Page 1 SERVICE AND PARTS MANUAL 4069RT ART_4480 Serial Number Range 13500001 - Up Part # 93080 November 2013...
Page 2 Original Release Date: November 2013 Date Reason for Update November New Release 2013 Aerial Platform Sales Corp. 1401 S. Madera Avenue • Kerman, CA 93630 USA Ph: 1-800-387-4575 • 1-559-842-1500 • FAX 1-559-842-1520 E-mail: info@mecAWP.com • Web: www.mecAWP.com 93080 | 4069RT...
Page 3: Table Of Contents
MEC Operator Policy ........
Page 4 Troubleshooting Chart ........... 4-22 March 2014 “4069RT” Service and Parts Manual Page ii...
Page 5 Electrical Schematics ........... . . 5-5 “4069RT” Service and Parts Manual...
Page 6 Service Table of Contents O T E S March 2014 “4069RT” Service and Parts Manual Page iv...
Page 7 MEC Operator Policy ........
Page 8: Machine Specifications
*Working Height adds 6 feet (2 m) to platform height. **Weight may increase with certain options. †Drive speed while elevated is inversely proportional to platform height; the higher the platform is, the lower the maximum elevated drive speed. The machine is driveable at full height. March 2014 “4069RT” Service and Parts Manual Page II...
Page 9: Mec Operator Policy
Any procedures not found within this manual must be evaluated by the individual to assure oneself that they are “proper and safe.” Your MEC Aerial Work Platform has been designed, built, and tested to provide many years of safe, dependable service. Only trained, authorized personnel should be allowed to operate or service the machine.
Page 10: Safety Symbols
It may also be used to alert against unsafe practices. “Caution” without alert symbol indicates a situation which, if not avoided, may result in property damage. March 2014 “4069RT” Service and Parts Manual Page IV...
Page 11: General Safety Tips
To set the Maintenance Lock, raise the platform enough to allow the Maintenance Lock to rotate to vertical. Carefully lower the platform until the pin above rests securely on the Maintenance Lock. ART_4283 “4069RT” Service and Parts Manual March 2014 Page V...
Page 12: Hydraulic System
IMMEDIATELY REPORT TO YOUR SUPERVISOR ANY DEFECT OR MALFUNCTION. ANY DEFECT SHALL BE REPAIRED PRIOR TO CONTINUED USE OF THE AERIAL WORK PLATFORM. INSPECTION AND MAINTENANCE SHOULD BE PERFORMED BY QUALIFIED PERSONNEL FAMILIAR WITH THE EQUIPMENT. March 2014 “4069RT” Service and Parts Manual Page VI...
Page 13: Primary Machine Components
Rack Maintenance Lock Air Filter Engine Hydraulic Pump Fuel Tank Entry Ladder Battery Disconnect Switch Controls Chassis Module Lower Controls Battery Hydraulic Manifold Hydraulic Tank Module Covers removed for clarity ART_4403 “4069RT” Service and Parts Manual March 2014 Page VII...
Page 14 115 - 122 85 - 90 115 - 122 950 - 1050 107 - 119 130 - 140 176 - 190 130 - 140 176 - 190 1300 - 1368 147 - 155 March 2014 “4069RT” Service and Parts Manual Page VIII...
Page 15 • The lower controls switch must be reset or the machine will not operate. • The machine will not operate from the lower controls if the upper controls switch is tripped. “4069RT” Service and Parts Manual March 2014 Page IX...
Page 16: Emergency Lowering
The Emergency Lowering System is used to lower the platform in case of power failure. To lower the platform, push down on the Emergency Lowering Switch, located on the Base Control panel. ART_4281 March 2014 “4069RT” Service and Parts Manual Page X...
Page 17 The brakes reset automatically when the motor is started. The brakes may be manually applied by pulling the Brake Release Valve out. BE SURE THAT THE BRAKES ARE ENGAGED BEFORE REMOVING THE WHEEL CHOCKS. “4069RT” Service and Parts Manual March 2014 Page XI...
Page 18: Lift And Support The Machine
O LOWER THE MACHINE 1. Tighten lug bolts to proper torque (refer to machine specifications). 2. Raise machine slightly and remove jack stands. 3. Lower the machine and remove the jack. 4. Remove chocks. March 2014 “4069RT” Service and Parts Manual Page XII...
Page 19 Cylinder Disassembly ......... 1-26 “4069RT” Service and Parts Manual...
Page 20 Typical Cylinders, Exploded View ........1-25 March 2014 “4069RT” Service and Parts Manual Page 1-2...
Page 21: Hydraulic System - General
Each function has a maximum pressure control limit set by pressure relief valve. Figure 1-1: Hydraulic System Upper Lift Cylinder Lower Lift Cylinder Functions Manifold Hydraulic Reservoir Front Wheel Motor/ Brake Hydraulic Pump Rear Wheel Motor/Brake Steer Outrigger Cylinder Cylinder x4 ART_4481 “4069RT” Service and Parts Manual March 2014 Page 1-3...
Page 22: Hydraulic Roadmap
Two (2) hydraulic cylinders control steering. LATFORM YSTEM The machine is equipped with two (2) hydraulic lift cylinder. UTRIGGER YSTEM On machines equipped with outriggers, four outrigger cylinders level the machine on uneven ground. March 2014 “4069RT” Service and Parts Manual Page 1-4...
Page 23: Hydraulic Fluid
1. With platform fully down, drain the hydraulic fluid from hydraulic reservoir into a clean, empty container. 2. When the hydraulic reservoir is empty, remove the hoses. 3. Flush the hoses with clean hydraulic fluid. “4069RT” Service and Parts Manual March 2014 Page 1-5...
Page 24 11. Check all leaks and correct as necessary. Machine is now ready to be placed back in operation. NOTE: Avoid mixing petroleum and synthetic base fluids. It is not advisable to mix fluids of different brands or types, except as recommended. March 2014 “4069RT” Service and Parts Manual Page 1-6...
Page 25: Hydraulic Fluid Reservoir
• Unscrew the filter assembly cap, then remove the filter • Place the new filter into position and press firmly into place • Carefully thread the filter assembly cap, then hand-tighten only. “4069RT” Service and Parts Manual March 2014 Page 1-7...
Page 26: Hydraulic Pump
3. Turn the pump until the bolt holes align with the mounting holes on the housing and install the bolts. Torque to 25-28 Ft. Lbs. (35-38 Nm). 4. Install the hydraulic hoses. 5. Check for leaks and check all hydraulic pressures. March 2014 “4069RT” Service and Parts Manual Page 1-8...
Page 27 5. Install the snap ring. 6. Install the shaft key. YDRAULIC EBUILD Pump rebuild should be performed only by a qualified mechanic. Contact MEC Technical Support before attempting to rebuild the pump. “4069RT” Service and Parts Manual March 2014 Page 1-9...
Page 28: Hydraulic Pump Seals
Piston Guide O-ring Shim Line Sense Snap Ring Port Shim Bearing Allen Head Screws Port Body Control Min Flow Valve Stopper Allen Suction Port Stop Nut Head Screws Cap Nut ART_3900 March 2014 “4069RT” Service and Parts Manual Page 1-10...
Page 29: Functions Manifold & Hydraulic Valves
2. Connect hydraulic hoses (as previously tagged). Be certain to tighten hoses. 3. Connect solenoid leads (as previously tagged). 4. Connect the battery. 5. Operate each hydraulic function and check for proper operation and leaks. 6. Adjust valve pressures. “4069RT” Service and Parts Manual March 2014 Page 1-11...
