5 in
7,062 lb**
36.0 ft *
3072RT
11.14 m
*
30.0 ft
54 in
9.14 m
1.4 m
108.5 in
78.5 in
3
1,000 lb
400 lb
2.75 m
1.99 m
3
454 kg
181 kg
0 – 0.4 mph
0 – 4.0 mph
43 ft *
3772RT
13.28 m
*
37 ft
61 in
105.75 in
74 in
3
750 lb
400 lb
11.28 m
1.5 m
2.62 m
1.88 m
3
340 kg
181 kg
3772RT HD
43 ft *
13.28 m
*
37 ft
61 in
11.28 m
1.5 m
105.75 in
74 in
3
1,000 lb
400 lb
2.62 m
1.88 m
3
454 kg
181 kg
4.01 m
2.79 m
1.52 m
1.10 m
15.0 cm
1.22 m
2.98 m
1.83 m
158 in
110 in
60 in
43.5 in
6.0 in
48 in
117.25 ft
72 in
4.01 m
2.79 m
1.52 m
1.10 m
15.0 cm
1.22 m
2.98 m
1.83 m
158 in
110 in
60 in
43.5 in
6.0 in
48 in
140 in
73.25 in
2.18 m
1.54 m
1.86 m
4.33 m
86.0 in
60.5 in
73.25 in
14 ft 2.5 in
2.18 m
1.54 m
1.86 m
4.33 m
86.0 in
60.5 in
73.25 in
14 ft 2.5 in
24 cm
3203 kg
**
9.5 in
7,975 lb**
24 cm
3589 kg
**
9.5 in
8,585 lb**
0 –0.6 km/h
2 Wheel Drive Standard, 4 Wheel Drive Option
0 – 0.4 mph
0 –0.6 km/h
0 – 0.4 mph
0 – 6.4 km/hr
0 – 4.0 mph
0 – 6.4 km/hr
0 – 4.0 mph
0 –0.6 km/h
0 – 6.4 km/hr
4.01 m
2.79 m
1.52 m
1.10 m
15.0 cm
1.22 m
3.56 m
1.86 m
2.18 m
1.54 m
1.86 m
4.33 m
24 cm
3863 kg
**
Lift/Lower S peed (Approx.)
Gradeability
Ground Pre ss ure/Wheel (Maximum)
Tire S izeS tandard
Tire Pre ss ure, 12 Ply Pneumatic
12 Ply Foam-Filled (Option)
Wheel Load
Wheel Lu g Nut Torque
Hydraulic Pre ss ure Main S y s tem
Lift S y s tem
S teer
Hydraulic Fluid Capacity
Fuel Capacity
26 sec / 28 sec
45% / 24.2°
26 sec / 28 sec
45% / 24.2°
91 psi
6.4 kg/cm²
26.0-12.0-380
60 psi
Foam-Filled
2,722 lb
75-85 ft/lb
2800 psi
2500 psi
1500 psi
4.14 bar
Foam-Filled
1235 kg
102-115 Nm
193 bar
172 bar
103 bar
28 sec / 31 sec
40% / 21.5°
97 psi
26.0-12.0-380
60 psi
Foam-Filled
2,921 lb
75-85 ft/lb
3000 psi
2500 psi
1500 psi
28 sec / 31 sec
40% / 21.5°
6.8 kg/cm²
4.14 bar
Foam-Filled
1325 kg
102-115 Nm
207 bar
172 bar
103 bar
28 sec / 31 sec
40% / 21.5°
100 psi
28 sec / 31 sec
40% / 21.5°
7.0 kg/cm²
26.0-12.0-380
60 psi
4.14 bar
Foam-Filled
2,996 lb
75-85 ft/lb
3000 psi
2500 psi
1500 psi
23 GAL
15 GAL
87 liters
57 liters
23 GAL
15 GAL
87 liters
57 liters
23 GAL
15 GAL
Power S y s tem – Volta
Alternator (Li g htin g g e
Coil)
12 Volts DC
40 Amp
En g ine Availability S tandard
Option
Meet s re qu irement s of AN S I A92.6-2006 S ection 4.
*Working height a dd s 6 feet (2 m) to pl a tform height.
**Weight m a y incre as e with cert a in option s or co u ntry s t a nd a rd s .
12 Volts DC
12 Volts DC
12 Volts DC
12 Volts DC
40 Amp
40 Amp
40 Amp
40 Amp
Kubota DF752E, 22 HP (16.4 kW), Dual Fuel, Liquid Cooled
Kubota D905E, 20 HP (14.9kW), Diesel, Liquid Cooled
Foam-Filled
1359 kg
102-115 Nm
207 bar
172 bar
103 bar
87 liters
57 liters
12 Volts DC
40 Amp
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page V
O
A u ss trigger em b ly
Pl a tform A ss em b ly
Rollo u t Deck
Lift A ss em b ly
Front
M a inten a nce
Lock
Power Mod u le
3772RT HD
3072RT
Upper Control s
Lift A ss em b ly
M a inten
Lock a nce
March 2008
Page VI
Front
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Control Mod u le
Li qu id Prop a ne
(D ua l F u el Option)
PRIMARY MACHINE COMPONENTS
Component
Platform Assembly
Uppe r Co n t r ol s
Deck a n d Rail s
Chai n Clo sur e
Optio n al Gate
Rollo u t Deck
Co n t r ol Te r mi n al S t r ip
Ho rn (optio n al)
Lift Assembly
Beam s
Mai n te n a n ce Lock
Lift Cyli n de rs
Limit S witch
Service Section
2 | 4 | 5
3
2 i n t r o i n t r o
1 | 3 | 4 | 5
2 | 4
Base Assembly
F r o n t D r ive Moto rs i n t r o | 1 | 3 | 4 | 5
R D r ive Moto rs w/B r ake s i n t r o | 1 | 3 | 4 | 5
S tee r i n g Compo n e n t s
S tee r i n g Compo n e n t s
1 | 3
1 | 3 | 4 | 5
Wheel s & Ti r e s
H u b s
S lide Block
Eme r ge n cy Lowe r i n g i n i i t n n r t t o | 3
1 r r o o
Ho s e s & Cable s
O u t r igge r (Optio n )
LPG (Optio n )
1 | 2 | 3 |
1 | 3 | 4 | 5
3
Parts Section
1 | 2
2
2
2
2
1
1
3
3
3 | 5
3
4 | 5 | 6
4 | 5 | 6
3 | 5 | 6
3 | 5 | 6
6
6
6
5 | 6
5 | 6
6
Component
Control Module
Lowe
Hyd
Pa
Eme
F
F
Powe
Tilt
O
P
O u u
To r u
Th u r r el Ta el r t eheat t ki r q ottle r r
S
Batte r a
S
Platfo u r n ge e r r
Relays
r
Co u h e lic Ma g B n n u
to Platfo ns igge
S igge k r r cy Lowe toff o r n r t ake Relea y & Di r ol s
Ma peed n m Powe s ifold co n r r
(Optio n r m nn ifold
) i n s g ect e
O u t r igge r Co n t r ol Mod u le
(O u t r igge r Optio n )
AC Ge n e r ato r (Optio n
AC Ge n e r ato r (Optio n )
)
Power Module
E n gi n e
Hyd r a u lic P u mp
Hyd r a u lic r e s e r voi r
Hyd r a u lic Filte r i i
3 | 4 | 5
1 | 3 | 4 | 5 n n t t r r o | 1 o | 1
6
6
6
6
Service Section Parts Section
2 | 3 | 4 | 5
1 | 3 | 4 | 5
1
1
2 | 3 | 4 | 5
2 | 3 | 4 | 5
1 | 3 | 4 | 5
2 | 5
5
2 | 4 | 5
2 | 4 | 5
2 | 4 | 5
2 | 4 | 5
3 | 4 | 5
5
1 | 6
5 | 6
6
6
6
6
6
5 | 6
6
5 | 6
6
6
1
6
6
6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page VII
LUBRICATION
NO.
ITEM SPECIFICATION
1 Hydraulic
Reservoir
Fill To The Middle Of The Sight Gauge
With Platform In The Stowed Position.
Mobile 424.
Do not substitute with lower grade oils as pump damage may result.
FREQUENCY
Check Daily.
Change Yearly Or Every 1,000
Hours, Whichever Occurs First.
2 Hydraulic
Filter
Filter Element
3
4
Front Hubs
Steering
Pivots
Slide Block
Lithium N.L.G. #2 EP
Purge Old Grease
Lithium N.L.G. #2 EP
Purge Old Grease
Change Every Six Months Or
500 Hours, Whichever Occurs
First For Normal Usage.
Change Every Three Months
Or 300 Hours, Whichever
Occurs First For Severe
Usage.
Monthly or Every 25 Hours,
Whichever Occurs First
Monthly or Every 25 Hours,
Whichever Occurs First
5 Fixed Lithium N.L.G. #2 EP
Purge Old Grease
Monthly or Every 25 Hours,
Whichever Occurs First
2
1
Dr a in Pl u g
X72-L ub e
March 2008
Page VIII
FRONT
REAR
3
4
Zerk Fitting s
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
5
Zerk Fitting s
SECTION 1:
HYDRAULIC
SYSTEM
SECTION 1:
HYDRAULIC SYSTEM .............................................................................. 1-1
Hydraulic System - General ........................................................................................................................... 1-2
Hydraulic Fluid ............................................................................................................................................... 1-3
Hydraulic Fluid Reservoir ............................................................................................................................... 1-6
Hydraulic Pump ............................................................................................................................................. 1-7
Wheel Drive ................................................................................................................................................... 1-7
Parking Brake and Towing Circuit ................................................................................................................ 1-14
Emergency Systems And Procedures ......................................................................................................... 1-15
Steering Circuit ............................................................................................................................................ 1-16
Platform Lift Circuit ....................................................................................................................................... 1-18
Optional Outriggers ...................................................................................................................................... 1-20
Cylinder Repair ............................................................................................................................................ 1-21
Hydraulic Manifold ....................................................................................................................................... 1-24
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-1
HYDRAULIC SYSTEM - GENERAL
The hydraulic system is an open center, open- loop type. Generally in this type of system, hydraulic fluid is provided by a variable displacement, pressure compensated, piston type pump which is directly coupled to the engine. As the engine turns, the hydraulic pump drains oil from the reservoir and pumps this fluid to the valve packages.
If no function is selected to perform, the pump remains on standby and no fluid is pumped through the manifold. Each function has a maximum pressure control limit set by pressure relief valve.
Hydraulic integrated circuit, generally known as the manifold system (valve type) 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.
March 2008
Page 1-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
HYDRAULIC FLUID
Handling Precautions
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. If irritation persists, medical advice should be sought.
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.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-3
Fluid Recommendations
MEC recommends the use of
Mobil 424
hydraulic fluid. Do not substitute with lower grade oils as pump damage may result.
Hydraulic Fluid Analysis
Use the following as a guide to determine when analysis of the hydraulic fluid is necessary:
• Anytime the hydraulic pump is replaced.
• If fluid discoloration is noticed in the hydraulic reservoir sight gauge tube.
• If after the first 50 hours of operation, the hydraulic filter element is plugged.
• Anytime the hydraulic filter element shows signs of metal contamination.
• Once every six (6) months, under normal operating conditions.
• Every three (3) months, in extremely dusty or dirty operating conditions.
The hydraulic fluid analysis must be done by a qualified laboratory. Always provide the following information with the test sample.
• Type of hydraulic fluid (see lubrication chart for recommended hydraulic fluid and/or your records).
• Model and Serial number of machine from which sample was taken.
• Purpose of analysis: pump failure, discoloration, etc.
• Type of analysis: complete to show additive breakdown, acid buildup, viscosity, type and percent of contaminants; also, comparison to new fluid and recommendations.
Following the above guidelines will prevent premature failure of pumps, cylinder seals, drive motors, and unnecessary downtime.
If system flushing and replacement of fluid is recommended, refer to the flushing procedure.
March 2008
Page 1-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
System Flushing Procedure
1. With platform fully down, drain hydraulic fluid from hydraulic reservoir into a clean, empty container. Use an oil filter cart so the fluid may be reused if analysis is good.
2. When the hydraulic reservoir is empty, remove suction strainer and hoses.
3. Remove the bypass filter and hose.
4. Flush the hoses with clean hydraulic fluid.
5. Discard old bypass filter element and replace.
6. Flush out the tank with hoses removed from the hydraulic reservoir.
7. Reinstall all hoses removed in the previous steps.
8. Fill hydraulic reservoir with filtered, fresh hydraulic fluid (refer to Lubrication Chart).
9. Loosen output hose fittings at pump to flood with hydraulic fluid. Tighten fittings.
10. Start up the machine. Briefly operate all functions. Two or three lift cycles may be necessary to purge all air from lift cylinder(s).
11. When the above procedures have been completed, fill hydraulic reservoir to full mark on sight gauge.
12. Check all leaks and correct as necessary. Machine is now ready to be placed back in operation.
NOTE:
AVOID MIXING PETROLEUM AND SYNTHETIC BASE OILS. IT IS NOT
ADVISABLE TO MIX OILS OF DIFFERENT BRANDS OR TYPES, EXCEPT AS
RECOMMENDED.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-5
HYDRAULIC FLUID RESERVOIR
This consists of the tank, a filler cap with breather, a drain plug, a sight gauge, and a bypass filter with a 10 micron filter element.
• Check tank for signs of leakage, every week.
Hydraulic Reservoir Assembly
All machines are produced with a filter. It is a 10 micron spin-on, bypassing filter. When the filter is clogged, hydraulic flow bypasses the filter element. The filter element must be changed every six
( 6) months or 500 hours. Extremely dirty conditions may require that the filter be replaced more often.
BEWARE OF HOT OIL. CONTACT WITH HOT OIL MAY CAUSE
SEVERE BURNS.
Filler Cap
Sight
Gauge
March 2008
Page 1-6
Filter Element
Drain Plug
ART_X72-L ub e1
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
HYDRAULIC PUMP
Note:
Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure.
Refer to Section 3 for Remove and Replace instructions.
An internal combustion engine drives a variable displacement axial piston pump. Flow is proportional to drive speed and displacement. The pump is not serviceable. A faulty pump must be replaced.
WHEEL DRIVE
Note:
Refer to
Section 3 for Remove and Replace instructions.
There are four (4) hydraulic, fixed-displacement gear wheel motors to provide power to all four wheels [two (2) front and two (2) rear].
Dynamic Braking Circuit
The two rear wheel motors have integral brakes that are spring held. Hydraulic pressure developed in the drive circuit, during drive mode, releases the brakes. A fixed orifice in the brake circuit controls the deceleration rate and initiates a smooth stop.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-7
Front Wheel Motors (DT-701)
Housing and Shaft Disassembly
1. Remove all shaft related components from the shaft. Secure the motor housing in a vise.
•
Remove the retaining ring from the grove in the pilot of the housing.
•
Remove the spacer from the housing.
•
Remove the shaft from the housing.
•
Remove the bearing, thrust bearing, and two (2) thrust washers from the shaft.
2. Being careful not to drop bearing rollers,
• pry out the shaft seal, backup seal, and dust seal from the bearing assembly.
NOTE: It is not necessary to remove the metal backup ring from the bearing to service the motor.
• remove the high pressure seal from the groove in the pilot of the housing.
• discard shaft seal, backup seal and high pressure seal.
3. Clean all parts in an oil-based solvent and dry using compressed air.
Housing and Shaft Assembly
1. Apply a light coating of oil to all new seals prior to installation.
• Install the high pressure seal into the groove in the pilot of the housing.
2. Place the shaft on a clean, flat surface with the output end facing up.
•
Place the first thrust washer, thrust bearing and second thrust washer over the shaft.
•
Using plastic installation sleeve, place the shaft seal over the shaft with the lip facing down.
•
Repeat for the backup seal, making sure the lip faces down.
•
If the metal backup ring came out in
Step 2 above, place it over the shaft with the large
O.D. facing down.
•
Lightly grease the bearing and place it over the shaft with the large O.D. facing down.
•
Use an arbor press to carefully press the bearing down to press the seal assembly into the bearing.
3. Place the shaft assembly into the housing.
•
Place the dust seal over the shaft with the lip facing up.
•
Place the bearing spacer and retaining snap ring over the shaft.
NOTE: It may be necessary to lightly tap the snap ring and bearing spacer to allow the retaining ring to seat properly.
•
Replace all shaft related components (i.e. keys, wire rings, nuts).
Motor Section Disassembly
1. Make a “V” shaped set of alignment marks on the endcover and housing to aid in the reassembly process.
•
Clamp the motor housing in a vise with the shaft facing down.
2. Remove the seven (7) bolts that hold the motor assembly together.
• Carefully remove the endcover - be aware that the piston and spring may fall out.
March 2008
Page 1-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
•
Carefully remove the piston from the endcover and set it aside.
•
Remove and discard the O-ring seal and backup seal.
•
Remove the spring and set it aside.
3. Lift commutator container and commutator from the motor and set aside.
•
Place commutator on a flat, clean surface with the seal facing up.
•
Gently tap on the seal with a small screwdriver until the opposite side of the seal lifts from the groove. Remove the seal and discard.
4. Remove the manifold, rotor set, and divider plate. Remove all seals and discard.
CAUTION: Do not allow rollers to drop from the rotor assembly when removing the rotor from the motor.
•
Remove the drive link from the motor and set aside.
5. Clean all parts in an oil-based solvent and dry using compressed air. Apply a light coating of oil to all new seals prior to installation.
Motor Section Assembly
1. Install the drive link into the end of the shaft with the tapered end facing up.
•
Place the rear housing seal in the groove in the housing.
•
Place the divider plate onto the housing.
•
Place body seals in grooves in both sides of the rotor.
•
Place the rotor onto the housing with the side of the rotor with chamfer in splines facing the housing.
•
Place the manifold over the rotor with the seal-groove side up.
•
Install the manifold seal
2. Install the commutator seal into the commutator with the metal side facing up.
•
Use finger pressure to press the seal down flush with the surface of the commutator.
•
Place the commutator onto the manifold and then place the commutator onto the protruding end of the drive link. Make sure that the seal side is facing up.
3. Install the remaining body seal in the groove on the endcover.
•
Install the piston spring into the endcover, then the white backup seal followed by the
O-Ring seal.
•
Line up the alignment pin with the hole in the endcover and press the piston into the endcover.
•
While holding the piston in place, lower the endcover assembly onto the motor. Align the
“V” shaped marks that were made on the housing and endcover before disassembly.
4. Install the seven (7) assembly bolts.
• Tighten bolts in sequence (see illustration)
•
Pre-torque to 10 ft. lbs. (13,6 Nm).
•
Final torque to 50 ft. lbs (67,8 Nm).
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-9
“V ” M a rk s for Re ass em b ly
5
4
1
6
TORQUE
S EQUENCE
3
2 7
PRE-TORQUE = 10 FT LB S
FINAL TORQUE = 50 FT LB S
7
19
22
2 3
24
11
7
8
6
3 1
21
20
1 3
15
2
4
3
5
16
12
14
1
9
10
25
3 0
17
26
27
2 8
1
29
8
3 4
5
DU S T S EAL
1.5" BEARING
S HAFT S EAL
BACKUP S EAL
METAL BACKUP RING
DT701 S erie s Motor Component s
D us t S e a l
2. * High Pre ssu re S e a l
3 . * Met a l B a ck u p S him
4. * B a ck u p S e a l
5. S h a ft S e a l
6. * Ho us ing S e a l
7. * Body S e a l s ( 3 )
8 . * M a nifold S e a l
9. * Comm u t a tor S e a l
10. * O-Ring S e a l
11. * B a ck u p S e a l
12. Ret a ining S n a p Ring
1 3 . Be a ring S p a cer
14. 1.5" Be a ring
15. Thr us t W as her s (2)
16. Thr us t Be a ring
17. Ho us ing
1 8 . Re a r Ho us ing Be a ring
19. Drive Link
20. Divider Pl a te
21. Rotor A ss em b ly
22. M a nifold
* Cont a ined in s e a l kit
2 3 . Comm u t a tor A ss em b ly
24. Endcover Pi s ton
25. Pi s ton S pring
26. Endcover
27. I.D. T a g A ss em b ly
2 8 . A ss em b ly Bolt s (7)
29. h a ft
3 0. S h a ft Key
3 1. S h a ft N u t
March 2008
Page 1-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Rear Wheel Motors with Brakes (DT-710)
Disassembly
1. Make a “V” shaped set of alignment marks on the endcover and housing to aid in the reassembly process.
•
Clamp the motor housing in a vise with the shaft facing down.
2. Remove the seven (7) bolts that hold the motor assembly together.
• Carefully remove the endcover - be aware that the piston and spring may fall out.
•
Carefully remove the piston from the endcover and set it aside.
•
Remove and discard the O-ring seal and backup seal.
•
Remove the spring and set it aside.
3. Lift commutator container and commutator from the motor and set aside.
•
Place commutator on a flat, clean surface with the seal facing up.
•
Gently tap on the seal with a small screwdriver until the opposite side of the seal lifts from the groove. Remove the seal and discard.
4. Remove the manifold, rotor set, and divider plate. Remove all seals and discard.
CAUTION: Do not allow rollers to drop from the rotor assembly when removing the rotor from the motor.
•
Remove the drive link from the motor and set aside.
5. Clean all parts in an oil-based solvent and dry using compressed air.
Assembly
1. Apply a light coating of oil to all new seals prior to installation.
2. Place the housing on a clean, flat surface with the output end facing up.
•
Install the dust seal with the lip on the seal facing up.
•
Clamp the housing in a vise with the pilot on the housing facing down.
•
Install the metal backup shim into the bore.
•
Install the backup seal into the housing bore with the lip on the seal facing up.
•
Install the shaft seal into the housing bore with the lip on the seal facing up.
•
Refer to illustration for seal orientation.
3. Install the bearing shims (not shown in illustration) in housing.
•
Install housing bearing.
•
Install the shaft being careful not to cut seal lip with the shaft keyway.
4. Locate the thick disk stamping and set it aside.
• Install one (1) disk stamping into the housing. Make sure that lugs or splines engage those in the housing.
•
Install one (1) friction disk engaging splines on the disk with those on the shaft.
•
Alternate disk stampings and friction disks until all disks except the thick disk stamping are installed.
•
Install the thick disk stamping on top of the disk assembly.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-11
5. Install the small O-Ring seal and large O-Ring seal into corresponding groves in the piston.
•
Install small seal and large seal in corresponding groves over the O-Ring seals.
•
Thoroughly coat the seals and sealing surfaces of the housing with clean oil.
•
Install the piston into the housing with the large O.D. side facing up.
•
Evenly press the piston down. Be careful not to pinch the seals.
IMPORTANT: If the disks and disk stampings are going to be replaced, the stack up on the new disks must be between .620 and .630 (15,7mm and 16mm) (see illustration).
6. Install spring on top of the piston.
•
Install O-Ring seal in groove in the rear surface of the housing.
•
Install the rear shaft bearing. Make sure that the snap ring that retains the bearing rolls faces out.
•
Place the rear housing onto the front housing and line up bolt holes.
•
Hold the motor assembly together, remove from the vise and place in an arbor press.
•
Press down on the rear housing until it contacts the front housing and lock the press
•
Install eight (8) capscrews and torque to 45 ft. lbs. (61 Nm).
7. Install the drive link into the end of the shaft with the tapered end facing up.
•
Place the body seals in the grooves in both sides of the rotor.
•
Place the rotor onto the housing with the side of the rotor with the chamfer in the splines facing the housing.
•
Place the manifold over the rotor with the seal groove side up.
• install the manifold seal.
8. Install the commutator seal into the commutator with the metal side facing out.
•
Use finger pressure to press the seal down flush with the surface of the commutator.
•
Place the commutator onto the manifold and then place the commutator onto the protruding end of the drive link. Make sure that the seal side is facing up.
9. Install the remaining body seal in the groove on the endcover.
•
Install the piston spring into the endcover, then the white backup seal followed by the
O-Ring seal.
•
Line up the alignment pin with the hole in the endcover and press the piston into the endcover.
•
While holding the piston in place, lower the endcover assembly onto the motor. Align the
“V” shaped marks that were made on the housing and endcover before disassembly.
10. Install the seven (7) assembly bolts.
• Tighten bolts in sequence (see illustration)
•
Pre-torque to 10 ft. lbs (13,6 Nm).
•
Final torque to 50 ft. lbs (67,8 Nm).
March 2008
Page 1-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
“ V ” M a rk s for Re ass em b ly
5
4
1
6
TORQUE
S EQUENCE
3
3 4
3 7
2
7
PRE-TORQUE = 10 FT LB S
FINAL TORQUE = 50 FT LB S
25
26
10
27
3 6
11
2 8
12
1 3
3 1
3 0
14
10
3 2
33
29 8
6
19
17
7
20
5
16
21
22
9
24
2 3
Pi s ton
Re a r Ho us ing Mo u nting Su rf a ce
16
1 8
15
3
3 5
.620
.6
3 0
2
4
1
Front Ho us ing
DT710 BRAKE MOTOR COMPONENT S
1. us t S e a l
2. a l B a ck u p S him
3 . B a ck u p S e a l
4. h a ft S e a l
5. m a ll Pi s ton O-Ring S e a l
6. m a ll Pi s ton S e a l
7. a rge Pi s ton O-Ring S e a l
8 . L a rge Pi s ton S e a l
O-Ring e a l
10. Body e a l s ( 3 )
11. M a nifold S e a l
12. Comm u t a tor S e a l
1 3 . O-Ring S e a l
14. B a ck u p S e a l
15. Ho us ing
16. S h a ft Be a ring
17. Friction Di s k s (10)
1 8 . Di s k S t a mping s (9)
19. Thick Di s k S t a mping s (2)
20. Pi s ton
21. S pring s (25)
22. S p a cer S him s (1– 3 )
2 3 . Re a r Ho us ing
24. C a p s crew s ( 8 )
25. Drive Link p a cer
26. Drive Link
27. Rotor A ss em b ly
2 8 . M a nifold
29. Comm u t a tor A ss em b ly
3 0. Endcover Pi s ton
3 1. Pi s ton S pring
3 2. Endcover
33 . I.D. T a g A ss em b ly
3 4. A ss em b ly Bolt s (7)
3 5. S h a ft
3 6. S h a ft Key
3 7. S h a ft N u t
1
15
2 3 4
16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-13
PARKING BRAKE AND TOWING CIRCUIT
Note:
Refer to Parts Section 5 for hose routing.
