Mec 3072ES Service And Parts Manual
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Mec 3072ES Service And Parts Manual

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SERVICE AND PARTS MANUAL
3072ES / 3772ES /
3772ES HD
15 15
ART_2546
Serial Number Range
Part # 91778 R1
11211001 - Present
October 2008

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  • Page 1 SERVICE AND PARTS MANUAL 3072ES / 3772ES / 3772ES HD 15 15 ART_2546 Serial Number Range Part # 91778 R1 11211001 - Present October 2008...
  • Page 2 Revision History Original Release Date: June 2008 Revision: October 2008 Page Reason for Update Section 5 Update table - ORF3=.067 - ORF4=.067 - ORF6=.042 Update hydraulic schematic Update electric schematic Parts Table of Contents Update Table of Contents Section C Update illustration Update parts list Update illustration...

  • Page 3: Table Of Contents

    Emergency Systems And Procedures ............. 1-12 Steering Circuit ....................1-13 Platform Lift Circuit ................... 1-14 Optional Outriggers ................... 1-16 Cylinder Repair ....................1-17 Hydraulic Manifold..................... 1-20 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page i...
  • Page 4 Rear Drive Motor with Brakes ................3-6 Steer Cylinder ...................... 3-7 Platform Removal ....................3-8 Lift Cylinder Removal and Installation ............... 3-9 Scissor Beam Assembly ................... 3-10 Outrigger Function .................... 3-11 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page ii...
  • Page 5 Electric Schematics: Upper Controls, Current Models........5-7 Electric Schematics: Base ................5-8 P600 Motor Control Module ................5-9 GP400 Matrix Module ..................5-10 Matrix Module Controller ................5-11 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page iii...
  • Page 6 Parts Manual SECTION A: CONTROL BOXES SECTION B: PLATFORM AND RAILS SECTION C: SCISSORS SECTION D: AXLES SECTION E: HYDRAULICS SECTION F: BASE SECTION G: DECALS October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page iv...

  • Page 7: Introduction

    The Service Section of this manual is designed to provide you, the customer, with the instructions needed to properly maintain the MEC self-propelled scissor 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 and repairs, and identifying and ordering the correct replacement parts.
  • Page 8 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 9: General Safety Tips

    GENERAL SAFETY TIPS Regular inspection and conscientious maintenance is the key to efficient economical operation of your MEC aerial work platform. It will help to assure that your equipment will perform satisfactorily with a minimum of service and repair. The actual operating environment of the machine governs the inspection schedule. Correct lubrication is an essential part of preventative maintenance to minimize wear on working parts and ensure against premature failure.

  • Page 10: 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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page IV...

  • Page 11: Primary Machine Components

    Outriggers Battery (Beams) (option) Compartment Ladder REAR Lift Cylinder Limit Switch Emergency Lowering Cable 3072ES Pump Lower Compartment Controls FRONT Power to Platform (option) ART_2345 R1 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page V...

  • Page 12: Primary Machine Components: Compartments

    Battery AC Connector Hydraulic Lowering Switch Charger Manifold (single) POWER MODULE 12 Volt DC Battery 3772ES Emergency Lowering Battery Pack ART_2381 Eight 6 Volt DC Batteries October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page VI...

  • Page 13: Primary Machine Components Locator

    1 | 3 | 4 | 5 E | F Power to Platform B | F Power Module Battery Pack intro | E-Lower Battery intro | "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page VII...

  • Page 14: Specifications: Ansi Models

    Meets requirements of ANSI A92.6-2006 Section 4. *Working height adds 6 feet (2 m) to platform height. **Weight may increase with certain options or country standards. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page VIII...

  • Page 15: Specifications: Ce Models

    SPECIFICATIONS: CE MODELS 3072ES 3772ES 3772ES HD 36.6 ft* 43.6 ft* 43.6 ft* 11.14 m* 13.28 m* 13.28 m* Working Height* 30.0 ft 37 ft 37 ft Platform Height 9.14 m 11.28 m 11.28 m 54 in 61 in 61 in 1.4 m...

  • Page 16: Lubrication

    Whichever Occurs First Fixed Lithium N.L.G. #2 EP MONTHLY or Purge old grease EVERY 25 HOURS, Whichever Occurs First Sight Gauge 15 15 REAR FRONT ART_2384 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page X...

  • Page 17: Hydraulics

    Parking Brake and Towing Circuit ..............1-11 Emergency Systems And Procedures ............1-12 Steering Circuit ....................1-13 Platform Lift Circuit ..................1-14 Optional Outriggers ..................1-16 Cylinder Repair ....................1-17 Hydraulic Manifold ..................1-20 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-1...

  • Page 18: Hydraulic Fluid

    THOROUGHLY using abundant quantities of water. If irritation persists, medical advice should be sought. Hydraulic Fluid Recommendations MEC recommends the use of ISO32 hydraulic fluid or equivalent. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-2...
  • Page 19 NOTE: Avoid mixing petroleum and synthetic base fluids. It is not advisable to mix fluids of different brands or types, except as recommended. Beware of hot fluid. Contact with hot fluid may cause severe burns. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-3...

  • Page 20: Hydraulic System Components

    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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-4...
  • Page 21 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). "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-5...
  • Page 22 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). October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-6...
  • Page 23 13. Bearing Spacer 29. Shaft 14. 1.5" Bearing 30. Shaft Key 15. Thrust Washers (2) 31. Shaft Nut 16. Thrust Bearing * Contained in seal kit ART_2548 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-7...
  • Page 24 • 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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-8...
  • Page 25 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). "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-9...
  • Page 26 34. Assembly Bolts (7) 16. Shaft Bearing 35. Shaft 17. Friction Disks (10) 36. Shaft Key 18. Disk Stampings (9) 37. Shaft Nut 19. Thick Disk Stampings (2) ART_2549 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-10...