Page 30 COUNTERBALANCE VALVE – DRIVE MANUAL OP. VALVE – BRAKE EMR. RELEASE COUNTERBALANCE VALVE – DRIVE Left Side Front Of Machine Of Machine Center Rear Of Machine Of Machine Functions Manifold ART_4471 4069 March 2014 “4069RT” Service and Parts Manual Page 1-12...
Page 31: Hydraulic Pressure Adjustment
• Before attempting to check or adjust pressure relief valves, operate the machine for 15 min- utes or long enough to sufficiently warm the hydraulic fluid. • Insert a 0-5000 psi gauge into gauge adapter fitting at Port GP of the Functions Manifold. “4069RT” Service and Parts Manual March 2014 Page 1-13...
Page 32 5. If pressure is HIGH, adjust main relief valve ¼ turn coun- terclockwise and recheck. Repeat until the Main Relief Lift Relief pressure is correct as listed in Table 1-1. ART_4484 March 2014 “4069RT” Service and Parts Manual Page 1-14...
Page 33 Repeat until the pressure is correct as listed in Table 1-1. (CBV1, CBV2) RIVE OUNTERBALANCE ALVES The Drive Counterbalance Valves are not adjustable and should be replaced if they are determined to be malfunctioning. “4069RT” Service and Parts Manual March 2014 Page 1-15...
Page 34: System Descriptions
Sense port of the pump. Unused fluid is routed back to the tank through Port T of the Functions Manifold. Pump case pressure drains back to the tank. Figure 1-7: Pump Circuit ART_4590 March 2014 “4069RT” Service and Parts Manual Page 1-16...
Page 35: Lift Circuit
Hydraulic fluid flows to the lift cylinders from Port LFT on the Functions Manifold and is returned to the to the manifold through the same hose. Figure 1-8: Lift Circuit ART_4591 “4069RT” Service and Parts Manual March 2014 Page 1-17...
Page 36: Lift Vent Circuit
Figure 1-9: Lift Vent Circuit Later Machines with upper vent hose on upper cylinder. Upper Lift Cylinder Lower Lift Cylinder ART_4592 March 2014 “4069RT” Service and Parts Manual Page 1-18...
Page 37: Steering Circuit
Pressurized fluid is supplied to the Steer Cylinders from Ports STRA and STRB on the Functions Manifold as shown below. Figure 1-10: Steering Circuit Right Side Front of Machine Left Side ART_4593 “4069RT” Service and Parts Manual March 2014 Page 1-19...
Page 38: Front Drive Circuit
R I V E I R C U I T Pressurized fluid is supplied to the front drive motors as shown below. Figure 1-11: Front Drive Circuit Right Front Left Front ART_4594 March 2014 “4069RT” Service and Parts Manual Page 1-20...
Page 39: Rear Drive Circuit
R I V E I R C U I T Pressurized fluid is supplied to the rear drive motors as shown below. Figure 1-12: Rear Drive Circuit Right Rear Left Rear ART_4595 “4069RT” Service and Parts Manual March 2014 Page 1-21...
Page 40: Brake Release Circuit
Release Circuit when the Drive function is enabled. When the Drive function is not enabled, fluid flows freely through it to Port T on the Functions Manifold, and from there returns to the tank. Figure 1-13: Brake Release Circuit Br Br ART_4596 March 2014 “4069RT” Service and Parts Manual Page 1-22...
Page 41: Drive Case Drain Circuit
Hoses connect the Case Drain ports of each wheel motor route the fluid back to the tank at the center return port of the Hydraulic Reservoir. Figure 1-14: Drive Case Drain Circuit ART_4597 “4069RT” Service and Parts Manual March 2014 Page 1-23...
Page 42: Outrigger Circuit
ORB circuit to Retract port ORA circuit ORB circuit i t t c i r i t t c i r c i r f r o i t t c i r ART_4598 March 2014 “4069RT” Service and Parts Manual Page 1-24...
Page 43 1. Tag hoses for proper reassembly. 2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination. 3. Remove cylinder from the machine as described in Section 3. “4069RT” Service and Parts Manual March 2014 Page 1-25...
Page 44: General Cylinder Repair
.007 in. (0.18 mm) replace the cylinder. Assembly is reverse of disassembly. Lubricate all seals with clean hydraulic fluid before assembly. Use Loctite when securing the piston to the rod. March 2014 “4069RT” Service and Parts Manual Page 1-26...
Page 45 Information Messages ......... . 2-29 “4069RT” Service and Parts Manual...
Page 46 Table 2-2: Battery Specific Gravity and Voltage ..... . . 2-6 March 2014 “4069RT” Service and Parts Manual Page 2-2...
Page 47: Electrical System - General
The Emergency Lowering System is used to lower the platform in case of power failure. To lower the platform, push down on the Emergency Lowering Switch, located at the Lower Control Box. ART_4281 “4069RT” Service and Parts Manual March 2014 Page 2-3...
Page 48 Module located inside the Lower Controls box. The LED located on the module should be ON. If the LED is OFF GP400 or FLASHING, refer to Section 4: Troubleshooting. Module Terminal Block Module Diagnostic LED ART_3093 March 2014 “4069RT” Service and Parts Manual Page 2-4...
Page 49: Batteries
• drops to 40% at 0°F (-32°C) Table 2-1: Recommended Battery Charge Intervals If Stored At Recharge Below 40°F (4°C) Every week 40°-60°F (4°-15°C) Every 2 weeks Above 60°F (15°C) Every month “4069RT” Service and Parts Manual March 2014 Page 2-5...
Page 50: Battery Maintenance (In Use)
Table 2-2: Battery Specific Gravity and Voltage Specific Gravity Volts DC Each Cell Per Cell 12V Battery Fully Charged 1.280 2.10 12.60 Fully Discharged 1.130 1.75 10.50 March 2014 “4069RT” Service and Parts Manual Page 2-6...
Page 51: Battery Replacement
2. Lift the battery from the compartment, put the battery aside and dispose of properly. O INSTALL A BATTERY 1. Position the battery in the compartment and secure with hold-down hardware. 2. Connect the positive battery cable, then the negative battery cable. “4069RT” Service and Parts Manual March 2014 Page 2-7...
Page 52: Controls
Press to start engine. Release when engine starts. 10 Start Delay Light Prevents over-cranking of engine. When lit, starter is disabled. After approximately 35 seconds the light will go out and starter will operate. March 2014 “4069RT” Service and Parts Manual Page 2-8...
Page 53: Upper Controls
*Machines equipped with optional Overload Sensing System **These controls operate only when the Enable Bar (#13) is depressed. The Enable Bar must be depressed before operating the function for correct control system safety sequence. “4069RT” Service and Parts Manual March 2014 Page 2-9...
Page 54: Alarms And Switches
EZFit Angle Sensor works in conjunction with the Two present on machines equipped with optional Pressure Transducer and Overload Sensing System ART_4488 a second redundant Angle Sensor located beside the first. March 2014 “4069RT” Service and Parts Manual Page 2-10...
Page 55 • disable lift, lower and drive operation. • sound audible alarms. • turn ON the OVERLOAD light on the upper control panel. Remove weight from the platform to restore function and continue. “4069RT” Service and Parts Manual March 2014 Page 2-11...
Page 56 TART ELAY Provides power to the starter solenoid. HROTTLE ELAY Provides power to the electric Preheat throttle solenoid. Throttle Start REHEAT ELAY ART_4491 Provides power to the diesel engine glow plugs. March 2014 “4069RT” Service and Parts Manual Page 2-12...