Machine can be winched or moved short distances in case of power failure at speeds not to exceed 5 MPH (8.05 kph).
PRIOR TO MANUALLY RELEASING BRAKES, INSURE WHEELS ARE
CHOCKED TO PREVENT MACHINE FROM MOVING.
Release Brakes Before Towing:
•
Push in the manual Brake Release valve located on the main manifold.
•
Using the hand pump on the manifold, pump valve until pressure is built.
•
Machine is now ready for towing.
H a nd P u mp
Rele as e V a lve
AFTER RELEASING THE BRAKES, THERE IS NOTHING TO STOP
THE MACHINE’S TRAVEL. MACHINE WILL ROLL FREELY ON
SLOPES. BE ON GUARD AGAINST RUNAWAY.
To Reset Brakes:
•
Brakes will reset when drive function is activated, or reset manually by pulling out the manual brake release valve.
March 2008
Page 1-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
EMERGENCY SYSTEMS AND PROCEDURES
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 BEAMS (SCISSORS)
ASSEMBLY.
BEFORE LOWERING PLATFORM, RETRACT THE DECK EXTENSION.
Emergency Lowering - 3072RT
Emergency Down system is used to lower the platform in case of power or valve failure. To lower the platform, pull the red
“T” handle located at the rear of the machine. Lowering stops when you release the “T” handle.
910 83
Emergency Lowering - 3772RT
The Emergency Down System is used to lower the platform in case of power or valve failure. To lower the platform, perform the following steps:
1. Push down on the toggle switch and hold it to lower the platform to the desired height.
2. Once the platform is fully lowered, release the toggle switch to close the valve
Emergency Lowering S witch
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-15
STEERING CIRCUIT
Note:
Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure.
Refer to Section 3 for Remove and Replace instructions.
Refer to Parts Section 5 for hose routing.
The steering system consists of the following components:
• The wheel motor housings have pivots on the top and bottom, and are mechanically linked together via a tie-rod.
• Steering is accomplished hydraulically by using two (2) double-acting cylinders, and a
4-way 3-position solenoidoperated, hydraulic directional control cartridge valve.
• Maximum steering pressure is limited by the relief valve (refer to
Relief Pressure Adjustment Procedure).
LEFT S IDE
S teer Relief V a lve
Co u nter ba l a nce
V a lve s
S teer Left
GRN/RED
4 W a y3 Po s ition S olenoid
Oper a ted Hydr au lic
Direction a l Control
C a rtridge V a lve
S teer Right
ORG/WHT
S teer Right
Port
S teer Left
Port
March 2008
Page 1-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Steer Cylinder
Note:
Refer to
Cylinder Repair.
Refer to Section 3 for Remove and Replace instructions.
Refer to the Parts Manual, Section 5 for parts list.
There are two (2) cylinders utilized in the steering system. These cylinders are a double acting type which requires oil flow to operate the cylinder rod in both directions. Directing oil forces the piston to travel towards the rod end of the barrel, extending the cylinder rod. By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the cylinder rod will retract.
Wheel Motor
S teer Cylinder
Tie Rod
Motor
Ho us ing
Pivot
Motor
Ho us ing
Motor
Ho us ing
Pivot
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-17
PLATFORM LIFT CIRCUIT
Note:
Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure.
Refer to Section 3 for Remove and Replace instructions.
• The lift system uses the hydraulic pump to obtain proportional lifting function controlled by the lift valve and proportional valve.
• Lowering is single speed controlled by the holding valves on the lift cylinder(s) and regulated by a fixed orifice located on the lift cylinder(s).
• Platform capacity is limited by a hydraulic relief valve in the lift circuit. (Refer to Machine
Specifications or the Hydraulic Schematic for proper setting).
Lift Cylinder
Note:
Refer to Cylinder Repair.
3072RT
One (1) single acting type hydraulic cylinder.
The cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for holding the platform in position. The valve is also externally actuated via a cable for manually lowering the platform.
3772RT
Two (2) single acting type hydraulic cylinders.
Each cylinder has an integrated
2-position, 2-way solenoid operated platform lower valve for holding the platform in position.
The valves are also externally actuated via a toggle switch for manually lowering the platform.
The normally closed holding valve prevents retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.
LEFT S IDE
Lift Relief V a lve
Lift Port
Orifice Under Fitting
Lift
RED/BLU
Co u nter ba l a nce
V a lve s
March 2008
Page 1-18
3 W a y S olenoid
Oper a ted Hydr au lic
S pool V a lve
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
B a r b ed El b ow Fitting
Be a ring
Relief V a
Ret u rn Ho s e
Ho s e Cl a mp
B a r b ed El b ow Fitting lve
Orifice
Ho s e Cl a mp
B a r b
Be a ring
Ho
Be a s e Cl ed Fitting ring a mp
Emergency Down C ab le
Ret u rn Ho s
Ret e u rn Ho
Relief V s a e lve
Down V a lve
Electric a lly
Oper a ted
Down V a lve
Electric a lly
Oper a ted
Down V a lve
3 772RT
UPPER LIFT CYLINDER
WITH BEARING S
Tee Fitting
Orifice
2 B a r b ed S tr a ight
Fitting s a nd
Ho s e Cl a mp s
Ret u rn Ho s e
Pre ssu re Ho s e
Pre ssu re S en s or
3 772RT
LOWER LIFT CYLINDER
WITH BEARING S
Orifice
Pre ssu re Ho s e
Pre ssu re S en s or
Cylinder V a lve M a nifold
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
3 072RT
LIFT CYLINDER
WITH BEARING S
March 2008
Page 1-19
OPTIONAL OUTRIGGERS
Note:
Refer to Section 3 for detailed description and troubleshooting.
Refer to Cylinder Repair.
Outrigger Hydraulic Manifold
The Optional outrigger manifold is located in the Control Module behind the Lower Control Box.
Cylinders
Four (4) double acting type hydraulic cylinders.
Retr a ct Coil
Extend Coil
OUTRIGGER
MANIFOLD
BA
CK
RIGHT
S
IDE
O u trigger
Retr a ct
V a lve
O u trigger
Extend
V a lve
OUTRIGGER EXTEND
OUTRIGGER RETRACT
O u trigger
S towed
S witch
(UP)
O u trigger
Pre ssu re
S witch
(DOWN)
LEFT
S
ID
E
FRONT
March 2008
Page 1-20
BACK
PORT ORL S
LEFT
PORT OR S
RIGHT
PORT ORR
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
CYLINDER REPAIR
CYLINDERS ARE HEAVY. SUPPORT CYLINDERS BEFORE
REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE
MACHINE.
Rod
S e a l s
S e a l s
Pi s ton
Ret u rn to T a nk
Vent to T a nk
Rod
He a d
Pi s ton S ec u ring N u t
Typic a l S ingle Acting Cylinder
S e a l s
B a rrel
Pre ssu re
S e a l s
Pi s ton
Pi s ton S ec u ring N u t
Pre ssu re a nd
Ret u rn
He a d
S e a l s
Typic a l D ua l Acting Cylinder
B a rrel
Removal
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.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-21
Preparation
Take care not to damage rod surface and guard against dirt or other foreign objects entering system.
1. Drain all oil from cylinder.
2. Clean all dirt and grit from outside of cylinder.
3. Insert cylinder into vise.
Cylinder Disassembly
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. Remove nut at the end of the shaft and pull head and piston off of the rod.
5. Remove all seals from the head and piston using a non-sharp seal tool. These tools are available from various seal suppliers.
9. Clean all oil and debris off of the head, piston, shaft, collar and barrel using solvent, rags, and an air hose.
10. 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.
March 2008
Page 1-22
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Cylinder Assembly
CAUTION:
• To insure a quality repair, cylinder parts must be thoroughly cleaned, dry, and free of solvents, and assembly must be performed in a clean area free of dust and contamination.
• To avoid cutting the seals, do not use sharp edged tools during seal replacement. After installing seals allow at least one hour for the seals to restore to their original shape before assembling the cylinder.
• Torque all hardware according to the
Hydraulic Components Torque Table unless otherwise specified.
1. Lubricate all components with clean hydraulic fluid.
2. Install new seal kit components. Install all seals on the head and piston using the nonsharp seal tool.
3. Place a small amount of oil on the inside seals of the head and reinstall it on the shaft, by slipping head over the piston end of the shaft being very careful not to damage the inside seals.
4. Place a small amount of oil on the inside seals of the piston and reinstall it on the shaft by slowly twisting the piston on over the threads of the shaft being very careful not to damage the inside seals.
5. Reinstall the shaft nut; torque 1 ½” nut to 160 ft.-lbs.
6. Grease the outside seals of the head and piston.
7. Reinstall the shaft into the barrel of the cylinder and push in until groove of the head lines up with the slot in the barrel.
17. Reinstall the cylinder retainer. Installation is reverse of removal.
18. Cycle the cylinder using air to check for proper operation.
NOTE:
It is very important to keep all parts clean when working with hydraulic cylinders, even one small piece of dirt or grit can damage the cylinder.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-23
HYDRAULIC MANIFOLD
Note:
Refer to Section 3 for Remove and Replace instructions, and the Parts Section for a list of hardware.
Tag all components as they are removed so as not to confuse their location during reassembly.
Hydraulic Manifold Removal
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 bolts that hold the manifold to the mounting bracket.
5. Remove the manifold block.
Disassembly
1. Remove coils from solenoid valves.
2. Remove valves.
3. Remove fittings, plugs, springs, balls, and orifices.
Cleaning and Inspection
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 O-rings, and proper operation.
4. Replace defective parts and O-rings.
Assembly
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 Locktite #424 or equivalent thread locker on each screw-in orifice.
2. Install valves.
Installation
1. Attach manifold assembly to mounting plate with mounting bolts.
2. Connect solenoid leads (as previously tagged).
3. Connect hydraulic hoses (as previously tagged). Be certain to tighten hoses.
4. Connect the battery.
5. Operate each hydraulic function and check for proper operation and leaks.
6. Adjust valve pressures.
March 2008
Page 1-24
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
DRIVE FORWARD
111 - GRY/RED
LIFT
204 - RED/BLU
GAUGE PORT
S TEER LEFT
10 8 - GRN/RED
FRONT
HIGH TORQUE
3 1 3 - YEL/BLK
DRIVE REVER S E
110 - GRY/BLK
HAND PUMP
BRAKE RELEA S E
S TEER RIGHT
107 - ORG/WHT
LEFT REAR B
RIGHT REAR A
RIGHT REAR B
PROPORTIONAL
333 - PPL/WHT
LIFT PORT
PRE SS URE PORT
- FROM PUMP -
LEFT
HIGH S PEED
21 3 - YEL/WHT
TO TANK
LOAD S EN S E
- TO PUMP -
BACK
RIGHT FRONT A
LEFT FRONT B
RIGHT REAR B
LEFT REAR A
LEFT FRONT A
BRAKE
MANUAL VALVE
FOR BRAKE
RELEA S E
S TEER RIGHT
S TEER LEFT
RIGHT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-25
March 2008
Page 1-26
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 2:
ELECTRICAL
SYSTEM
SECTION 2:
ELECTRICAL SYSTEM ............................................................................ 2-1
Electrical System - General ............................................................................................................................... 2-2
Deutsch Connectors .......................................................................................................................................... 2-3
Battery ................................................................................................................................................................. 2-4
Battery Preventative Maintenance: ................................................................................................................ 2-5
Battery Replacement ..................................................................................................................................... 2-6
Alarms and Switches ......................................................................................................................................... 2-7
Tilt Alarm ........................................................................................................................................................ 2-8
Relays ............................................................................................................................................................ 2-9
Limit Switch ...................................................................................................................................................... 2-10
Optional Outriggers Switches ......................................................................................................................... 2-10
Continuity Checks ............................................................................................................................................ 2-11
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-1
ELECTRICAL SYSTEM - GENERAL
The electrical control system consists of a base control station and a platform control station.
Base Control Station
The base control station will operate all functions except steering and drive.
Platform Control Station
The platform control station will operate all functions including drive/steer and lift/lower. Momentary bidirectional rocker switch on the drive controller handle (joystick) provides the steering function. The control system for operation of drive/steer and lift/lower are electric-over-hydraulic type. The drive system is a proportional system controlled by position and direction of the upper control box controller handle (joystick).
March 2008
Page 2-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
DEUTSCH CONNECTORS
Deutsch connectors used on MEC equipment is 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.
Male Plug Connector
• 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.
Female receptacle Connector
• 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.
Locking Fingers
• 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.
Heavy Duty Plug
• 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.
Crimping
ART_2041
Deutsch Connector Field Kit
MEC part # 84091
• Strip 1/4 in. (6mm) 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.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-3
BATTERY
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 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 OR FUEL VAPORS.
A 12 volt battery supplies the electrical power required to operate the electrical circuits.
Battery Maintenance (in storage)
Follow these procedures for maintenance of battery on a machine not in use:
• Keep battery clean. Electrolyte of batteries should be checked regularly and kept at proper level.
• Never stack one battery directly on top of another because post or container damage can result. 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)
Recommended Intervals
If Stored At: Recharge:
Below 40°F (4°C)
Above 60°F (15°C)
40°-60°F (4°-15°C)
None required
Every month
Every 2 months
March 2008
Page 2-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Battery Maintenance (in use)
Check battery 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 can indicate that a battery has been overcharged, has been subjected to excessively high temperatures, or is nearing the end of its service life.
Battery Preventative Maintenance:
Every 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.
Battery Specific Gravity and Voltage Table
SPECIFIC GRAVITY
EACH CELL
Fully Charged
Fully Discharged
1.280
1.130
VOLTS DC
PER CELL 12V BATTERY
2.10
1.75
12.60
10.50
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-5
Battery Replacement
To remove battery, follow these procedures.
BEFORE REMOVING THE BATTERY FROM THE MACHINE, TURN
OFF THE SELECTOR/ KEY SWITCH. THERE SHOULD BE NO
POWER.
Battery is located in the Control Module of the machine.
Always disconnect the negative battery cable first.
Remove bolts holding battery. Lift the battery from the compartment. Put the battery to the side and dispose of properly.
Prevent damage to battery and/or electrical system;
• Always disconnect the negative battery cable first.
• Always connect the positive battery cable first.
To install battery, reverse the process by positioning the battery in the compartment securely with hold down bolts. Connect battery cables. Always connect the positive cable first.
March 2008
Page 2-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ALARMS AND SWITCHES
Emergency Stop Button
Lift / Drive
There are two red emergency stop buttons: one located on the platform control console and the other on the base control panel. This stop button, when in the “OUT” (ON) position, provides power to the desired control station. Also, the stop button, in the event of an emergency can be used to turn off the power by pushing “IN” (OFF). All functions stop immediately when depressed.
Engine
S t a rt / S top
Turn the button clockwise to reset.
S peed / Tor qu e
Emergency S top
Choke / Glow Pl u g
Gener a tor (Option a l)
Horn (Option a l)
Drive En ab led Indic a tor
(Option a l)
O u trigger Extend/Retr a ct
(Option a l)
NOTE:
As a safety feature, selecting and operating the base controls will override the platform controls, except the platform emergency stop button.
The base control emergency stop button will stop all machine operations, even if the selector switch is switched to platform controls.
R a i s e
(Green)
Lower
(Green)
Throttle
(Green)
Emergency S top
Ho u r Meter
Selector Switch
Machine can be operated from the base/ ground or platform controls. Activation of one or the other is achieved with this switch.
Engine S top
(Red)
Pl a tform /
Ch ass i s
Circ u it Bre a ker
G as oline/Prop a ne (D ua l F u el)
Engine S t a rt
(Green)
Choke/Prehe a t
(Bl a ck)
With the platform controls selected, from the base control panel, if the platform up/lower function is operated there should be NO movement. Similarly with the base controls selected, from the platform control console if any machine function is operated, there should be NO movement.
Diagnostic LED’s
There are Diagnostic LED’s located on the Printed Circuit Board inside the Base
Control box. Each LED represents a function. When the LED is ON the function is ENERGIZED. Refer to the
DIAG-
NOSTIC LED’S label to identify the LED function.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-7
Tilt Alarm
The tilt sensor is located in the Control Module.
Tilt Alarm Audible
An audible warning is activated once machine is in the raised position and reaches an unsafe angle; all functions are disabled in this condition except Platform Lower.
Level B ubb le
Fl a nge N u t
Tilt Alarm Test
Fl a nge n u t
This can be tested by manually tipping the sensor. This
“Push-To-Test” feature enables tilt alarm to be tested without losing its adjustment. Individually push down on each of the three fastened corners of the tilt alarm. There should be enough travel to cause the alarm to sound as
Tilt B as e
Mo u nting Pl a te each corner is pressed. (There is approximately a three second delay). If the alarm does not sound, the flange nuts have been tightened too far. Loosen the nut on the 90° corners and repeat this test procedure.
Tilt Alarm Sensor Adjustment
• Before attempting to adjust the alarm, park the machine on a firm, flat, level surface. Use of an inclinometer is recommended to ensure front and rear of base is level.
• Adjust the three flange nuts until the bubble on top of the sensor is centered.
• Check that the electrical connections are correct and secured tight.
Master Disconnect Switch
Battery disconnect is provided in the Control Module to facilitate servicing and also to prevent unauthorized use of vehicle by using a padlock (to provide security).
Movement Alarm - Light (optional)
This light is activated as soon as the platform control console joystick (controller) lever is moved off the center “Neutral” position.
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.
March 2008
Page 2-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Relays
There are relays located inside the control module and inside the Upper
Controls. (Refer to the Section 5 for relay functions and interconnect).
Upper Control Power Relay
Purpose: Cuts power to Upper Controls when Lower Controls are selected.
Power Rel a y
Torque/Speed Relay
Purpose: Disperses power to Torque
Solenoid Valve when high speed or low speed is selected.
M as ter
Di s connect
S witch
Outrigger Relay (option)
Purpose: Cuts power to Lift circuits until
Outriggers are fully deployed and in firm contact with the ground.
Throttle Relay
Purpose: The electric throttle solenoid receives its power through the Throttle
Relay.
Glow Plug Relay
Purpose: The diesel engine glow plug receives its power through the Glow Plug
Relay.
Tilt
S en s or
Upper
Control s
O u trigger Mod u le (option)
Tor qu e/ S peed Rel a y
O u trigger
Rel a y (option)
Control
Mod u le
Throttle S olenoid
Throttle Rel a y
Glow Pl u g Rel a y (Die s el only)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Power
Mod u le
March 2008
Page 2-9
LIMIT SWITCH
The Limit Switch indicates Platform Height above approximately 10 feet (3m). The switch operates in conjunction with the circuit board located in the lower control box and the proportional circuit board located in the upper control box.
Lower Controls Circuit Board
When the platform is elevated above 10 feet (3m) the limit switch is activated, causing the circuit board to;
• enable tilt sensor cutout operation
• lockout outrigger operation.
Upper Controls Proportional Circuit Board
When the platform is elevated above 10 feet (3m) the limit switch is activated, causing the proportional circuit board to;
• enable elevated drive speed.
OPTIONAL OUTRIGGERS SWITCHES
If the machine is equipped with outriggers, each of the four (4) outriggers has a Stowed Switch and a Pressure Switch.
Outrigger Stowed Switch
• Indicates full retraction of the outrigger cylinder.
•
Drive Function:
The machine will drive when the Outrigger
Stowed Switch on all four (4) outriggers is engaged. If one (1) or more Outrigger Stowed Switch is open (not engaged) the machine will not drive.
•
Lift Function:
If one (1) or more Outrigger Stowed Switch is open (not engaged) the machine will not lift unless all four (4) outriggers are fully deployed.
Outrigger Pressure Switch
• Indicates full deployment of the outrigger.
•
Lift Function:
When deployment begins the Outrigger
Stowed Switches open and lift function is disabled. When all four (4) outriggers reach full deployment the Outrigger Pressure Switches close (engage) and lift function is restored.
O u trigger S towed
S witch
O u trigger
Pre ssu re
S witch
March 2008
Page 2-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
CONTINUITY CHECKS
Check Toggle Switch:
• Disconnect wires and connect one probe of ohm meter to the connection on toggle switch and other probe on other connection.
• When toggle is open, there should be no reading, and when closed there should be a low reading.
Check Selector Switch
• Disconnect wires and connect one probe to common of switch and the other to normally open terminal.
• With the switch flipped, there should be a low resistance.
Check Emergency Stop Button
• Disconnect wires and connect one probe of ohm meter to connection on button and other probe on other connection.
• There should be no reading with the button pressed and a low resistance with it reset.
Check Relay Operation (refer to illustration)
• 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.
Check Limit Switch Operation (refer to illustration)
• Loosen cover screw and lift cover from switch.
• Mark and disconnect wires.
B−
8 5
RELAY DETAIL
(relay energized)
3 0
8 7A
8 7
8 6
B+
ART_2330
• With one probe of ohm meter to “A” and other probe to “B”, release the plunger.
- Low resistance should be seen. Same result should be seen between “C” and “D”.
• With one probe of ohm meter to “A” and other probe to “B”, depress the plunger.
- High resistance should be seen. Same result should be seen between “C” and “D”.
• “E” and “F” should show opposite results as seen on previous tests though there may not be any circuits on these terminals.
SWITCH RELEASED
A - B CLOSED
C - D CLOSED
E - F OPEN
E
F
C
D
A
B
Cover
S crew
Cover
E C A
SWITCH DEPRESSED
A - B OPEN
C - D OPEN
E - F CLOSED
Pl u nger
F D B
ART_2331
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-11
March 2008
Page 2-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 3:
MECHANICAL
COMPONENTS
SECTION 3:
MECHANICAL COMPONENTS ................................................................ 3-1
Torque Specifications ........................................................................................................................................ 3-2
Mechanical Components ................................................................................................................................... 3-3
Base/ Undercarriage ...................................................................................................................................... 3-3
Raising the Machine ...................................................................................................................................... 3-3
Tires ............................................................................................................................................................... 3-4
Drive Motors .................................................................................................................................................. 3-5
Steer Cylinder ................................................................................................................................................ 3-6
Hoses and Cables ......................................................................................................................................... 3-7
Platform Removal .......................................................................................................................................... 3-7
Lift Cylinder Removal and Installation ............................................................................................................ 3-8
Scissor Beam Assembly ................................................................................................................................ 3-8
Engine Maintenance ........................................................................................................................................... 3-9
Diesel Engine ................................................................................................................................................. 3-9
Gasoline and Dual Fuel Engine ................................................................................................................... 3-12
Outrigger Function ........................................................................................................................................... 3-14
Outrigger Calibration .................................................................................................................................... 3-15
GP106 Outrigger Control Module Troubleshooting ...................................................................................... 3-17
Outrigger Module GP106 LED Flash Codes ................................................................................................ 3-18
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-1
TORQUE SPECIFICATIONS
Fasteners
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
9/16 - 18
5/8 - 11
5/8 - 18
3/4 - 10
3/4 - 16
7/8 - 9
7/8 - 14
1 - 8
1 - 14
1/4 - 20
1/4 - 28
5/16 - 18
5/16 - 24
3/8 - 16
3/8 - 24
7/16 - 14
7/16 - 20
1/2 - 13
1/2 - 20
9/16 - 12
CAP SCREW
SIZE
- inches FT. LBS
MIN
TORQUE
MAX
Nm
MIN MAX
111
126
152
238
274
350
407
537
670
31
41
51
65
76
95
6.25
8
14
17.5
26
123
139
168
262
302
386
448
592
740
34
45
55
72
84
105
7.25
9
15
19
28
150
171
206
322
371
474
551
728
908
8.5
11
19
23
35
42
55.5
69
88
103
129
188
228
255
409
523
607
802
1003
61
74.5
97.5
114
142
167
10
12
20
26
38
46
168
203
318
365
466
543
716
894
55
68
86
102
127
148
8.25
10.5
18.5
23
35
41
TORQUE
FT. LBS
MIN MAX MIN
Nm
MAX
185
224
350
402
515
597
790
987
9.5
12
20
25
37
45
60
75
96
112
140
164
228
275
431
495
92
116
138
172
200
631
736
970
1211
11
14
25
31
47.5
55.5
74.5
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
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
- millimeters-
8.8
10.9
FT. LBS
TORQUE TORQUE
Nm FT. LBS Nm
MIN MAX MIN MAX MIN MAX MIN MAX
172
247
332
423
637
872
6
16
29
52
85
130
8
20
35
62
103
158
210
301
404
517
779
1066
8
21.5
39
70
115
176
233
335
450
573
863
1181
11
27
47
84
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
293
398
577
780
992
1488
15
36.5
70
123
198
2027
Torque value s apply to fa s teneer s a s received from the s upplier, dry or when lubricated with normal en g ine oil.
If s pecial g raphite g rea s e, molydi s ulphide g rea s e, or other extreme pre ss ure lubricant s are u s ed, the s e torque value s
do not apply
.
Hydraulic Components
Use the following values to apply torque to hydraulic components. Always lubricate threads with clean hydraulic oil prior to installation.
TYPE: SAE PORT SERIES
#4
#6
#8
#10
#12
#16
March 2008
Page 3-2
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
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
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
MECHANICAL COMPONENTS
Following is a description of the major mechanical components of the scissor lift.
