Mec Speed Level Series Service & Parts Manual

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RT - Internal Combustion

ES - Electric

Service & Parts Manual

Speed Level Series

2684ES Serial Number Range 12700000 - Up

2684RT Serial Number Range 12800000 - Up

3084ES Serial Number Range 11700000 - Up

3084RT Serial Number Range 11800000 - Up

Part # 91885 R1

January 2019

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Page 1 Service & Parts Manual Speed Level Series RT - Internal Combustion 2684ES Serial Number Range 12700000 - Up Part # 91885 R1 ES - Electric 2684RT Serial Number Range 12800000 - Up January 2019 3084ES Serial Number Range 11700000 - Up...
Page 2 Date Reason for Update January 2019 Speed Level Mk. 2 Update MEC Aerial Work Platforms 1401 S. Madera Avenue, Kerman, CA 93630 USA Toll Free: 1 - 877 - 632 - 5438 Phone: 1 - 559 - 842 - 1500 Fax: 1 - 559 - 842 - 1520 info@MECawp.com...
Page 3: Table Of Contents
Service Introduction �� Section 1 - MEC Operator Policy �� MEC Operator Polcy �� ...
Page 4 January 2019 Lower Controls - 3084RT Dual Fuel/Desel �� 48 Lower Controls - 3084ES Electrc �� ...
Page 5 January 2019 EZ-Cal Adjustment�� EZ-Cal Setup �� ...
Page 6 January 2019 Upper Control Box Assembly, Early Style �� Lower Controls, 3084ES Electrc Models �� Lower Controls, 3084RT Dual Fuel Models ��...
Page 7 January 2019 Power Module – ES �� Control Module RT, Drawng 1 of 2 �� ...
Page 8: Chapter 1 - Service
All parts represented here are manufactured and supplied in accordance with MEC quality standards. We recommend that you use genuine MEC parts to ensure proper operation and reliable performance. To obtain maximum benefits from your MEC Aerial Work Platforms, always follow the proper operating and maintenance procedures.
Page 9: Section 1 - 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: Section 2 - Safety Symbols & General Safety Tips
Safety Symbols & General Safety Tips Safety Symbols & General Safety Tips MEC manuals and decals use symbols, colors and signal words to help you recognize important safety, operation and maintenance information. RED and the word DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury��...
Page 11: Section 3 - Specifications
Secton 3 - Specfcatons January 2019 RT Models Specifications RT Models Specifications 2684RT 3084RT Working Height* 32 ft* 10.0 m* 36 ft* 11.0 m* Platform Height 26 ft 7.9 m 30 ft 9.0 m Stowed Height Rails Up 107 in 2.72 m 105 in 2.67 m...
Page 12: Es Models SpecFCatOns
Secton 3 - Specfcatons January 2019 ES Models Specifications 2684ES 3084ES Working Height* 32 ft* 10.0 m* 36 ft* 11.0 m* Platform Height 26 ft 7.9 m 30 ft 9.0 m Stowed Height Rails Up 107 in 2.72 m 105 in 2.67 m Rails Folded Down 72 in...
Page 13: Section 4 - General Information
Secton 4 - General Informaton January 2019 Key Safety Tips Key Safety Tips NEVER PERFORM SERVICE ON THE MACHINE WITH THE PLATFORM ELEVATED WITHOUT FIRST SUPPORTING THE PLATFORM/BOOM ASSEMBLY�� • Use a crane with chains and straps of adequate lifting capacity to support the platform.
Page 14: HydraulC System
Secton 4 - General Informaton January 2019 Hydraulic System HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY, BLINDNESS, AND EVEN DEATH�� CORRECT LEAKS IMMEDIATELY�� Hydraulic fluid leaks under pressure may not always be visible�� Check for pin hole leaks with a piece of cardboard, not your hand��...
Page 15: PrMary MachNe Components
Secton 4 - General Informaton January 2019 Primary Machine Components Document Box Loading Gate Lanyard Points (Option) Upper Controls Entry Gate Platform and Rails 91 84 Ladder Upper Boom Boom Support Wheel Lift Cylinder Control Module Pivot Gear Axle Float Cylinders Lower Boom Steering Components Front Drive Motors...
Page 16 Secton 4 - General Informaton January 2019 Control Module Leveling GP400 Module Hydraulic Manifold Alarm Battery Disconnect Switch Power to Platform AC Connector Terminal Block Module Lower Controls Emergency Lowering Switch 12 Volt DC Battery Main Hydraulic Manifold Fuel Reservoir Power Module Hydraulic Hydraulic Fluid...
Page 17 Secton 4 - General Informaton January 2019 Bolt Torque Specification - American Standard Fasteners Use the following values to apply torque unless a specific torque value is called out for the part being used American Standard Cap Screws SAE Grade Cap Screw Torque Torque...