Page 57: Deutsch Connectors
O N N E C T O R S EUTSCH ONNECTORS Deutsch connectors used on MEC equipment are designed so that individual parts may be replaced without replacing the entire component. Special tools and detailed instructions are provided in Deutsch Connector field kits, MEC part no. 84091.
Page 58 • Move second probe to bottom normally open terminal. • With toggle UP there should be no reading. Normally Open • With the toggle DOWN there should be a low resis- tance. Common Normally Open ART_2563 March 2014 “4069RT” Service and Parts Manual Page 2-14...
Page 59: Continuity Checks
Normally Open Normally Open • With the toggle UP (closed) there Common Common should be no reading. Normally Open Normally Open • Repeat for both rows of two-row switch. ART_2564 “4069RT” Service and Parts Manual March 2014 Page 2-15...
Page 60 • Confirm normally closed (#87A) contacts are opening. Continuity with #30 will be broken. B− • Confirm normally open (#87) contacts are clos- ing. Continuity with #30 will be made. ART_2330 March 2014 “4069RT” Service and Parts Manual Page 2-16...
Page 61: Gp400 Control Module Setup
Diagnostic information can be found in Section 4: Troubleshooting. Wiring information can be found in Section 5: Schematics. Figure 2-19: Module Locations Upper Controls Lower Controls GP400 Control Module Terminal Block Module GP400 Matrix Module Diagnostic LED ART_3156 “4069RT” Service and Parts Manual March 2014 Page 2-17...
Page 62: General Description
KEY FUNCTIONS GP400 Module ESC/ENTER BUTTONS To move back and forth between menu and sub-menu Diagnostic LED LEFT/RIGHT BUTTONS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values ART_3969 March 2014 “4069RT” Service and Parts Manual Page 2-18...
Page 63 READ ALL INSTRUCTIONS CLOSELY BEFORE ATTEMPTING EACH STEP OF THE CALIBRATION PROCEDURE. The EZ-Cal hand-held device (MEC part # 90888) is required to access the GP400 for troubleshooting and calibration. The GP400 processor relies on sensors to monitor platform elevation at all times. These sensors send varied voltages to the GP400 that relate directly to their respective position.
Page 64 5. Press Up and Right Arrow to enter code 1775. Press Enter. • Display reads ACCESS LEVEL 2. 6. Press Right Arrow to SETUPS, Press Enter. • Display reads CHANGE DEFAULTS March 2014 “4069RT” Service and Parts Manual Page 2-20...
Page 65 4. Plug EZ-Cal into connector P9 on GP400 Control Module. EZ-Cal display reads HELP: PRESS ENTER 5. Press right arrow to ACCESS LEVEL 3, Press Enter. • Display reads CODE 0000 “4069RT” Service and Parts Manual March 2014 Page 2-21...
Page 66 21. Hold switch in down position until platform is in the fully lowered position. • Display reads TOTAL DATA #XX, then BUILDING TABLES, then CALDATE mm/dd/yy. 22. Enter current date using Up, Down and Right Arrows. • Display reads FINISHED. 23. Disconnect EZ-Cal. March 2014 “4069RT” Service and Parts Manual Page 2-22...
Page 67 10. Hold lower controls switch in the up position until machine is fully elevated, then release switch. • Display reads PLEASE LOWER. 11. Hold switch in down position until platform is in the fully lowered position. Release switch. • Display reads FINISHED. “4069RT” Service and Parts Manual March 2014 Page 2-23...
Page 68: Calibration Problems
DIAGNOSTICS / SENSORS to see the output. A reading of 0V or 5V is probably due to a wiring problem. F11:NOT UP This message occurs at the start of the DYNAMIC lift if the operator selects a function other than UP. March 2014 “4069RT” Service and Parts Manual Page 2-24...
Page 69 This message occurs if the platform height is not 0% after the platform has been fully low- ered at the end of a calibration step. The platform must return to the same height each time it is fully lowered. Check DIAGOSTICS / SYSTEM to check the height. “4069RT” Service and Parts Manual March 2014 Page 2-25...
Page 70 Check DIAGNOSTICS / SYSTEM to check the height. F24:TOO MANY This message occurs if too many static measurements are taken during a calibration step. In the rare event that this occurs, please call MEC for assistance. F25:CHECK ELEV F26:CHECK ELEV This message indicates a problem with the elevation switch (P7-5) during the STATIC phases.
Page 71 This message indicates that the elevation switch opened more than once during the DYNAMIC lift. F47:CHECK ELEV This message indicates that the elevation switch closed more than once during the DYNAMIC lower. “4069RT” Service and Parts Manual March 2014 Page 2-27...
Page 72 Re-start the calibration sequence and proceed through each sequence in the specified order. A “Redo” prompt will appear before each sequence. Answer “NO” if there is no reason to repeat or “YES” if the phase must be completed. March 2014 “4069RT” Service and Parts Manual Page 2-28...
Page 73: Information Messages
This message is displayed when the platform is stopped during either STATIC phase, when the GP400 takes a measurement. There will be a short delay while the machine is allowed to stabilize after movement is stopped. “4069RT” Service and Parts Manual March 2014 Page 2-29...
Page 74 If the previous EMPTY calibration was in error, or if the pressure sensor is replaced, it will be necessary to redo the EMPTY phase. REDO LOADED: This message is displayed if the LOADED phase of load calibration has previously been completed. March 2014 “4069RT” Service and Parts Manual Page 2-30...
Page 75 TOTAL DATA: This message is displayed at the end of each phase, to confirm the number of measure- ments recorded by the GP400. No operator input is required during this process. “4069RT” Service and Parts Manual March 2014 Page 2-31...
Page 76 O N T R O L O D U L E E T U P A L I B R A T I O N R O B L E M S O T E S March 2014 “4069RT” Service and Parts Manual Page 2-32...
Page 77 DUAL FUEL Engine Maintenance ....... . . 3-17 “4069RT” Service and Parts Manual...
Page 78 Diesel Engine Throttle Adjustments ....... . 3-16 March 2014 “4069RT” Service and Parts Manual Page 3-2...
Page 79: Base
3. Remove lug bolts and pull the wheel off. Note the position of the centering washers. 4. Install the replacement wheel. 5. While ensuring the correct positioning of the centering washers, install lug bolts and torque to 55 lb-ft. (75 Nm). 6. Remove the chocks. “4069RT” Service and Parts Manual March 2014 Page 3-3...
Page 80: Hoses And Cables
8. Slide the platform assembly backwards until the slide blocks clear the front of the plat- form. THE PLATFORM MAY SHIFT SUDDENLY WHEN IT CLEARS THE SLIDE BLOCKS. 9. Remove the platform assembly. March 2014 “4069RT” Service and Parts Manual Page 3-4...
Page 81 • Use Loctite 242 or equivalent on mounting bolts. • Torque all bolts to specifications listed in the Introduction Section of this manual. Figure 3-1: Platform Removal Slide Block Fixed Block ART_4492 “4069RT” Service and Parts Manual March 2014 Page 3-5...
Page 82: Scissor Stack
6. Attach a suitable lifting device to the scissor assembly. Apply slight lifting pressure. 7. Remove the stationary pins at the rear end of the machine. Figure 3-2: Scissor Assembly Removal Strap securing scissor assembly Stationary Pin ART_4493 March 2014 “4069RT” Service and Parts Manual Page 3-6...