Base/ Undercarriage
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 turn in their mounting , which will indicate sheared retaining pins.
Raising the Machine
THE USE OF SUBSTANDARD LIFTING DEVICES AND/OR JACK
STANDS MAY CAUSE THE MACHINE TO FALL RESULTING IN DEATH
OR SERIOUS PERSONAL INJURY.
The following are needed to safely raise and support the machine;
• a jack with a lifting capacity of two (2) tons or more.
• jack stands with a rating of one (1) ton or more.
To raise the machine
1. Move machine to a firm level surface capable of 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, loosen but
do not remove
lugs 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.
To lower the machine
1. Tighten lugs 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.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-3
Tires
Inspect for cuts, chunking, side-wall damage, or abnormal wear. Any tire faults MUST BE COR-
RECTED before further machine operation. Refer to Parts Manual Section for replacement tires.
FAILURE TO USE APPROVED PARTS MAY CAUSE DEATH OR
SERIOUS PERSONAL INJURY.
NOTE:
Replace tires with the correct tires to maintain the rating of this equipment.
Changing Tires
FOAM FILLED TIRES ARE EXTREMELY HEAVY. CARE MUST BE
TAKEN TO AVOID PERSONAL INJURY.
Always block the wheels before raising the machine.
When a tire change is necessary, follow these tips:
1. Chock tires on one end of machine and raise the other end of machine (see Raising the
Machine).
2. Remove lug nuts and pull wheel off.
3. Install the replacement wheel.
4. Fasten lug nuts and tighten to proper torque. (Refer to machine specifications)
5. Lower the machine and remove the chocks.
March 2008
Page 3-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Drive Motors
There are two (2) hydraulic motors on the front axle and two (2) drive motor brakes on the rear drive axle. These can be damaged or leaks may occur; repair or replace as necessary.
CAUTION:
• Clean all fittings before disconnecting hoses.
• Tag hoses for proper reassembly.
• Plug all openings to prevent contamination.
Front Drive Motors
Remove
1. Raise and support the front end of machine
(see Raising the Machine).
2. Remove the wheel and tire assembly to access drive motor.
3. Remove the hub from the drive motor shaft.
4. Disconnect the cylinder end and tie-rod from the motor housing.
MOTOR
HUB
5. Turn the motor housing to gain access to the motor and hose assemblies.
6. Disconnect hose assemblies from drive motor.
7. Remove the cap screws and remove the drive motor.
Replace
Installation is reverse of removal.
DRIVE
MOTOR
MOTOR
HOU S ING
Rear Drive Motor with Brakes
Remove
1. Raise and support the rear end of machine
(see
Raising the Machine).
2. Remove the wheel and tire assembly to access drive motor.
3. Disconnect hose assemblies from drive motor.
4. Remove the relief valve.
5. Remove the cap screws and remove the drive motor from the housing.
Replace
Installation is reverse of removal.
RELIEF
VALVE
MOTOR
HUB
DRIVE
MOTOR
MOTOR
HOU S ING
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-5
Steer Cylinder
There are two (2) double acting type steer cylinders on this machine. During operation, cylinder(s) should not leak, but a slight damping at the rod seal is acceptable. The pins should be checked for wear.
To replace steer cylinder:
CAUTION:
• Clean all fittings before disconnecting hoses.
• Tag hoses for proper reassembly.
• Plug all openings to prevent contamination.
1. Raise and support the front end of machine (see
Raising the Machine).
1. Disconnect hydraulic hoses and cap them.
2. Remove the nut and bolt holding the steer cylinder to the motor mounting bracket.
3. Remove the pin and cotter pin holding the steer cylinder to the steer axle cross member
(tie-rod).
4. Carefully lift off the steer cylinder.
5. Position the new steer cylinder and install pin and cotter pin to hold cylinder to the steer axle cross member.
6. Install nut and bolt to hold cylinder to motor mounting bracket.
7. Connect hydraulic hoses.
8. To purge air from cylinder;
• place a suitable container beneath the hose connections to catch spilled oil,
• loosen hose fittings slightly,
• actuate steer function,
• when all air is purged, tighten hose connections.
Steer Cylinder Seal Replacement
Refer to Section 1 for seal replacement instructions.
S teer Cylinder
Tie Rod
Wheel Motor
Motor
Ho us ing
Pivot
March 2008
Page 3-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Motor
Ho us ing
Motor
Ho us ing
Pivot
Hoses and Cables
Note:
Refer to
Parts Section 5 for detailed hydraulic hose diagrams.
Inspect all hoses and electrical cables for security and damage. Hoses and cables should be examined for rubbing and chafing.
Check for leaks at fittings. Replace any damaged hose or cable.
1. Tag hoses for proper reassembly.
2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.
3. Torque hose fittings according to the Hydraulic Torque Specification Table.
Platform Removal
1. Raise platform about three (3) feet (1.0 m) and block the arms in the raised position. Also, connect overhead crane by appropriate lifting device to platform.
2. Disconnect all platform wires.
3. Remove the bolts from both platform brackets at the rear of the machine.
4. Slide platform and roll out deck off the machine.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
EV10 8
March 2008
Page 3-7
Lift Cylinder Removal and Installation
Note:
Refer to Section 1 for seal replacement instructions.
Refer to
Parts Section 3 for detailed parts list and illustration.
CAUTION:
• Clean all fittings before disconnecting hoses.
• Tag hoses for proper reassembly.
• Plug all openings to prevent contamination.
1. Raise the scissor arm assembly and support using the maintenance lock.
2. Disconnect hoses and wires and cables to the lift cylinder(s).
3. Use a suitable lifting device to support the lift cylinder.
4. Remove retaining pins and rod end pin.
5. Lift the cylinder from the scissor assembly using a suitable lifting device.
CAUTION: Attach the lifting device to the cylinder body.
Lifting by the rod end will cause the cylinder to extend.
Scissor Beam Assembly
Note:
Refer to Parts Section 3 for detailed parts list and illustration.
Clean the beams once a year or as necessary and inspect along the beam’s surface, especially weld and brackets.
Scissor Beam Removal
1. Remove the platform and lift cylinder(s).
2. Attach a suitable lifting device ti the scissor assembly.
3. Lift the scissor assembly
Installation is reverse of removal.
March 2008
Page 3-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ENGINE MAINTENANCE
Diesel Engine
Always wear protective eye-wear when working with fuel and oil.
Engine should be OFF when replacing filter elements.
For complete service information consult the engine manual that came with the machine.
Oil and Oil Filter- Diesel
Dispose of used oil and filters properly.
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 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 until the dipstick indicates FULL.
Capacity is 5.4 US quarts (5,1 l).
4. Recheck dipstick after running engine. Fill as necessary.
Air Filter Element- Diesel
1. Remove the hoses from the canister.
2. Loosen the bracket and remove the canister.
3. Remove the wing-bolt, remove old filter and replace with a new filter.
Replace and tighten the wing-bolt.
Do not run the engine with the air filter element removed.
4. Replace the canister and attach the hoses. Tighten the canister bracket and hose clamps.
F u el Filter
R a di a tor Dr a in
Cool a nt
Recovery T a nk
Air Filter
C a ni s ter
Oil Dr a in Acce ss
Under C ab inet
Oil Dip s tick
R a di a tor
Fill C a p
Oil Fill
C a p
Oil Filter
Air Filter
Element
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-9
Fuel Filter- Diesel
1. Turn OFF valve at fuel filter.
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.
F u el Filter
Ho us ing
F u el Filter
C a rtridge
W a ter
S eper a tor
¼ T u rn to Remove
F u el Filter
Bleed
S crew
• 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.
Do not attempt to start the engine until
Step 5 has been performed.
F u el Injector
P u mp
Throttle
S olenoid
Idle S top
S crew
.020
F u el Injector
Bleed S crew
High S peed
S top S crew
Lift
P u mp
6. If fuel becomes contaminated with water, use the Water Seperator Valve at the bottom of the fuel cartridge to drain water.
Throttle
Lever
Idle Speed Adjustment - Diesel
1. Bring engine to operating temperature.
Throttle
S olenoid
Pi s ton
Throttle
Clevi
S olenoid
Adj us tment s
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 a nd
Lever
High Speed Adjustment - Diesel
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 3200 with the Throttle Lever against the High Speed Stop Screw.
5. Turn off the engine and reconnect the Throttle Solenoid linkage at the clevis.
6. Hold the High Speed Stop Screw while tightening the jam nut to prevent change in adjustment.
March 2008
Page 3-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Throttle Solenoid Adjustment - Diesel
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.
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.
High S peed
S top S crew
.020
Throttle
S olenoid
Idle S top
S crew
Clevi s
Throttle S olenoid Pi s ton
(Thre a ded Rod)
Throttle S olenoid
Adj us tment
Throttle Lever
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-11
Gasoline and Dual Fuel Engine
Always wear protective eye-wear when working with fuel and oil.
Engine should be OFF when replacing filter elements.
For complete service information consult the engine manual that came with the machine.
Oil and Oil Filter - Gasoline and Dual Fuel
Dispose of used oil and filters properly.
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.
Throttle
S olenoid
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.
Oil Dip s tick
Fuel Filter - Gasoline
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
C a ni s ter
F u el Filter
Cool a nt
Recovery T a nk
Oil Fill
C a p
Oil Filter
Oil Dr a in Acce ss
Under C ab inet
March 2008
Page 3-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Air Filter Element - Gasoline and Dual Fuel
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 wing-nut.
5. Replace the canister cover and lock the catches.
Engine Adjustment - Gasoline and Dual Fuel
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 Adj us tment S crew
Choke Adj us tment S crew
Choke Adjustment - Gasoline and Dual Fuel
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
S olenoid
Adj us tment
Choke
S olenoid
Throttle
Link a ge
4. Allow the choke plate to open slightly and tighten the Choke Adjustment Screw.
Throttle S olenoid
5. Check Choke Solenoid operation to ensure that the choke plate travel does not prevent the Choke Solenoid from retracting fully.
Idle Speed Adjustment - Gasoline and Dual Fuel
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.
High Speed Adjustment - Gasoline and Dual Fuel
1. Bring the engine to operating temperature.
2. Loosen the adjusting nuts on the Throttle Solenoid.
3. Have an assistant press the Throttle Button on the Lower Controls panel.
4. Adjust the nuts on the Throttle Solenoid Piston until the engine RPM is 3850±50.
5. Tighten the nuts to secure the adjustment.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-13
OUTRIGGER FUNCTION
The outriggers on the RT series MEC Scissor Lifts are a One-Touch Activation system. To deploy the outriggers, simply push the outrigger toggle switch down until the outriggers level the unit and the engine returns to idle. You are now ready to lift the platform. The outrigger control module is a
“smart” unit, which will level the unit in all but extreme terrain so you don’t have to attempt to level it yourself.
Operational Characteristics
· To deploy the outriggers, push the Outrigger Switch down and hold until the engine returns to idle. The unit will self-level.
· The outrigger legs can not be operated individually.
· The outriggers system will not operate when the platform is elevated above approximately
10 feet (3m)
· Travel is locked out when the outriggers are deployed. A Drive Indicator Light, above the outrigger switch, will illuminate when the outriggers are fully retracted.
· The engine will not return to idle when the outriggers are fully retracted. The drive indicator light is your signal that the outriggers are fully retracted.
· If the slope of the terrain is in excess of the outrigger’s leveling capabilities, the outrigger control system will continue to attempt to level and the engine will not return to idle. In this case, if the platform remains outside of the pre-described tilt sensor parameters, the unit will not elevate above 6 feet (2m) and the alarm will sound, indicating the out-of-level situation.
· The outrigger system uses a Top-out limit switch and a Pressure switch on each leg to monitor their respective positions.
· Each outrigger leg uses a Retract valve and an Extend valve to control cylinder stroke.
These are located under the protective cover atop the outrigger leg.
· A 4-way, 3-position valve, on the outrigger hydraulic manifold controls the direction of oil flow to the outrigger legs.
· The GP106 Outrigger Control Module controls all outrigger valve and interlock duties as well as sensing unit level.
· Diagnosis of the GP106 Outrigger Control Module is possible by counting the number of flashes from the red LED and referring to Outrigger Module GP106 LED Flash Codes at the end of this section. Diagnosis and calibration of the outrigger module can also be done through the use of the EZ-Cal scan tool MEC part # 90888. (See GP106 troubleshooting in this section)
· If the GP106 Outrigger Control Module is ever replaced or removed or if you suspect that it requires calibration, you must use the EZ-Cal scan tool and the following directions to calibrate the outrigger module.
March 2008
Page 3-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Outrigger Calibration
Before attempting the calibration procedure, move the machine to an area that is level as measured by a spirit level or other leveling device. An EZ-Cal hand-held device (MEC part # 90888) is required to carry out all calibration procedures on the GP106 Outrigger Control Module.
Calibrator
MEC P/N 90888
S YMBOL KEY FUNCTION S
E S C/ENTER BUTTON S
To move ba ck a nd forth b etween men u a nd sub -men u
LEFT/RIGHT BUTTON S
S elect men us a nd s etting to b e a dj us ted
UP/DOWN BUTTON S
Adj us t s etting v a l u e s
GP106 Outri gg er Control Module
Connect s to P1
O u trigger s Rel a y
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-15
Outrigger Tilt Sensor Calibration
The integral tilt sensor of the GP106 Outrigger Control Module must be calibrated to compensate for variations due to installation and vehicle construction. This procedure must be done if the control module is ever repositioned or replaced.
a. Drive machine to level ground.
b. Plug EZ-Cal into connector P1 on the control module.
Display reads HELP: PRESS ENTER.
c. Press right arrow to ACCESS LEVEL 3, Press Enter.
Display reads CODE 0000.
d. Press up and right arrows to enter code 1775, Press Enter.
Display reads ACCESS LEVEL 2.
e. Right arrow to MACHINE SETUP, Press Enter.
Display reads CHANGE DEFAULTS.
f. Right arrow to CALIBRATE LEVEL, Press Enter.
Display reads CALIBRATE LEVEL: YES:ENTER,NO:ESC.
g. Press Enter. Display reads TILT 0.0’,0.0’ h. Press ESC, ESC i. Disconnect EZ-Cal from the outrigger control module.
Outrigger calibration is now complete.
March 2008
Page 3-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
GP106 Outrigger Control Module Troubleshooting
When the
EZ-Cal
hand-held device is connected to the
GP106
control module, the first menu available is “HELP” – just press the
ENTER
button to see a message describing the current status of the
GP106
; this can be very helpful in diagnosing problems with the system.
When an
EZ-Cal
is unavailable, an LED on the
GP106
flashes to provide limited diagnostics
The following messages might be displayed:
EVERYTHING OK
The
GP106
detects no problems.
If problems are being experienced with the system, use the DIAGNOSTICS menus to check for wiring problems.
B+ SUPPLY TOO LOW
The
GP106
is designed for use on 12V and 24V battery powered vehicles; it cannot operate with a supply below about 9V.
The “BATTERY” voltage can be checked in the “SYSTEM” menu (available in the
“DIAGNOSTICS” menu).
CANNOT LEVEL: BAD TILT SENSOR
Ensure that the
GP106
is correctly installed – if it is wrongly oriented, its integral tilt sensor will be unable to measure vehicle tilt correctly.
CHECK OUTRIGGERS SUPPLY (P4-9)
An auto-level or auto-retract signal has been detected by the
GP106
(on P2-5 or P2-6) but there is no supply on P4-9 to power the outrigger legs.
OUTRIGGERS MANUALLY CONTROLLED
The outrigger system cannot be manually controlled, but this message may appear. It indicates a wiring problem to terminal P2-2.
OUTRIGGERS CANNOT BE MOVED
The outrigger system will be unable to operate if the machine is on a steep slope greater than ten (10) degrees.
RELEASE OUTRIGGER DEMAND!
The
GP106
is waiting for an active signal on P2-5 or P2-6 to be released (due to activating a switch when power is applied, or in conjunction with manual use of the outriggers, or activating both switches together).
VEHICLE TILTED
Either the “X” or “Y” tilt (measured by the
GP106
integral tilt sensor) exceeds three degrees.
This does not affect operation of outriggers.
OUTRIGGER WIRING FAULT
The system has detected voltage on P2-2 but voltage is not present on P2-5 or P2-6. Check wiring to P2-5/6.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-17
Outrigger Module GP106 LED Flash Codes
The
GP106
has a built-in LED to provide simple diagnostics when no
EZ-Cal
is available. Please note that the use of an EZ-Cal provides significantly better diagnostics through the HELP messages listed previously.
LED on steady
This indicates power to, and no fault with, the
GP106
LED off always
This indicates no power to the
GP106
LED flash code 1
Wiring Fault. Check connection to P2-2.
LED flash code 2
This indicates a fault with the switch inputs to the
GP106
. Check wiring to connector P2.
LED flash code 3
This indicates a fault with the “stable” output of the
GP106
– a short to the supply has been detected. Check wiring from pin P2-8
LED flash code 4
This indicates that the outriggers cannot be operated because the machine is on a slope greater than ten (10) degrees. Move machine to a different location.
LED flash code 5
This indicates a fault with the “stable” output of the
GP106
– a short to 0V (ground) has been detected. Check wiring from pin P2-8
LED flash code 6
This indicates a fault with the “auto” inputs of the
GP106
– check the wiring to pins P2-5 &
P2-6
LED flash code 7
This indicates a fault with the supply to the
GP106
– check battery supply at least 8V on pins
P2-12 & P4-9
LED flash code 8
This indicates that the machine is not level. It is not a fault and will not affect operation of outriggers.
LED flash code 9
This indicates that the
GP106
is performing startup tests.
March 2008
Page 3-18
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 4:
TROUBLESHOOTING
SECTION 4:
TROUBLESHOOTING ............................................................................. 4-1
Troubleshooting ................................................................................................................... 4-3
General Troubleshooting Tips ............................................................................................ 4-3
Common Causes of Hydraulic System Malfunctions: ....................................................... 4-3
Hydraulic Pressure Adjustment Procedures ..................................................................... 4-9
Proportional Speed Adjustment.........................................................................................4-12
Controls and Switches ........................................................................................................4-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-1
HYDRAULIC MANIFOLD
DRIVE FORWARD
111 - GRY/RED
LIFT
204 - RED/BLU
GAUGE PORT
LEFT REAR B
RIGHT REAR A
RIGHT REAR B
PROPORTIONAL
333 - PPL/WHT
LIFT PORT
LIFT RELIEF
RV1
S TEER RELIEF
RV2
PRE SS URE PORT
- TO PUMP -
DIAGNO S TIC LED s
S TEER LEFT
108 - GRN/RED
FRONT
LEFT
HIGH TORQUE
3 1 3 - YEL/BLK
DRIVE REVER S E
110 - GRY/BLK
HAND PUMP
BRAKE RELEA S E
S TEER RIGHT
107 - ORG/WHT
PULL VALVE
BRAKE RELEA S E
HIGH S PEED
21 3 - YEL/WHT
TO TANK
LOAD S EN S E
- TO PUMP -
BACK
RIGHT FRONT A
LEFT FRONT B
RIGHT REAR B
LEFT REAR A
LEFT FRONT A
COUNTERBALANCE
VALVE S
RIGHT
BRAKE PORT
S TEER RIGHT
S TEER LEFT
March 2008
Page 4-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
TROUBLESHOOTING
The 3072RT and 3772RT are designed for ease of diagnostics. There is a terminal strip located under the work platform for checking signals to and from Upper Controls. There are also LED’s located in the Lower Controls box to indicate outputs from the circuit board.
Diagnostic Example: if the lift LED does not illuminate when attempting to lift, either the main power is not on, or board is not receiving a signal for lift. If LED is illuminated but machine does not lift, there would be an electrical problem between the Circuit board and the valve, or a hydraulic problem. The main valve block is equipped with a quick disconnect gauge port to help diagnose the hydraulic system.
General Troubleshooting Tips
Before investigating a malfunction, check the following items:
• Check that battery switch is turned on.
• Check that battery connections are secure and battery if fully charged.
• Check that the emergency stop button is released (UP/OUT position).
• Check that the hydraulic fluid is at the correct level.
• Check that the circuit breaker is in the “ON” position (not tripped).
Common Causes of Hydraulic System Malfunctions:
• Incompatible hydraulic fluids mixed, destroying the additives and causing varnish build up, resulting in the valves sticking.
• Water in the hydraulic fluid due to a damp climate.
• Improper hydraulic fluid used. Viscosity too high in cold climates. Viscosity too low in warm climates.
• Hydraulic oil contaminated with debris - filter change interval neglected.
NOTE:
Mobil Fluid 424 Hydraulic Oil, is a multiple viscosity oil that is light enough for cold climates and resists thinning in warm climates. Only Mobil Fluid 424 or equivalent must be used. Substituting with a lower grade oil will result in pump failure.
Following is a step by step basic troubleshooting guide.
NOTE:
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 covered/plugged during maintenance activities.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-3
PROBLEM
General Power Issue
No operation from upper or
Upper Control station
PROBABLE CAUSE
Main battery switch turned off
Emergency switch pushed in or Ignition switch turned off
Dead Battery
Blown fuse
Circuit breaker tripped
Damaged Upper Controls box harness
REMEDY/SOLUTION
Located left of Lower Controls box
Upper or lower Emergency Stop switch will cut all power as will the Ignition switch in the Platform Controls box
Charge battery
Sealed unit just below Lower Controls box
Reset - Located in Lower Controls box panel
Inspect from harness plug to terminal strip under platform
Test/replace. Located inside Lower Controls box
Replace circuit board in Lower Controls box
Failed 25 AMP diode
Failed Power Relay on Circuit board
Functions from Upper
Controls but not from Upper
Controls
Faulty relay, located in Upper Controls box
Interlock switch (Joystick)
Check power on wire 101 from Key switch
Check power on wire 101A from relay to Joystick plug
Check power to RED wire (power to switch) and power to
PURPLE wire (power out of switch) at Joystick plug
Lift/Lower
Platform will not Raise
Platform will not lower or lowers slowly
Lowers but not completely
(3772RT only)
Excessive weight on Platform
Lift Relief valve out of adjustment
Lift Valve SV-1 not energized
Lowering valve SV-5 stuck open
(located at base of lift cylinder CYL-1)
Level Sensor out of level
(platform elevated above 6')
Main system pressure inadequate
Proportional control out of adjustment
(High Range Adjustment)
Maintenance Lock in maintenance position
Lowering valve not energized
Lowering valve not shifting
Lowering orifice (ORF-3) plugged
Down valve on one cylinder inoperative
Reduce weight to within platform capacity
Adjust relief valve to rated capacity
Check lift circuit from Upper Controls box to SV-1 valve
Check and remove contamination, E-Down cable damaged or replace valve
Reposition machine to firm level surface,
Check Level Sensor function
Check pump output pressure (see Hydraulic Pump Adjustment in this section)
See section on
Proportional Controller Adjustment in this section
Return Maintenance Lock to the stowed position
Check lowering circuit from Upper Controls box to Lowering valve SV-5
Clean debris, replace
Clean orifice
Check valve coils
Emergency lowering not working
3772RT ONLY
Lowers but not completely
March 2008
Page 4-4
E-Down cable broken or frayed (3072)
Lowering valve not shifting
Lowering orifice (ORF-3) plugged
E-Down battery discharged
Valve coil failed on either cylinder
Down valve on one cylinder inoperative
Replace E-Down cable
Clean debris, replace
Clean orifice
Charge, check charge diode & connections
Test, replace
Check valve coils, wiring
continued…
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
PROBLEM
Drive
No drive function
PROBABLE CAUSE REMEDY/SOLUTION
(with outriggers option)
No drive elevated
(with outriggers option)
Slow drive with Platform stowed
Drive in one direction only
No low speed (high torque mode)
Valve SVD1 not energizing Check forward/reverse LEDs lighting up at circuit board inside
Lower Controls box
Check connections at valve
Check voltage at valve
Check ground to valve
Check valve for proper functioning
Check OD1 brake orifice for contamination
See Proportional Controller Adjustment in this section brakes not releasing
Proportional Control out of adjustment
(High Speed adjustment)
Outriggers lowered
Outrigger Retracted switch/s inoperative
Check Drive Enable light - raise outriggers
Check enable light on Platform Controls box
Check outrigger switches located on top of each outrigger jack for continuity
See Proportional Controller Adjustment in this section Proportional Control out of adjustment
(Low Range adjustment)
Jumper - axle float bypass missing from circuit board, Lower Controls box
Outriggers lowered
Unit out of level
High torque enabled
Limit switch not functioning
Forward Reverse LEDs not lighting up at Lower Controls circuit board? Install jumper wire.
Check Drive Enable light - raise outriggers
Lower and reposition the machine.
Check Level Sensor malfunction
Check Speed/Torque switch in Platform Controls Box
Limit switch at left-rear of base
Check continuity between wire 2 TAN/ORG and wire 20 RED/
WHT. Continuity = platform stowed.
12 volts to “R” terminal on circuit board in Platform Controls box = High Range
See
Proportional Controller Adjustment in this section
Upper Controls circuit board running in slow speed mode
Proportional Control out of adjustment
(Low Range adjustment)
Engine not running to full potential
Wheel motor/s not functioning correctly
RV3 or RV4 not adjusted correctly
Rev-Up or FWD-Down micro-switch failure
Drive valve SVD1 not energizing in one direction
Counterbalance valve CBV1 or CBV2 not functioning correctly
Speed/Torque selector switch inoperative
Valve SV3 not functioning
EP1 poppet valve not functioning
Check engine operation as per engine manufacturer guidelines
Inspect wheel motors for excessive bypass
Check and adjust relief valves
Check micro-switches on Joystick controller for function or adjustment
Check 12 volts to appropriate coil, check coil, check valve function
Swap Counterbalance valves to see if functioning direction changes.