Page 18: Bolt Torque SpecFCatOn - MetrC Standard
Secton 4 - General Informaton January 2019 Bolt Torque Specification - Metric Standard Fasteners Use the following values to apply torque unless a specific torque value is called out for the part being used Metric Cap Screws Metric Grade 8�� 8 10��...
Page 19: HydraulC Components Torque Table
Secton 4 - General Informaton January 2019 Hydraulic Components Torque Table Note:Always lubricate threads with clean hydraulic fluid prior to installation. Use the following values to torque hydraulic components when a specific value is not available. Always check for torque values in the following places before relying on the Hydraulic Components Torque Table.
Page 20: Emergency Systems And Procedures
Secton 4 - General Informaton January 2019 Emergency Systems And Procedures IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED, HAVE AN EXPERIENCED OPERATOR USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE PLATFORM�� DO NOT ATTEMPT TO CLIMB DOWN ELEVATING ASSEMBLY�� Emergency Stop The machine is equipped with an EMERGENCY STOP switch on both control panels.
Page 21: ParkNg Brake And TowNg CRcuT
Secton 4 - General Informaton January 2019 Parking Brake And Towing Circuit The machine can be winched or moved short distances in case of power failure at speeds not to exceed 5 MPH (8.05 km/h). Before towing or winching the machine, it is necessary to release the brake.
Page 22: LFt And Support The MachNe
Secton 4 - General Informaton January 2019 Lift And Support The Machine DEATH OR SERIOUS PERSONAL INJURY MAY RESULT FROM THE USE OF SUBSTANDARD LIFTING DEVICES AND/OR JACK STANDS�� ENSURE THAT ALL LIFTING DEVICES AND JACK STANDS ARE OF ADEQUATE CAPACITY AND IN GOOD WORKING CONDITION BEFORE USE��...
Page 23: TransportNg The MachNe
Safety Information THIS INFORMATION IS PROVIDED FOR REFERENCE AND DOES NOT SUPERSEDE ANY GOVERNMENT OR COMPANY POLICY REGARDING THE LOADING, TRANSPORT OR LIFTING OF MEC MACHINERY�� DRIVERS ARE RESPONSIBLE FOR LOADING AND SECURING MACHINES, AND SHOULD BE PROPERLY TRAINED AND AUTHORIZED TO OPERATE MEC MACHINERY��...
Page 24: HydraulC System - General
Secton 5 - Hydraulc System January 2019 Hydraulic System – General Hydraulic System – General The hydraulic integrated circuit, generally known as the manifold system (valve type) is designed to control all or part of machine functions by integrating various hydraulic cartridge valves into a manifold to provide directional, pressure, flow, and load control.
Page 25 Secton 5 - Hydraulc System January 2019 Hydraulic Roadmap Hydraulic Reservoir Hydraulic fluid is held in the reservoir for delivery to the various components and then returned to the reservoir. Returning hydraulic fluid is routed through a filter before entering the reservoir. The reservoir also serves as the oil cooling device.
Page 26: HydraulC FluD
FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE�� Fluid Recommendations MEC recommends the use of Mobile Fluid DTE 10, DTE 13 M or AW32 hydraulic fluid. Do not substitute with lower grade fluids as pump damage may result. System Flushing Procedure With platform fully down, drain hydraulic fluid from hydraulic reservoir into a clean, empty container.
Page 27: HydraulC FluD ReservoR
Secton 5 - Hydraulc System January 2019 Hydraulic Fluid Reservoir Consists of the reservoir, a filler cap with breather, a drain plug, a sight gauge, and a bypass filter with a 10 micron filter element. • Check reservoir for signs of leakage weekly. Hydraulic Reservoir Assembly All machines are produced with a spin-on, bypassing filter.
Page 28: HydraulC Pump - 3084Rt
Secton 5 - Hydraulc System January 2019 Hydraulic Pump - 3084RT Note:For Hydraulic Pressure Adjustment Procedures refer to Section 8. Refer to Parts Section 16. An internal combustion engine drives a variable displacement axial piston pump. Remove Turn the Battery Disconnect Switch (inside Control Module) to the OFF position. Place a large container under the engine and pump to catch fluid that will be lost during pump replacement.
Page 29: HydraulC Pump Seals - 3084Rt
Install the snap ring. Install the shaft key. Hydraulic Pump Rebuild Pump rebuild should be performed only by a qualified mechanic. Contact MEC Technical Support before attempting to rebuild the pump. Page 22 Speed Level Seres - Servce & Parts Manual...
Page 30 Secton 5 - Hydraulc System January 2019 Hydraulic Pump Snap Ring 3084RT Shaft Seal Snap Ring Housing Shaft Seal Drive shaft splines Snap Ring Covered with tape Groove To protect seal during Installation Roller Bearing Bearing Bearing Shell Drive Shaft Seal Installation Shaft Case Drain Port...