Page 83 Clean all parts before installation. Replace worn or damaged parts with new parts. Installation is reverse of removal. • Use Loctite 242 or equivalent on mounting bolts. • Torque all bolts to specifications listed in the Introduction Section of this manual. “4069RT” Service and Parts Manual March 2014 Page 3-7...
Page 84: Lift Cylinders
6. Remove the lower retaining pin. 7. While supporting the cylinder, carefully remove the cylinder mount pin and two nylon washers. THE CYLINDER MAY SHIFT SUDDENLY WHEN THE PIN IS REMOVED. March 2014 “4069RT” Service and Parts Manual Page 3-8...
Page 85 • Torque all bolts to specifications listed in the Introduction Section of this manual. Figure 3-4: Lift Cylinder Cylinder Mount Pin Retaining Nylon Washer Lift Cylinder Nylon Washer Support Beam Retaining Nylon Ring Washer ART_4495 “4069RT” Service and Parts Manual March 2014 Page 3-9...
Page 86: Steer Cylinders
• Use Loctite 242 or equivalent on mounting bolts. • Torque all bolts to specifications listed in the Introduction Section of this manual. • To purge air from cylinder, cycle the steering system fully left and right 4-5 times. March 2014 “4069RT” Service and Parts Manual Page 3-10...
Page 87: Drive Motors
5. Remove the bolts that attach the motor to the chassis. Installation Installation is reverse of removal. • Use Loctite 242 or equivalent on mount- ing bolts. • Torque all bolts to 55 lb-ft (75Nm). ART_4497 “4069RT” Service and Parts Manual March 2014 Page 3-11...
Page 88: Front Drive Motors
ART_4498 motor from the steering yoke. Installation Installation is reverse of removal. • Use Loctite 242 or equivalent on mounting bolts. • Torque all bolts to 55 lb-ft (75Nm). March 2014 “4069RT” Service and Parts Manual Page 3-12...
Page 89: Lubrication
Normal Conditions Change every six months or 300 hours, whichever occurs first Severe Conditions--very dusty, exceptionally hot or exceptionally cold conditions Change every three months or 150 hours, whichever occurs first “4069RT” Service and Parts Manual March 2014 Page 3-13...
Page 90: Diesel Engine Maintenance
2. Remove old filter and replace Radiator with a new filter. Drain Plug 3. Replace and tighten the wing-bolt. Do not run the engine with the air filter element removed. ART_4602 March 2014 “4069RT” Service and Parts Manual Page 3-14...
Page 91 4. Adjust the High Speed Stop Screw until the RPM is 3000 with the Throttle Lever against the High Speed Stop Screw. 5. Turn off the engine and reconnect the Throttle Solenoid linkage at the clevis. “4069RT” Service and Parts Manual March 2014 Page 3-15...
Page 92 • Reconnect the clevis and measure again. Repeat until the measurement is correct. Figure 3-11: Diesel Engine Throttle Adjustments High Speed Stop Screw .020 Throttle Solenoid Idle Stop Screw Throttle Lever Throttle Link Throttle Clevis Solenoid Piston (Threaded Rod) Throttle Solenoid Adjustment ART_4002 March 2014 “4069RT” Service and Parts Manual Page 3-16...
Page 93 ART_4607 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. “4069RT” Service and Parts Manual March 2014 Page 3-17...
Page 94 4. Allow the choke plate to open slightly and tighten the Choke Adjustment Screw. 5. Check Choke Solenoid operation to ensure that the choke plate travel does not pre- vent the Choke Solenoid from retracting fully. March 2014 “4069RT” Service and Parts Manual Page 3-18...
Page 95 3. Have an assistant press the enable trigger on the Upper Controls joystick. 4. Adjust the nuts on the Throttle Solenoid Piston until the engine RPM is 3400±50. 5. Tighten the nuts to secure the adjustment. “4069RT” Service and Parts Manual March 2014 Page 3-19...
Page 96 D U AL F U E L E N G I N E A I N T E N A N C E O T E S March 2014 “4069RT” Service and Parts Manual Page 3-20...
Page 97 EZ-Cal Flow Chart: Diagnostics ........4-11 “4069RT” Service and Parts Manual...
Page 98 Troubleshooting Chart ......... . . 4-22 March 2014 “4069RT” Service and Parts Manual Page 4--2...
Page 99: General Troubleshooting Tips
• Hydraulic fluid contaminated with debris--filter change interval neglected, or debris intro- duced into the hydraulic system. In machines equipped with the optional cold climate package, MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates.
Page 100: Electrical System Troubleshooting
USE OF HIGH PRESSURE WASHING EQUIPMENT DIRECTLY ON THE MODULES CAN FORCE WATER INTO SEALED CONNECTION AND CAN CAUSE A TEMPORARY SYSTEM SHUT-DOWN. HIGH PRESSURE WASHING WITHIN THE VICINITY OF THE MODULES IS HIGHLY DISCOURAGED. March 2014 “4069RT” Service and Parts Manual Page 4-4...
Page 101: Gp400 Module
P2-2 — not used P8-11 — not used P2-3 — not used P8-12 — not used P8-13 — Ground P8-14 — Ground P8-15 — Ground EZ-Cal NOT USED Connection Diagnostic ART_3185 “4069RT” Service and Parts Manual March 2014 Page 4-5...
Page 102: Matrix Module
This arrangement protects the BASE Selected system against voltage drop ANALOG (AMP) conditions that can be COMMON B+ detrimental to the electrical system. POSITIVE OUTPUT (B+) Supply To various circuits ART_3186 March 2014 “4069RT” Service and Parts Manual Page 4-6...
Page 103: Ez-Cal Scan Tool
O O L EZ-C The EZ-Cal (MEC part # 90888; not part of the machine) is a hand-held scan tool that interfaces with the system to provide various information and adjustments. The EZ-cal receives its power from the GP400 when connected. The system must be powered up by closing the Battery disconnect switch and pulling both emergency stop switches.
Page 104 • Use the right and left arrows to scroll through sub menus, then press Enter again to choose a sub menu. • The up/down arrows are used to change settings only. Press ESC to back up one level. March 2014 “4069RT” Service and Parts Manual Page 4-8...
Page 105 ACCESS LEVEL 1 PROVIDES ACCESS TO CHANGE PERSONALITIES NORMALLY PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS. PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION AS LISTED IN THE FOLLOWING TABLES.
Page 106 101% 2.0 SEC -CE 4F-9 101% 4C-8b Y TILT TARGET 4K-8b @ HEIGHT 0.2 DEG 101% ANSI SCALE 9% CE 4F-10 100% TILT SLACK 0.3 DEG ART_4486 = DO NOT CHANGE March 2014 “4069RT” Service and Parts Manual Page 4-10...
Page 107 DRIVE REVERSE OUTRIGGERS 2F-16 EXTENDED 2A-15 BOOM GP400 P5-6 ALL CIRCUITS 12V ONLY ALARM OUTRIGGERS RETRACTED 2F-17 2A-16 P5-7 HIGH TORQUE OUTRIGGERS 2F-18 STATUS 2A-17 P5-8 HIGH SPEED OUTRIGGERS ART_4487 AUTO-RETRACT “4069RT” Service and Parts Manual March 2014 Page 4-11...
Page 108: Ez-Cal Diagnostics
NOTE: The ID number will not appear on the EZ-Cal display. It is shown in the Diagnostics Menu for reference only. Press ESC to go back one level (necessary to change selection). March 2014 “4069RT” Service and Parts Manual Page 4-12...