Check for 12 volts on terminals 2 & 3 of Speed/Torque switch in Platform Controls box with drive enabled
Check for 12 volts and ground to valve
Check for faulty valve spool
Check or replace valve
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications continued…
March 2008
Page 4-5
Drive
PROBLEM
No Mid Speed
No High Speed
PROBABLE CAUSE
SV3 or SV4 powered and/or shifted
Speed/Torque selector switch malfunction
Speed/Torque selector switch inoperative
Faulty diode block DB1
Valve SV4 not functioning
EP2 poppet valve not functioning
REMEDY/SOLUTION
These valves should not have 12 volts, in mid-speed, check valve function
Should not have power at terminals 1 & 3 of Speed/Torque switch in Platform Controls box with drive enabled
Check for 12 volts on
all
terminals of Speed/Torque switch in
Platform Controls box with drive enabled
Test DB-1 in Platform Controls box.
Check voltage and ground to valve check for faulty valve spool
Check or replace valve
Multi-Function
No drive or Lift function from
Upper Controls with steer operational
PWM circuit board in Platform Controls box not functioning correctly
Proportional valve malfunction
Check battery + and - terminals at board.
Check PWM output at A terminal.
Check connections between A terminal and Proportional valve.
Check, for 1 AMP at valve during full Joystick stroke. Replace
Proportional valve SP-1
Check, replace valve EC1
No steering With Drive operational
EC1 pressure compensation valve not functioning
SV2 not functioning
Faulty lift/drive selector switch
Faulty steer switch
Steering Cylinder/s internal leakage
RV1 steer relief valve not functioning
Check voltage and ground to valve
Check for faulty SV2 valve
Check power on wire #25A on switch
Check switch in Joystick handle
Check for internal leakage - repair
Check adjustment or replace
March 2008
Page 4-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications continued…
PROBLEM
Diesel Engine
Starter inoperative
PROBABLE CAUSE
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
No Engine start:
Starter operates
Low diesel fuel level
Fuel valve closed - located at fuel tank
Air in injector lines
Fuel filter clogged
Run solenoid not activating
Engine starts but dies when starter disengaged
Glow plugs inoperative
Faulty oil pressure switch
Faulty Fuel solenoid
REMEDY/SOLUTION
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill diesel tank, (see Section 3 for Fuel Priming instructions)
Open valve
See
Section 3 for Fuel Priming instructions
Replace fuel filter
Check power at WHT/BLK wire #320 from starter to run solenoid while cranking (WHT/BLK pull in, GRN/WHT hold wire)
See “
Glow Plugs Inoperative” in this section
Check switch and wiring
Check 12 volts on GRN/WHT wire #116 -
Replace Fuel Solenoid
Dual Fuel Engine - Gas
Starter inoperative
No Engine start:
Starter operates
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
Low gas level
Fuel valve closed - located at fuel tank
Clogged Fuel Filter
Faulty fuel selector switch
Faulty fuel shut off solenoid
Faulty fuel pump
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill gas tank
Open valve
Replace fuel filter, located on fuel hose below engine
Check power to BLK/WHT wire #23 while cranking engine
Check power and ground at gas solenoid,
Check solenoid operation located in float bowl
Check power and ground at fuel pump during engine crank.
Check fuel pump operation
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications continued…
March 2008
Page 4-7
PROBLEM
Dual Fuel Engine - LP
Starter inoperative
PROBABLE CAUSE REMEDY/SOLUTION
No Engine start:
Starter operates
Propane tank empty or valve closed
Faulty carburetor mounted Propane solenoid
Faulty propane shut off solenoid
Engine runs rough, no power, poor throttle response
Faulty fuel selector switch
Clogged Propane Filter Located under the propane tank shelf
Vapor withdrawal tank installed
Low engine coolant level
Clogged Propane Filter Located under the propane tank shelf
Propane regulator malfunction
Throttle, Choke & Glow Plugs
Throttle does not operate Misadjusted Throttle Solenoid (misadjusted throttle solenoid will result in the failure of the solenoid) maladjusted
Throttle Solenoid failure
Throttle Relay (located on side of engine)
Failed diode block (Large) located in Upper
Controls box
Failed Throttle solenoid
Clean, tighten cables
Check power to wire #20 at Key switch while cranking
Check power to YEL/RED #220 wire at starter,
Check ground cable to engine bell housing
Check
input
on plug A pin-17, ORG/RED wire #20 on Lower
Controls circuit board
Check
output
on plug B pin-1, YEL/RED wire #220 on Lower
Controls circuit board.
12 volts in - 0 volts out = replace circuit board
Fill tank - open valve
Check power and ground at Proportional solenoid,
Check solenoid operation
Check power and ground at Shut-off solenoid,
Check solenoid operation
Check power to BLU/WHT wire #22 while cranking engine
Turn Off Propane valve before filter inspection or replacement
Replace tank with Liquid withdrawal type
Check, add coolant.
Turn Off Propane valve before filter inspection or replacement
Replace Propane Regulator
Adjust throttle linkage
NOTE: throttle linkage adjustment is critical on diesel engine)
Check + and - to solenoid while operating Throttle
Test for 12 volts on RED wire #00 and ORG wire # 225 while throttle is requested
Power on these wires should = 12 volts on ORG/BLK wire 325
Test and/or replace diode block
Check for Throttle LED on Upper Control board
Replace Throttle Solenoid Throttle does not remain energized
Choke does not operate
Battery Cables loose or corroded
Key switch not functioning
Starter not functioning
Circuit board relay failed
Glow Plugs inoperative
March 2008
Page 4-8
Choke Solenoid failure
Failed Choke switch
Failed Glow Plug Switch
Failed Glow Plug Relay - located on side of engine
Failed glow plugs
Check + and - to solenoid while operating Choke
Try Choke switch on opposite control panel
Check for Choke LED on Lower Controls circuit board
Try Glow Plug switch on opposite control panel,
Check for LED on Lower Controls circuit board.
Test for 12 volts on RED #00 wire and on ORG/WHT wire #124 while operating glow plugs.
Power on these wires should = 12 volts on ORG/BLU wire 224
Check for 12 volts at glow plugs while operating glow plugs.
end Trouble Table
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
HYDRAULIC PRESSURE ADJUSTMENT PROCEDURES
•
Before attempting to check and/or adjust pressure relief valves, operate the machine for
15 minutes or long enough to sufficiently warm the hydraulic oil.
•
Insert a 0-5000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no. 8 434
Pressure Adjustment Table
MODEL
3072RT
3772RT
MAIN
2800 PSI 193 bar
2800 PSI 193 bar
LIFT
2500 PSI 172,4 bar
2500 PSI 172,4 bar
STEER
1500 PSI 103,4 bar
1500 PSI 103,4 bar
STAND-BY
500-550 PSI 35-38 bar
500-550 PSI 35-38 bar
LEFT S IDE
G au ge Port
(Te s t Port)
RV1
Lift Relief
RV2
S teer Relief
Pre
M a in Relief
S ssu t a nd-By re Relief
RV4
Overpre ssu re Relief
LIFT CYLINDER
MANIFOLD, 3 772
PUMP
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-9
Pump Adjustment
The Hydraulic Pump used in this model is a Variable Displacement, Pressure Compensated,
Piston type pump. Proper adjustment is critical for normal operation of the machine. The following paragraphs will guide you through the various steps however, you must perform all steps, in their listed sequence, in order to achieve proper adjustment and machine performance.
Main Relief and Standby Adjustments
1. Start engine and operate the unit for 15 minutes or until the hydraulic oil is warm.
2. Insert a 0 – 5000 PSI (0-345BAR) gauge onto the manifold pressure gauge port.
3. Remove the acorn nut from the Main Relief adjustment screw. Loosen the jam nut and turn the screw counterclockwise 3 turns. Tighten the jam nut and install the acorn nut.
4. Remove the acorn nut from the Standby adjustment screw and loosen the jam nut. Turn the screw clockwise 3 turns or until the needle on the gauge stops climbing. At this point the gauge is reading full main relief pressure.
5. Access the Main Relief screw again and adjust it until the gauge settles at 2 8 00 PSI
(193.5bar). Tighten the jam nut and install the acorn nut.
6. Check the gauge reading again to ensure the setting did not change.
7. Turn the Standby adjustment screw counterclockwise until the gauge reads 550 PSI
(3 8 bar). Tighten the jamb nut and install the acorn nut.
8 . Check the gauge reading again to ensure the setting did not change.
Pump Displacement Adjustment
This adjustment is set at the factory and should not be tampered with. The Displacement adjustment controls the maximum amount of oil flow that the pump will produce per revolution.
Excessive flow will result in severe engine loading and stalling. Reduced flow will result in slower functions with no engine loading. If you suspect that the sitting is incorrect, please call MEC
Product Support at ( 8 00) 3 8 7-4575 for assistance.
Main Relief
See Pump Adjustment Procedure.
Stand-By Pressure
See Pump Adjustment Procedure.
Lift Relief (RV1)
The Lift Relief valve is located on the left-side, center of the valve manifold. It will be necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE CAP WHILE
THE ENGINE IS RUNNING WILL RESULT IN OIL LEAKAGE.
To check Lift Relief valve setting, park the machine on a firm level surface free from overhead obstructions. Using the lift switch on the lower panel, elevate the platform to full elevation. While maintaining the lift command, record the reading on the gauge.
March 2008
Page 4-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Steering Relief (RV2)
The steering Relief valve is located on the left side, lower of the valve manifold. It will be necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE
CAP WHILE THE ENGINE IS RUNNING WILL RESULT IN OIL LEAKAGE.
To check Steering Relief valve setting, operate steer in one direction. While maintaining the steer command, record the reading on the gauge.
Lift Cylinder Overpressure Valves (RV4) 3772RT Only
The Lift Cylinder Overpressure valves are located on each of the lift cylinder valve blocks on the
3772RT model only.
Proper valve adjustment is not possible by the consumer. Considering their importance to the safe operation of the machine, they must not be tampered with. If the valve is suspected to be out of adjustment or tampered with, it must be replaced.
Setting Counterbalance Valves
1. Loosen the locknut on one of the valves.
2. Turn the adjustment screw counterclockwise (to the left) until it reaches the internal stop and the screw will turn no further.
3. Turn the adjustment screw clockwise (to the right) 2¾ turns.
4. Tighten the locknut while holding the adjustment screw in position to prevent it from rotating.
5. Repeat steps 1 through 4 on the other Counterbalance valve.
6. Adjustment is complete.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Co u nter ba l a nce
V a lve s
March 2008
Page 4-11
PROPORTIONAL SPEED ADJUSTMENT
Proportional Circuit Board Adjustment should only be performed after all other components are deemed to be in proper working order.
There are many factors that may contribute to excessively fast or slow drive speeds. Proportional
Circuit Board Adjustment should only be performed after all other components are deemed to be in proper working order and not contributing to abnormal driving speeds. Failure to do so may result in incorrect speeds once the offending component has been repaired.
Circuit Board Setting Test Procedure
Before you begin, ensure there are no overhead obstructions preventing lift to full height. Lay out a course measured at 20 feet (6 meters) long. Ensure there are no obstructions preventing a straight travel over the distance of the course including leading up to and away from the course.
Try not to steer while driving the timed course.
RUN-IN 20 FT (6m) RUN-OUT
High Speed Drive Test:
With the platform fully lowered, drive the machine over the course, crossing the start line at full speed. Record the time it takes for a (predetermined) point on the machine to cross both lines and compare with the chart below using the ‘High Range’ column figure.
Elevated Speed Drive Test:
Elevate the platform above 12 feet (3.6 meters). Drive the machine over the course, crossing the start line at full speed. Record the time it takes for a (predetermined) point on the machine to cross both lines and compare with the chart below using the ‘Low Range’ column figure.
Speed Adjustment Table: 20 ft. (6 m) Course
TRIM POT
High Range
Low Range
TRAVEL TIME
IN SECONDS
3.5 to 4.0
27 to 33
March 2008
Page 4-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Adjustment Procedure
Note:
Proportional Controller adjustments should only be made when the possibility of unauthorized tampering exists or after the
Proportioning Valve or Proportional Circuit board was replaced. Though testing the proportional output should be part of routine maintenance, adjustments should not be necessary as a routine maintenance procedure.
The Trim Pots are located in the Platform Controls box
(see illustration).
PLATFORM
CONTROL S
ADJU S TMENT
S CREW
HI RANGE
1. Turn the RAMP trim pot counterclockwise until a clicking noise is heard.
2. Ensure there are no overhead obstructions preventing lift to full height. Select LIFT mode, pull the enable and move the Joystick in reverse slowly to the point that the engine accelerates and hold it at that point. While holding the Joystick in that position, adjust the THRESH trim pot until the platform does NOT lift. Once adjusted, slight additional reverse motion of the Joystick should result in very slow and controlled lift action.
THRE S H
LO RANGE
RAMP
•
Counterclockwise trim pot adjustment increases the amount of Joystick travel before platform movement.
• Clockwise trim pot adjustment will allow platform movement sooner in the
Joystick travel.
3. If the machine was slow in the High Speed portion of the test, turn the HI RANGE trim pot clockwise until a clicking noise is heard.
4. If the Elevated Speed Drive Test resulted in speeds other then those listed, turn the LO
RANGE trim pot clockwise to increase elevated drive speed or counterclockwise to decrease elevated drive speed to the proper speed. Repeat the Elevated Speed Drive
Test.
5. The RAMP trim pot controls the smoothness of the motion start-up and linear ramp-up response. Turn the RAMP trim pot clockwise until the slowest machine start-up can be achieved while maintaining good proportional ramp-up through the travel of the Joystick.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-13
CONTROLS AND SWITCHES
Power Rel a y
Engine
S t a rt / S top
MicroS witche s
S teering
En ab le S witch
Rever s e/Down
Rocker S witch
Forw a rd/Up
Rocker S witch
Potentiometer
Lift / Drive
S peed / Tor qu e
Emergency S top
O
Drive En
(Option u
Choke / Glow Pl u g
Gener a tor (Option a l)
Horn (Option a l) trigger Extend/Retr
(Option a a l) ab l) led Indic
R a i s e
(Green)
Lower
(Green)
Throttle
(Green)
Engine S top
(Red)
Pl a tform /
Ch ass i s
Emergency S top
Ho u r Meter
Circ u it Bre a ker
G as oline/Prop a ne (D ua l F u el)
Engine S t a rt
(Green)
Choke/Prehe a t
(Bl a ck) a a tor ct
March 2008
Page 4-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 5:
SCHEMATICS
SECTION 5:
SCHEMATICS .............................................................................................. 5-1
Hydraulic Schematic ............................................................................................................ 5-2
Main Hydraulic Manifold .................................................................................................... 5-4
Optional Outriggers Hydraulic Manifold ............................................................................ 5-5
Electric Schematics ............................................................................................................. 5-6
Circuit Board ..................................................................................................................... 5-8
Controls............................................................................................................................5-10
Engine ..............................................................................................................................5-13
Optional Outriggers ..........................................................................................................5-15
Optional Generator ..........................................................................................................5-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-1
HYDRAULIC SCHEMATIC
Callout
CYL2
MA3
SV5
ORF3
LF
LR
RV3
RF
RR
RV3
P1
CYL3
MA5
SV6
RV4
ORF4
CYL4
MA4
SV6
RV4
ORF6
FL1
CYL1
CYL5
SV7
SV8
SV9
Description
Lift Cylinder Components (3072RT)
Cylinder
Manifold, Lift Cylinder
Solenoid Valve - 12V Cable Attach
Orifice - 0.073
Lift Cylinder Components (3772RT)
Cylinder, Upper
Manifold, Lift Cylinder, Upper
Solenoid Valve - 12V Dual Coil
Relief Valve - 3200 PSI
Orifice - 0.073
Cylinder, Lower
Manifold, Lift Cylinder, Lower
Solenoid Valve - 12V Dual Coil
Relief Valve - 3200 PSI
Orifice - 0.047
Wheel Motor Components
Wheel Motor - Left Front
Wheel Motor - Left Rear
Relief Valve - 3000 PSI - Cross Port Relief
Wheel Motor - Right Front
Wheel Motor - Right Rear
Relief Valve - 3000 PSI - Cross Port Relief
Pump - Variable Displacement
Pressure Compensated
Return Filter - 10 Micron
Cylinder, Steering
Optional Outriggers Components
Outrigger Cylinder
Solenoid Valve, Poppet N.C.
Solenoid Valve, Poppet N.C.
Spool Valve, 4Way - 3 Position
Callout
MA1
SVD1
SV1
SV2
SV3 - SV4
SP1
RV1
RV2
PD1 - PD2 - PD3
EP1 - EP2
MP1
LS1 - LS2 - LS3
CBV1 - CBV2
CL1
CL2
CL3
HP1
FD1 - FD2
EC1
CV1 - CV2
OD1
OPL2
OPL5 - OPL6
ORF5
Description
Manifold Components
Manifold, Main Valve Block
Spool Valve, Drive, 4 Way - 3 Position
Spool Valve, Lift, 3 Way
Spool Valve, Steer, 4 Way - 3 Position
Spool Valve, Series Parallel, 4 Way - 3 Position
Proportional Valve - 12V
Relief Valve, Lift - 2500 PSI
Relief Valve, Steer - 1500 PSI
Piloted Spool Valve, 4 Way - 3 Position
Piloted Poppet Valve
Manual Pull Valve
Load Sense Shuttle Check Valve
Counter Balance Valve
Coil, Series 8 - 12V
Coil, Series 10 - 12V
Coil, Series 10 E-Coil - 12V
Hand Pump, Brake Release
Flow Divider / Combiner
Pressure Compensator
Check Valve, Load Sense
Orifice Disc, Brake - 0.035
Orifice Plug, Steer - 0.080
Orifice Plug, Flow Divider Bleed - 0.025
Orifice, Decent Control - 0.093
March 2008
Page 5-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-3
Main Hydraulic Manifold
RV2 RV1
S P1
CL3
PLG4
RRA
OPL6 PLG4
OPL6
G S TR
OR S
P
LFT
RFB
LRB
CV1
CV2
PLG4 L
S 1
PLG6
LEFT
S V1
CL2
S V2
CL1
CL1
EC1
HP1
GP
FRONT
S VD1
EP1
FD1
PLG4
S V3
CL1
EP1 PLG4
L S
ORL S
L S 3
BACK
BOTTOM
L S 2
PLG4
PLG4 PLG4
T
CBV1
OPL5 PLG4
S TL
S TR
GL S
March 2008
Page 5-4
B
LFA
RRB
LRA
LFB
RFA
ORR
PLG4
PD1
PD2
MP1 OD1
RIGHT
CBV2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
PLG6
TOP
S V4
CL1
PLG4
FD2
PLG4
PD3
Optional Outriggers Hydraulic Manifold
ORB
LEFT
OR S
S V1 CL1 CL1
CAV1 PLG10
FRONT
CV1
CV2
RIGHT
ORA
ORR
PLG4
ORL S
BOTTOM
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-5
ELECTRIC SCHEMATICS
A
March 2008
Page 5-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
B
C
D
A
B
C
C
A
TILT
SENSOR
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-7
Circuit Board
The Circuit Bard schematic is broken into two pages for clarity. The cable connections are shown on this page. Match the numbers to line-up the traces.
March 2008
Page 5-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-9
Controls
38 PNK/WHT
104 BLU/RED
13 WHT/BLK
71 RED/WHT
PC BOARD
March 2008
Page 5-10
S
S TATION #2
DT06-6
UPPER
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
N TATIO
S A
S
DT06-12
UPPER
35 BLK/RED
35 BLK/RED
3
4
1
2
GRN
ORG
BLK
WHT
38 PNK/WHT
104 BLU/RED
13 WHT/BLK
71 RED/WHT
PC BOARD
S
S TATION #2
DT06-6
UPPER
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
S A
S TATION
DT06-12
UPPER
March 2008
Page 5-11
March 2008
Page 5-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Engine
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-13
March 2008
Page 5-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Optional Outriggers
4 3
4 3
UPPER CONTROL S TATION
RETRACT EXTEND
4
6
1
3
2
5
PLATFORM
POWER
RELAY
IN S IDE
UPPER
CONTROL BOX
BLK/RED
2 1
CABLE
A SS EMBLIE S
2 1
RED/BLU 301
PLATFORM DOWN
S WITCH
RED/WHT
LR
PPL PPL PPL
RR RF
OUTRIGGER PRE SS URE S WITCHE S
LF
PPL
OUTRIGGER
CYLINDER S
GRN/RED 67
GRY/WHT 66
GRY/RED 65
GRY/BLK 64
BRN/YEL 63
BRN/RED 62
GRN 61
BRN/BLK 60
LR
BLK/ORG
PNK/WHT 69
YEL 68
PCB TERMINAL S
IN
17
B+ (VCC1)
ALARM TERMINAL
THROTTLE S WITCH
TERMINAL 4
S
PCB TERMINAL S 5
LOWER CONTROL BOX
GRY 57
IDE LOWER CONTROL S
1 YEL/WHT 304
2 RED/WHT 201
3 ORG/BLU 125
4 BLK/ORG 125
P4-9 P2-12
P2-6
P2-5
P2-1
P2-2
P2-3
P2-4
P4-1
P4-2
P4-3
GRY/WHT 66
GRY/BLK 64
BRN/RED 62
P4-4
P4-5
P4-6
BRN/BLK 60
GRN/RED 67
GRY/RED 65
P4-7
P4-8
BRN/YEL 63
GRN 61
GP106
P2-10
P2-7
EXTEND OUTPUT
RETRACT OUTPUT
P2-8
ALL LEG S DOWN OUTPUT
P2-9
P2-11
THROTTLE UP OUTPUT
BLK 15
BLK/ORG 125
YEL/BLK 168
PPL/WHR 169
BRN 156
ORG/BLU 125
86
87
LIFT ENABLE
RELAY
30 87
BLK/ORG BLK/ORG
RR RF
OUTRIGGER S TOWED S WITCHE S
OUTRIGGER
MANIFOLD
BLK 15
RETRAC LR
EXTEND LR
RETRACT RR
EXTEND RR
RETRACT RF
EXTEND RF
RETRACT LF
EXTEND LF
BLK 15
LF
BLK 15
EXTEND VALVE
RETRACT VALVE
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-15
Optional Generator
Ge n e r ato r Optio n , RT
P u blicatio n A r t #: ART_2496
RED/WHT
30
BLK
85
RED/WHT
BLK
GENERATOR
VALVE
87
87a
N.O.
ORG/GRN
86
ORG
TO:
CIRCUIT
BOARD
PIN 12
PIN 5
INTERMEDIATE
HARNESS
BLK
ORG
DUAL FUEL
EXI S TING UPPER CONTROL CABLE
RED/WHT 71
UPPER CONTROL S
GENERATOR
TOGGLE S WITCH
WHT/RED
12 VDC
BATTERY
RED
ALT
10 GA RED
S TARTER
14 GA RED
YEL/RED
THROTTLE RELAY
87
ORG/BLK
30
87a
N.C.
85 86
ORG
PIN 1
PIN 2
PIN 12
PIN 5
BLK
ORG
ORG/GRN
ENGINE HARNESS
THROTTLE
S OLENOID
GEN
THROTTLE
S OLENOID
POWER
MODULE
WHT
GRN
BLK
CONTROL
MODULE
TO:
GENERATOR
CONTROL
MODULE
March 2008
Page 5-16
RED/WHT
RED/WHT
30
BLK
85
BLK
GENERATOR
VALVE
87
87a
N.O.
ORG/GRN
86
ORG
TO:
CIRCUIT
BOARD
PIN 12
PIN 5
INTERMEDIATE
HARNESS
BLK
ORG
DIE S EL
EXI S TING UPPER CONTROL CABLE
RED/WHT 71
UPPER CONTROL S
GENERATOR
TOGGLE S WITCH
WHT/RED
S
12 VDC
BATTERY
RED
ALT
10 GA RED
TARTER
14 GA RED
12 GA RED
YEL/RED
THROTTLE RELAY
87
ORG/BLK
30
87a
N.C.
85 86
ORG
PREHEAT RELAY
87
ORG/BLU
30
87a
N.C.
85 86
ORG/WHT
ENGINE RUN
S OLENOID
ORG/GRN
PIN 1
PIN 2
PIN 12
PIN 5
PIN 3
BLK
ORG
ORG/WHT
GEN THROTTLE RELAY
87
30
87a
N.C.