Page 31: HydraulC Pump - 3084Es
Secton 5 - Hydraulc System January 2019 Hydraulic Pump - 3084ES The hydraulic pump and electric motor used on the 3084ES model contain no serviceable parts, and must be replaced rather than repaired. See the Parts Manual for more information. Hydraulic Pump &...
Page 32: HydraulC ManFold
Secton 5 - Hydraulc System January 2019 Hydraulic Manifold Note:Refer to Parts Section 15. • Tag all components as they are removed to aid in reassembly. Hydraulic Manifold Removal Disconnect the negative battery terminal. Tag and disconnect the solenoid valve leads. Tag and disconnect hydraulic hoses, and IMMEDIATELY cap the openings to prevent contamination.
Page 33 Secton 5 - Hydraulc System January 2019 Hydraulic Manifold 3084RT HIGH SPEED HIGH TORQUE 213 - YEL/WHT 313 - YEL/BLK DRIVE FORWARD DRIVE REVERSE 111 - GRY/RED 110 - GRY/BLK TO TANK LIFT HAND PUMP 204 - RED/BLU BRAKE RELEASE ORLS GAUGE PORT LINE SENSE...
Page 34 Secton 5 - Hydraulc System January 2019 Hydraulic Manifold - Alternate Configuration 3084ES HIGH SPEED HIGH TORQUE 213 - YEL/WHT 313 - YEL/BLK DRIVE FORWARD DRIVE REVERSE 111 - GRY/RED 110 - GRY/BLK TO TANK LIFT HAND PUMP 204 - RED/BLU BRAKE RELEASE ORLS GAUGE PORT...
Page 35 Secton 5 - Hydraulc System January 2019 FRONT BOTTOM ORIFICE PLUG ORIFICE PLUG AXLE LOCK CYLINDERS TILT TILT FRONT TO REAR SIDE TO SIDE TILT TILT FRONT TO REAR SIDE TO SIDE CHECK VALVE RIGHT LEFT MAIN MANIFOLD MAIN MANIFOLD RESERVOIR ORLS MAIN...
Page 36: DrVe And Brake System Wheel DrVe
Secton 5 - Hydraulc System January 2019 Drive And Brake System Wheel Drive Note:Refer to Section 7 for Remove and Install instructions. Refer to Parts Section 14. There are four (4) hydraulic fixed-displacement gear wheel motors to provide power to all four wheels. Dynamic Braking Circuit The two (2) rear wheel motors have integral spring-held brakes.
Page 37 Secton 5 - Hydraulc System January 2019 • Replace all shaft-related components (i.e. keys, wire rings, nuts). Motor Section Disassembly Make a “V” shaped set of alignment marks on the end-cover and housing to aid in the reassembly process. • Clamp the motor housing in a vise with the shaft facing down.
Page 38 Secton 5 - Hydraulc System January 2019 “V” Marks for Reassembly TORQUE SEQUENCE PRE-TORQUE = 10 FT LBS FINAL TORQUE = 50 FT LBS DT701 Series Motor Components 1. * Dust Seal 17. Housing 2. * High Pressure Seal 18. Rear Housing Bearing SHAFT SEAL 3.
Page 39 Secton 5 - Hydraulc System January 2019 Rear Wheel Motors With Brakes (DT-710) Refer to page 34. Disassembly Make a “V” shaped set of alignment marks on the end-cover and housing to aid in the reassembly process. • Clamp the motor housing in a vise with the shaft facing down. Remove the seven (7) bolts that hold the motor assembly together.
Page 40 Secton 5 - Hydraulc System January 2019 IMPORTANT: If replacing the disks and disk stampings, the new stack must be between .620 and .630 in. thick (15.7 mm and 16 mm) (see illustration). Install spring on top of the piston. •...
Page 41 Secton 5 - Hydraulc System January 2019 “V” Marks for Reassembly TORQUE SEQUENCE PRE-TORQUE = 10 FT LBS FINAL TORQUE = 50 FT LBS Rear Housing Mounting Surface Piston 15.7 mm .620 in. 16 mm .630 in. Front Housing DT710 BRAKE MOTOR COMPONENTS 1.
Page 42: FloatNg Axle Lock CylNders
Secton 5 - Hydraulc System January 2019 Floating Axle Lock Cylinders Note:Refer to Cylinder Repair. Refer to Section 7 for Remove and Install instructions. Refer to the Parts Manual Section 15 for parts list. There are two (2) cylinders in the floating axle system. These cylinders allow fluid to transfer from one side to the other while the platform is in the stowed position.
Page 43: SteerNg CRcuT
Secton 5 - Hydraulc System January 2019 Steering Circuit Note:Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure. Refer to Section 7 for Remove and Install instructions. Refer to the Parts Manual Section 15 for hose routing. The steering system consists of the following components: •...
Page 44: Platform LevelNg System
Secton 5 - Hydraulc System January 2019 Platform Leveling System There are two (2) hydraulic cylinders in the platform leveling system. These cylinders work in conjunction with a pivot mount to allow the platform and boom to tilt front-to-rear and side-to-side in order to provide a level work platform.