Page 109 • The system cannot operate – for example both the PLATFORM & GROUND inputs are active together. CHECK CANBUS • The system cannot operate – CANBUS communications is not successful (for example wire damage to the platform) “4069RT” Service and Parts Manual March 2014 Page 4-13...
Page 110 • Neither platform drive nor platform lift select is active, or both are active at the same time CHECK JOYSTICK • Both platform joystick directions are active at the same time STEER FAULTY • Both platform steer directions are active at the same time March 2014 “4069RT” Service and Parts Manual Page 4-14...
Page 111 EXTERNAL ALL, EXTERNAL DRIVE, EXTERNAL LIFT • An external cutout input is preventing functions – determine the cause of the external cutout (for example, a limit switch) “4069RT” Service and Parts Manual March 2014 Page 4-15...
Page 112: Mode Messages
• A platform function is selected but the trigger switch is not closed. VEHICLE TILTED _______________________________________ (no flash code) • The vehicle is tilted beyond the limits, some functions may be prevented. March 2014 “4069RT” Service and Parts Manual Page 4-16...
Page 113 CHANGE DEFAULTS menu, scroll to the correct machine from this menu, the press Right Arrow to select the appropriate model. NOTE: Selecting the incorrect customer or model will cause the machine to operate incorrectly or go into fault mode. “4069RT” Service and Parts Manual March 2014 Page 4-17...
Page 114 • Platform joystick switches were closed at power-on, or closed for too long without trigger switch (see SETUPS/INTERLOCKS/TRIGGERwait). RELEASE OUTRIGGER SWITCHES! _______________________ Flash Code: 2/2 • Outrigger switches were closed at power-on. March 2014 “4069RT” Service and Parts Manual Page 4-18...
Page 115 FAULT: MOTOR OVERLOAD! ______________________________ Flash Code: 3/5 • The power protection circuits in the controller have activated to protect from extreme over- load. • Check for short-circuit power wiring; check for a seized or shorted motor. “4069RT” Service and Parts Manual March 2014 Page 4-19...
Page 116 • The “5V sensor” supply is out of range; this supply is available to power external 5V-powered sensors – check that is has not been overloaded or short-circuited to other wiring (CE mod- els). March 2014 “4069RT” Service and Parts Manual Page 4-20...
Page 117: Other Messages
IMPORTANT: – Never use a vehicle in factory override; this state is ONLY intended for use during manufacture! While factory override is active, the LED is rapidly flashed on/off. “4069RT” Service and Parts Manual March 2014 Page 4-21...
Page 118: Troubleshooting Chart
Main system pressure inadequate Check pump output pressure Battery discharged - no charge output Check battery voltage, alternator output (14.5 volts) Clean, service and charge battery System interruption Check HELP messages using EZ-cal March 2014 “4069RT” Service and Parts Manual Page 4-22...
Page 119 Check coil Check valve function Counterbalance valve CBV1 or CBV2 not Swap counterbalance valves to see if functioning direction functioning correctly changes No output from GP400 Check switch position output from GP400 “4069RT” Service and Parts Manual March 2014 Page 4-23...
Page 120 Inspect and replace as needed. Outrigger hoses connected incorrectly See Section 1 of this manual for hose routing detail. Pressure relief valve set too low Set main relief valve RV1 to 3500PSI. March 2014 “4069RT” Service and Parts Manual Page 4-24...
Page 121: Hydraulic Schematics Table
Electrical Schematic, 3 of 3 ........5-7 “4069RT” Service and Parts Manual...
Page 122 Motor, Right Front Solenoid Valve, Down Valve, Lower Lift Cyl Motor, Right Rear SVCL1 Solenoid Valve, Drive Forward ORF1 Orifice, Steer Speed .063 SVCL2 Solenoid Valve, Drive Reverse ORF3 Orifice, Flow Divider Bypass.025 March 2014 “4069RT” Service and Parts Manual Page 5-2...
Page 123 WHEEL MOTOR/BRAKE WHEEL MOTOR/BRAKE SV14 SV15 CYL7 CYL7 CYL8 CYL8 LEFT SIDE RIGHT SIDE STEER CYLINDER STEER CYLINDER CYL3 CYL3 CYL4 CYL4 SV17 SV16 2500 PSI Hydraulic Schematic ART_4467 4069 RT “4069RT” Service and Parts Manual March 2014 Page 5-3...
Page 124 COUNTERBALANCE VALVE – DRIVE MANUAL OP. VALVE – BRAKE EMR. RELEASE COUNTERBALANCE VALVE – DRIVE Left Side Front Of Machine Of Machine Center Rear Of Machine Of Machine Functions Manifold ART_4471 4069 March 2014 “4069RT” Service and Parts Manual Page 5-4...
Page 125 Y D R A U L I C C H E M A T I C O T E S “4069RT” Service and Parts Manual March 2014 Page 5-5...
Page 126 C H E M A T I C S LECTRICAL CHEMATICS Figure 5-3: Electrical Schematic, 1 of 4 REAR WHEEL BYPASS VAL LOWER CONTROL BOX DOOR DEUTSCH 70 PIN DEUTSCH 4 PIN Electrical Schematic, 1 of 4 4069RT ART_4468 March 2014 “4069RT” Service and Parts Manual Page 5-6...
Page 127 (CE ONLY) ANGLE TRANSDUCER HEIGHT 2 (CE ONLY) DEUTSCH 12 PIN DOWN VALVES OUTRIGGER SWITCHES DEUTSCH 6 PIN DEUTSCH 70 PIN DEUTSCH 4 PIN Electrical Schematic, 2 of 4 ART_4469 4069RT “4069RT” Service and Parts Manual March 2014 Page 5-7...
Page 128 DRIVE GLOW PLUG P3-6 ENABLE OUTRIGGER UP P3-10 OUTRIGGER DOWN P3-11 TILT IND. LAMP P4-4 TILT ALARM P4-5 TILT IND LIGHT DRIVE ENABLE P4-6 Electrical Schematic, 3 of 4 ART_4470 4069RT March 2014 “4069RT” Service and Parts Manual Page 5-8...
Page 129 TO MAIN BATTERY DISCONNECT SWITCH DIESEL ENGINE and optional Generator DUAL FUEL ENGINE and optional Generator COIL DEUTSCH 12 PIN ¼” SPADE TO MAIN BATTERY DISCONNECT SWITCH Electrical Schematic, 4 of 4 ART_4603 4069RT “4069RT” Service and Parts Manual March 2014 Page 5-9...
Page 130 L E C T R I C A L C H E M A T I C S O T E S March 2014 “4069RT” Service and Parts Manual Page 5-10...
Page 131 Steering Components ........... D-7 “4069RT” Parts Section...
Page 132 Decals, GSE Diesel Option, CE Specification........H-7 March 2014 “4069RT” Parts Section Page ii...
Page 133 Option -- Onboard Diagnostic Center ....... A-11 “4069RT” Parts Section...
Page 134 *Std Machine -- Amber Lens Optional Overload System -- Red Lens Optional Overload System only Optional Outriggers only Optional GSE Lighting only Upper Controls 4069RT ART_4086 March 2014 “4069RT” Parts Section Page A-2...
Page 135: Platform Controls
Harness, Removable (See Wire Harness, Section F) Cable, Removable (See Wire Harness, Section F) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page A-3...
Page 136 TO CONTROL BOX Control Box Cover Assembly Reference: ART_13868 ART_2220 R3 March 2014 “4069RT” Parts Section Page A-4...