85 86
ORG/GRN
ENGINE HARNESS
THROTTLE
S OLENOID
TO:
GLOW
PLUG S
GEN
THROTTLE
S OLENOID
POWER
MODULE
TO:
GENERATOR
WHT
GRN
BLK
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Table of Contents
Parts Sections
SECTION 1:
CONTROL BOXES
U
PPER
C
ONTROLS
, ANSI .............................................................................................. 1-3
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
.......................................................................... 1-5
U
PPER
C
ONTROL
J
OYSTICK
............................................................................................ 1-7
B
ASE
C
ONTROL
B
OX
..................................................................................................... 1-9
SECTION 2:
PLATFORM AND RAILS
P
LATFORM
A
SSEMBLY
.................................................................................................... 2-3
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
....................................................................................... 2-5
R
OLLER
A
SSEMBLY
........................................................................................................ 2-7
E
NTRY
C
HAIN
............................................................................................................... 2-9
S
WING
G
ATE
(O
PTION
) ................................................................................................ 2-11
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
............................................................................. 2-13
P
OWER TO
P
LATFORM
.................................................................................................. 2-15
A
IRLINE
T
O
P
LATFORM
(O
PTION
) ................................................................................... 2-15
L
ANYARD
A
TTACHMENT
(O
PTION
) ................................................................................... 2-17
SECTION 3:
SCISSORS
B
EAM
A
SSEMBLY
, 3072RT ............................................................................................ 3-3
B
EAM
A
SSEMBLY
, 3772RT ............................................................................................ 3-7
L
IMIT
S
WITCH
I
NSTALLATION
.......................................................................................... 3-11
SECTION 4:
AXLES
R
EAR
A
XLE
A
SSEMBLY
.................................................................................................. 4-3
F
RONT
A
XLE
A
SSEMBLY
................................................................................................. 4-5
W
HEEL
M
OTOR
, R
EAR
................................................................................................... 4-7
W
HEEL
M
OTOR
, F
RONT
................................................................................................. 4-9
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Table of Contents
SECTION 5:
HYDRAULICS
M
ANIFOLD
A
SSEMBLY
.................................................................................................... 5-3
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
................................................................................. 5-5
M
ANIFOLD
- O
UTRIGGER
(O
PTION
) .................................................................................. 5-7
H
OSE
K
IT
- A
XLES
........................................................................................................ 5-9
H
OSE
K
IT
S
TEERING
, B
RAKE
R
ELEASE AND
A
XLE
R
ETURN
................................................ 5-11
H
OSE
K
IT
P
UMP AND
R
ETURN
...................................................................................... 5-13
H
OSE
K
IT
O
UTRIGGER
O
PTION
..................................................................................... 5-15
H
OSE KIT
- G
ENERATOR
O
PTION
.................................................................................. 5-17
L
IFT
C
YLINDER
, 3072RT ............................................................................................ 5-19
L
IFT
C
YLINDER
, L
OWER
, 3772RT ................................................................................. 5-21
L
IFT
C
YLINDER
, U
PPER
, 3772RT ................................................................................. 5-23
S
TEERING
C
YLINDER
................................................................................................... 5-25
O
UTRIGGER
C
YLINDER
(O
PTION
) ................................................................................... 5-27
SECTION 6:
BASE
B
ASE
A
SSEMBLY
........................................................................................................... 6-3
B
ALLAST
(C
OUNTERWEIGHT
) I
NSTALLATION
........................................................................ 6-5
M
ODULES
I
NSTALLATION
................................................................................................. 6-7
C
ONTROL
M
ODULE
........................................................................................................ 6-9
P
OWER
M
ODULE
......................................................................................................... 6-13
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
.................................................................... 6-17
E
NGINE
, D
UAL
F
UEL
................................................................................................... 6-21
E
NGINE
, D
IESEL
......................................................................................................... 6-25
W
IRE
H
ARNESS
.......................................................................................................... 6-29
O
UTRIGGER
I
NSTALLATION
............................................................................................. 6-31
G
ENERATOR
- O
PTION
, D
UAL
F
UEL
................................................................................ 6-33
G
ENERATOR
- O
PTION
, D
IESEL
...................................................................................... 6-35
SECTION 7:
DECALS
D
ECAL
K
IT
, U
PPER
C
ONTROL
B
OX
................................................................................... 7-3
D
ECAL
K
IT
, S
IDES
, 3072RT .......................................................................................... 7-5
D
ECAL
K
IT
, E
NDS
, 3072RT .......................................................................................... 7-7
D
ECAL
K
IT
, S
IDES
, 3772RT .......................................................................................... 7-9
D
ECAL
K
IT
, E
NDS
, 3772RT ......................................................................................... 7-11
D
ECALS
- A
NCHORAGE
P
OINTS
O
PTION
.......................................................................... 7-13
March 2008 "3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 1:
CONTROL BOXES
SECTION 1: ........................................................................................................................... 1-1
CONTROL BOXES ................................................................................................................ 1-1
U
PPER
C
ONTROLS
, ANSI ............................................................................................................ 1-3
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
....................................................................................... 1-5
U
PPER
C
ONTROL
J
OYSTICK
.......................................................................................................... 1-7
B
ASE
C
ONTROL
B
OX
................................................................................................................... 1-9
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-1
LIFT/ DRIVE
GRN/WHT
PPL
BLU/RED
25A
3
104
4
1
2
3
BLK
PPL
BLU
PWM
14 3 15 - 55
A + – X R
No Connection
ORG/GRN
18 19 20
To Potentiometer
17
15
1
ORG/BLK
PNK/WHT
WHT/BLK
SPEED/
TORQUE
6
3 8
1 3
1
2
3
6
E-STOP
WHT
1
WHT/YEL
1A
7
2
No Connection
3
YEL/WHT
JUMPER
8
1A
KEY
SWITCH
1
4
20
3
2
101
ORG/RED
YEL/WHT
WHT/RED
BLK/WHT
11
101
24
CHOKE/
PREHEAT
1
2
3
WHT/RED
No Connection
POWER RELAY
RED
BLK/RED
101A
3 5
86
87
87A
3 0
85
101
15
14
21
28
BLK
1 3
WHT/RED
BLK
PNK/WHT
WHT/RED
TIME DELAY
101 3 8 15
1 2
3
6
3
12
PPL
27
22
RED/GRN
24
DRIVE
INDICATOR
45 45A
RED
WHT
RED/BLK
25
26
2 3
OUTRIGGER
PNK/WHT
RED/BLU
YEL
69
3 01
68
1 4
2 5
3 6
57
3 01
57
GRY
JUMPER
RED/BLU
WHT/RED
9
101
7 3
HORN
BUTTON
10
GENERATOR
BLK/WHT/RED
WHT/RED
71
101
1
2
OPTION
ART ControlBox-X72
March 2008
Page 1-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
17 91107
1 8 90 8 14
19 90 8 33
20 5364
21 9102 8
22 91294
23 5694
24 907 8 9
25 16312
26 90 8 33
27 5364
2 8 9102 8
6 6905
7 7 8 00
8 91159
8 0 8 2
8 0 8 3
9 8 044
10 5630
11 7423
12 911 8 6
13 911 8 4
14 91375
15 91027
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROLS
, ANSI
9110 8
1 16242
2 13 8 65
3 6350
4 6234
-
1
1
.5FT
1
CONTROL BOX ASSEMBLY, ANSI
WELDMENT, CONTROL BOX
BRACKET, CONTROL BOX HOLDER
TAPE, FOAM
SWITCH, TOGGLE, LIFT/DRIVE
1
1
1
1
1
1
1
1
1
1
1
1
SWITCH, TOGGLE, SPEED/TORQUE
SWITCH, EMERGENCY STOP
KEYSWITCH
CONTACT BLOCK, NO
CONTACT BLOCK, NC
SWITCH, HORN BUTTON (OPTION)
SWITCH, TOGGLE, GENERATOR (OPTION)
SWITCH, TOGGLE, CHOKE/PREHEAT
RELAY, TIME DELAY
WIRE HARNESS, CONTROL BOX
RELAY, POWER
DIODE BLOCK, 2 POSITION
2
2
1
2
1
PWM CARD
SPACER
SCREW, 6-32 X 3/4"
NUT, 6-32
DIODE BLOCK, 4 POSITION
OUTRIGGER OPTION
HARNESS, OUTRIGGER CONTROL
SWITCH, TOGGLE
1
1
1 LED, GREEN, DRIVE ENABLED
1 PLATE, MOUNTING, OUTRIGGER PLUG
2 SCREW, 6-32 X 3/4"
2 NUT, 6-32
1 DIODE BLOCK, 4 POSITION
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-3
1
2 3
4 5 6
7
8
9
10
11
12
1 3
14
15
29
16 17
18 19 20
28
27
26
28
27
26
25 2 3 22 24
21
TO CONTROL BOX
ART_A SS Y1 3 868
March 2008
Page 1-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROL
B
OX
C
OVER
A
SSEMBLY
1 13647
2 3772
3 7 8 75
4 7 88 2
5 HDW376 8
6 7 8 19
7 8 435
8 100/ 8 34 8
9 HDW7 88 7
10 13502
11 3763
12 13402
13 HDW 8 531
14 HDW7 88 1
15 37 8 2
16 13403
1
1
2
1
1
1
1
1
1
1
1
1
1
CONTROL BOX COVER ASSEMBLY
CONTROL ARM COVER
1 COVER
1 GASKET
1 O-RING, 7/ 8 " ID X 1 1/ 8 " OD
WASHER, FLAT
BEARING, BRONZE, FLANGED
SPRING, JOYSTICK, CENTERING
PIN, HOLD DOWN
SCREW, #6-32, 1/2" LG
BRACKET, CENTERING
SPACER, STEP
GEAR, LARGE
WASHER, FLAT
WASHER, BEVEL
CAM. DIRECTIONAL
PLATE, BOTTOM
17 6917
1 8 7 8 1 8
19 HDW3771
20 5736
21 HDW 8 399
22 HDW 8 567
23 8 3 8 9
24 91522
1
1
1
1
4
2
1
1
CLAMP, CABLE 1/4"
BEARING, BRONZE, FLANGED
WASHER, FLAT
RING, RETAINING, 1/2"
SCREW, #4 - 40, 5/
WASHER, FLAT
GEAR, SPUR
POTENTIOMETER
8 " LG
25 HDW7 888 12 SCREW, #10 - 32, 1/2" LG
26 3764 2 PLATE, SPACER
27 8 696
2 8 3765
29 3766
2
2
1
SWITCH, LIMIT, MICRO V7
PLATE, STRAP
PLATE, TOP
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-5
1
2
8
11
4
3
1 3
12
5
7
6
March 2008
Page 1-6
ART_JoystickHandle
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
U
PPER
C
ONTROL
J
OYSTICK
13647
1 8 750
2 8 453
3 HDW 8 455
4 8 752
5 8 751
6 1363 8
7 8 74 8
8 8 456
7476
8 630
8 761
8 0 8 9
7777
4
1
1
1
1
CONTROL ARM ASSEMBLY, JOYSTICK
PIN (SERVICE ONLY)
SWITCH ACTUATOR (SERVICE ONLY)
SCREW, 6-1/2" LG (SERVICE ONLY)
GRIP-TOP HALF (SERVICE ONLY)
GRIP-BOTTOM HALF (SERVICE ONLY)
1
5
1 CONTROL ARM WITHOUT WIRE
1 TRIGGER (SERVICE ONLY)
1
ROCKER BOOT (SERVICE ONLY)
AMP PINS
HANDLE, GRIP
SWITCH ASSEMBLY (NOT SHOWN)
1' WIRE, BLK 1 8 GA 300 V
2 TERMINAL, PUSH ON, 3/16"
11 8 447
12 8 753
13 8 44 8
1
1
2
SWITCH SEPARATOR (SERVICE ONLY)
MOTION SWITCH, ON-OFF (SERVICE ONLY)
SWITCH (SERVICE ONLY)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-7
1 Emergency S top
Raise (Green)
3
Lower (Green)
3
Throttle (Green) 3
Engine S top (Red) 5
2
3
4
Hour Meter
Engine S tart (Green)
Choke/Preheat (Black)
1
Platform/Chassis
16
9
Circuit Breaker
6
Gasoline/Propane (Dual Fuel)
7
Plug (Diesel)
2
Green
3
Black
4
Dual Fuel
6
Diesel
7
16
9
Red 5
Green 3
Mounting Plate
Platform/Base - N.O.
14
15
Raise - N.O. 10
12
1 3
Circuit Board
Alarm
Hardware supplied with Alarm
9
Circuit Breaker
11
Propane/Gasoline - N.C.
(Dual Fuel)
9 Circuit Breaker
10 Engine
S tart - N.O.
10 Choke/Preheat - N.O.
11 Engine
S top- N.C.
10 Throttle - N.O.
11 Emergency
S top - N.C.
10 Lower - N.O.
ART_2093
March 2008
Page 1-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
ASE
C
ONTROL
B
OX
91169
1 7 8 00
2 7909
3 91533
4 91534
5 91535
6 91536
7 91329
-
1
1
4
1
1
1
1
BASE CONTROL PANEL - COMPONENTS
SWITCH, EMERGENCY STOP
HOUR METER
SWITCH, BUTTON, GREEN
SWITCH, BUTTON, BLACK
SWITCH, BUTTON, RED
SWITCH, 2-POSITION (DUAL FUEL)
PLUG (DIESEL)
9 7235
10 91537
91537
11 9153 8
12 91539
13 91370
14 90714
15 8 0 8 2
16 9549
1
2
1
1
8
4
2
6
1
CIRCUIT BREAKER, 15 AMP
BLOCK, CONTACT, N.0. (DIESEL)
BLOCK, CONTACT, N.0. (DUAL FUEL)
BLOCK, CONTACT, N.C.
ALARM, 107DB
CIRCUIT BOARD
BASE, CONTACT MOUNT
BLOCK, CONTACT, N.O.
SWITCH, 3-POSITION, KEYED
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 1-9
March 2008
Page 1-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 2:
PLATFORM AND RAILS
SECTION 2: ........................................................................................................................... 2-1
PLATFORM AND RAILS ....................................................................................................... 2-1
P
LATFORM
A
SSEMBLY
.................................................................................................................. 2-3
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
..................................................................................................... 2-5
R
OLLER
A
SSEMBLY
..................................................................................................................... 2-7
E
NTRY
C
HAIN
............................................................................................................................. 2-9
S
WING
G
ATE
(O
PTION
) ...............................................................................................................2-11
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
...........................................................................................2-13
P
OWER TO
P
LATFORM
.................................................................................................................2-15
A
IRLINE
T
O
P
LATFORM
(O
PTION
) ..................................................................................................2-15
L
ANYARD
A
TTACHMENT
(O
PTION
) ..................................................................................................2-17
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-1
2 3
7
8
1
25
6
5
26
3 0
27
28
4
21
24
20
19
17
22
27
24
9
16
18
2 3
29
14
1 3
15 11
10
12
3 1
ART_PLATFORM
March 2008
Page 2-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
LATFORM
A
SSEMBLY
1 16222
2 7 8 05
1
1
REAR RAIL WELDMENT
PADDING, RAIL (OPTIONAL)
3 704 8
4 HDW7119
5 HDW5217
6 HDW 8 304
7 HDW7593
1
2
4
6
6
COVER, RAIL PADDING (OPTIONAL)
SCREW, 5/16” - 1
NUT, 5/16” - 1 8
8 , 2 ¼” LG, GR 5
FLAT WASHER, .343 ID × .6
88
PIN, WIRE LOCK, SQUARE, 3/
OD × .063 THK
8 ” × 2 ¼” LG
8 16176
9 14301
10 16177
11 8 909
12 HDW5723
13 HDW 8 294
14 HDW 8 267
15 14415
1
1
1
1
8
4
4
2
SIDE RAIL WELDMENT, LH
SIDE RAIL WELDMENT - EXTENSION
FRONT RAIL WELDMENT
MANUAL ENCLOSURE
SCREW, ¼” - 20, ½” LG
FLAT WASHER, .32
NUT, ¼” - 20
8 ID × 1.000 OD × .100 THK
BRACKET, EXTENSION STOP
16 HDW5724 20 SCREW, 5/16” - 1 8 , ¾” LG, GR 5
17 14152 2 CHANNEL, EXTENSION
1 8 16202 1 EXTENSION PLATFORM WELDMENT
19 16196
20 HDW 88 56
21 HDW 8 457
22 14313
2
1
1
2
MAIN PLATFORM WELDMENT
SCREW, ½”-13, 5” LG
NUT, ½” - 13
RIGHT SIDE RAIL WELDMENT - EXTENSION
23 HDW 8 974
24 6 8 23
1
2
PIN, WIRE LOCK, SQUARE, 3/ 8 ” × 3” LG
CAP PLUG, 1 ¼"
25 16224 1 SIDE RAIL WELDMENT, RH
26 HDW 8 279 10 SCREW, 3/ 8 -16, 2½" LG
27 HDW 8 26 8 10 NUT, 3/ 8 -16
2 8 20552 1 COVER, PLATFORM CORD (NOT SHOWN)
29 912 8 4 1 PIN HITCH 3/ 8 " × 4
30 HDW5355 20 WASHER, FLAT, .43
8 ID×1.00 OD×.07
8 THK
31 HDW6434 3 SCREW, 3/ 8 -16×2" LG
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-3
4
5
8
3
6
9
8
7
1
ART 769 R1
March 2008
Page 2-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
R
OLLOUT
L
OCK
P
IN
A
SSEMBLY
1 13737
2 71 8 4
3 88 14
4 14344
5 HDW 8 303
6 HDW 8 304
7 740 8
8 HDW7031
9 HDW 8 513
1 PIN, EXTENSION LOCK
3.7 FT CABLE, COATED AND ROLLED
2
1
SLEEVE, ALUMINUM OVAL
HANDLE
1
1
SCREW, 5/16” - 1 8 , 2” LG
LOCKNUT, 5/16” - 1 8
1
1
1
SPRING, DECK LOCK
WASHER, FLAT, ½” ID 7/ 8 ” OD
PIN, SPRING, 1/ 8 ” DIA. ¾” LG
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-5
4
5
3
2
1
Art Number
Roller Assembly
March 2008
Page 2-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
R
OLLER
A
SSEMBLY
1 591 8
2 HDW 8 370
3 13230
4 14062
5 HDW5724
1 RETAINING RING, HEAVY DUTY 1”
1 WASHER, FLAT, 1.015 ID × 1.375 OD × .062 THK
1 ROLLER
1 ROLLER PLATE WELDMENT
4 SCREW, 5/16” - 1 8 , ¾” LG
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-7
1
2
3
ART 1 3 850
March 2008
Page 2-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NTRY
C
HAIN
1
2
3
13
5239
8 7
8
8
46
1
1
2
1
CHAIN CLOSURE
CHAIN
S-HOOK, CONNECTING LINK
SNAP, CHAIN LINK
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-9
1
2
3
4
17
14
16
7
15
6
5
7
8
1 3
12
5
10
11
9
March 2008
Page 2-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
S
WING
G
ATE
(O
PTION
)
1 40003
2 7055
3 40006
4 HDW6434
5 8 1 8 7
6 40014
7 HDW 8 294
8 HDW 8 4 8 6
9 6 8 23
10 8 300
11 13272
12 40015
13 40017
14 30 8 14
15 HDW 8 303
16 HDW7120
17 HDW 8 26 8
1
1
1
1
1
1
6
4
2
2
1
1
1
1
1
2
1
LATCH PIN, REAR GATE
SPRING, LATCH, .4
8 0 DIA. OD × 1.5” LG
ROD, LATCH LEVER, REAR GATE
SCREW, 3/ 8 -16 × 2” LG
BEARING, NYLINER, 5/ 8 ” ID × 5/ 8 ” LG
MOUNTING BRACKET, UPPER
WASHER, .32
8 ” ID × 1” OD × .100” THK
SCREW, 5/16” - 1 8 , 1 7/ 8 ” LG, GR 5
CAP PLUG, 1 ¼” SQUARE
SPRING, TORSION, 1” DIA. OD × 4” LG
BLOCK, PIVOT, REAR GATE
MOUNTING BRACKET, LOWER
SWING GATE WELDMENT
STRIKE PLATE
SCREW, 5/6”-1 8 , 2” LG, GR 5
NUT, 5/16”-1 8 , GR 5
NUT, 3/ 8 -16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-11
1
2
3
5
7
8
9
11
10
Art CtnrlCCableInst
March 2008
Page 2-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
C
ABLE
/H
ORN
I
NSTALLATION
1 9716
2 HDW5217
3 HDW6455
1
2
5
HORN, 12-4 8 V (OPTION)
WASHER, FLAT, .343 ID × .6
88 OD × .063 THK
SCREW, ¼”-20, ½” LG, GR 5
5 HDW5363
6 HDW5364
7 6947
8 6964
9
10 14604
11 5 8 63
3
3
SCREW, #6-32, 1” LG, GR 5
NUT, KEPS, #6-32 , GR 5
1
1
TERMINAL STRIP
CLAMP, CABLE, 1” DIA.
REF CABLE, UPPER CONTROL
1 COVER, TERMINAL STRIP
2 GROMMET, 1.5 ID × 1.75 OD × .1
8 7 THK
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-13
4
7
8
9
1
5
10
11
12
6
2
3
1 3
ART_PowerOutlet
March 2008
Page 2-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER TO
P
LATFORM
1 90 8 27
2 90 8 2 8
3 HDW5636
4 HDW6455
5 HDW 8 267
6 53 8 1
7 8 20 8
8 8 209
9 8 479
10 88 33
11 16221
12 HDW5724
13 HDW 8 304
1
2
2
1
1
1
1
1
2
1
1
2
1
BOX, RECEPTACLE
DUPLEX RECEPTACLE COVER
SCREW #6 - 32 × 0.25"
SCREW, ¼" - 20, ½" LG
LOCKNUT ¼" - 20
RECEPTACLE, DUPLEX
CONDUIT, 3/ 8 " FLEXIBLE
FERRULE, 3/ 8 "
BUSHING, ¾" ID
CONNECTOR, OUTLET BOX 3/ 8 " CONDUIT
BRACKET
SCREW, 5/16–1 8 × ¾"
NUT, 5/16–1 8
HDW 8 501
7617
2
*
CLIP, SELF RETAINING
WIRE, 14 GA
*3072RT = 50 FT.
* 3772RT = 5 8 FT.
HDW5217 2 FLAT WASHER 11/32" ID
5351
91399
1
*
A
IRLINE
T
O
P
LATFORM
(O
PTION
)
NOT SHOWN
CABLE TIE
HOSE, 3/ 8 " AIRLINE
*3072RT = 49 FT.
* 3772RT = 57 FT.
8 559 2
HDW91500 2
5 88 2 2
CLAMP, HOSE
FITTING, ¼" MALE, MALE HOSE BARB
CABLE CLAMP
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-15
5
3
4
1
2
March 2008
Page 2-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
ANYARD
A
TTACHMENT
(O
PTION
)
145 8 3 LANYARD ATTACHMENT
1 HDW6433 10 SCREW, 3/ 8 ” - 16, 1” LG, GR 5
2 HDW 8 26 8 10 NUT, 3/ 8 ” - 16, GR 5
3 8 605 5 DECAL, LANYARD ATTACH POINT
4 3923
5 8 606
5
1
BRACKET, ATTACH POINT
DECAL, WARNING, POS RESTRAINTS
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 2-17
March 2008
Page 2-18
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 3:
SCISSORS
SECTION 3: ........................................................................................................................... 3-1
SCISSORS ............................................................................................................................. 3-1
B
EAM
A
SSEMBLY
, 3072RT .......................................................................................................... 3-3
B
EAM
A
SSEMBLY
, 3772RT .......................................................................................................... 3-7
L
IMIT
S
WITCH
I
NSTALLATION
.........................................................................................................3-11
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-1
1
2
3
3 5
4
28
7
27
21
22
19
18
20
29
3 4
3 0
26
3 1
3 2
33
.250
5
27
.313
25
17 11
12
1 3
.313
2 3 24
10
.250
.250
.313
.313
7
6
9
6a
8
.250
ART 3 072BEAM S
March 2008
Page 3-2
DENOTE S LOCATION OF HDW1 3 175, TOTAL QUANTITY OF 16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
, 3072RT
1 144 88
2 4044 8
2
1
BLOCK, SLIDE, PLATFORM
BEAM, 6 × 8 × .250, TOP SLIDE, W/PINS
3 400 8 4
4 400 8 1
5 40444
6 40459
6A 6669
1 BEAM, 6 × 8 × .313 W/PINS
1 BEAM, 6 × 8 × .313 W/PINS
1
2
2
BEAM, 6 × 8 × .250, BOTTOM FIXED, W/PINS
LOWER PIVOT, MACHINED CASTING
BEARING, 2” × 2”
7 5432
8 HDW 8 457
9 HDW 8 2 8 4
10 HDW 88 99
11 1453 8
12 HDW6455
13 14537
2
4
4
6
6 SCREW, ½” - 13, 2” LG, GR 8
2 RING, RETAINING (NOT SHOWN)
2
GREASE FITTING
LOCKNUT, ½” - 13, GR B
BRACKET, CYLINDER RETAINING
SCREW, ¼” - 20, ½” LG
PIN, CYLINDER MOUNT
17 6701
1 8 95 8 7
19 90235
10 RING, RETAINING, 2”
2 WEAR PAD, SLIDE BLOCK, BOTTOM
2 WEAR PAD, ANGLE, SLIDE BLOCK TOP
20 40306
8 7 8 5
21 7160
22 40446
23 14990
24 8 675
25 25429
26 91020
27 400 8 3
6669
2 8 14 8 06
29 162 8 3
2 SLIDE PVT, LWR CAST, MACHINED
.67 FT TAPE, DOUBLE COATED
2 BEARING, 1 ¾” × 2”
1 BEAM, 6 × 8 × .250, BOTTOM SLIDE, W/BEARINGS
1 MAINTENANCE LOCK WELDMENT
1 BEARING, 2 ¼” × 2” × 1 ½” LG (NOT SHOWN)
12 SPACER BLOCK - BEAMS
1 LIFT CYLINDER
2
4
1
2
BEAM, 6 × 6 × .313
BEARING, 2” × 2” (NOT SHOWN)
SUPPORT BEAM WELDMENT
CYLINDER MOUNT
CONTINUED . . .