Page 45: Platform LFt CRcuT
Secton 5 - Hydraulc System January 2019 Platform Lift Circuit Note:Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure. Refer to Section 7 for Remove and Install instructions. On model 3084RT, the lift system uses the hydraulic pump to obtain proportional lifting function controlled by the lift valve and proportional valve.
Page 46: LFt CylNder
Secton 5 - Hydraulc System January 2019 Lift Cylinder Note:Refer to Cylinder Repair. One (1) single acting type hydraulic cylinder. The cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for holding the platform in position. The valve is also electrically actuated via a toggle switch for manually lowering the platform.
Page 47: General CylNder RepaR
Secton 5 - Hydraulc System January 2019 General Cylinder Repair CYLINDERS ARE HEAVY�� SUPPORT CYLINDERS BEFORE REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE MACHINE�� Return to Tank Piston Seals Seals Vent to Tank Head Piston Securing Nut Barrel Pressure Typical Single Acting Cylinder Piston Securing Nut Seals...
Page 48 Secton 5 - Hydraulc System January 2019 Insert shaft into a soft jawed vise so that the head and piston can be removed. Be sure the shaft and vise are both clean before using. Remove nut at the end of the shaft and pull head and piston off of the rod. Remove all seals from the head and piston using a non-sharp seal tool.
Page 49: Generator OptOn - 3084Rt
Secton 5 - Hydraulc System January 2019 Generator Option - 3084RT Note:Refer to Parts Sections 15 and 16. This option is available only on model 3084RT. Speed Control Valve Solenoid Valve Engine Generator Throttle Control Solenoid Generator Relay Generator Idle Control Solenoid Generator Switch...
Page 50: ElectrCal System - General
Secton 6 - Electrcal System January 2019 Electrical System – General Electrical System – General The electrical control system consists of lower controls located on the machine base and upper controls located on the machine platform. Emergency lowering controls are also located on the machine base.
Page 51 Secton 6 - Electrcal System January 2019 Diagnostic LED If the machine fails to operate, inspect the GP400 Module located inside the control box. The LED located on the processor should be ON. If the LED is OFF or FLASHING, refer to Section 8 or 9 for Troubleshooting.
Page 52: BatterEs
Secton 6 - Electrcal System January 2019 Batteries Discharged batteries can freeze, causing damage to the battery and/or battery case�� A broken battery case will allow electrolyte to leak out�� CHARGING BATTERIES CREATE EXPLOSIVE HYDROGEN GAS�� KEEP SPARKS, FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES�� ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH BATTERIES��...
Page 53 Secton 6 - Electrcal System January 2019 Check battery terminals for: • Corrosion: Regularly clean connections and apply a nonmetallic grease or protective spray to retard corrosion. • Loose connections: Be sure all cable connections are tightly secured, and that good contact is made with terminals.
Page 54: Battery Replacement
Secton 6 - Electrcal System January 2019 Battery Replacement TURN OFF THE BATTERY DISCONNECT SWITCH BEFORE REMOVING ANY BATTERY FROM THE MACHINE�� Prevent damage to the battery and/or electrical system; • Always disconnect the negative battery cable first�� • Always connect the positive battery cable first�� To Remove A Battery;...
Page 55: Lower Controls - 3084Rt Dual Fuel/DEsel
Secton 6 - Electrcal System January 2019 Lower Controls - 3084RT Dual Fuel/Diesel Emergency Stop Hour Meter Start Delay Raise (Green) Lower (Green) Battery Disconnect Choke (Dual Fuel) Glow (Diesel) Keyswitch Start Fuel Select Switch Circuit Breaker Emergency (Dual Fuel Only) Lowering ART_3091 Control...
Page 56: Lower Controls - 3084Es ElectrC
Secton 6 - Electrcal System January 2019 Lower Controls - 3084ES Electric Emergency Stop Hour Meter Charge Indicator Raise (Green) Lower (Green) Battery Disconnect Emergency Keyswitch Lowering Circuit Breaker ART_3245 Control Description Platform Select to operate from the platform control panel. Selector Switch (Key Can Be Removed In Base...
Page 57: Upper Controls - 3084Rt Dual Fuel/DEsel
Secton 6 - Electrcal System January 2019 Upper Controls - 3084RT Dual Fuel/Diesel Emergency Stop Speed / Torque Horn (Optional) Tilt Indicator 6 Generator (Option) Lift / Drive Preheat (Diesel) Choke (Dual Fuel) Start Switch 5 CE Models Preheat Steering Overload Indicator Horn Joystick...
Page 58: Upper Controls - 3084Es ElectrC
Secton 6 - Electrcal System January 2019 Upper Controls - 3084ES Electric Overload Indicator Lamp Speed / Torque Lift / Drive OFF | ON Switch 5 Emergency Stop Steering Horn (Optional) Joystick Automatic Leveling Manual Level: Front to Rear Enable Bar Manual Level: Side to Side ART_3244 Control...