Page 137: Upper Control Box Cover Assembly
Spring, Joystick Centering 91824 Potentiometer Assembly Wire Harness, (see Wire Harness, Section F) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page A-5...
Page 138 Connect Purple and Blue wires Purple together at #13 Blue Control Arm (Joystick) Reference: ART_188 ART_2221 R1 March 2014 “4069RT” Parts Section Page A-6...
Page 139: Upper Control Joystick
Switch Assembly (not shown) -- includes item #9, item #11 (x2), wire and connectors • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page A-7...
Page 140 Circuit Breaker Hour Meter Start - N.O. Platform / Base - N.O. Lower - N.O. 30 Sec Delay (Red) Preheat - N.O. Raise - N.O. 16 Emergency Stop (complete switch) Base Controls 4069RT ART_4464 March 2014 “4069RT” Parts Section Page A-8...
Page 141: Base Controls
Terminal Block Module (TBM) 91290 Deutsch Connection, DT14-4P-L012 92016C Control Box 91921 Lanyard • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page A-9...
Page 142: Option -- Onboard Diagnostic Center
OPTION -- Onboard Diagnostic Center 4069 ART_4465 March 2014 “4069RT” Parts Section Page A-10...
Page 143 Bracket, Onboard Diagnostics Center 50422 Screw, Button Head Cap M6 x 18 50047 Nut, M6 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page A-11...
Page 144 OTES March 2014 “4069RT” Parts Section Page A-12...
Page 145 OPTION -- Material Clamps/Pipe Racks ......B-19 “4069RT” Parts Section March 2014...
Page 146 Platform Assembly 4069 ART_4459 March 2014 “4069RT” Parts Section Page B-2...
Page 147: Platform Assembly
Nut, Roller, M8 Nylock 50040 Bolt, M12 x 35 50050 Nut, M12 Nylock • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-3...
Page 148 At each rail base Main Platform 4069 ART_4461 March 2014 “4069RT” Parts Section Page B-4...
Page 149: Main Platform
Gate Toe Board 92836 Gate Latch 21390 Left Side Rear Rail 50182 Spring Clip • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-5...
Page 150: Deck Extension
At each rail base 16 15 Deck Extension 4069 ART_4460 March 2014 “4069RT” Parts Section Page B-6...
Page 151 50004 Washer M16 Std. 87125 Roller 50398 Nut, 5/8 Nylock 87124 Roller 26450 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-7...
Page 152: Option -- Gse Platform
OPTION -- GSE Platform 4069 ART_4454 March 2014 “4069RT” Parts Section Page B-8...
Page 153 QTY DESCRIPTION 21618 Platform, 4069 GSE Option 21617 Deck Extension 21615 Main Platform • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-9...
Page 154: Option -- Gse Deck Extension, 1
OPTION -- GSE Deck Extension, 1 of 2 4069 ART_4455 March 2014 “4069RT” Parts Section Page B-10...
Page 155 Left Side Top Tray 93359 T-Handle 21520 Side Beam 21511 Wear Pad, Large, Left Side Top • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-11...
Page 156: Option -- Gse Deck Extension, 2
OPTION -- GSE Deck Extension, 2 of 2 4069 ART_4456 March 2014 “4069RT” Parts Section Page B-12...
Page 157 Wear Pad Guide Rail 21541 Deck Extension Weldment, without deck plate 21583 Deck Plate • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-13...
Page 158: Option -- Gse Main Platform, 1
OPTION -- GSE Main Platform, 1 of 2 4069 ART_4457 March 2014 “4069RT” Parts Section Page B-14...
Page 159 Guard Rail Beam 21505 Wear Pad, Bottom Large 21506 Wear Pad, Bottom Small • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-15...
Page 160: Option -- Gse Main Platform, 2
OPTION -- GSE Main Platform, 2 of 2 4069 ART_4458 March 2014 “4069RT” Parts Section Page B-16...
Page 161 Bolt, M6 x 45 21586 Gate Toe Board 21589 Gate Stopper, Left 92251 Gate Latch, Left • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-17...
Page 162: Option -- Material Clamps/Pipe Racks
Pipe Rack Configuration Material Clamp Configuration OPTION -- Material Clamp/Pipe Rack 4069 ART_4462 March 2014 “4069RT” Parts Section Page B-18...
Page 163 50182 Spring Clip 50401 Spring Clip 92852 Wear Strip 92863 Wear Strip 92942 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page B-19...
Page 164 OTES March 2014 “4069RT” Parts Section Page B-20...
Page 165: Section C: Scissor Assembly
Scissor Assembly ..........C-3 “4069RT” Parts Section...
Page 166 Between all pivoting parts 16 places Upward-facing sides of beams 4 places Each end of both cylinders 28 19 20 2 places Each side of forward end of base section Elevating Assembly 4069 ART_4429 March 2014 “4069RT” Parts Section Page C-2...
Page 167 7160 Bearing 40301 Slide Casting 90235 Upper Slide Pad 30407 26449 Platform Block • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page C-3...
Page 168 OTES March 2014 “4069RT” Parts Section Page C-4...
Page 169: Section D Wheel Assemblies
Steering Components ..........D-7 “4069RT” Parts Section...
Page 170 Tires/Wheels 4069 ART_4431 March 2014 “4069RT” Parts Section Page D-2...
Page 171: Wheels & Hubs
Lug Bolt, M10 x 30 Socket Head *USE ONLY FOAM-FILLED FOR CE AND GSE-SPEC MACHINES. • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page D-3...
Page 172 Wheel Motors & Steering Components 4069 ART_4428 March 2014 “4069RT” Parts Section Page D-4...
Page 173: Wheel Motors & Steering Yoke Components
50031 Bolt, M8 x 25 50001 Washer, M8 Std 50025 Bolt, M8 Carriage • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page D-5...
Page 174 Steering Components 4069 ART_4430 March 2014 “4069RT” Parts Section Page D-6...
Page 175: Steering Components
21344 Steering Yoke, Right Side 17492 Pin Clip 21345 Steering Yoke, Left Side • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page D-7...
Page 176 OTES March 2014 “4069RT” Parts Section Page D-8...
Page 177 Hoses -- Outrigger Circuit ........E-39 “4069RT” Parts Section...
Page 178: Hydraulic Components
Machines equipped with optional Outriggers Hydraulic Components 4069RT ART_4463 March 2014 “4069RT” Parts Section Page E-2...
Page 179: Functions Manifold, 1
Hydraulic Pump 21398 Steer Cylinder 93031 Option -- Outrigger Cylinder 93280 Proportional Valve • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-3...
Page 180 R A S T R Functions Manifold, 1 of 2 4069 ART_4476 March 2014 “4069RT” Parts Section Page E-4...
Page 181 Fitting, MB-MFFOR-6-4 50838 Fitting, MB-MFFOR-12-8 50835 Fitting, MB-MFFOR-6-6 51004 Fitting, MB-HB90-12-16 50858 Fitting, MB-MFFOR-MFFORT-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-5...
Page 182 R A S T R beneath plug Functions Manifold, 2 of 2 4069 ART_4478 March 2014 “4069RT” Parts Section Page E-6...
Page 183: Functions Manifold, 2
93503 Counterbalance Valve 93499 Shuttle Valve 93495 Orifice Plug, .063 93498 Flow Regulator • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-7...
Page 184: Hydraulic Reservoir
Later Machines Early Machines Hydraulic Reservoir 4069 ART_4477 March 2014 “4069RT” Parts Section Page E-8...