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-3
1
2
3
3 5
4
28
7
27
21
22
19
18
20
29
3 4
3 0
26
3 1
3 2
33
.250
5
27
.313
25
17 11
12
1 3
.313
2 3 24
10
.250
.250
.313
.313
7
6
9
6a
8
.250
ART 3 072BEAM S
March 2008
Page 3-4
DENOTE S LOCATION OF HDW1 3 175, TOTAL QUANTITY OF 16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
, 3072RT (C
ONTINUED
)
30 HDW 8 303
31 HDW5217
8
8
SCREW, 5/16” - 1 8 , 2” LG
WASHER, FLAT, .343 ID × .6
88 OD × .063 THK
32 HDW 8 294
33 HDW 8 304
34 144 8 7
35 40447
8
8
2
1
WASHER, FLAT, .32
NUT, 5/6” - 1 8
8 ID × 1.000 OD × .100 THK
BLOCK, SLIDE, PLATFORM
BEAM, 6 × 8 × .250, TOP FIXED, W/BEARINGS
HDW13175 16 WASHER, 2.062 ID × 2.620 OD × .030 THK (NOT SHOWN)
911 8 5 1 CABLE, MAIN CONTROL (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-5
1
40
3 8
3 9
3 4
3 5
44
19
20
21
3 1, 3 2
42
8
7
33
4 3
41
9
12
.188
10
14
.250
11
17
.188
15
16
1 3
18
4
3
2
5
6
.188
.250
.188
.375
3 6
.375
.375
17
24
25
22
26
2 3
.375
ART 3 772BEAM S
March 2008
Page 3-6
DENOTE S LOCATION OF HDW1 3 175, TOTAL QUANTITY OF 29
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
, 3772RT
1 16290
2 144 8 7
1
2
BEAM 6 ×6 ×.1
88
BLOCK, SLIDE, PLATFORM
3 HDW5217
4 HDW 8 303
5 HDW 8 294
6 HDW 8 304
7 40124
8
8
8
8
1
WASHER, FLAT, .343 ID × .6
SCREW, 5/16" - 1
NUT, 5/16 - 1 8
8
WASHER, FLAT, .32
BEAM 6 × 6 × .250
, 2.00" LG
8
88 OD × .063THK
ID × 1.000 OD × .100 THK
8 162 8 9
9 30407
10 16292
11 91314
12 25429
13 162 8 5
14 90235
15 40306
16 7160
17 5432
1 8 95 8 7
1
1
2
2
1 BEAM 6 ×6 ×.1
88
1 PIN 2.00 DIA × 25.90" LG
2
4
BEAM 6 ×6 ×.375 W/BEARINGS
LIFT CYLINDER, LOWER
16 SPACER BLOCK - BEAMS
1 BEAM 6 ×6 ×.375, BOTTOM FITTED
WEAR PAD, ANLE, SLIDE BLOCK, TOP
SLIDE PIVOT LOWER CAST MACHINED
BEARING, 1 ¾" × 2" - 2
GREASE FITTING
8 DU32
2 WEAR PAD, SLIDE BLOCK, BOTTOM
19 162 8 6
6669
20 40106
6669
21 162 8 4
6669
22 40459
23 6669
24 HDW6491
25 HDW 8 2 8 4
26 HDW 8 457
31 3051 8
32 8 675
33 91315
1
2
1 BEAM 6 ×6 ×.1
88
2 BEARING, 2.0 × 2.0 - 32DU32
BEAM 6 ×6 ×.375
BEARING, 2.0 × 2.0 - 32DU32
2
2
1 BEAM 6 ×6 ×.375
2 BEARING, 2.0 × 2.0 - 32DU32
CASTING, MACHINED, LOWER PIVOT
BEARING, 2.0 × 2.0 - 32DU32
6 WASHER, FLAT, .562 ID × 1.375 OD × .109 THK
6 BOLT, ½" - 13, 2.00" LG GR 8
6 LOCKNUT, ½" - 13, GR 8
1 MAINTENANCE LOCK WELDMENT
1 BEARING, 2 ¼" × 2" × 1 ½" LG (NOT SHOWN)
1 LIFT CYLINDER, UPPER
…CONTINUED
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-7
1
40
3 8
3 9
3 4
3 5
44
19
20
21
3 1, 3 2
42
8
7
33
4 3
41
9
12
.188
10
14
.250
11
17
.188
15
16
1 3
18
4
3
2
5
6
.188
.250
.188
.375
3 6
.375
.375
17
24
25
22
26
2 3
.375
ART 3 772BEAM S
March 2008
Page 3-8
DENOTE S LOCATION OF HDW1 3 175, TOTAL QUANTITY OF 29
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
B
EAM
A
SSEMBLY
, 3772RT (C
ONTINUED
)
34 HDW6455
35 1453 8
36 14 8 06
37 162 8 3
3 8 14537
39 6701
40 144 88
41 162 8 7
42 HDW 88 99
43 162 88
44 162 8 2
8 SCREW, ¼" - 20, ½" LG
4 BRACKET, CYLINDER RETAINING
1 SUPPORT BEAM WELDMENT
4 MOUNT CYLINDER W/CAP
4 PIN, CYLINDER MOUNT, 1.99
8 × 6.40
8
15 RING, RETAINING, 2" SHAFT
2 BLOCK, SLIDE PLATFORM
1 BEAM 6 ×6 ×.1
88 W/PINS
4 RING, RETAINING (NOT SHOWN)
1 BEAM 6 ×6 ×.250 W/BEARINGS
1 SUPPORT BEAM W/BEARINGS
HDW13175 16 WASHER, 2.062 ID × 2.620 OD × .030 THK (NOT SHOWN)
91321 1 CABLE, MAIN CONTROL (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-9
6
7
8
9
4
10
11
3
ART_Limit S witch
March 2008
Page 3-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
IMIT
S
WITCH
I
NSTALLATION
3 HDW 8 267
4 40604
2
1
NUT, ¼”-20
COVER, LIMIT SWITCH
6 13 8 3 8
7 90996
8 HDW 8 4 8 2
9 HDW 8 273
10 HDW5251
11 40524
1
1
2
BRKT, LIMIT SWITCH
LIMIT SWITCH, SLOW SPEED
# 8 -32, 1 ½” LG, GR 2
4 ¼”-20, 1” LG, GR 8
2 NUT, # 8 -32
1 CAM, SLOW SPEED, 2.75 DIA.
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 3-11
March 2008
Page 3-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 4:
AXLES
SECTION 4: ........................................................................................................................... 4-1
AXLES ................................................................................................................................... 4-1
R
EAR
A
XLE
A
SSEMBLY
................................................................................................................ 4-3
F
RONT
A
XLE
A
SSEMBLY
............................................................................................................... 4-5
W
HEEL
M
OTOR
, R
EAR
................................................................................................................ 4-7
W
HEEL
M
OTOR
, F
RONT
............................................................................................................... 4-9
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-1
17
Case Drain
16
Drive Ports
A
B
18
Brake Port
Hydraulic Wheel Motor with Brake
3
3
2
24
14
11
9
15
1 3
10
2
19
20
21
10
12
2 3
22
ART_2492
March 2008
Page 4-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
3072RT / 3772RT Rear Axle
ITEM PART NO.
QTY DESCRIPTION
R
EAR
A
XLE
A
SSEMBLY
1 4025 8 2 MOUNT, MOTOR, REAR AXLE, MACHINED
2 HDW5994 12 WASHER, LOCK, .640 ID X 1.050 OD X .165 THK
3 8 2 8 3 8 BOLT, 5/ 8 ” - 11, 1 ½” LG
8 90765
9 91319
4
2
HOSE PROTECTION (NOT SHOWN)
WHEEL MOTOR, HYD W/BRAKE
10 HDW59 8 9 12 SCREW, 5/ 8 ”-11, 2 1/4” LG, GR 5
11 14773 2 HUB
12 91165
91167
91166
9116 8
1
1
1
1
WHEEL/TIRE ASSY, RH - 10 PLY - PNEUMATIC
WHEEL/TIRE ASSY, RH - 10 PLY - FOAM -
OPTION
WHEEL/TIRE ASSY, LH - 10 PLY - PNEUMATIC
WHEEL/TIRE ASSY, LH - 10 PLY - FOAM -
OPTION
911 8 0
911 8 1 -
WHEEL (SERVICE)
TIRE 26X12.00-3 8 0 (SERVICE)
13 HDW9037 NUT, CASTLE, M42 X 3 (SERVICE)
14 HDW6677 12 NUT, LUG, ½” - 20, GR 5
15 8 925
16 HDW 8 9 8 4
2 PIN, COTTER, .250 DIA. X 3" LG
4 FITTING, MB-MJ-128
17 HDW91235 2
1 8 HDW 888 1 2
FITTING, MB-MJ45-4-5
FITTING, MB-MJ-4-4
19 91326
20 91464
2
2
RELIEF VALVE (IF SOLENOID VALVE USE ITEMS 20 & 21)
VALVE, N/C POPPET (IF RELIEF VALVE USE ITEM 19)
21 91141
22 6633
23 16349
24 1634 8
2 COIL 12V DEUTSCH (IF RELIEF VALVE USE ITEM 19)
4 NUT, 5/ 8 "-11
2 COVER, LOWER, VALVE SHIELD, LEFT AND RIGHT
2 COVER, UPPER, VALVE SHIELD, LEFT AND RIGHT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-3
3 0
Case Drain
29
Drive Ports
A
B
Hydraulic Wheel Motor
8
24
9
7
6
5
4
3
2
1
28
2 3
8
18a
19
11
11
22
25
12
11
19
21
20
18a
25
8
14
1 3
9
18
17
11
16
26
25
ART FrontAxle
March 2008
Page 4-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
F
RONT
A
XLE
A
SSEMBLY
1 HDW5920 2
2 HDW90770 2
3 91019
90990
2
4 91263
5 HDW7326
4
2
6 HDW9219
7 7292
8 HDW 8 56 8
9 20311
11 20312
12 902 8 2
13 HDW7043
14 7300P
15 90765
16 40464
4030 8
PIN, COTTER, .12 DIA. X 1” LG
PIN, CLEVIS, ½ DIA. X 1 3/
CYLINDER, STEERING
SEAL KIT, STEER CYLINDER (NOT SHOWN)
HOSE ASSEMBLY ½" (
SCREW, 5/ 8
8
8 ” LG
M3K-
” - 11. 4” LG, GR 5
8 FJX8 FJX90S-37")
6
4
4
2
WASHER, .656 ID X 1.312 OD X .093 THK
BEARING, SLEEVE, BRONZE
NUT, 1 1/ 8 ” - 1 8
WASHER, 1.375 ID X 2.75 OD X .250 THK
8 WASHER, THRUST
1 HOSE ASSEMBLY 5/16" (NOT SHOWN)
8 SCREW, ½”-13, 2.50” LG, GR 8 , SOCKET HEAD
2 MOTOR, WHEEL, HYD.
8 HOSE PROTECTION (NOT SHOWN)
1 MOUNT, WHEEL MOTOR, LH, FRONT (CAST 40463)
1 MOUNT, WHEEL MOTOR, RH, FRONT (CAST 40367)
17 HDW6633
1 8 40334
1 8 A 9307
19 9607
4
2
2
4
NUT, LOCK, 5/ 8 ” - 11, GR 5
MOUNT, MOTOR W/BEARINGS
BEARING, 1.50 X 1.0 DIA
FITTING, GREASE, 90°
20 HDW5994 16 WASHER, LOCK, .640 ID X 1.050 OD X .165 THK
21 HDW90410 16 SCREW, 5/ 8 ” - 11, 2” LG, GR 8 , SOCKET HEAD
22 HDW 8 457
23 10709
8
2
NUT, ½”-13, GR
HUB
8
24 91165
91167
1
1
WHEEL/TIRE ASSY, RH - 10 PLY - PNEUMATIC
WHEEL/TIRE ASSY, RH - 10 PLY - FOAM -
OPTION
91166
9116 8
1 WHEEL/TIRE ASSY, LH - 10 PLY - PNEUMATIC
1 WHEEL/TIRE ASSY, LH - 10 PLY - FOAM -
OPTION
25 HDW5290 6 PIN, COTTER, .156 DIA. X 1.75” LG
26 HDW6677 12 NUT, LUG, ½” - 20, GR 5
2 8 14331
29 HDW 8 9 8 4
1
4
ROD, TIE STEERING
FITTING, MB-MJ-128
30 HDW91236 2 FITTING, MB-MJ90-4-5
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-5
S
Drive
Link
S pacer haft Nut
Drive
Link
10
Commutator
Assembly
12
1 3
Piston
S pring
Endcover
11
I.D. Tag
Assembly
14
Endcover
Piston
10
8
Piston
Assembly Bolts (7)
16
S
S pacer hims (1– 3 )
Capscrews (8)
Rear Housing
Manifold
Rotor
Assembly
Friction
Disks (10)
Thick Disk
S tampings (2)
S haft Key
6
5
7
S prings (25)
9
Piston
Rear Housing Mounting S urface
3
S haft
S haft
Bearing
Disk
S tampings (9)
.620
.6
3 0
2
4
1
Front Housing
DT710 BRAKE MOTOR COMPONENT S
1
Front
Housing
2 3 4
S haft
Bearing
ART_DT710
March 2008
Page 4-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
10
11
12
13
14
8
9
6
7
ITEM PART NO.
QTY DESCRIPTION
W
HEEL
M
OTOR
, R
EAR
91319
97 8 1
WHEEL MOTOR W/BRAKE
SEAL KIT
3
4
1
2
5
1
1
DUST SEAL
METAL BACKUP SHIM
1 BACKUP SEAL
1 SHAFT SEAL
1 SMALL PISTON O-RING SEAL
1
1
3
1
1 SMALL PISTON SEAL
1 LARGE PISTON O-RING SEAL
1 LARGE PISTON SEAL
1 O-RING SEAL
1
BODY SEAL
MANIFOLD SEAL
COMMUTATOR SEAL
O-RING SEAL
BACKUP SEAL
9113 8 DISK KIT
10 FRICTION DISK
9 DISK STAMPING
2 THICK DISK STAMPING
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-7
Drive
Link
6
S haft Nut
7
Endcover
Piston
11
7
Commutator
Assembly
Endcover
Manifold
8
Assembly Bolts (7)
I.D. Tag
Assembly
9
10
Piston
S pring
Rear Housing
Bearing
Rotor
Assembly
S haft Key
Divider
Plate
Bearing
S pacer
2
4
Thrust
Washers (2)
5
Thrust
Bearing
3
Housing
S haft
Retaining
S nap
Ring
1
1.5" Bearing
3 4
5
DU S T S EAL
1.5" BEARING
S HAFT S EAL
BACKUP S EAL
METAL BACKUP RING
DT701 S eries Motor Components
ART_DT701
March 2008
Page 4-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
W
HEEL
M
OTOR
, F
RONT
7300P
90592
-
1
MOTOR WHEEL HYD PAINTED
SEAL KIT
1 -
2 -
3 -
4 -
5 -
1
1
1
1
1
DUST SEAL
HIGH PRESSURE SEAL
METAL BACKUP SHIM
TEFLON BACK UP SEAL
SHAFT SEAL
6 -
7 -
8 -
9 -
10 -
11 -
1
3
1
1
1
1
HOUSING SEAL
BODY SEALS
MANIFOLD SEAL
COMMUTATOR SEAL
O-RING SEAL
TEFLON BACKUP SEAL
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 4-9
March 2008
Page 4-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 5:
HYDRAULICS
SECTION 5: ........................................................................................................................... 5-1
HYDRAULICS ........................................................................................................................ 5-1
M
ANIFOLD
A
SSEMBLY
.................................................................................................................. 5-3
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
............................................................................................... 5-5
M
ANIFOLD
- O
UTRIGGER
(O
PTION
) ................................................................................................ 5-7
H
OSE
K
IT
- A
XLES
...................................................................................................................... 5-9
H
OSE
K
IT
S
TEERING
, B
RAKE
R
ELEASE AND
A
XLE
R
ETURN
...............................................................5-11
H
OSE
K
IT
P
UMP AND
R
ETURN
.....................................................................................................5-13
H
OSE
K
IT
O
UTRIGGER
O
PTION
....................................................................................................5-15
H
OSE KIT
- G
ENERATOR
O
PTION
.................................................................................................5-17
L
IFT
C
YLINDER
, 3072RT ...........................................................................................................5-19
L
IFT
C
YLINDER
, L
OWER
, 3772RT ................................................................................................5-21
L
IFT
C
YLINDER
, U
PPER
, 3772RT ................................................................................................5-23
S
TEERING
C
YLINDER
..................................................................................................................5-25
O
UTRIGGER
C
YLINDER
(O
PTION
) ..................................................................................................5-27
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-1
11
19
18
21
15
22 2 3
17
1
7
RIGHT
BA
CK
LEFT
FRONT
19
17
14
1 3
ART_91140-A SS Y
March 2008
Page 5-2
21
3
8
10
9
18
20
16
14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
6
1
12
7
1
4
5
2
25
24
ITEM PART NO.
QTY DESCRIPTION
M
ANIFOLD
A
SSEMBLY
91140 MANIFOLD ASSEMBLY
1 91141
2 91142
3 91143
4 91144
5 91145
6 91146
7 91147
8 9114 8
9 91149
10 91150
11 91151
12 91152
13 91153
14 91154
15 91350
16 91353
17 HDW7314
HDW7061
1 8 74 8 4
HDW743 8
19 91351
20 91355
21 91356
22 91012
23 91354
24 91015
25 91352
3
2
1
1
2
1
1
1
1
2
2
1
1
4
1
1
2
2
2
1
1
2
2
2
2
1
1
COIL, SERIES 8 , 12V
COIL, SERIES 10, 12V
COIL, SERIES 10 E-COIL, 12V
VALVE, DRIVE, 4 WAY 3 POSITION
VALVE, LIFT SPOOL, 3 WAY
VALVE, STEER, 4 WAY 3 POSITION
VALVE, SERIES PARALLEL SPOOL, 4 WAY 3 POSITION
VALVE, PROPORTIONAL, 12 V
VALVE, RELIEF, LIFT
VALVE, RELIEF, STEER
VALVE, PILOTED SPOOL 4 WAY 3 POSITION
VALVE, PILOTED POPPET
VALVE, LOAD SHUTTLE CHECK
VALVE, LOAD SHUTTLE CHECK
VALVE, COUNTERBALANCE
VALVE, CHECK
PORT PLUG M ¼", O-RING, RBG-4
ADAPTER (W/ OUTRIGGER OPTION)
PORT PLUG M 0.3
8 " O-RING, RBG-6
ADAPTER (W/ OUTRIGGER OPTION)
FLOW DIVIDER / COMBINER
ORIFICE PLUG, STEER
ORIFICE PLUG, FLOW DIVIDER BLEED
VALVE, MANUAL — PULL
ORIFICE DISC
HAND PUMP, BRAKE RELEASE
PRESSURE COMPENSATOR
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-3
29
28
29
3 8
3 0
3 1
29
28
RIGHT
BA
CK
LEFT
FRONT
3 1
3 2
3 5
3 4
3 6 3 7
ART_91140-A SS Y-HDW
March 2008
Page 5-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
M
ANIFOLD
A
SSEMBLY
– H
ARDWARE
2 8 HDW9124 8 3 ELBOW, 90°, MALE, ½", O-RING, MALE, ½", MB-MJ90LL8 8
29 HDW90764 5 ELBOW, 90°, MALE, ½", O-RING, MALE, ½", MB-MJ908 8
30 HDW 88 77 2 ELBOW, 90°, MALE ¼” O-RING, MALE ¼”, MB-MJ90-4-4
31 HDW910 8 1 1 ELBOW, 90°, MALE ¼” O-RING, MALE ¼”, MB-MJ90LL-4-4
32 HDW91244 1 ELBOW, 90°, MALE ¾” O-RING, MALE ¾”, MB-MJ90-12-12
34 HDW91245 1
35 HDW9157 1
36 HDW7971 1
37 HDW91243 1
3 8 HDW 888 1 1
ELBOW, 90°, M ¾” O-RING, M ¾”,MB-MJ90LL-12-12
ELBOW, 90°, M .37 JIC, M .37 O-RING, MB-MJ90LL-6-6
FITTING, MALE DISCONNECT, ¼" NPT
ADAPTER MALE ¼" ORNG M ¼" NTP, MP-MB-4-4
ADAPTER, MALE ¼”, O-RING, MALE ¼” 37° MB-MJ-4-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-5
MAIN MANIFOLD
LEFT
FRONT
RIGHT
BA
CK
OUTRIGGER EXTEND
OUTRIGGER RETRACT
5
6
2
1
2
ORB
OR S
ORR
ORL S
ORA
3
TO
OUTRIGGER S
CYLINDER S
TO
MAIN MANIFOLD OR S
4
TO
MAIN MANIFOLD ORR
TO
MAIN MANIFOLD ORL S
ART_91268A SS Y
March 2008
Page 5-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
TO
OUTRIGGER S
CYLINDER S
ITEM PART NO.
QTY DESCRIPTION
M
ANIFOLD
- O
UTRIGGER
(O
PTION
)
1
3
5
9126
HDW
8
2 HDW7601
888 1
4 HDW743 8
91142
6 9100 8
SEE HOSE KIT FOR HOSES
1 MANIFOLD ASSEMBLY
3
1
1
2
1
ELBOW 90° MALE 3/ 8 " O-RING - MALE 3/
ADAPTER MALE ¼" O-RING - MALE ¼" JIC
ADAPTER MALE 3/
COIL
8 " O-RING - MALE 3/
VALVE SPOOL 4-WAY 3-POSITION
8
8 " JIC
" JIC
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-7
OPTIONAL OUTRIGGER S
5
6
8
7
POWER
CABINET
3
4
1
9
10
CONTROL
CABINET
2
1
OPTIONAL OUTRIGGER S
ART_X72HosesAxles
March 2008
Page 5-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
- A
XLES
9027 8 HOSE KIT
1 91263
2 93 8 9
3 93 8 6
4 91261
5 9125 8
6 91257
7 91260
8 91259
9 91192
10 91193
4
2
1
1
1
1
1
1
4
4
HOSE ASSY, ½"×37", 8 M3K8 FJX8 FJX90S-37"
HOSE ASSY, ½" × 44", 8 M3K8 FJX8 FJX
HOSE ASSY, ½" × 6 8 ", 8 M3K8 FJX8 FJX-6 8 "
HOSE ASSY, ½" × 61", 8 M3K8 FJX8 FJX
HOSE ASSY, ½" × 57", 8 M3K8 FJX8 FJX45
HOSE ASSY, ½" × 49", 8 M3K8 FJX8 FJX45
HOSE ASSY, ½" × 9 8 ", 8 M3K8 FJX8 FJX45
HOSE ASSY, ½" × 8 4", 8 M3K8 FJX8 FJX45
ADAPTER MALE ½" JIC - ½" JIC BULKHEAD
JAMNUT ¾-16
CONTINUED…
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-9
OPTIONAL OUTRIGGER S
12
11
11
1
14
11
POWER
CABINET
11
18
11
17
18
15
15
CONTROL
CABINET
16
11
3
OPTIONAL OUTRIGGER S
ART_X72HosesS teer
March 2008
Page 5-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
S
TEERING
, B
RAKE
R
ELEASE AND
A
XLE
R
ETURN
9027 8 HOSE KIT CONTINUED
11 645 8
12 9227
13 91256
14 91255
15 90275
16 91254
17 HDW9557
1 8 91249
2
1
3
1
2
1
1
HOSE, RETURN LINE, CUT TO LENGTH
HOSE ASSY, ¼"× 8 3", 4G1-4FJX-4FJX90S
HOSE ASSY, ¼"×42", 4G1-4FJX-4FJX90S
HOSE ASSY, ¼" × 15", 90°, 4G1-4FJX-4FJX90S
HOSE ASSY, ¼" × 17", 4G1-4FJX-4FJX
HOSE ASSY, ¼" × 6 8 ", 4G1-4FJX-4FJX
TEE M 0.25 JIC M 0.25 JIC
TEE M 0.31 HS BR BNN
CONTINUED…
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-11
OPTIONAL OUTRIGGER S
25
24
2 3
20
22
POWER
CABINET
21
PUMP
CA S E
DRAIN
S UCTION
LOAD S EN S E
3 0
29
26
27
PRE SS URE
28
CONTROL
CABINET
ART_X72HosesPump
March 2008
Page 5-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
P
UMP AND
R
ETURN
9027 8 HOSE KIT CONTINUED
`
20 90276
21 9 8 47
22 91264
23 91247
24 HDW91246 2
25 91265 1
26 91161
27 91162
1
1
2 8 91163 1
29 HDW91176 1
30 HDW 88 77 2
1
1
HOSE ASSY, ¼"×24",( 4G1-4FJX-6FJX-24)
HOSE ASSY, ¼" × 76", (4G1-4FJX-4FJX)
HOSE ASSY, ¾" × 66", (12M3K-12FJX-12FJX45)
6FT HOSE ASSY, ¾", 12LOLA BULK
FITTING FEMALE ¾" JIC MALE ¾" HOSE BARB
HOSE ASSY, 1" × 22", (16GMV-16FJX-16FJX-22")
FLANGE KIT #16
FLANGE KIT #12
ADAPTER ¾" FLANGE, MALE ¾" JIC 90°
ADAPTER 1" FLANGE, MALE 1" JIC
ELBOW, 90°, MALE ¼" O-RING, MALE ¼" JIC
LIFT HOSES
SEE CYLINDER ART
CONTINUED…
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-13
33
33
3 5
3 2
3 1
3 2
POWER
CABINET
3 8
3 4
3 7
3 6
CONTROL
CABINET
3 9
3 1
33
33
3 5
3 2
ART_X72HosesOutrig
March 2008
Page 5-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
3 2
ITEM PART NO.