  • Page 27: Parking Brake And Towing Circuit

    Brakes will reset when drive function is Release Valve Hand Pump activated, or; ART_2423 • Brakes will reset manually by pulling out the manual brake release valve. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-11...

  • Page 28: Emergency Systems And Procedures

    To lower the platform, push down and hold the toggle 1 5 1 5 Emergency Lowering Switch switch. Lowering stops when you release the toggle switch. ART_2550 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-12...

  • Page 29: Steering Circuit

    ORG/WHT Steer Left Hose Motor Steer Right Hose Housing Pivot Left Steer Cylinder Motor Wheel Motor Right Steer Cylinder Housing Pivot Motor Tie Rod Housing ART_2551 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-13...

  • Page 30: Platform Lift Circuit

    The valve is also externally actuated for lowering the platform in emer- gency situations. 3072ES The 3072ES is equipped with one (1) single acting type hydraulic cylinder. The down valve is also externally actuated via a cable for manually lowering the platform. 3772ES Two (2) single acting type hydraulic cylinders.
  • Page 31 Relief Valve Tee Fitting 2 Barbed Straight Fittings and Hose Clamps Return Hose Pressure Hose Orifice Pressure Sensor Down Valve and Solenoid Emergency Lowering Solenoid ART_2553 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-15...

  • Page 32: Optional Outriggers

    OUTRIGGER EXTEND OUTRIGGER RETRACT Outrigger Outrigger Retract Stowed Valve Switch (UP) Outrigger Pressure Switch Outrigger (DOWN) Extend FRONT Valve LEFT RIGHT PORT ORS PORT ORR ART_2554 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-16...

  • Page 33: Cylinder Repair

    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 . "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-17...
  • Page 34 • Polishing is a sign of uneven loading. Check for roundness. If a polished surface is not round within .007 inch (0.18 mm) replace the cylinder. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-18...
  • Page 35 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. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-19...

  • Page 36: Hydraulic Manifold

    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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-20...
  • Page 37 RIGHT REAR B COUNTERBALANCE VALVES LIFT PORT LIFT RELIEF BRAKE PORT STEER RELIEF STEER RIGHT STEER LEFT PULL VALVE BRAKE RELEASE PRESSURE PORT - TO PUMP - ART_2555 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 1-21...
  • Page 38 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 1-22...

  • Page 39: Electrical System

    Battery Replacement ................. 2-6 Battery Charger ..................2-7 Controls ......................2-10 Lower Controls ..................2-10 Upper Controls ..................2-11 Alarms and Switches ................2-12 Limit Switch ....................2-12 Continuity Checks ..................2-14 Motor Controller ..................2-16 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-1...

  • Page 40: Electrical System - General

    Master Disconnect Switch Battery disconnect is provided in the control module to facilitate servicing and also to prevent unauthorized use of machine by using a padlock. ART_2387 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-2...

  • Page 41: Deutsch Connectors

    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 the Deutsch Connector Field Kit, MEC part number 84091. Male Plug Connector •...

  • Page 42: Batteries

    “Wet” batteries should be kept fully charged. A “wet” battery, while in storage, should be re- charged to full charge at recommended intervals. Leaving the MEC charger connected to an un-switched AC power source during prolonged storage will maintain battery voltage automati- cally.
  • Page 43 SPECIFIC GRAVITY VOLTS DC EACH CELL PER CELL 6 V BATTERY 12 V BATTERY Fully Charged 1.280 2.10 6.30 12.60 5.19 10.50 Fully Discharged 1.130 1.75 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-5...

  • Page 44: Battery Replacement

    Battery (12 V DC) Master Disconnect Switch 1 5 1 5 Battery Hold-Down CONTROL MODULE POWER MODULE To Master Chassis Disconnect Ground Switch Diode BATTERY PACK ART_2556 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-6...

  • Page 45: Battery Charger

    50 / 60 Hz Phase Single Single Voltage 29.6 V DC 61 V DC Maximum Current 25.0 A DC 25.0 A DC Output Power 750 Watts 1500 Watts "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-7...
  • Page 46 DC Battery Positive (+) – red Interlock Wires – black and white (prevents machine operation while charging) IMPORTANT: All MEC electric scissor lifts are equipped with lead acid type flooded batteries. The yellow wire loop on the back of the charger must be intact.
  • Page 47 D O N OT C H A N G E T H E I N PU T V BEFORE “ALL THE LEDS TURN OFF” 0 3 0 6 0 70 0 9 8 HB750-24 ART_2373 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-9...

  • Page 48: Controls

    The hour meter records the time that the machine is in operation. Check the hour meter daily to determine if the machine is due for service. Charge Indicator The charge indicator indicates the state of charge of the battery pack. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-10...

  • Page 49: Upper Controls

    The indicator light is ON when all four outriggers are fully raised and it is safe to drive the machine. The machine will not drive if the indicator light is OFF. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008...

  • Page 50: Alarms And Switches

    10 feet (3 m) the limit switch is activated will; • enable tilt sensor cutout operation • lockout outriggers operation. • reduce drive speed. ART_2559 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-12...
  • Page 51 Stowed switches open and lift function is disabled. When all four outriggers reach full deployment the Outrigger Pressure switches close (engage) and lift function is restored. ART_2560 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-13...

  • Page 52: Continuity Checks

    • • Connect second probe of ohm meter to bottom terminal. Common • With toggle in ANY POSITION there should be no reading. Normally Open ART_2563 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-14...
  • Page 53 With the button in the neutral (open) position there should be no reading. Common • With the button pushed (closed) there should be a low resistance. Normally Open ART_2565 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 2-15...

  • Page 54: Motor Controller

    The GP400 Matrix Module is located in the upper control box. Diagnostic information can be found in Section 4: Troubleshooting. Wiring information can be found in Section 5: Schematics . October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 2-16...