Page 185 Later Machines -- Fitting, MP-MJ-4-4 92569 Suction Strainer 51004 Fitting, MB-HB90-12-16 HDW6727 Fitting, 1/4 NPT, 5/16 Barb • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-9...
Page 186: Hydraulic Pump
Hydraulic Pump 4069RT ART_4479 March 2014 “4069RT” Parts Section Page E-10...
Page 187 50665 Fitting, MB-MJ90-4-4 91161 Flange Kit, Suction (includes bolts) 51012 Suction Fitting, FL-MJ90-16-16 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-11...
Page 188 Right Rear Right Front Left Rear Left Front *Item #4 on front wheel motors only. Rear wheel motors have two of Item #3 Wheel Motor/Brake Units 4069 ART_4475 March 2014 “4069RT” Parts Section Page E-12...
Page 189: Wheel Motor/Brake Unit
93233 Wheel Motor/Brake Unit 51118 Fitting, MFFOR-MBSPP-04-02 50837 Fitting, MB-MFFOR-10-8 50980 Fitting, MB-MFFOR90-10-8 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-13...
Page 190: Lift Cylinders
Lift Cylinders 4069 ART_4473 March 2014 “4069RT” Parts Section Page E-14...
Page 191 IMPORTANT -- Both cylinders must be changed out if an Old Style cylinder requires replacement. DO NOT pair a New Style cylinder with and Old Style cylinder. • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-15...
Page 192 Steer Cylinders 4069 ART_4472 March 2014 “4069RT” Parts Section Page E-16...
Page 193: Steer Cylinders
QTY DESCRIPTION 21398 Steer Cylinder 93616 Seal Kit 50831 Fitting, MB-MFFOR-4-4 50675 Fitting, MB-MFFOR45-4-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-17...
Page 194 OPTION -- Outrigger Cylinders 4069 ART_4474 March 2014 “4069RT” Parts Section Page E-18...
Page 195: Option -- Outrigger Cylinders
QTY DESCRIPTION 93031 Outrigger Cylinder 93617 Seal Kit 50832 MB-MFFORT-6-4 91464 Valve 93615 Coil • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-19...
Page 196 Pump & Manifold 4069RT ART_4554 March 2014 “4069RT” Parts Section Page E-20...
Page 197: Hoses -- Pump & Manifold
Hose Assy, 1/4 x 60 inch, 04G-04FFORX-04G-06FFORX 52475 Hose Assy, 1/2 x 64 inch, 08G-08FFORX -08G-12FJX90S PP-PV • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-21...
Page 198 Lift Circuit 4069 ART_4546 March 2014 “4069RT” Parts Section Page E-22...
Page 199: Hoses -- Lift Circuit
Fitting, MJ-MJ-FXT-6 52451 Hose Assy, 3/8 x 161.5" inch, 06G-06FJX -06G-06FFORX90L LWR LIFT • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-23...
Page 200 Later Machines with Upper Lift upper vent hose Cylinder on upper cylinder. Lower Lift Cylinder Lift Cylinder Drain, Current Machines 4069 ART_4547 March 2014 “4069RT” Parts Section Page E-24...
Page 201: Hoses -- Lift Cylinder Drain, Current Machines
Fitting, MJ-MJ-MPT-5-5-4 50959 as req Hose, 5/16” Fuel Line HDW6727 Fitting, 5/16 Barbed 90 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-25...
Page 202 Upper Lift Cylinder Lower Lift Cylinder Lift Cylinder Drain, Early Machines 4069 ART_4555 March 2014 “4069RT” Parts Section Page E-26...
Page 203: Hoses -- Lift Cylinder Drain, Early Machines
Fitting, MJ-MJ-MPT-4-4-4 52480 Hose Assy, 04G-04FJX- 04G-04FJX45, 49.5 inches JUMP VENT 50664 Fitting, MJ-MP90-4-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-27...
Page 204 Right Side Front of Machine Left Side Steer Circuit 4069 ART_4545 March 2014 “4069RT” Parts Section Page E-28...
Page 205: Hoses -- Steer Circuit
Hose Assy, 1/4 x 67 inch, 04G-04FFORX-04G-04FFORX90S STR-B 52459 Hose Assy, 1/4 x 67.25 inch, 04G-04FFORX-4G-4FFORX 45 STR A • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-29...
Page 206 Right Front Left Front Drive Circuit -- Front Wheels 4069 ART_4548 March 2014 “4069RT” Parts Section Page E-30...
Page 207: Hoses -- Drive Circuit, Front Wheels
Hose Assy, 1/2 x 55.5 inch, 08G-08FFORX -08G-08FFORX D-LF-A-MF 52446 Hose Assy, 1/2 x 55.5 inch, 08G-08FFORX -08G-08FFORX45S D-LF-B-MF • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-31...
Page 208 Right Rear Left Rear Drive Circuit -- Rear Wheels 4069 ART_4549 March 2014 “4069RT” Parts Section Page E-32...
Page 209: Hoses -- Drive Circuit, Rear Wheels
Hose Assy, 1/2 x 66 inch, 08G-08FFORX -08G-08FFORX90S D-LR-A 52441 Hose Assy, 1/2 x 67 inch, 08G-08FFORX -08G-08FFORX90S D-LR-B • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-33...
Page 210 Br Br Brake Circuit 4069 ART_4550 March 2014 “4069RT” Parts Section Page E-34...
Page 211: Hoses -- Brake Circuit
Hose Assy, 1/4 x 48.5 inch, 04G-04FFORX-4G-4FFORX 45 LR-BRK 52465 Hose Assy, 1/4 x 22 inch, 04G-04FFORX-4G-4FFORX 45 MF-T-BRK • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-35...
Page 212 Case Drain Circuit 4069 ART_4551 March 2014 “4069RT” Parts Section Page E-36...
Page 213: Hoses -- Case Drain Circuit
Hose Assy, 1/4 x 59 inch, 04G-04FFORX-04G-04FFORX LR-CD 52470 Hose Assy, 1/4 x 18.25 inch, 04G-04FFORX-04G-04FFORX90S TNK-CD • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-37...
Page 214 ORA circuit ORB circuit i t t c i r i t t c i r c i r f r o i t t c i r OPTION -- Outrigger Circuit 4069 ART_4552 March 2014 “4069RT” Parts Section Page E-38...
Page 215: Hoses -- Outrigger Circuit
51074 Fitting, FFORX-MB90-4-4 51137 Fitting, MB-FB-6-4 93288 Relief Valve Assembly 51127 Fitting, MB-MFFOR-6-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page E-39...
Page 216 OTES March 2014 “4069RT” Parts Section Page E-40...
Page 217 Wiring Harness Components ........F-24 “4069RT” Parts Section...
Page 218: Control Module
Control Module 4069RT ART_4432 March 2014 “4069RT” Parts Section Page F-2...
Page 219 14896 Door Slide Block 8841 Switch, Battery Cutoff 90749 Plug, Power To Platform • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-3...
Page 220 Engine Module, 1 of 2 4069RT ART_4447 March 2014 “4069RT” Parts Section Page F-4...
Page 221: Engine Module
91091 Filler Cap 21492 Bracket 21493 Relay Mount 92103 Relay Base 92400 Relay • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-5...
Page 222 DIESEL MODELS Diesel Engine, 1 of 3 4069RT ART_4448 March 2014 “4069RT” Parts Section Page F-6...