QTY DESCRIPTION
H
OSE
K
IT
O
UTRIGGER
O
PTION
9027 8 HOSE KIT
31 91047
32 91346
33 91347
34 HDW7391
35 HDW9557
36 903 8
37 90316
3 8 759 8
39 8 31 8
4
2
4
4
4
HOSE ASSY, ¼"×63" (4G1-4FJX-6FJX)
HOSE ASSY, ¼"×35" (4G1-4FJX-4FJX90 S)
HOSE ASSY, ¼"×5 8 " (4G1-4FJX-4FJX90 S)
TEE, MALE 3/ 8 " JIC
TEE, MALE ¼" JIC
2
1
HOSE ASSY, 3/ 8 "×46" (6M3K-6FJX-6FJX)
HOSE ASSY, ¼"×21" (4G1-7FJX-7FJX)
1 HOSE ASSY, 3/ 8 "×2 8 " (6M3K-6FJX-6FJX)
1 HOSE ASSY 3/ 8 "×24" (6M3K-6FJX-6FJX90)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-15
HYDRAULIC TANK
March 2008
Page 5-16
5
9
EXISTING HOSE
FILTER
TANK RETURN
BACK
MAIN HYDRAULIC
MANIFOLD
LEFT S IDE
T
2
1
6
GENERATOR
& GEAR PUMP
7
3
ORLS
EXISTING HOSE
P
4
9
PRESSURE
PORT
8
HYDRAULIC
PUMP
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
H
OSE KIT
- G
ENERATOR
O
PTION
1 91346
2 8 317
3 91259 1
4 HDW91467 1
1
1
5 HDW91466 1
6 HDW 88 77 1
HOSE ASSY, ¼" × 35" (4GI–4FJX–4FJX90S)
HOSE ASSY, ½" × 19" (
HOSE ASSY, ½" × 8 4" (
8
8
M3K–
M3K–
8
8
FJX–
FJX–
8
8
FJX)
FJX45)
ADAPTER, TEE, ¾" W/SWIVEL FEMALE
ADAPTER, TEE, ¾" MALE O-RING, ¾" MALE JIC
ADAPTER, MALE ¼" O-RING, MALE ¼" JIC 90°
7 HDW90764 1
8 HDW90967 1
ADAPTER, MALE ½" O-RING, MALE ½" JIC 90°
ADAPTER, MALE 5/ 8 " O-RING, MALE ¼" JIC 90°
9 HDW9146 8 1 ADAPTER, FEMALE ¾" JIC, MALE ½" JIC 90°
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-17
5
1
S eal Kit
Rod
Rod Wiper
Rod S eal
S eal Retainer
S tatic S eal
Wear Ring
8
14
Wear Ring
Piston S eal
Wear Ring
Piston
12
Barrel
TO
R
E
S
ER
VO
IR
5
9
15
16
7
6
5
11
4
3
2
5
ART 91020
March 2008
Page 5-18
91020 LIFT CYLINDER WITH BEARING S
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, 3072RT
1 91020
2 909 8 5
3 HDW7601
4 90361
5 6669
6 91051
7 91141
8 HDW6727
9 HDW 8 152
1
1
2
4
1
1
1
1 CYLINDER, LIFT 3072RT
1 HOSE ASSEMBLY, 3/ 8 "
FITTING, ELBOW ADAPTOR
ORIFICE
BEARING, 2" ID × 2" LG
VALVE, 2 WAY, N.C. CABLE ATTACH
COIL, 12 VOLT, DEUTSCH
FITTING, PIPE 90°, MALE BARB
SCREW, ¼" - 20 × ¾" LG
11 16062
12 645 8
1 BRACKET, LIFT CYLINDER VALVE GUARD
21 FT HOSE, RETURN LINE
14 77 88
15 911 8 2
16 HDW91240 1
1 CLAMP, HOSE
1 CABLE, E-DOWN
NUT, COUPLING 10-32 × ¾"
91460
N/A 91069
REF KIT, SEAL-LIFT CYLINDER (SERVICE)
1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-19
8
14
12
Rod
Rod Wiper
Rod S eal
S eal Retainer
S tatic S eal
S eal Kit
Wear Ring
Piston S eal
Wear Ring
Piston
Barrel
5
ART 91 3 14LiftCyl
March 2008
Page 5-20
5
1
15
11
9
6
5
16
91 3 14 LIFT CYLINDER WITH BEARING S
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
4
3
18
TO
RE
S
ER
VOIR
17
18
12
5
2
TO
MANIFOLD
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, L
OWER
, 3772RT
1 91314
2 9039
3 HDW7601
4 90361
5 90993
6 91462
1
1
1
1
4
1
CYLINDER, LOWER LIFT, 3772RT
HOSE ASSEMBLY, LIFT CYLINDER 3/ 8 "
FITTING, ELBOW 90°, .37JIC × 37 ORING
ORIFICE
BEARING, BRONZE, 2" ID × 2" LG
VALVE, 2 WAY, N.C. POPPET DUAL COIL
8 HDW6727
9 HDW 8 152
1
2
FITTING, PIPE 90°, MALE BARB
SCREW, ¼" - 20 × ¾" LG
11 16062
12 645 8
1 BRACKET, LIFT CYLINDER VALVE GUARD
21 FT HOSE, RETURN LINE
14 77 88
15 90969
16 91141 2
17 HDW90943 1
1 8 HDW90945 2
1 CLAMP, HOSE, 5/ 8 MAX
1 RELIEF VALVE
COIL, 12 VOLT, DEUTSCH CONNECTOR W/DIODE
FITTING, TEE ADAPTOR
FITTING, FEMALE SWIVEL
909 88
N/A 910 8 5
REF KIT, SEAL-LIFT CYLINDER - LOWER (SERVICE)
1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-21
S eal Kit
Rod
Rod Wiper
Rod S eal
S eal Retainer
Wear Ring
Piston
Barrel
5
ART 91 3 15 LiftCyl
March 2008
Page 5-22
5
1
15
11
5
6
9
4
3
TO RESER
VOIR
8
14
12
5
2
16
91 3 15 LIFT CYLINDER WITH BEARING S
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
L
IFT
C
YLINDER
, U
PPER
, 3772RT
1 91315
2 91377
3 HDW7601
4 90439
5 90993
6 91462
1
1
1
1
4
1
CYLINDER, UPPER LIFT, 3772RT
HOSE ASSEMBLY, LIFT CYLINDER 3/ 8 " × 370"
FITTING, ELBOW ADAPTOR
ORIFICE
BEARING, BRONZE, 2" ID × 2" LG
VALVE, 2 WAY, N.C. DUAL COIL
8 HDW6727
9 HDW 8 152
1
2
FITTING, PIPE 90°, MALE BARB
SCREW, ¼" - 20 × ¾" LG
11 16062
12 645 8
14 77 88
15 90969
16 91141
1 BRACKET, LIFT CYLINDER VALVE GUARD
40 FT HOSE, 5/16", RETURN LINE
1
1
2
CLAMP, HOSE
RELIEF VALVE
COIL, 12 VOLT, DEUTSCH CONNECTOR W/DIODE
909 8 7 REF KIT, SEAL-LIFT CYLINDER (SERVICE)
N/A 910 8 6 1 HARNESS, WIRE DOWN, VALVE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-23
1
2
PI S TON
PI S TON S EAL
WEAR RING
S EAL KIT
S TATIC S EAL
ROD S EAL
ROD WIPER
S EAL
RETAINER
ART_91019-EXP
March 2008
Page 5-24
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
3
4
ITEM PART NO.
QTY DESCRIPTION
S
TEERING
C
YLINDER
91019 STEERING CYLINDER
1 HDW 888 1
2 HDW 88 76
3 HDW5925
4 7293
1
1
1
1
ADAPTER MALE ¼" O-RING-MALE ¼" JIC
ADAPTER MALE ¼ O-RING-MALE ¼" JIC TEE
JAMNUT 5/ 8 -1 8
ROD END
90990 REF SEAL KIT (SERVICE)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-25
11
9
8
10
1
2
7
6
4
5
WEAR RING
PI S TON S EAL
S TATIC S EAL
ROD S EAL
ROD WIPER
PI S TON
S EAL
RETAINER
ART_91278-A SS Y
March 2008
Page 5-26
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
O
UTRIGGER
C
YLINDER
(O
PTION
)
1 9127 8
2 912 8 1
4
1
CYLINDER, OUTTRIGGER
SWITCH, OUTRIGGER PRESSURE N.O.
4 10907
5 HDW 8 476
6 HDW9761
7 91277
8 91464
9 91141
10 HDW91465 2
2
2
1
1
1
1
11 90439 1
WASHER ACTUATOR
NUT JAM ¼-20
SCREW, SOCKET HEAD ¼-20 × 2½
SWITCH, OUTRIGGER RETRACT LIMIT N.O.
VALVE N.C. POPPET
COIL 12V DEUTSCH
ADAPTER 3/ 8 MALE O-RING, ¼ MALE JIC
ORIFICE
91463 REF SEAL KIT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 5-27
March 2008
Page 5-28
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 6:
BASE
SECTION 6: ........................................................................................................................... 6-1
BASE ..................................................................................................................................... 6-1
B
ASE
A
SSEMBLY
......................................................................................................................... 6-3
B
ALLAST
(C
OUNTERWEIGHT
) I
NSTALLATION
...................................................................................... 6-5
M
ODULES
I
NSTALLATION
............................................................................................................... 6-7
C
ONTROL
M
ODULE
...................................................................................................................... 6-9
P
OWER
M
ODULE
.......................................................................................................................6-13
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
...................................................................................6-17
E
NGINE
, D
UAL
F
UEL
..................................................................................................................6-21
E
NGINE
, D
IESEL
........................................................................................................................6-25
W
IRE
H
ARNESS
.........................................................................................................................6-29
O
UTRIGGER
I
NSTALLATION
............................................................................................................6-31
G
ENERATOR
- O
PTION
, D
UAL
F
UEL
...............................................................................................6-33
G
ENERATOR
- O
PTION
, D
IESEL
.....................................................................................................6-35
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-1
7
14
7
14
10
1 3
6
2
1
12
11
10
15
12
16
ART_X72 Base Assy
March 2008
Page 6-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
12
14
ITEM PART NO.
QTY DESCRIPTION
B
ASE
A
SSEMBLY
1 40159
2 16160
16293
6 16206
7 14993
1
1
1
1
2
BASE WELDMENT
LADDER WELDMENT, 3072RT STANDARD
LADDER WELDMENT, 3772RT STANDARD
COVER, SLIDER PAN
SUPPORT, MODULE
10 HDW8283 16 SCREW, ½" - 13, 1 ½" LG. GR8
11 HDW8531 4 WASHER, .531 ID × 1.0 OD × .063 THK
12 HDW8457 16 NUT, ½" - 13, GR 5
13 HDW5723 12 SCREW, ¼–12 × ¾"
14 HDW8267 12 NUT, ¼-20
15
16
16735
90749
7617
1
1
Serial Number Break
3072RT: 9201083 and up — 3772RT: 9301182 and up
On previous models, Power to Platform Plug was located in the Control Module (see Page 6-9)
BRACKET, POWER TO PLATFORM
POWER TO PLATFORM PLUG
50' WIRE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-3
1
2
3
8
7
3 072RT
3 772RT
1
3
5
6
4
2
3
8
ART_X72Ballast
March 2008
Page 6-4
7
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
4
3
5
6
ITEM PART NO.
QTY DESCRIPTION
B
ALLAST
(C
OUNTERWEIGHT
) I
NSTALLATION
1 40159
2 HDW8457
REF BASE WELDMENT
8 NUT, LOCK, ½”-13, GR 5
3 HDW13195 16 WASHER, FLAT, .515 ID × 1.512 OD × .098 THK
4 40590 1 BAR, BALLAST WEIGHT
5 HDW90460 16 WASHER, FLAT, .531 ID × 2.000 OD × .062 THK
6 HDW90951 4 SCREW, ½”-13, 6” LG, GR 5
7 HDW7018
8 90406
90406
4
6
SCREW, ½”-13, 3” LG, GR 5
PLATE, BALLAST WEIGHT 3072RT
12 PLATE, BALLAST WEIGHT 3772RT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-5
1
10
3
8
5
10
6
7
4
7
2
ART_X72CabinetInstall
March 2008
Page 6-6
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
M
ODULES
I
NSTALLATION
1 16156
16220
2 8386
3 16213
4 16165
4 16313
5 16153
6 16164
7 HDW5723
8 HDW5417
9 HDW5355
10 HDW8267
8
8
1
1
8
8
4
1
1
1
1
1
DOOR WELDMENT, CONTROL MODULE
DOOR WELDMENT, POWER MODULE (NOT SHOWN)
LATCH TRIGGER
CABINET WELDMENT, ENGINE
COVER, HOSE TRAY, LH 3072RT
COVER, HOSE TRAY, LH 3772RT
CABINET WELDMENT, CONTROL MODULE
COVER, HOSE RH
BOLT, ¼”-20, ¾” LG, GR 5
SCREW, 3/8”-16, 1.25” LG, GR 8
WASHER, .438 ID × 1.000 OD × .078 THK
NUT, ¼-20
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-7
40
44
16
16
3
33
4
3 0
4 3
41
16
42
46
29
5
2 8
3 2
5 3
4 8
5 8
56
55
16
52
16
57
5
54
5
17
45
47
16
51
12
1 3
49
50
10
7
1
8
Note: Power to Platform re-located to the base near the ladder
15
5
1 3
14
1 8
5
16
2
4 5
20
6
3
19
X72_Control-CabAN S I
March 2008
Page 6-8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
M
ODULE
1 16153
2 14896
3 HDW8273
4 HDW5217
1
4
4
4
CONTROL MODULE WELDMENT
BLOCK, SLIDE, DOOR
SCREW, ¼–20, 1" LG
WASHER, .343 ID × .680 OD × .063 THK
5 HDW8267 18 NUT, ¼–20, GR 5
6 16154 1 BRACKET, CROSS SUPPORT
7
8
HDW5724
7115
4
1
SCREW, 5/16–18, ¾" LG, GR 5
HOLE PLUG
Power to Platform Plug re-located
10 25429
12 91140
13 HDW6433
14 HDW7783
15 16225
2
1
4
4
1
(RT: see Page 6-3 – HD: see Page 6-31)
PAD
HYDRAULIC MANIFOLD
SCREW, 3/8 × 1"
LOCK WASHER, 3/8
BRACKET, FUEL TANK
16 HDW5723 18 SCREW, ¼-20 × ¾"
17 16152
18 HDW8268
19 91023
1
5
1
BULKHEAD
NUT, 3/8
FUEL TANK, PLASTIC
20 91091
6919
HDW91279 1
7788 1
1
1
FUEL TANK CAP
FUEL SHUTOFF (NOT SHOWN)
ADAPTER, MALE 1/8 NPT, 5/16 HOSE BARB (NOT SHOWN)
CLAMP (NOT SHOWN)
6458 72" HOSE, FUEL LINE (NOT SHOWN)
HDW91233 1 PLUG (DUAL FUEL) 1/8 NPT, 3/19 HOSE BARB (NOT SHOWN)
HDW91320 1 ADAPTER (DIESEL)
28 16226
29 HDW7888
30 91169
91170
32 91375
2
1
1
4
1
BRACKET, CONTROL BOX
SCREW, 10-32 × ½"
LOWER CONTROL BOX
HARNESS, MAIN (NOT SHOWN)
RELAY, SPEED/TORQUE, DRIVE
CONTINUED …
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-9
40
44
16
16
3
33
3
4
0
4 3
41
16
42
46
29
5
2 8
3 2
5 3
4 8
5 8
56
55
16
52
16
57
5
54
5
17
45
47
16
51
12
1 3
49
50
10
7
1
8
Note: Power to Platform re-located to the base near the ladder
15
5
1 3
14
1 8
5
16
2
4 5
20
6
3
19
X72_Control-CabAN S I
March 2008
Page 6-10
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
ITEM PART NO.
QTY DESCRIPTION
C
ONTROL
M
ODULE
C
ONTINUED
33 16229
34 8841
9438
9012
9013
7172
7173
1
1
1
1
1
1
1
BATTERY DISCONNECT BRACKET
BATTERY DISCONNECT
BATTERY CABLE, RED, 15 INCH LONG (NOT SHOWN)
BATTERY CABLE, RED, 72 INCH LONG (NOT SHOWN)
BATTERY CABLE, BLACK, 72 INCH LONG (NOT SHOWN)
BOOT, BLACK (NOT SHOWN)
BOOT, RED (NOT SHOWN)
40 6854
41 2987
42 HDW6110
43 3436
44 91174
2
1
1
2
1
BATTERY, 12VDC
HOLD DOWN ROD
WING NUT
HOLD DOWN BAR
LEVEL SENSOR
45 91280 1
46 HDW90880 4
OUTRIGGER OPTION
CONTROL MODULE (OUTRIGGER OPTION)
SCREW, 10-32 × 1"
47 HDW90803 4 NUT, 10-32 NYLOCK
48 91375 1 RELAY (OUTRIGGER OPTION)
49 91268 1
50 HDW91332 2
51 HDW8304 2
OUTRIGGER MANIFOLD, (OPTION)
SCREW, 5/16-18 × 3½"
NUT, 5/15-18
52 16620
53 16619
54 90898
55 25480 1
56 HDW90833 2
57 HDW5364
58 7423
2
1
91072
90905
1
1
1
1
1
3772RT EMERGENCY LOWERING
BATTERY SHELF (3772RT)
BATTERY BRACKET (3772RT)
BATTERY, 12VDC (3772RT)
BRACKET, EMERGENCY DOWN SWITCH (3772RT)
SCREW, 6–32 × ¾" LG
NUT, 6 –32
SWITCH, TOGGLE, 1 POLE 2 POS (3772RT)
HARNESS, E-DOWN TO BATTERIES (NOT SHOWN)
HARNESS, E-DOWN W/DIODE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-11
11
5
7
6
19
1 8
3 5
3
4
16
14
1 3
17
8
9
10
15
2
12
1
ART_CabinetPower-X72
March 2008
Page 6-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
1 16213
2 16247
3 25429
4 40620
5 14896
6 14826
7 HDW8273
8 HDW5217
9 HDW8267
10 HDW5724
4
4
4
4
REF WELDMENT, POWER MODULE
1 GUARD, ENGINE MODULE
2
2
PAD
SPACER, INSULATOR, 1.59" LG
4
1
BLOCK, SLIDE, DOOR
BRACKET, CROSS SUPPORT
SCREW, ¼–20, 1" LG
WASHER, .343 ID × .680 OD × .063 THK
NUT, ¼–20, GR 5
SCREW, 5/16–18, ¾" LG, GR 5
11 9370
12 HDW9200
13 HDW6727
14 HDW7500
15 91164
16 6714
17 HDW9268
18 6156
19 9367
1
1
1
1
2
1
1
1
1
HYDRAULIC TANK INSTALLATION
LEVEL GUAGE
PLUG, ¼ NPT
ELBOW, 90° ¼ NPT – 5/16 BARB
ELBOW, 90° ¼ NPT – 3/8 JIC
ELBOW, 90° 1 1/8 NPT – 1 JIC
FILTER HEAD
ELBOW, 90° ¾ NPT – ¾ JIC
FILTER CARTRIDGE
FILLER/STRAINER
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-13
17
2
12
14
15
1 3
12
3
9
10
7
8
11
16
ART_EngineMount DF
March 2008
Page 6-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
UAL
F
UEL
2 16211
3 16210
2
2
ENGINE MOUNT, DUAL FUEL
SPACER
6 91131
7 91127
8 HDW5723
9 HDW8267
10 6458
11 16295
HDW5723
HDW8267
12 7736
13 40620
14 HDW8567
15 HDW8279
16 HDW8268
1
1
RADIATOR BRACKET KIT
COOLANT OVERFLOW TANK
3 FT HOSE
1 AIR INTAKE WELDMENT
4
4
8
4
2
4
2
2
4
SCREW, ¼-20 × ¾
NUT, ¼-20
SCREW, ¼-20 × ¾"
NUT, ¼–20, GR 5
INSULATOR RUBBER
SPACER ISOLATOR
WASHER, 3/8 FLAT
SCREW, 3/8-16 × 2 ½ GR8
NUT, 3/8-16
17 HDW91234 12 SCREW, M10-1.25 × 25 8.8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-15
17
2
12
14
15
4
3
1 3
12
9
10
7
8
11
16
ART_EngineMount D S L
March 2008
Page 6-16
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
P
OWER
M
ODULE
: E
NGINE
M
OUNT
- D
IESEL
2 16209
3 16210
4 16207
2
1
1
ENGINE MOUNT, DIESEL
SPACER
BRACKET, SOLENOID MOUNT
7 91127
8 HDW5723
9 HDW8267
10 6458
11 16295
HDW5723
HDW8267
1 COOLANT OVERFLOW TANK
2
2
SCREW, ¼-20 × ¾
NUT, ¼-20
3 FT HOSE
1 AIR INTAKE WELDMENT
2
4
SCREW, ¼-20 × ¾"
NUT, ¼–20, GR 5
12 7736
13 40620
14 HDW8567
8
4
4
INSULATOR RUBBER
SPACER ISOLATOR
WASHER, 3/8 FLAT
15 HDW8279
16 HDW8268
4
4
SCREW, 3/8-16 × 2 ½ GR8
NUT, 3/8-16
17 HDW91234 12 SCREW, M10-1.25 × 25 8.8
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-17
3
5
2
1
10
5
4
11
6
7
9
8
ART_X72-LP_IN S TALL
March 2008
Page 6-18
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
LP T
ANK
I
NSTALLATION
, D
UAL
F
UEL
1 6859
2 6868
3 6890
4 7406
5 HDW6894
6 6861
7 6860
8 16246
9 HDW6433
10 HDW8268
11 6938
1
1
1
1
3
1
LP TANK
QUICK DISCONNECT
HOSE ASSEMBLY, 30"
HOSE ASSEMBLY, 90"
ELBOW, BRASS, NPT TO SAE
BULKHEAD FILTER
6
6
1
1
BRACKET, TANK MOUNT
TANK SUPPORT WELDMENT
SCREW, 3/8-16 × 1"
LOCKNUT, 3/8
1 RELIEF VALVE
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-19
48
24
20
47
22
23
19
10
12
8 50
25
46
21
26 27
Coil
15 16
17 18
11
13
5
4
6
3
42
41
30
45
32
9
43
3772RT
Exhaust Setup
31
3072RT
Exhaust Setup
53
34
52
2
35
28 29
44
52
54
39
51
40
37
36
1
7
14
33
49
ART_2490
March 2008
Page 6-20
Dual Fuel Engine, Kubota DF752
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
UAL
F
UEL
91035
1 91125
1
1
ENGINE SUBASSEMBLY, DUAL FUEL
ENGINE, KUBOTA DF752
2 90239
3 20212
4 9502
5 9498
6 20204
1
1
1
1
1
MUFFLER
CHOKE BRACKET
CHOKE SOLENOID
CHOKE LINKAGE
SPACER
7 HDW91283 1
8 91133 1
9 91188
10 21020
1
1
11 91119
12 91177
13 91375
14 9252
1
1
1
1
SCREW, M6–1.0 × 25
CARBURETOR FLANGE
INTAKE HOSE
BRACKET, COMPONENTS
SOLENOID, THROTTLE
FUEL PUMP
RELAY, THROTTLE
THROTTLE LINKAGE
15 HDW9247 1 SCREW, CAP SOCKET HEAD, ¼–28 × 1.0"
16 HDW91231 2 JAMNUT, ¼–28
17 HDW5723 6 SCREW, ¼-20 × ¾"
18 HDW8267
19 6458
20 7788
21 HDW8303
22 HDW8304
23 91132
24 HDW6894
25 91197
26 91198
27 91232
28 91175 1
29 HDW91187 1
30 90227 1
6 NUT, ¼–20
REF HOSE, FUEL, 5/16
5
2
HOSE CLAMP, 5/16
SCREW, 5/16–18 × 2
2
1
NUT, 5/16–20
VALVE, LOCKOFF
1 ELBOW, 90° BRASS
10 IN LP HOSE, ½"
60 IN RADIATOR HOSE, 3/8"
6 HOSE CLAMP, #8
OIL PRESSURE SWITCH
FITTING, 1/8 NPT, M-F
ALTERNATOR, 40 AMP
CONTINUED . . .