  • Page 55: Mechanical Components

    Rear Drive Motor with Brakes ..............3-6 Steer Cylinder ....................3-7 Platform Removal ................... 3-8 Lift Cylinder Removal and Installation ............3-9 Scissor Beam Assembly ................3-10 Outrigger Function ..................3-11 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 3-1...

  • Page 56: Torque Specifications

    58 - 62 79 - 84 79 - 85 107 - 115 83 - 87 113 - 118 136-144 184 - 195 100 - 110 136 - 149 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-2...

  • Page 57: Base / Undercarriage

    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. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 3-3...

  • Page 58: Raising The Machine

    5. Lower the machine to rest on the jack stands and inspect for stability. To lower the machine 1. Raise machine slightly and remove jack stands. 2. Lower the machine and remove the jack. 3. Remove chocks. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-4...

  • Page 59: Tires/Wheels

    4. Install the replacement wheel and tighten the lug nuts. 5. Lower the machine to the ground. 6. Torque lug nuts to 75 to 85 ft.-lbs. (102 to 115 Nm). "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 3-5...

  • Page 60: Drive Motors

    4. Remove the relief valve. 5. Remove the cap screws and MOTOR remove the drive motor from the HOUSING housing. Replace DRIVE Installation is reverse of removal. MOTOR MOTOR ART_2567 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-6...

  • Page 61: Steer Cylinder

    Steer Cylinder Seal Replacement Refer to Section 1: Cylinder Repair for seal replacement instructions. Steer Cylinder Tie Rod Motor Wheel Motor Housing Pivot Motor Motor Housing Housing Pivot ART_2569 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 3-7...

  • Page 62: Platform Removal

    7. Remove the platform assembly. 8. Installation is reverse of removal. Slide Block Fixed Block TORQUE Ft. lbs. Fixed Block Bolts 86 - 96 116 - 180 ART_2589 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-8...

  • Page 63: Lift Cylinder Removal And Installation

    Beam 10. Installation is reverse of removal. Retaining Nylon Ring Washer TORQUE Ft. lbs. ART_2203 Retaining Plate Bolts 6¼ - 7¼ 8.5 - 10 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 3-9...

  • Page 64: Scissor Beam Assembly

    Switch Ladder TORQUE Ft. lbs. Slide Track Stationary Mount Bolts 86 - 96 116 - 180 Ladder Mount Bolts 86 - 96 116 - 180 ART_2570 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-10...

  • Page 65: Outrigger Function

    Diagnosis of the GP400 Control Module is possible by counting the number of flashes from the red LED and referring to Section 4: Troubleshooting . Diagnosis and calibration of the GP400 module can also be done through the use of the EZ-Cal scan tool MEC part # 90888. (See Section 4: Troubleshooting ).
  • Page 66 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 3-12...

  • Page 67: Troubleshooting

    Retrieve Mode And Help Messages From The Ez-Cal ........ 4-21 EZ-Cal HELP Messages ................4-24 Trouble Table ....................4-30 Hydraulic Pressure Adjustment Procedures ..........4-35 Troubleshooting Battery Charger ..............4-38 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-1...

  • Page 68: General Troubleshooting Tips

    GENERAL TROUBLESHOOTING TIPS The 3072ES and 3772ES Aerial Work Platforms operate on a "Motor Control" theory in which fluid flow volume is controlled by varying the speed of the DC electric motor. 100% of the fluid produced by the pump goes to the selected function.
  • Page 69 RIGHT REAR B COUNTERBALANCE VALVES LIFT PORT LIFT RELIEF BRAKE PORT STEER RELIEF STEER RIGHT STEER LEFT PULL VALVE BRAKE RELEASE PRESSURE PORT - TO PUMP - ART_2555 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-3...

  • Page 70: Electrical System Troubleshooting

    ELECTRICAL SYSTEM TROUBLESHOOTING The electronic control system used on the 3072ES and 3772ES is designed for very low mainte- nance and long trouble free operation. All wire harness plug connections are waterproof to avoid moisture related problems that can lead to short terminal life. The system consists of three electronic microprocessor controlled modules;...
  • Page 71 P2-9 — not used Matrix Module (inside Upper Control Box) P2-10 — Potentiometer 21 510 411 P2-11 — Potentiometer P2-12 — Switch Supply Serial Number 11211037 - UP ART_2575 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-5...
  • Page 72 P6-2 — CAN BUS L P7-2 — CAN BUS L P8-2 — 48 Volts DC INPUT P6-3 — Ground P7-3 — Ground to GP400 to Upper Controls ART_2572 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-6...
  • Page 73 P15-8 — LOAD SENSE, Front Left P15-9 — not used P15-10 — LOAD SENSE Switch Supply P15-11 — STOWED Switch Supply ART_2573 P15-12 — not used "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-7...

  • Page 74: Ez-Cal Scan Tool

    LEFT/RIGHT BUTTONS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values EZ-Cal Calibrator MEC P/N 90888 GP400 Control Module Connect to P9 Diagnostic ART_2576 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-8...
  • Page 75 PERSONALITIES ARE PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS. PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AERIAL AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-9...
  • Page 76 TARGET 5I-8a 5I-8b 0.2º 5A-8a 5A-8b 5C-8a 5C-8b @HEIGHT SCALE 100% AUTO AUTO TIME @HEIGHT 5F-10 below 2.0 sec 0.0 sec 101% TILT SLACK ART_2577 0.3º October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-10...
  • Page 77 ON = weight on all 4 legs OFF = 1 or more legs up P15-7 PRESSURE, RIGHT FRONT 2F-21 P15-8 PRESSURE, LEFT FRONT P15-10 PRESSURE, SWITCH SUPPLY ART_2578 P15-11 STOWED, SWITCH SUPPLY "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-11...
  • Page 78 TARGET 5I-8a 5I-8b 0.2º 5A-8a 5A-8b 5C-8a 5C-8b @HEIGHT SCALE 100% AUTO AUTO TIME @HEIGHT 5F-10 below 2.0 sec 0.0 sec 101% TILT SLACK ART_2724 0.3º October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-12...
  • Page 79 OFF = 1 or more legs up P15-7 PRESSURE, RIGHT FRONT 2F-21 P15-8 PRESSURE, LEFT FRONT P15-10 PRESSURE, SWITCH SUPPLY P6-10 ART_2725 P15-11 STOWED, SWITCH SUPPLY "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-13...