Page 59: Alarms And SwTches
Secton 6 - Electrcal System January 2019 Alarms And Switches Movement Alarm The Movement Alarm is activated as soon as the DOWN operation is activated from either control station. This is the default setting. If desired, the movement alarm setting can be modified to activate the alarm during other functions (refer to Section 8 or 9 for Troubleshooting).
Page 60 Secton 6 - Electrcal System January 2019 CAN Tilt Angle Transducer Provides level information to GP400. • Platform Level located on the mast assembly, accessible through the rear of the mast. Provides platform level information to the GP400 through the CAN-bus system. •...
Page 61: Deutsch Connectors
January 2019 Deutsch Connectors 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 62: ContNuTy Checks
Secton 6 - Electrcal System January 2019 Continuity Checks Selector Switch – On-Off • Disconnect wires. Normally Normally • Connect first probe of ohm meter to common terminal. Open Closed • Connect second probe to any normally open terminal. • With switch OFF (open) there should be no reading.
Page 63 Secton 6 - Electrcal System January 2019 Toggle Momentary Switch • Disconnect wires. • Connect first probe of ohm meter to common terminal. Test top position • Connect second probe to top normally open terminal. • With the toggle in the neutral (open) position there should be no reading.
Page 64: Gp400 Control Module Setup
Secton 6 - Electrcal System January 2019 GP400 Control Module Setup Upper Controls Lower Controls GP400 Control Module Location • The GP400 Control Module processor is located Terminal in the lower control box. Block • The GP400 Matrix Module is located in the upper Module control box.
Page 65: General DescrPtOn
ONLY TRAINED AND AUTHORIZED PERSONNEL SHALL BE PERMITTED TO CALIBRATE THE PLATFORM OVERLOAD SENSING SYSTEM�� READ ALL INSTRUCTIONS CLOSELY BEFORE ATTEMPTING EACH STEP OF THE CALIBRATION PROCEDURE�� Calibrator GP400 Control Module MEC P/N 90888 GP400 Lower Controls Module Terminal Block...
Page 66 Secton 6 - Electrcal System January 2019 GP400 Calibration The EZ-Cal hand held device (MEC part # 90888) is required to access the GP400 for troubleshooting and calibration. The GP400 processor relies on angle and pressure sensors to monitor machine position at all times.
Page 67 Secton 6 - Electrcal System January 2019 provides information as to the position of the axle relative to the chassis. This information is used to allow or disallow drive when the platform is in the elevated position. If the front axle is more then 3 degrees out of parallel with the chassis, drive will be turned off to prevent the loss of stability.
Page 68 Secton 6 - Electrcal System January 2019 • Display reads CHANGE DEFAULTS Press Right Arrow to HEIGHT SETUPS, Press Enter. • Display reads CALIBRATE HEIGHT Press Enter. • Display reads PLATFORM DOWN? Verify that platform is fully lowered. Press Enter. •...
Page 69 Secton 6 - Electrcal System January 2019 • Display reads CODE 0000 Press up and right arrow to enter code 2222, Press Enter. • Display reads ACCESS LEVEL 2. • On later models, the display may continue to read “ACCESS LEVEL 3”. Repeat step b. and enter code 1775.
Page 70 Secton 6 - Electrcal System January 2019 The Platform Overload Sensing System is now calibrated. CE Height Calibration For this procedure it is not necessary to place any load in the platform. Drive machine to a flat, level surface where it can reach full elevation. Turn selector switch to Base controls.
Page 71: CalBratOn Problems
Secton 6 - Electrcal System January 2019 Calibration Problems Failure Messages Various problems can be detected by the EZ-Cal that prevent successful calibration. These problems are reported with a flashing message including an “F” code. The following descriptions are helpful in solving the problem.
Page 72 Secton 6 - Electrcal System January 2019 problem. F11:NOT UP • This message occurs at the start of the DYNAMIC lift if the operator selects a function other than F12:TOO MANY • This message occurs if the DYNAMIC lift takes too long. •...
Page 73 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 74 Secton 6 - Electrcal System January 2019 F33:REJECT CURVE • The DYNAMIC pressure curve is unacceptable. • There should be a lowest pressure about halfway through the lift (i.e.: near 50% height); the lowest pressure measured is at too high a height. •...
Page 75 Secton 6 - Electrcal System January 2019 F46:CHECK ELEV • This message indicates that the elevation switch opened more than once during the DYNAMIC lift. F47:CHECK ELEV • This message indicates that the elevation switch closed more than once during the DYNAMIC lower.
Page 76: InformatOn Messages
Secton 6 - Electrcal System January 2019 Information Messages During calibration the following messages will be displayed. They are informational prompts only and do not indicate a failure. BUILDING TABLES • This message indicates that the STATIC measurements are being used to build calibration data - the process should take no more than 5s.