Page 223: Diesel Engine, 1
16207 Throttle Solenoid Plate 16210 Spacer Plate 16209 Mounting Plate 7736 Engine Mount • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-7...
Page 224: Diesel Engine, 2
DIESEL MODELS Diesel Engine, 2 of 3 4069RT ART_4449 March 2014 “4069RT” Parts Section Page F-8...
Page 225 Bolt, M8 x 20 Carriage 91113 Radiator 16345 Bracket, Radiator Mount 91429 Engine, Kubota D1105 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-9...
Page 226: Diesel Engine, 3
DIESEL MODELS Diesel Engine, 3 of 3 4069RT ART_4450 March 2014 “4069RT” Parts Section Page F-10...
Page 227 91114 Fuel Return Check Valve 91116 Fuel Filter Assembly 91123 Fuel Filter Element • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-11...
Page 228: Dual Fuel Engine, 1
DUAL FUEL MODELS 10 11 12 13 Coil 32 33 Dual Fuel Engine, 1 of 2 ART_4604 March 2014 “4069RT” Parts Section Page F-12...
Page 229 KTR Housing Kit, DF752 -- Includes Item #30 91765 Ring Gear 91766 Flywheel • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-13...
Page 230: Dual Fuel Engine, 2
DUAL FUEL MODELS Dual Fuel Engine, 2 of 2 ART_4605 March 2014 “4069RT” Parts Section Page F-14...
Page 231 Hose Clamp 91340 Hose, 2.00" I.D. Flex 91136 Air Filter Element 91188 Intake Hose • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-15...
Page 232 DUAL FUEL MODELS 4069RT Dual Fuel LP Tank ART_4606 March 2014 “4069RT” Parts Section Page F-16...
Page 233: Dual Fuel Lp Tank
Bulkhead Filter HDW6727 Elbow, Brass NPT to SAE 90 7406 Hose Assembly, 90” • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-17...
Page 234: Counterweight Assembly
Not used on machines equipped with optional outriggers. Counterweight Assembly 4069RT ART_4451 March 2014 “4069RT” Parts Section Page F-18...
Page 235 6/12 Nut, M12 Nylock 15140* Ballast Plate *Not used on machines equipped with optional outriggers. • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-19...
Page 236: Ladders
Standard Machines without Outriggers Machines with optional GSE Platforms Ladders 4069 ART_4453 March 2014 “4069RT” Parts Section Page F-20...
Page 237 50003 Washer, M12 Std 50050 Nut, M12 Nylock 21533 Ladder Weldment, GSE Option • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-21...
Page 238: Option -- Outriggers
Each Outrigger OPTION -- Outriggers 4069 ART_4452 March 2014 “4069RT” Parts Section Page F-22...
Page 239 Washer, 5/8 Std. 21477 Outrigger Foot Pad HDW91395 Clevis Pin, 5/8 x 5 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page F-23...
Page 240: Wiring Harness Components
75 ft. Cable, Power To Platform, Arctic (Plug at rear of Controls Module, Outlet at platform) 21633 Elevating Assembly Harness (J5, Transducers, Down valves) 21631 OPTION -- Outrigger Harness (J6, J7, Outriggers) 91293 Harness, Joystick March 2014 “4069RT” Parts Section Page F-24...
Page 241 Decals, ANSI Specification ........G-3 “4069RT” Parts Section...
Page 242 Option Optional Material Clamps/ Pipe Racks inside each side inside inside each side Optional Outriggers x4 Lanyard Attachments x6 ART_4406 March 2014 “4069RT” Parts Section Page G-2...
Page 243: Decals, Ansi Specification
Decals, ANSI Specification ITEM PART NO. QTY DESCRIPTION 93209 Decal, 4069RT White 93210 Decal, 4069RT Gray 92416 Decal, Website White 92547 Decal, Website Gray 90730 Decal, Platform Warning 90721 Decal, Danger 93059 Decal, Platform Capacity 90722 Decal, Warning 8911 Decal, Manual Inside...
Page 244 REPLACE TIRES WITH MANUFACTURER’S EQUIPMENT ONLY. 9052 92767 FAILURE TO USE MANUFACTURER’S TIRES MAY CAUSE MACHINE INSTABILITY. MEC Aerial Work Platform Sales Corp. REFER TO SERVICE AND PARTS MANUAL 1401 S. Madera Ave Kerman, CA 93630 FOR REPLACEMENT PART NUMBER. 90725 MATERIAL RACK CAPACITY MAX.
Page 245: Decals, Ce Specification
Decals, CE Specification ......... . H-3 Decals, GSE Diesel Option, CE Specification......H-7 “4069RT” Parts Section March 2014...
Page 246 Australia Only Optional Material Clamps/ Pipe Racks inside 2 at each corner inside inside each side inside inside each side Optional Outriggers x4 Lanyard Attachments x6 ART_4409 March 2014 “4069RT” Parts Section Page H-2...
Page 247 Decals, CE Specification ITEM PART NO. QTY DESCRIPTION 93209 Decal, 4069RT White 93210 Decal, 4069RT Gray 92416 Decal, Website White 92547 Decal, Website Gray 90730 Decal, Platform Warning 90721 Decal, Danger 93204 Decal, Platform Capacity 90722 Decal, Warning 8911 Decal, Manual Inside...
Page 248 XXX° SIDE 5° IN-LINE 36 Volt DC 92089 11026730 220 bar 12.5 m/s 4 Places MANUFACTURED BY MEC AERIAL WORK PLATFORMS, 1401 S. MADERA AVE, KERMAN, CA 93630 USA 92768 90268 11026730 6873 7155 7982 cut short to fit 92119...
Page 249 OTES • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “4069RT” Parts Section March 2014 Page H-5...
Page 250 2 at each corner 23 33 25 1 inside each side 10 locations-- inside one on each guardrail section *Cut off word “Inside” and discard for these 6 locations two locations if using 93368 ART_4409 March 2014 “4069RT” Parts Section Page H-6...
Page 251 Decal, Locate 7982 Decal, Warning Stripe 8503 Decal, Keep Clear 9910 Decal, Pinch 90739 Decal, Made in USA 93412 Decal, MEC Oval, Gray 93051 Decal, Material Rack Capacity 90751 Decal, Power To Platform 91930 Decal, Lower Controls 90725 Decal, Tires 92768...
Page 252 113 KG 400 N XXX° SIDE 5° IN-LINE 36 Volt DC 7982 220 bar 12.5 m/s 4 Places MANUFACTURED BY MEC AERIAL WORK PLATFORMS, 1401 S. MADERA AVE, KERMAN, CA 93630 USA 92768 9910 6873 90717 8503 90739 2 Places 90725...
Page 253 7Service Parts Order Form Fax to 559-263-9631 Please fill out completely Date: ______________________________ Ordered By: _________________________ Account: ___________________________ Your Fax No.: _______________________ Bill to: _____________________________ Ship to: ____________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ Ship VIA___________________________ Purchase Order Number ______________ **Fed Ex shipments require Fed Ex account number **All orders MUST have a Purchase Order Number Part Number...
Page 254 OTES...
Page 255 MEC Aerial Platform Sales Corp’s then current flat rate, provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp. and is found upon inspection by MEC Aerial Platform Sales Corp. to be defective in material and/or workmanship.
Page 256 Aerial Platform Sales Corp. 1401 S. Madera Avenue • Kerman, CA 93630 USA Ph: 1-800-387-4575 • 1-559-842-1510 • FAX 1-559-842-1520 E-mail:info@mecAWP.com • Web:www.mecAWP.com...

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