  • Page 80: Ez-Cal Adjustment

    Ramp up time to maximum 5D-4 Decel 0.2 sec Ramp down to stop 5D-5 Not Used Not Used Power-out deck (not used) 5E DECK 5E– continued… October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-14...
  • Page 81 % of elevation lift down still operates in overload 5K-6 Overload #2 Not Used 5K-7 Tilt #2 ANSI: 0% || CE: 74% Reduced degree of tilt at % elevation 5K-8 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-15...

  • Page 82: Ez-Cal Setup

    Delay enable pulled before timeout 6E-1 INTERLOCKS Trigger Wait 0.0 sec Delay before function after enable pulled 6E-2 Function Hold 0.2 sec Time function holds after enable released 6E-3 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-16...

  • Page 83: Ez-Cal Diagnostics

    O/R Status current o/r status will be displayed 2A-14c O/R Test Y/N Follow EZ-Cal instruction sequence for outrigger valve and switches test (next page) 2A-14d continued … "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-17...

  • Page 84: Ez-Cal Outrigger Test Mode

    5. Continue on the sequence through the other three outrigger legs. If all legs extend and retract properly through the sequence the display will read EVERYTHING OK. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-18...
  • Page 85 P15-9 Not used 2E ANALOGS P8-2 Current state of angle transducer (overload option only) 2E-1 P8-6 Current state of pressure transducer (overload option only) 2E-2 continued… "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-19...
  • Page 86 Date of Load Sense calibration (Euro option only) 2H-1 Software Should read 'V22.3' This is MEC specific software. 2H-2 Powered Accumulated time GP400 powered up (red LED on) 2H-3 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-20...

  • Page 87: Retrieve Mode And Help Messages From The Ez-Cal

    • The system is preparing to operate, immediately after power-on. SHUTDOWN! • The system cannot operate – for example both the PLATFORM & GROUND inputs are active together. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-21...
  • Page 88 CHECK JOYSTICK • Both platform joystick directions are active at the same time STEER FAULTY • Both platform steer directions are active at the same time October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-22...
  • Page 89 OUTRIGGERS • Drive is prevented if the outriggers are not all retracted. Green LED, located on upper control box, will illuminate when outriggers are retracted. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-23...

  • Page 90: Ez-Cal Help 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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-24...
  • Page 91 The operator must release and re-select DOWN to continue lowering (after the delay timeout). • If the armguard feature is not wanted, set ADJUSTMENTS/LIFT/ ARMGUARD/TIME to 0.0s. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-25...
  • Page 92 • 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. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-26...
  • Page 93 FAULT: BATTERY VOLTAGE TOO HIGH! ----------------------------------------------- Flash Code: 4/4 • The battery supply is too high – check that the correct battery and charger are installed. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-27...
  • Page 94 • Check for open- and short- circuit problems with CAN bus wiring; ensure that the CAN bus is wired correctly pin-to-pin; ensure that the vehicle chassis is not erroneously shorted to the chassis (for example, due to insulator breakdown in the motor). October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-28...
  • Page 95 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. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-29...

  • Page 96: Trouble Table

    Information on the use of the EZ-cal tool plus helpful Flow Charts and graphs can be found earlier in the troubleshooting section. You are advised to read and faliliarize yourself with all of the information provided in the troubleshooting section before attempting to diagnose or repair the 3072ES, 3772ES models.
  • Page 97 Check charge diode & connections Valve coil failed on either cylinder Test, replace Lowers but not Down valve on one cylinder inoperative Check valve coils, wiring completely continued… "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-31...
  • Page 98 Swap counterbalance valves to see if functioning direction changes. functioning correctly No output from GP400 Scan using EZ-Cal and troubleshooting charts EZ-Cal chart ID# 4f-7 – FWD or 2f-9 – Reverse continued… October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-32...
  • Page 99 Pressure relief valve set too low Set steer relief valve to 2000 p.s.i. King pin/s seizing in the bore Disassemble and inspect Repair Replace bushings continued… "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-33...
  • Page 100 NOTE: To test for proper switch and solenoid operation and wire routing, follow the outrigger test sequence found in Ez-Cal Outrigger Test Mode on page 4- 18. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-34...

  • Page 101: Hydraulic Pressure Adjustment Procedures

    Main Relief Overpressure Relief 1 5 1 5 LIFT CYLINDER MANIFOLD, 3772 LEFT SIDE Gauge Port (Test Port) Lift Relief FRONT Hydraulic Pump Steer Relief ART_2579 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-35...
  • Page 102 If the valve is suspected to be out of adjustment or tampered with, it must be replaced. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-36...
  • Page 103 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. Counterbalance Valves ART_2580 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-37...