Page 77 Secton 6 - Electrcal System January 2019 MEASURING # • This message is displayed when the platform is stopped during either STATIC phase, when the GP400 takes a measurement. • There will be a short delay while the machine is allowed to stabilize after movement is stopped. MUST GO DOWN! •...
Page 78 Secton 6 - Electrcal System January 2019 completed. • Press ENTER when “NO” is displayed if there is no need to redo the EMPTY phase. • Press UP or DOWN to display “YES” then press ENTER if it is necessary to redo the EMPTY phase.
Page 79 Secton 7 - Mechancal System January 2019 Mechanical Components Mechanical Components This section describes the major components of the machine and the steps required to service them. Base When steam cleaning the base/undercarriage, cover electrical components to prevent water penetration�� Steam clean the base as necessary, and inspect all welds and brackets.
Page 80 Secton 7 - Mechancal System January 2019 rear drive axle. Repair or replace as necessary when damage or leaks occur. Clean all fittings before disconnecting hoses�� Tag hoses for proper reassembly�� Plug all openings immediately to prevent contamination�� Front Drive Motors Refer to “Lift and Support The Machine”...
Page 81 Secton 7 - Mechancal System January 2019 Rear Drive Motor Refer to “Lift and Support The Machine” on page 15 for instructions and safety precautions. Upper Hose Guard Bypass Valve Solenoid Hose Fitting Lower Hose Guard Drive Motor Motor Housing Assembly ART_3165 Remove...
Page 82 Secton 7 - Mechancal System January 2019 Steer Left To Replace Steer Cylinder: Steer Port Control Clean all fittings before disconnecting hoses�� Valves Steer Relief Tag hoses for proper reassembly�� Valve Steer Right Steer Left Steer Right Port Plug all openings immediately to prevent contamination�� GRN/RED ORG/WHT Left Steer Cylinder...
Page 83: FloatNg Axle Lock CylNders
Secton 7 - Mechancal System January 2019 Floating Axle Lock Cylinders There are two Floating Axle Lock Cylinders located at the front of the machine. Remove Raise and support the front end of machine. Disconnect hydraulic hoses. Immediately cap and plug all openings to prevent contamination. Remove the bolt and banjo pin that secures the pivot pin to the frame and remove the pivot pin.
Page 84 Secton 7 - Mechancal System January 2019 Test Locking And Center Position Place a block approximately 4 inches Pivot Pin (10 cm) high behind one of the front tires. Axle Lock Cylinder Elevate the platform to 10-11 feet (3-3.4 Banjo Pin Slowly drive the tire onto the block.
Page 85 Secton 7 - Mechancal System January 2019 Hoses And Cables Note:Refer to Parts Section 15 for detailed hydraulic hose diagrams. Inspect all hoses and electrical cables for security and damage. Hoses and cables should be examined for rubbing and chafing. Check all ties and clamps that keep hoses secure.
Page 86 Secton 7 - Mechancal System January 2019 Remove the bolt and nut that secure the cylinder head to the mounting pin on the boom assembly. While supporting the cylinder, carefully remove the mounting pin and lower the cylinder to the chassis.
Page 87: Boom - ElevatNg Assembly
Secton 7 - Mechancal System January 2019 Boom - Elevating Assembly Remove the platform (see “Platform Removal” on page 78). Remove the platform pivot. CYLINDER PIN Attach a crane to the platform pivot and apply enough lift to MOUNTING PIN BANJO PIN provide support.
Page 88: LubrCatOn
Secton 7 - Mechancal System January 2019 Lubrication ART_3085 No�� Item Specification Frequency Mobile Fluid DTE 10, DTE 13 M, or AW32 M Routine Maintenance Check Daily Do not substtute wth lower grade fluds as pump Hydraulic damage may result�� Reservoir Scheduled Maintenance Change yearly or every 1000 hours, whichever...
Page 89: EngNe MaNtenance
Secton 7 - Mechancal System January 2019 Engine Maintenance Diesel Engine Models For complete service information consult the engine manual that came with the machine. Always wear protective eye-wear when working with fuel and oil�� Engine should be OFF when replacing filter elements�� Oil Filter Oil And Oil Filter, Diesel Dispose of used oil and filters properly��...
Page 90 Secton 7 - Mechancal System January 2019 Fuel Filter, Diesel Turn OFF valve on bottom of fuel tank. Fuel Filter Bleed Screw Place a suitable container beneath the fuel filter assembly to catch spilled fuel. Clean the filter area. Turn filter cartridge ¼ counterclockwise remove. Wipe the Fuel Filter filter seal contact surface with a clean towel and install a Housing...
Page 91 Secton 7 - Mechancal System January 2019 Throttle Solenoid Adjustment, Diesel IMPORTANT: This final adjustment must be made after all other throttle speed adjustments. The solenoid must be free to retract fully in order to turn OFF the High Amperage Pull Circuit.