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-21
48
24
20
47
22
23
19
10
12
8 50
25
46
21
26 27
Coil
15 16
17 18
11
13
5
4
6
3
42
41
30
45
32
9
43
3772RT
Exhaust Setup
31
3072RT
Exhaust Setup
53
34
52
2
35
28 29
44
52
54
39
51
40
37
36
1
7
14
33
49
ART_2490
March 2008
Page 6-22
Dual Fuel Engine, Kubota DF752
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
UAL
F
UEL
(
CONTINUED
)
31 91129
32 91340
33 7545
34 91376
35 91134
36 9696
37 9868
38 40620
39 HDW8279
40 HDW8268
41 91130
42 91160
43 HDW6433
44 8516
45 8472
46 9833
47 8514
48 7406
49 91136
50 91617
51 8365
52
53 16372
54 91637
2
1
1
1
1
2
KTR HOUSING KIT, DF752
HOSE, 2.00" I.D. FLEX
HOSE CLAMP
DOWN PIPE (3772RT ONLY)
EXHAUST PIPE
MUFFLER HANGER
2
1
1
1
1
1
2
1
MUFFLER CLAMP
SPACER
SCREW, 3/8–16 × 2 ½"
NUT, 3/8–16
HUB
HYDRAULIC PUMP
SCREW, 3/8-16 × 1"
OIL FILTER
1 RADIATOR
1 LPG REGULATOR
1 FUEL FILTER
REF HOSE ASSEMBLY, LP
1 AIR FILTER ELEMENT
1
1
CARBURETOR ASSEMBLY
STARTER
2
1
4
EXHAUST GASKET
SPACER (3072RT ONLY)
EXHAUST STUD (3072RT ONLY)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-23
28
23 24
18 39
19
Throttle Relay
37
20
21
25
Glow Plug Relay
41
40
3
27
38
1
2
36
13
15
14
16
26
34
ART_2491
March 2008
Page 6-24
11
32
30
29
35
5
4
6 7 31
Engine, Diesel, Kubota D950, X72RT Configuration
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
IESEL
91036
1 91110
2 91113
9831
1
1
ENGINE SUBASSEMBLY, DIESEL
ENGINE KIT, D905
RADIATOR KIT
RADIATOR
1 3 91111
8667
4 91115 1
AIR CLEANER KIT
AIR FILTER ELEMENT
MUFFLER KIT
5
9830
91118
6 9696
7 9868
8 40620
9 HDW8279
10 HDW8268
11 91175 1
12 HDW91187 1
1
1
1
1
1
1
13 91116
91123
1
MUFFLER
EXHAUST PIPE
MUFFLER HANGER
MUFFLER CLAMP
SPACER
SCREW, 3/8–16 × 2 ½"
NUT, 3/8–16
OIL PRESSURE SWITCH
FITTING, 1/8 NPT, M–F
FUEL FILTER ASSEMBLY
FUEL FILTER ELEMENT
14 6458
15 91199
16 91114
17 7788
18 91589
19 16207
20 10695
21 91117
8 FT HOSE, FUEL, 5/16
6 FT HOSE, FUEL, 3/16
1
5
1
1
1
1
VALVE, CHECK
HOSE CLAMP
SOLENOID, THROTTLE
BRACKET, SOLENOID
THROTTLE STUD
CLEVIS
22 HDW91231 2 JAMNUT, ¼–28
23 HDW5723 2 SCREW, ¼–20 × ¾"
24 HDW8267
25 91112
2
1
NUT, ¼–20
KTR HOUSING KIT, D905
CONTINUED…
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-25
28
23 24
18 39
19
Throttle Relay
37
20
21
25
Glow Plug Relay
41
40
3
27
38
1
2
36
13
15
14
16
26
34
ART_2491
March 2008
Page 6-26
11
32
30
29
35
5
4
6 7 31
Engine, Diesel, Kubota D950, X72RT Configuration
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
E
NGINE
, D
IESEL
(
CONTINUED
)
26 91375
27 7545
2
2
RELAY
HOSE CLAMP
28 91340
29 91130
30 91160
31 HDW6433
32 91376
1
1
1
2
1
HOSE, 2.00" I.D. FLEX
HUB
HYDRAULIC PUMP
SCREW, 3/8-16 × 1"
MUFFLER EXTENSION (3772RT ONLY)
34 8665
35 8413
36 8001
37 90227
38 9832
OIL FLTER
STARTER
FUEL SOLENOID
ALTERNATOR
GLOW PLUGS
39 91588
40 16347
41 HDW5217
42 HDW91590 1
43 HDW5290 1
1
2
1
WASHER, ¼" RUBBER
THROTTLE LINK
WASHER, FLAT, 5/16"
CLEVIS PIN, 5/16" × 1"
COTTER PIN, 1/8" × 1"
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-27
FIXED CONTROL BOX
3
REMOVABLE CONTROL BOX
12
TERMINAL BLOCK ON UNDER S IDE
OF PLATFORM DECK
10
ART_2495
March 2008
Page 6-28
5
4
9
5
4
POWER MODULE
6
8
CONTROL MODULE
TO: GROUND
TO: S TARTER
17
16
11
7
15
1
14
2
1 3
Control Cable and Harnesses, RT Series
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
W
IRE
H
ARNESS
1 91170
2 91185
1
1
HARNESS, MAIN (ANSI) [CONTROL MODULE]
CONTROL CABLE, 3072RT
2 91321
3 91184
4 91294
5 91295
6 91296
1
1
1
1
1
CONTROL CABLE, 3772RT
HARNESS, CONTROL BOX [INSIDE UPPER CONTROL BOX]
CABLE, OUTRIGGER [UPPER CONTROL BOX]
CABLE, OUTRIGGER [DECK TO CONTROL BOX]
HARNESS, OUTRIGGER [CONTROL MODULE TO DECK]
7 91171
7 91543
1
1
HARNESS, ENGINE, INTERMEDIATE
HARNESS, ENGINE INTERMEDIATE, GENERATOR OPTION
[CONTROL MODULE TO ENGINE MODULE]
1
1
HARNESS, ENGINE, DUAL FUEL [ENGINE MODULE]
HARNESS, ENGINE, DIESEL [ENGINE MODULE]
8 91172
8 91173
9 91189
10 91557
11 91595
12
13 90905
14 91378
15 9438
16 9013
17 9012
1
1
1
1
1
1
1
1
CABLE, UPPER CONTROLS, REMOVABLE
CABLE, UPPER CONTROLS, FIXED
HARNESS, LOWER CONTROLS [INSIDE CONTROL BOX]
JOYSTICK CONTROL [INSIDE UPPER CONTROL BOX]
HARNESS, E-DOWN WITH DIODE (3772RT)
HARNESS, E-DOWN TO BATTERY (3772RT)
BATTERY CABLE, RED, 15 INCHES LONG
BATTERY CABLE, BLACK, 72 INCHES LONG
BATTERY CABLE, RED, 72 INCHES LONG
NS 91276
NS 91069
NS
NS
91085
91086
1
1
1
1
HARNESS, OUTRIGGER
[CONTROL MODULE TO OUTRIGGERS]
HARNESS, LIFT CYLINDER DOWN VALVE (3072RT)
[CONTROL MODULE TO LIFT CYLINDER]
HARNESS, LOWER LIFT CYLINDER DOWN VALVE (3772RT)
[CONTROL MODULE TO LIFT CYLINDER]
HARNESS, UPPER LIFT CYLINDER DOWN VALVE (3772RT)
[CONTROL MODULE TO LIFT CYLINDER]
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-29
1
11
10
7
8
7
4
6 7
14
2 3
22
3
2
12
1 3
7
14
15
20
16
5
1 8
19
5 7
21
17
10
9
3
2
ART_OutRigInst
March 2008
Page 6-30
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
O
UTRIGGER
I
NSTALLATION
1 16279 1 WELDMENT, OUTRIGGER MOUNT, REAR
2 HDW7938 16 SCREW, 5/8–11 × 3" LG
3 HDW6633 16 LOCKNUT, 5/8–11
4 21168 4 WELDMENT, OUTER OUTRIGGER
5 HDW7052
6 HDW8498
8
4
SCREW, ½–13 × 3 ½" LG
SCREW, ½–13 × 4"
7 HDW8457 20 NUT, ½–13
8 16258 1 LADDER, 3072RT W/OUTRIGGERS
16294
9 16278
1
1
LADDER , 3772RT W/OUTRIGGERS
WELDMENT, OUTRIGGER MOUNT, FRONT
10 21170 4 COVER, OUTRIGGER CYLINDER
11 HDW6455 20 SCREW, ¼–20 × ½"
12 HDW91328 4
13 91278 4
SHOULDER SCREW, 5/8 × 4.75"
CYLINDER, OUTRIGGER
14 90663
15 10335
16 HDW5916
64 SPACER
4 TUBE, INNER OUTRIGGER
4 SCREW, ½–13 × 4.0"
17 20998 4
18 HDW91395 4
19 HDW9219
20 HDW5920
21 21002 4
4
4
BRACKET PIVOT
CLEVIS PIN, 5/8 × 5.0"
WASHER, FLAT
PIN, COTTER, 1/8 × 1"
PAD WELDMENT
22 16735
23 90749
NS 7617
Serial Number Break
3072RT: 9201083 and up — 3772RT: 9301182 and up
On previous models, Power to Platform Plug was located in the Control Module (see Page 6-9)
1
1
BRACKET, POWER TO PLATFORM
POWER TO PLATFORM PLUG
50' WIRE (NOT SHOWN)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-31
TO:
BASE
CONTROL BOX
9
8
7
12
11
10
16
4
5
6
1
2
3
7
8
9
5
6
3
4
1
2
10
11
12
220
15
124
PLUGGED
00
00
16
15
225
116
23
22
RED
RED
FUSE
RED
BATTERY
ORG/GRN
BLK
1 2
6
85 86 87 87a 30
85 87a
87
YEL/RED
BLK
ORG/WHT
ORG
GRN/WHT
BLK/WHT
BLU/WHT
ORG/GRN 171
RED/GRN
BLK
2
PLUGGED
PLUGGED
PLUGGED
220
15
124
225
116
23
22
16
15
7
8
9
5
6
3
4
1
2
10
11
12
4
5
6
1
2
3
TO:
ENGINE
HARNESS
9
8
7
12
11
10
10
11
12
6
7
8
9
3
4
5
1
2
220
YEL/RED
15
124
BLK
ORG/WHT
225
116
ORG
16
15
ORG/GRN 171
Upper
Controls
STARTER
BATTERY +
10 GA RED 00
14 GA RED 00
RED/WHT 71
Throttle
S olenoid
Relay
85 87a
87
85
86
87
87a
30
ORG/GRN 171
ORG/BLK 325
BLK 15
5
3
4
Throttle
S olenoid
Control
Module
ART_2493
March 2008
Page 6-32
17
1 8
7
11
21
1
22
2 3
9
15
1 3
Gen Throttle
S olenoid
11
8
19
20
12
Generator Option, RT, Dual Fuel
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
G
ENERATOR
- O
PTION
, D
UAL
F
UEL
1
3
5
91550
2 5630
91551
4 91002
91546
6 91375
1
1
1
1
1
1
REFER TO PARTS SECTION 5 FOR HOSE KIT
GENERATOR, 2000 WATT
SWITCH, TOGGLE
VALVE, SOLENOID, 2-WAY, N.C.
COIL, 12V 10 SERIES
NEEDLE VALVE
RELAY. SPDT
7 91544
8 91545
9 7594
1
2
1
PLUG,MALE, 3 PRONG
RECEPTACLE, FEMALE
STRAIN RELIEF
11 7617
12 91556
13 9502
6 FT WIRE, 14GA, 3 CONDUCTOR
1 LABEL, AC GENERATOR
1 SOLENOID, GENERATOR-THROTTLE
15 91469
16 REF
17 6434
18 90480
19 8268
20 5204
21 8304
22 16369
23
2 FT CHAIN, SASH #8
1 HARNESS, ENGINE INTERMEDIATE, GENERATOR OPTION
4 BOLT
1
1
4 WASHER
4 NUT
4 BOLT
4 NUT
BRACKET, GENERATOR MOUNT
GROMMET (PUSH-ON WEATHER STRIPPING)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-33
TO:
BASE
CONTROL BOX
9
8
7
12
11
10
16
4
5
6
1
2
3
7
8
9
5
6
3
4
1
2
10
11
12
220
15
124
PLUGGED
00
00
16
15
225
116
23
22
RED
RED
FUSE
RED
BATTERY
ORG/GRN
BLK
Control
Module
1 2
6
85 87a
87
YEL/RED
BLK
ORG/WHT
ORG
GRN/WHT
BLK/WHT
BLU/WHT
ORG/GRN 171
RED/GRN
BLK
85 86 87 87a 30
2
RED/WHT 71
PLUGGED
PLUGGED
PLUGGED
220
15
124
225
116
23
22
16
15
7
8
9
5
6
3
4
1
2
10
11
12
4
5
6
1
2
3
TO:
ENGINE
HARNESS
9
8
7
12
11
10
10
11
12
6
7
8
9
3
4
5
1
2
220
YEL/RED
15
124
BLK
ORG/WHT
225
116
ORG
16
15
ORG/GRN 171
Upper
Controls
STARTER
BATTERY +
14 GA RED 00
12 GA RED 00
Preheat
Relay
Throttle
S olenoid
Relay
Gen Throttle
S olenoid
Relay
85 87a
87
85 87a
87
85 87a
87
85
86
87
87a
30
85
86
87
87a
30
85
86
87
87a
30
5
3
4
Glow Plugs
ORG/BLU 224
ORG/GRN 171
ORG/BLK 325
BLK 15
Throttle
S olenoid
14
6
17
1
1 8
7
11
21
22
2 3
9
15
1 3
Gen Throttle
S olenoid
11
8
ART_2494
March 2008
Page 6-34
19
20
12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Generator Option, RT, Diesel
ITEM PART NO.
QTY DESCRIPTION
G
ENERATOR
- O
PTION
, D
IESEL
1
3
5
91550
2 5630
91551
4 91002
91546
6 91375
1
1
1
1
1
2
REFER TO PARTS SECTION 5 FOR HOSE KIT
GENERATOR, 2000 WATT
SWITCH, TOGGLE
VALVE, SOLENOID, 2-WAY, N.C.
COIL, 12V 10 SERIES
NEEDLE VALVE
RELAY. SPDT
7 91544
8 91545
9 7594
1
2
1
PLUG,MALE, 3 PRONG
RECEPTACLE, FEMALE
STRAIN RELIEF
11 7617
12 91556
13 91589
14 91727
15 91469
16 REF
17 6434
18 90480
19 8268
20 5204
21 8304
22 16369
23
6 FT WIRE, 14GA, 3 CONDUCTOR
1
1
1
1
1
LABEL, AC GENERATOR
SOLENOID, GENERATOR-THROTTLE
BRACKET, SOLENOID MOUNT
2 FT CHAIN, SASH #8
1 HARNESS, ENGINE INTERMEDIATE, GENERATOR OPTION
4 BOLT
4 WASHER
4 NUT
4 BOLT
4 NUT
BRACKET, GENERATOR MOUNT
GROMMET (PUSH-ON WEATHER STRIPPING)
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 6-35
March 2008
Page 6-36
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
SECTION 7:
DECALS
SECTION 7: ........................................................................................................................... 7-1
DECALS ................................................................................................................................ 7-1
D
ECAL
K
IT
, U
PPER
C
ONTROL
B
OX
................................................................................................ 7-3
D
ECAL
K
IT
, S
IDES
, 3072RT ........................................................................................................ 7-5
D
ECAL
K
IT
, E
NDS
, 3072RT........................................................................................................ 7-7
D
ECAL
K
IT
, S
IDES
, 3772RT ........................................................................................................ 7-9
D
ECAL
K
IT
, E
NDS
, 3772RT........................................................................................................7-11
D
ECALS
- A
NCHORAGE
P
OINTS
O
PTION
.........................................................................................7-13
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 7-1
90729
1
2
91190
3
91158
6
7156
7156
7156
71
55
LO
CA
R
N
O
R
TE
C
M
A
L O
PE
NT
RO
R
AT
IO
N
L B
OX
O
F T
I
H
ER
S
U
N
IT
E
5
7155
LOCATE CONTROL BOX HERE
FOR NORMAL OPERATION OF THI S UNIT
7155
DRIVE
ENABLED
RET
RACT
AUTOMA
TIC
RS
OUTRIGGE EXTEND
HOLD SWITCH
DES
IRE
D DI
REC
IN
TIO
N
913
49
4
91 3 49
DRIVE
ENABLED
AUTOMATIC
OUTRIGGERS
RETRACT
EXTEND
HOLD SWITCH IN
DESIRED DIRECTION
91349
ART_Decals_UpCtrl-DOM
March 2008
Page 7-2
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, U
PPER
C
ONTROL
B
OX
1 DECAL, UPPER CONTROL BOX, SIDE 1 90729
2 91190 1 DECAL, CONTROL BOX MODEL, X72RT
3 9115 8
4 91349
5 7155
6 7156
1
1
1 DECAL, UPPER CONTROLS
1 DECAL, OUTRIGGER CONTROLS
DECAL, LOCATE CONTROL BOX HERE
DECAL, FRONT
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 7-3
3072RT
Control S ide
2
8402
1 3
907 3 2
12
9052
19
91109
11
90267
14
8867
15
6948
Dual Fuel
6
91221 Diesel 91157 Dual Fuel
Inside
Control
Cabinet
16
99 3 2
9910
3072RT
Power S ide
91156
1
8402
2
91156
9910
Inside Power Cabinet
10
687 3
HYDRAULIC OIL
687 3
H
YD
R
AU
LIC
O
IL
1
3
7982
9910
7
9910
4
850 3
9
90717
9910
9910
91266
5
9910
7
9910
MEC AERIAL PLATFORM SALES CORP.
SELMA, CA, USA 1775 PARK STREET, SUITE 77
0 m/s
12.5 m/s
MFG. DATE MODEL NUMBER ERIAL NUMBER
XX/XX XXXXXX XXXXXXXXX
MAX. ALLOWABLE MAX.
MAX. PLATFORM CAPACITY INCLUDING PER ON + XXX kg EQUIPMENT XXX kg = X PER ON
XXX kg = X PER ON + XXX kg EQUIPMENT
MANUAL FORCE XXX N
XXX N
X.X m
MODEL YEAR
20XX
PLATFORM HEIGHT
INCLINATION MAX. ALLOWABLE
X.X° x X.X°
100-220 VAC ELECTRICAL VOLTAGE
50/60 Hz
SS URE PER WHEEL MAX. GROUND
X.X kg/cm²
PER WHEEL
XXX kg
X.X m
MACHINE WEIGHT
XXXX kg
90982
18
90747 -or- 9155 3
March 2008
Page 7-4
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, S
IDES
, 3 072RT
1 91156
2 8 402
3 79 8 2
4 8 503
5 91266
6 91221
91157
7 9910
9 90717
10 6 8 73
11 90267
12 9052
13 90732
14 88 67
15 694 8
16 9932
2
2
2
1
2
1
1
4
1
1
1
1
1
1
1
1
DECAL, MEC 3072RT
DECAL, RAIL STRIPE
DECAL, SAFETY STRIPE
DECAL, KEEP CLEAR
DECAL, QUAD TRAX 4WD
DECAL, LOWER CONTROLS, DIESEL
DECAL, LOWER CONTROLS, DUAL FUEL
DECAL, PINCH POINT
DECAL, MAINTENANCE LOCK
DECAL, HYDRAULIC OIL
DECAL, BRAKE RELEASE
DECAL, BATTERY DISCONNECT AND LOCK
DECAL, WARNING, PRESSURE WASH
TAG, WARNING,
WARNING, LPG
DECAL, PLATFORM CAPACITY, SMALL
1 8 90747
1 8 91553
19 91109
1
1
1
SERIAL PLATE:
SERIAL PLATE:
BEFORE SN 9201060
AFTER SN 9201061
DIAGNOSTIC LABEL
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
March 2008
Page 7-5
3072RT
Front
17
90719
18
8519
3 0
8502
2 3
8911
24
907 3 9
8911
25
9 3 78
6872
Dual Fuel
29
9108 3
March 2008
Page 7-6
90721
19
90722
22
91155
90721
20
90721
21
907 3 0
18
8519
3 0
8502
26
6556
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
3072RT
Rear
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, E
NDS
, 3 072RT
17 90719
1 8 8 519
19 90722
20 90721
21 90730
22 91155
23 8 911
24 90739
25 937 8
6 8 72
26 6556
1
4
1
1
1
2
1
1
1
1
1
DECAL, MEC OVAL
DECAL, WARNING, TIRE REPLACEMENT
DECAL, WARNING PANEL
DECAL, DANGER, ELECTRIC - TIPOVER - WIND RATING
DECAL, WARNING, SHEET LOADING
DECAL, CAPACITY, 1000 LB
DECAL, MANUAL CASE
DECAL, MADE IN USA
DECAL, DIESEL ONLY
DECAL, GASOLINE ONLY
DECAL, FORK LIFT POCKET
29 910 8 3
30 8 502
1 EMERGENCY LOWERING
4 DECAL, INFLATE TIRE
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
March 2008
Page 7-7
3772RT
Control S ide
19
91109
12
9052
11
90267
14
8867
1
907
3
3 2
15
6948
Dual Fuel
6
91221 Diesel 91157 Dual Fuel
21
90918
Inside
Control
Cabinet
9910
16
90268
3772RT
Power S ide
HD Model
10
687 3
8402
HYDRAULIC OIL
687 3
2
91661
1
MEC 3772RT HD
Inside Power Cabinet
H
YD
R
AU
LIC
O
IL
EMERGENCY LOWERING
SWITCH INSIDE
8402
2
91 3 2 3
1
9910
3
7982
9910
4
850 3
7
9910
20
91 3 74
EMERGENCY LOWERING
SWITCH INSIDE
91 3 74
9910
9910
HD MODEL
(EACH OUTRIGGER)
17
9465
March 2008
Page 7-8
0 m/s
12.5 m/s
MAX. PLATFORM CAPACITY INCLUDING PER ON + XXX kg EQUIPMENT XXX kg = X PER ON
XXX kg = X PER ON + XXX kg EQUIPMENT
XXX N MANUAL FORCE
XXX N
X.X m PLATFORM HEIGHT
X.X° x X.X°
MEC AERIAL PLATFORM SALES CORP.
1775 PARK STREET, SUITE 77 SELMA, CA, USA
INCLINATION MAX. ALLOWABLE 100-220 VAC ELECTRICAL VOLTAGE
50/60 Hz
MFG. DATE MODEL NUMBER ERIAL NUMBER
XX/XX XXXXXX XXXXXXXXX
MAX. ALLOWABLE MAX.
MODEL YEAR
20XX
PRE URE PER WHEEL SS
X.X kg/cm²
PER WHEEL
XXX kg
X.X m
MACHINE WEIGHT
XXXX kg
90982
18
90747 or 915 33
MEC AERIAL PLATFORM SALES CORP.
1775 PARK STREET, SUITE 77
SELMA, CA, USA
0 m/s
12.5 m/s
MFG. DATE MODEL NUMBER
XX/XX
MAX. PLATFORM CAPACITY INCLUDING PER S
XXX kg = X PER S S + XXX kg EQUIPMENT
XXX kg = X PER S S + XXX kg EQUIPMENT
XXXXXX
S ERIAL NUMBER
XXXXXXXXX
MAX. ALLOWABLE
MANUAL FORCE
XXX N
XXX N
MAX.
MODEL YEAR
20XX
PLATFORM HEIGHT
X.X m
MAX. ALLOWABLE
INCLINATION
X.X° x X.X°
ELECTRICAL VOLTAGE
100-220 VAC
50/60 Hz
PRE
MAX. GROUND
URE PER WHEEL
X.X kg/cm²
MAX. LOAD
PER WHEEL
XXX kg
X.X m
MACHINE WEIGHT
XXXX kg
90982
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
5
91266
3
7982
4
850 3
9910
7
9910
9
90717
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, S
IDES
, 3 772RT
1 91323
2
3
4
5
6
7
8
8
402
79 8 2
503
91266
91221
91157
9910
1
1
4
1
2
2
2
2 DECAL, MEC 3772RT
2 DECAL, MEC 3772RT HD (W/OUTRIGGERS)
DECAL, RAIL STRIPE
DECAL, SAFETY STRIPE
DECAL, KEEP CLEAR
DECAL, QUAD TRAX 4WD
DECAL, LOWER CONTROLS, DIESEL
DECAL, LOWER CONTROLS, DUAL FUEL
DECAL, PINCH POINT
9 90717
10 6 8 73
11 90267
12 9052
13 90732
14 88 67
15 694 8
16 90269
17 9465
1
1
1
1
1
1
1
1
4
DECAL, MAINTENANCE LOCK
DECAL, HYDRAULIC OIL
DECAL, BRAKE RELEASE
DECAL, BATTERY DISCONNECT AND LOCK
DECAL, WARNING, PRESSURE WASH
TAG, WARNING,
WARNING, LPG
DECAL, PLATFORM CAPACITY, SMALL
DECAL, DANGER, KEEP CLEAR OUTRIGGERS (HD)
1 8 90747
1 8 91553
19 91109
20 91374
21 9091 8
1
1
SERIAL PLATE:
BEFORE SN 9 3 01060
SERIAL PLATE:
AFTER SN 9 3 01061
1
1
1
DIAGNOSTIC LABEL
DECAL, EMERGENCY LOWERING SWITCH INSIDE
DECAL, EMERGENCY LOWERING SWITCH
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
March 2008
Page 7-9
17
90719
18
8519
3 0
8502
3772RT
Front
19
90722
20
90721
90721
2 3
8911
24
907 3 9
90721
91
22
3 22
21
907 3 0
90751
27
3 772RT: Locate on Bracket
3 772HD: Locate on Outrigger Crossmember
3772RT
Rear
25
9 3 78
6872
Dual Fuel
March 2008
Page 7-10
3772HD OUTRIGGER
26
6556
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
18
8519
3 0
8502
ITEM PART NO.
QTY DESCRIPTION
D
ECAL
K
IT
, E
NDS
, 3 772RT
17 90719
1 8 8 519
19 90722
20 90721
21 90730
22 91322
23 8 911
24 90739
25 937 8
6 8 72
26 6556
27 90751
29 910 8 3
30 8 502
1
4
1
1
1
2
1
1
1
1
1
1
1
4
DECAL, MEC OVAL
DECAL, WARNING, TIRE REPLACEMENT
DECAL, WARNING PANEL
DECAL, DANGER, ELECTRIC - TIPOVER - WIND RATING
DECAL, WARNING, SHEET LOADING
DECAL, CAPACITY, 750 LB
DECAL, MANUAL CASE
DECAL, MADE IN USA
DECAL, DIESEL ONLY
DECAL, GASOLINE ONLY
DECAL, FORK LIFT POCKET
DECAL, POWER TO PLATFORM
EMERGENCY LOWERING
DECAL, INFLATE TIRE
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Update: March 2008
March 2008
Page 7-11
5
3
4
1
2
March 2008
Page 7-12
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
ITEM PART NO.
QTY DESCRIPTION
D
ECALS
- A
NCHORAGE
P
OINTS
O
PTION
5 8 606 1 DECAL, WARNING, POS RESTRAINTS
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications March 2008
Page 7-13
March 2008
Page 7-14
"3072RT / 3772RT / 3772RT HD" Service & Parts Manual - ANSI Specifications
Service 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 backordered parts will be shipped when available via the same ship method as original order unless noted below:
• Ship complete order only - no backorders
• Ship all available parts and contact customer on disposition of backordered parts
• other (please specify)
___________________________________________________________________
___________________________________________________________________
THIS P
AGE IS LEFT INTENTIONALL
Y BLANK
Limited Owner W arranty
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.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: 559-891-2448
E-mail:[email protected] • Web:www.mecawp.com

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Key features
- Maximum platform height of nearly 40 feet
- Maximum horizontal outreach of nearly 55 feet
- Spacious platform
- 360-degree continuous rotation turntable
- Powerful hydraulic system
- Platform lift circuit
- Optional outriggers