  • Page 104: Troubleshooting Battery Charger

    The MEC battery charger is a fully automatic type with a maintenance feature that will maintain battery voltage indefinitely when connected to an AC power source. The battery charger should be plugged into an unswitched AC power source if the machine is stored for long periods of time.
  • Page 105 Note: Over 1/2 of all battery chargers returned as “failed” are good. Please follow the troubleshooting procedures carefully and check all other items before returning the charger. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-39...
  • Page 106 Plug charger into a different AC outlet on a different circuit. If charger operates or fuse blown properly the AC line may require repair. If charger fails and AC line checks “good” the charger should be replaced. October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-40...
  • Page 107 Note: Over 1/2 of all battery chargers returned as “failed” are good. Please follow the troubleshooting procedures carefully and check all other items before returning the charger. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-41...
  • Page 108 • Battery pack too large for charger. Use higher output charger or unplug then plug-in charger to restart charge cycle to complete charging. continued . . . October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-42...
  • Page 109 The yellow wire loop on the back of the charger is damaged, broken or cut, putting the charger in GEL (sealed) type charging mode. • Repair the wire. • If GEL LED remains ON, the charger should be replaced. "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 4-43...
  • Page 110 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 4-44...

  • Page 111: Schematics

    Electric Schematics: Upper Controls, Current Models ....... 5-7 Electric Schematics: Base ................. 5-8 P600 Motor Control Module ............... 5-9 GP400 Matrix Module ................5-10 Matrix Module Controller................5-11 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-1...

  • Page 112: Hydraulic Schematic

    Return Filter - 10 Micron CYL1 Cylinder, Steering Optional Outriggers Components CYL5 Outrigger Cylinder Solenoid Valve, Poppet N.C. Solenoid Valve, Poppet N.C. Spool Valve, 4-way, - 3-Position October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-2...
  • Page 113 RRA RFB ø.064 ORF5 MA-1 ORLS ø.025 OPL5 OPL6 ø.025 OPL2 ø.080 2500 CBV1 CBV2 ø.035 SVD1 2000 GSTR 3000 PSI MAIN RELIEF ART_2581 R1 PUMP "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-3...

  • Page 114: Main Hydraulic Manifold

    PLG4 SV4 CL1 SVD1 SV3 CL1 PLG4 ORLS SV2 CL1 CL1 LEFT RIGHT PLG4 OPL6 PLG4 OPL5 CBV1 PLG4 CBV2 PLG4 MP1 OD1 OPL2 GSTR ART_2582 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-4...

  • Page 115: Main Relief Hydraulic Manifold

    Main Relief Hydraulic Manifold LEFT FRONT RIGHT BOTTOM ART_2583 Optional Outriggers Hydraulic Manifold LEFT FRONT RIGHT BOTTOM SV1 CL1 CL1 PLG4 CAV1 PLG10 ORLS ART_2584 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-5...

  • Page 116: Electric System

    LIFT P3-9 not used P3-10 not used P3-11 OUTRIGGERS not used P3-12 (option) not used P3-13 O/R UP SWITCH P3-14 O/R DOWN SWITCH P3-15 UPPER CONTROLS October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-6...

  • Page 117: Electric Schematics: Upper Controls, Current Models

    LEVEL INDICATOR LAMP P4-4 DRIVE ENABLE (CE only) ALARM (CE) P4-5 DRIVE ENABLE LAMP (O/R) P4-6 not used P4-7 not used P4-8 UPPER CONTROLS not used P4-9 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-7...

  • Page 118: Electric Schematics: Base

    PRESSURE, SWITCH SUPPLY P15-10 STOWED, SWITCH SUPPLY P15-11 LR PRESSURE RR PRESSURE RF PRESSURE LF PRESSURE 6 VOLTS 6 VOLTS 6 VOLTS 6 VOLTS 48 VOLTS BATTERY PACK October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-8...

  • Page 119: P600 Motor Control Module

    P6-2 — CAN BUS L P7-2 — CAN BUS L P8-2 — 48 Volts DC INPUT P6-3 — Ground P7-3 — Ground to GP400 to Upper Controls ART_2572 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-9...

  • Page 120: Gp400 Matrix Module

    P15-8 — LOAD SENSE, Front Left P15-9 — not used P15-10 — LOAD SENSE Switch Supply P15-11 — STOWED Switch Supply ART_2573 P15-12 — not used October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-10...

  • Page 121: Matrix Module Controller

    P2-9 — not used Matrix Module (inside Upper Control Box) P2-10 — Potentiometer 21 510 411 P2-11 — Potentiometer P2-12 — Switch Supply Serial Number 11211037 - UP ART_2575 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual October 2008 Page 5-11...
  • Page 122 October 2008 "3072ES / 3772ES / 3772ES HD" Service & Parts Manual Page 5-12...
  • Page 123 Scissor Guards - 3072ES, CE Models ........
  • Page 124 Decals, CE Models (continued) ......... . . G-11 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page ii...
  • Page 125 Lower Controls ..........A-11 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 126 WHT/RED HORN BUTTON BLK/WHT/RED DRIVE INDICATOR RED/GRN RED/BLK OUTRIGGER JUMPER PNK/WHT RED/BLU RED/BLU FIXED CABLE REMOVABLE CABLE Upper Controls 3072ES, 3772ES, 3772 ES HD ANSI ART_2571 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-2...

  • Page 127: Upper Controls, Ansi Models

    LED, Green, Drive Enabled (HD Models) 5694 Switch, Toggle (HD Models) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page A-3...
  • Page 128 JUMPER WHT/RED YEL/WHT WHT/RED HORN BUTTON BLK/WHT/RED DRIVE INDICATOR RED/GRN RED/BLK OUTRIGGER JUMPER PNK/WHT RED/BLU RED/BLU REMOVABLE CABLE Upper Controls 3072ES, 3772ES, 3772 ES HD ART_2723 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-4...

  • Page 129: Upper Controls, Ce Models

    LED, Green, Drive Enabled (HD Models) 5694 Switch, Toggle (HD Models) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page A-5...
  • Page 130 TO CONTROL BOX Control Box Cover Assembly, ES Machines Reference: ART_13868 ART_2220 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-6...