Page 92: GasolNe & Dual Fuel EngNe Models
Secton 7 - Mechancal System January 2019 Gasoline & Dual Fuel Engine Models For complete service information consult the engine manual that came with the machine. Always wear protective eye-wear when working with fuel and oil�� Engine should be OFF when replacing filter elements�� Throttle Solenoid Oil And Oil Filter - Gasoline &...
Page 93 Secton 7 - Mechancal System January 2019 Air Filter Element - Gasoline & Dual Fuel Air Filter Canister Unlock the catches holding the filter canister cover. Remove the wing-nut from the filter assembly and Catch remove the filter element. Filter Inspect the canister for debris and clean as necessary.
Page 94 Hydraulic fluid contaminated with debris - filter change interval neglected. Note:MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Use only the recommended hydraulic fluid. Substituting with a lower grade fluid will result in pump failure.
Page 95: ElectrCal System TroubleshootNg - 3084Rt
Secton 8 - Troubleshootng - 3084RT Models January 2019 Electrical System Troubleshooting - 3084RT The electronic control system used on the 3084RT was designed for low maintenance and long trouble free operation. The system consists of two microprocessor based modules; The Matrix Module and the GP400 Processor.
Page 96: Gp400 Module
Secton 8 - Troubleshootng - 3084RT Models January 2019 GP400 Module The GP400 module is “the brains” of the system. It receives and processes a variety of inputs both from the machine and the operator, then controls all the operative functions of the machine. It also has a feature that allows the technician to access and monitor all functionality of the system, along with a technician-friendly series of fault messages that can be accessed through the use of the EZ- Cal scan tool.
Page 97 Secton 8 - Troubleshootng - 3084RT Models January 2019 Matrix Module & Terminal Block Module (TBM) Matrix Module The Matrix Module is the remote module located inside the upper control box. It received inputs from the operator and relays them to the GP400. P4-1 —...
Page 98: Ez-Cal Scan Tool
January 2019 EZ-Cal Scan Tool 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 99: UsNg The Ez-Cal WTh The Flow Charts
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 100 Secton 8 - Troubleshootng - 3084RT Models January 2019 2684RT, 3084RT (SPEED LEVEL) EZ-Cal Flow Chart Adjustments & Setups EZ-CAL MENU Chart 1 of 2 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted RUN SYSTEM HELP...
Page 101 Secton 8 - Troubleshootng - 3084RT Models January 2019 XX84RT SERIES ANSI & CE EZ-Cal Flow Chart DIAGNOSTIC EZ-CAL MENU SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Use in conjunction with Menu and sub-menu DIAGNOSTICS Diagnostic tables for LEFT/RIGHT BUTTONS Thorough explanation Select menus and setting to be adjusted...
Page 102 Secton 8 - Troubleshootng - 3084RT Models January 2019 2684RT, 3084RT (SPEED LEVEL) EZ-Cal Flow Chart Adjustments & Setups EZ-CAL MENU Chart 1 of 2 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted RUN SYSTEM HELP...
Page 103 Secton 8 - Troubleshootng - 3084RT Models January 2019 XX84RT SERIES ANSI & CE EZ-Cal Flow Chart DIAGNOSTIC EZ-CAL MENU SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Use in conjunction with Menu and sub-menu DIAGNOSTICS Diagnostic tables for LEFT/RIGHT BUTTONS Thorough explanation Select menus and setting to be adjusted...
Page 104: Ez-Cal Adjustment
Secton 8 - Troubleshootng - 3084RT Models January 2019 EZ-Cal Adjustment Refer to “Using the EZ-Cal Scan Tool” on page 91. Adjustments possible in Access Level 1 Only. Before changing personalities, ensure that the correct customer and model have been selected in the SETUPS menu.
Page 105 Secton 8 - Troubleshootng - 3084RT Models January 2019 Operation Personality Factory Setting Explanation 5F-1 Outriggers Not Used 5F-2 Extend O/R speed before all legs down 5F-3 Level O/R speed after all legs touch down 5F-4 Retract Maximum speed potential OUTRIGGERS 5F-5 Debounce...
Page 106 Secton 8 - Troubleshootng - 3084RT Models January 2019 Operation Personality Factory Setting Explanation Identifies Base Model 6A-1 Customer 5: XX84RT Must be set when GP400 is Replaced CHANGE 5 = ANSI DEFAULTS 6A-2 Model Select from these choices only 6 = CE Follow instructions in Section 7- Level 6B-1...
Page 107: Ez-Cal DAgnostCs
Secton 8 - Troubleshootng - 3084RT Models January 2019 EZ-Cal Diagnostics The EZ-Cal Diagnostics menu provides the ability to view and test individual circuits for irregularities. Whether diagnosing a failure or testing functions during preventative maintenance, the Diagnostics Menu provides a quick view at the inputs and outputs as registered by the GP400 Control Module in real time.