  • Page 131: Upper Control Box Cover Assembly

    Wire Harness (see Wire Harness, Section F) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page A-7...
  • Page 132 Control Arm (Joystick) Reference: ART_188 ART_2221 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-8...

  • Page 133: Upper Control Joystick

    TERMINAL, PUSH ON, 3/16" – 8630 HANDLE, GRIP • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page A-9...

  • Page 134: Lower Controls

    Raise - N.O. Lower - N.O. Emergency Stop - N.C. Platform / Base - N.C. Platform / Base - N.O. Circuit Breaker Emergency Lowering (3772ES) Lower Controls ART_2590 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-10...

  • Page 135: Lower Controls

    Block, Contact, N.O. 17082 Bracket, Alarm Mount • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page A-11...
  • Page 136 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page A-12...
  • Page 137 Lanyard Attachment: CE Standard – ANSI Option ..... B-17 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008...
  • Page 138 Platform and Rails ART_2094 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-2...

  • Page 139: Platform Assembly

    Washer, Flat, .438 ID×1.00 OD×.078 THK HDW6434 Screw, 3/8-16×2" LG • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-3...
  • Page 140 Roll-out Deck Lock Pin Assembly ART_2133 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-4...

  • Page 141: Rollout Lock Pin Assembly

    Pin, Spring, 1/8" DIA. ¾" LG • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-5...
  • Page 142 Roll-out Deck Roller Reference: ART_687 ART_2095 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-6...

  • Page 143: Roller Assembly

    Screw, 5/16" - 18, ¾" LG • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-7...
  • Page 144 Entry Chain Reference: ART_13850 ART_2096 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-8...

  • Page 145: Entry Chain, Ansi Models

    S-hook, Connecting Link 8781 Snap, Chain Link • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-9...
  • Page 146 Gate ART_2097 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-10...

  • Page 147: Swing Gate, Ce Standard / Ansi Option

    Nut, 5/16"-18, GR 5 HDW8268 Nut, 3/8-16 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-11...
  • Page 148 Control Cable Installation ART_2591 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-12...

  • Page 149: Control Cable / Horn Installation

    NUT, KEPS, #6-32 , GR 5 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-13...
  • Page 150 Power to Platform ART_2099 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-14...

  • Page 151: Power To Platform - Airline To Platform

    Fitting, ¼" Male, Male Hose Barb – 5882 Cable Clamp • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-15...
  • Page 152 Lanyard Anchorage Points ART_2100 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-16...

  • Page 153: Lanyard Attachment: Ce Standard - Ansi Option

    Bracket, Attach Point 8606 Decal, Warning, Pos Restraints • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page B-17...
  • Page 154 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page B-18...

  • Page 155: Section C Scissors

    Limit Switch Installation ......... . C-15 Scissor Guards - 3072ES, CE Models ......C-17 Scissor Guards - 3772ES, CE Models .
  • Page 156 .250 31 32 .313 .313 .313 .313 .250 23 24 .250 DENOTES LOCATION OF HDW13175, TOTAL QUANTITY OF 16 Early Style Scissor Assembly, 3072 ART_2592 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-2...

  • Page 157: Scissor Assembly, 3072Rt: Up To Serial #11211099

    Washer, 2.062 ID × 2.620 OD × .030 THK (not shown) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-3...
  • Page 158 .250 .188 .188 .375 .250 .375 .188 31 32 .375 .375 DENOTES LOCATION OF HDW13175, TOTAL QUANTITY OF 29 Early Style Scissor Assembly, 3772 ART_2593 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-4...

  • Page 159: Scissor Assembly, 3772Rt: Up To Serial #11211099

    Washer, 2.062 ID × 2.620 OD × .030 THK (not shown) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-5...
  • Page 160 .250 .250 .313 .313 .313 .313 .250 .250 3072RT - 3072ES: Sheet 1 of 2 Scissor Assembly, Beams Install ART_2594 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-6...

  • Page 161: Scissor Assembly, 3072Rt: Serial #11211100 - Up

    Spacer Block - Beams … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-7...
  • Page 162 32 33 3072RT - 3072ES: Sheet 2 of 2 Scissor Assembly, Cylinder Install ART_2595 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-8...

  • Page 163: Scissor Assembly, 3072Rt: Serial #11211100 - Up (Continued

    BLOCK, SLIDE, PLATFORM 91020 Lift Cylinder • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-9...
  • Page 164 .188 .188 .250 .250 .188 .188 .375 .375 .375 .375 Scissor Assembly, Cylinder Install 3772RT - 3772ES: Sheet 1 of 2 ART_2596 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-10...

  • Page 165: Scissor Assembly, 3772Rt: Serial #11211100 - Up

    Spacer Block - Beams … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-11...
  • Page 166 3772RT - 3772ES: Sheet 2 of 2 Scissor Assembly, Cylinder Install ART_2597 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-12...

  • Page 167: Scissor Assembly, 3772Rt: Serial #11211100 - Up (Continued

    Lift Cylinder, Upper 91314 Lift Cylinder, Lower • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-13...

  • Page 168: Limit Switch Installation

    Limit Switch Installation ART_2598 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-14...
  • Page 169 40524 CAM, Slow Speed, 2.75 DIA. • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-15...
  • Page 170 Scissor Guards 3072RT - 3072ES CE MODELS ART_2745 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-16...

  • Page 171: Scissor Guards - 3072Es, Ce Models

    Mid Panel, Scissor Guard 16332 Spacer • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-17...
  • Page 172 Scissor Guards 3772RT - 3772ES CE MODELS ART_2744 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-18...

  • Page 173: Scissor Guards - 3772Es, Ce Models

    Side Panel, Scissor Guard 16359 Side Panel, Scissor Guard • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page C-19...
  • Page 174 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page C-20...
  • Page 175 Wheel Motor, Front ..........D-9 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 176 Drive Ports Case Drain Hydraulic Wheel Motor with Brake Brake Port X72 Rear Axle ART_2599 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page D-2...

  • Page 177: Rear Axle Assembly

    16349 Cover, Lower Control Valve Shield • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page D-3...
  • Page 178 Drive Ports Case Drain Hydraulic Wheel Motor X72 Front Axle ART_2600 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page D-4...

  • Page 179: Front Axle Assembly

    HDW8984 Fitting, MB-MJ-12-8 HDW91236 Fitting, MB-MJ90-4-5 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page D-5...
  • Page 180 Rear Housing Mounting Surface Shaft Shaft Nut Bearing Piston .620 .630 Front Housing Shaft Front Bearing Housing X72 Wheel Motor, Rear DT710 BRAKE MOTOR COMPONENTS ART_2397 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page D-6...

  • Page 181: Wheel Motor, Rear

    Disk Stamping – Thick Disk Stamping • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page D-7...
  • Page 182 Retaining 1.5" Bearing Snap Ring SHAFT SEAL 1.5" BEARING BACKUP SEAL DUST SEAL METAL BACKUP RING X72 Wheel Motor, Front DT701 Series Motor Components ART_2701 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page D-8...

  • Page 183: Wheel Motor, Front

    O-RING SEAL – TEFLON BACKUP SEAL • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page D-9...
  • Page 184 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page D-10...
  • Page 185 Outrigger Cylinder ..........E-27 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 186 R I G F R O L E F Sheet 1 of 2 X72ES Manifold Assembly ART_2702 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-2...

  • Page 187: Main Manifold Assembly

    Port plug M ¼", O-Ring, RBG-4 … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-3...
  • Page 188 R I G F R O L E F Sheet 2 of 2 X72ES Manifold Assembly, Hardware ART_2703 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-4...

  • Page 189: Main Manifold Assembly (Continued

    Adapter, Male ¼”, O-ring, Male ¼” 37° MB-MJ-4-4 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-5...
  • Page 190 Main Relief Manifold 3072ES - 3772ES - 3772ES HD ART_2704 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-6...

  • Page 191: Main Relief Manifold Assembly

    91657 Main Relief Valve 91716 Fitting • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-7...
  • Page 192 L E F R I G OUTRIGGER EXTEND OUTRIGGER RETRACT OUTRIGGERS OUTRIGGERS CYLINDERS CYLINDERS MAIN MANIFOLD ORS MAIN MANIFOLD ORR Outrigger Manifold Installation 3772ES HD ART_2705 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-8...

  • Page 193: Manifold - Outrigger (Hd Models

    Valve Spool 4-way 3-position HDW7314 Port Plug • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-9...
  • Page 194 POWER MODULE F R O L E F HD Models: OUTRIGGERS Hose Kit - Axles 3072ES - 3772ES - 3772ES HD: Sheet 1 of 4 ART_2706 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-10...

  • Page 195: Hydraulic Hoses - Axles

    Adapter Male ½" JIC - ½" JIC Bulkhead 91193 Jamnut ¾-16 … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-11...
  • Page 196 F R O L E F HD Models: OUTRIGGERS Hose Kit - Steering, Motor Case Drain, Brake 3072ES - 3772ES - 3772ES HD: Sheet 2 of 4 ART_2707 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...

  • Page 197: Hydraulic Hoses - Steering, Brake Release And Axle Return

    TEE M 0.31 HS BR BNN … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-13...
  • Page 198 F R O L E F HD Models: OUTRIGGERS Hose Kit - Pump and Lift 3072ES - 3772ES - 3772ES HD: Sheet 3 of 4 ART_2708 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-14...

  • Page 199: Hydraulic Hoses - Pump And Return

    7391 TEE, 3772ES Only … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-15...
  • Page 200 POWER MODULE F R O L E F HD Models: OUTRIGGERS Hose Kit - Outriggers 3072ES - 3772ES - 3772ES HD: Sheet 4 of 4 ART_2709 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-16...

  • Page 201: Hydraulic Hoses - Outrigger (Hd Models

    Hose Assy, 3/8"×28" (6M3K-6FJX-6FJX) 8318 Hose Assy 3/8"×24" (6M3K-6FJX-6FJX90) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-17...
  • Page 202 Rod Seal Seal Retainer Static Seal Wear Ring Seal Kit Wear Ring Piston Seal Wear Ring Piston Barrel 3072 Lift Cylinder 91020 LIFT CYLINDER WITH BEARINGS ART_2710 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-18...

  • Page 203: Lift Cylinder, 3072

    91460 REF Kit, Seal-Lift Cylinder (service) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-19...
  • Page 204 Rod Seal Seal Retainer Static Seal Wear Ring Seal Kit Piston Seal Wear Ring Piston Barrel 3772 Lower Lift Cylinder 91314 LIFT CYLINDER WITH BEARINGS ART_2711 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-20...

  • Page 205: Lift Cylinder, Lower, 3772

    REF Kit, Seal-Lift Cylinder - Lower (Service) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-21...
  • Page 206 Rod Wiper Rod Seal Seal Retainer Wear Ring Seal Kit Piston Barrel 3772 Upper Lift Cylinder 91315 LIFT CYLINDER WITH BEARINGS ART_2712 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-22...

  • Page 207: Lift Cylinder, Upper, 3772

    90987 REF Kit, Seal-lift Cylinder (Service) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-23...
  • Page 208 SEAL KIT PISTON SEAL WEAR RING STATIC SEAL ROD SEAL ROD WIPER PISTON SEAL RETAINER X72 Steering Cylinder 91019 Steering Cylinder ART_2713 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-24...

  • Page 209: Steering Cylinder

    – 90990 REF Seal Kit (Service) • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-25...

  • Page 210: Outrigger Cylinder

    WEAR RING PISTON PISTON SEAL STATIC SEAL SEAL RETAINER ROD SEAL ROD WIPER Outrigger Cylinder 91278 Cylinder Assembly ART_2714 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-26...
  • Page 211 Orifice – 91463 REF Seal Kit • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page E-27...
  • Page 212 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page E-28...

  • Page 213: Section F Base

    Outrigger Installation (3772ES HD) ........F-17 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...

  • Page 214: Base Assembly

    Base Assembly 3072 - 3772 ART_2715 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-2...
  • Page 215 Screw, ¼–12 × ¾" HDW8267 Nut, ¼-20 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-3...
  • Page 216 3072 3772 Ballast 3072 - 3772 ART_2716 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-4...

  • Page 217: Ballast (Counterweight) Installation

    Plate, Ballast Weight 3772RT HDW13195 Washer, Flat • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-5...

  • Page 218: Modules Installation

    Modules Installation 3072ES - 3772ES ART_2717 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-6...
  • Page 219 Washer, .438 ID × 1.000 OD × .078 THK HDW8267 Nut, ¼-20 • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-7...

  • Page 220: Control Module

    Control Module 3072ES - 3772ES ART_2718 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-8...
  • Page 221 Bolt, 32 × 1.57 … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-9...
  • Page 222 Control Module 3072ES - 3772ES ART_2718 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-10...

  • Page 223: Control Module (Continued

    Manifold, Main Relief 16995 Cover 16995 Cover • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-11...

  • Page 224: Power Module

    Power Module 3072ES - 3772ES ART_2719 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-12...
  • Page 225 Nut, ¼–20, GR 5 HDW5723 Screw, ¼–20 x ¾ • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-13...
  • Page 226 DE SI Disconnect Chassis Switch Ground Diode BATTERY PACK CONTROL MODULE Underside of Platform Master Disconnect Switch SCISSOR ASSEMBLY Upper Controls 3072ES, 3772ES, 3772 ES HD ART_2721 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-14...

  • Page 227: Wire Harness

    QTY DESCRIPTION 91671 Harness, Main –Control Module - Base & Valves] 91069 Harness, Lift Cylinder Down Valve (3072ES) - Control Module to Lift Cylinder] 91085 Harness, Lower Lift Cylinder Down Valve (3772ES) - Control Module to Lift Cylinder] 91086 Harness, Upper Lift Cylinder Down Valve (3772ES) - Control Module to Lift Cylinder]...
  • Page 228 Outrigger Installation 3772RT HD - 3772 ES HD ART_2720 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-16...

  • Page 229: Outrigger Installation (3772Es Hd

    Pin, Cotter, 1/8 × 1" 21002 Pad Weldment • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page F-17...
  • Page 230 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page F-18...

  • Page 231: Section G Decals

    Decals, CE Models (continued) ........G-11 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 232 NOTE: Decal placement is subject to the original country of the equipment destination. Decals 3072ES - 3772ES - 3772ES HD ANSI Models: Sheet 1 of 4 ART_2746 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-2...

  • Page 233: Decals, Ansi Models

    Decal, Keep Clear (3772ES) … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-3...
  • Page 234 NOTE: Decal placement is subject to the original country of the equipment destination. Decals 3072ES - 3772ES - 3772ES HD ANSI Models: Sheet 2 of 4 ART_2747 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-4...

  • Page 235: Decals, Ansi Models (Continued

    Decal, Lower Controls 90651 Serial Plate • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-5...
  • Page 236 3772ES HD 3772ES 3772ES 1 5 1 5 3772ES Decals, Front and Control Side 3072ES - 3772ES - 3772ES HD ANSI Models: Sheet 3 of 4 ART_2748 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-6...
  • Page 237 3772ES HD MODELS HD MODELS STANDARD 3072ES MODELS Decals, Rear and Power Side 3072ES - 3772ES - 3772ES HD ANSI Models: Sheet 4 of 4 ART_2749 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-7...
  • Page 238 NOTE: Decal placement is subject to the original country of the equipment destination. Decals 3072ES - 3772ES - 3772ES HD CE Models: Sheet 1 of 4 ART_2750 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-8...

  • Page 239: Decals, Ce Models

    Decal, Capacity, 1000 LB … continued • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-9...
  • Page 240 NOTE: Decal placement is subject to the original country of the equipment destination. Decals 3072ES - 3772ES - 3772ES HD CE Models: Sheet 2 of 4 ART_2751 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-10...

  • Page 241: Decals, Ce Models (Continued

    Decal, Lower Controls 90586 Serial Plate • as req: as required • INCL: Included with assembly • NS: Not a Stock item • REF: Reference only “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-11...
  • Page 242 1 5 1 5 3772ES 3072ES 3772ES Decals, Front and Control Side 3072ES - 3772ES - 3772ES HD CE Models: Sheet 3 of 4 ART_2752 R1 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-12...
  • Page 243 HD MODELS HD MODELS STANDARD 3072ES MODELS 3072ES 3772ES Decals, Rear and Power Side 3072ES - 3772ES - 3772ES HD CE Models: Sheet 4 of 4 ART_2753 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual October 2008 Page G-13...
  • Page 244 OTES October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual Page G-14...
  • Page 245 3766 ........A-7 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 246 8750 ........A-9 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 247 91347 ........E-17 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 248 HDW7031 ........B-5 October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 249 HDW8568 ........D-5 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 250 Part Number Index Part Number Page Part Number Page October 2008 “3072ES / 3772ES / 3772ES HD” Service and Parts Manual...
  • Page 251 Service 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 252 OTES...
  • Page 253 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 254 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:info@mecawp.com • Web:www.mecawp.com...

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