Page 108 Secton 8 - Troubleshootng - 3084RT Models January 2019 Selection EZ-Cal Readout Explanation 2A-15a Level / Off Level Status of axle position as read by GP400 - Not used on all models Status of oscillating axle lock valves, locked = no oscillation - Not 2A-15b Locked Y/N Sub Menu...
Page 109 Axle Lock Valves. ON= Axle valves powered, front axle will oscillate 2G-1 Cal Date Date of Load Sense calibration (CE option only) 2G-2 Software MEC specific software version 2G-3 Powered Accumulated time GP400 powered up (red LED on) Page 102 Speed Level Seres - Servce & Parts Manual...
Page 110: Ez-Cal RetrEve Mode And Help Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 EZ-Cal Retrieve Mode And Help Messages Note:It is important to understand that an error message will only be available if the red Diagnostic LED is flashing. If the machine is not operating properly and the red Diagnostic LED is not flashing, the trouble may lie with something not monitored by the electronic control system, i.e.
Page 111 Secton 8 - Troubleshootng - 3084RT Models January 2019 SHUTDOWN! • The system cannot operate – for example both the PLATFORM & GROUND inputs are active together. CHECK CANBUS • The system cannot operate – CANBUS communications is not successful (for example wire damage to the platform) PLATFORM, GROUND •...
Page 112 Secton 8 - Troubleshootng - 3084RT Models January 2019 • A platform steer function is selected but not allowed (for example, the switch was closed at power-on) UP LOCKED, DOWN LOCKED • A platform lift/lower function is selected but not allowed (for example, the switch was closed at power-on) CHECK DRIVE/LIFT •...
Page 113 Secton 8 - Troubleshootng - 3084RT Models January 2019 be allowed again when the heatsink cools to below 70ºc. • The heatsink temperature can be viewed in the DIAGNOSTICS/SYSTEM/ TEMPERATURE display, ID # 2a5. • The heatsink must be bolted to a significant metal panel of the vehicle, capable of dissipating heat to the environment.
Page 114: Ez-Cal Help Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 EZ-Cal Help Messages In addition to the MODE messages detailed above, the GP400 provides a HELP message to identify failure modes. Some error messages may also be identified by counting the number of times the red LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible.
Page 115: FunctOn ActVe Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 Function Active Messages The following HELP messages indicate that there is no problem with the GP400 but that a function is active – the vehicle should be moving as requested by the operator. DRIVING! _____________________________________________ (no flash code) LIFTING! ______________________________________________ (no flash code) LOWERING! ___________________________________________ (no flash code)
Page 116: Shutdown Help Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 Shutdown Help Messages This section lists “shutdown” HELP messages – functions can be shut down to prevent them being used: SHUTDOWN - CHECK EMS SWITCHES! ____________________ Flash Code: 2/1 • The Base/Platform selector switch position indicates the mode in which the system must operate if both are active together;...
Page 117 Secton 8 - Troubleshootng - 3084RT Models January 2019 • There is a problem with the platform drive/lift select switch – both modes are selected together. CHECK JOYSTICK SWITCHES! ___________________________ Flash Code: 2/2 • There is a problem with the platform joystick switches – both directions are selected together. RELEASE TRIGGER! ____________________________________ Flash Code: 2/2 •...
Page 118: Supply Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 Supply Messages The following are “supply” HELP messages – problems have been detected which are likely due to supply issues: FAULT: LOW OIL PRESSURE!_____________________________ Flash Code: 4/1 • Engine oil pressure switch open after start sequence initiated. Engine stalled or unable to start. FAULT: BAD INTERNAL 5V!_______________________________ Flash Code: 4/2 •...
Page 119: Sensor Messages Ce Models
Secton 8 - Troubleshootng - 3084RT Models January 2019 Sensor Messages CE Models The following are “sensor” HELP messages – problems have been detected which are likely due to sensor issues (CE models). FAULT: CHECK HEIGHT1 SENSOR _________________________ Flash Code: 6/1 FAULT: CHECK HEIGHT2 SENSOR _________________________ Flash Code: 6/1 •...
Page 120: Other Messages
Secton 8 - Troubleshootng - 3084RT Models January 2019 Other Messages The following are other HELP messages: SOME BIG BAD PROBLEM! ______________________________ Flash Code: 9/9 • This message should not occur! FACTORY OVERRIDE___________________________ Flash Code: (fast flashing) • When the controller is first shipped, prior to initial calibration, it is configured in a special “factory override”...
Page 121: TroubleshootNg Chart
Secton 8 - Troubleshootng - 3084RT Models January 2019 Troubleshooting Chart The following chart is a guide to help the technician find the area of a problem. In order to benefit from the information, you are advised to fully assess the symptoms by operating all machine functions.
Page 122 Secton 8 - Troubleshootng - 3084RT Models January 2019 Problem Possible Cause Remedy/Solution Maintenance lock in maintenance position Return maintenance lock to the stowed position Lowering valve not energized Check wiring to lowering valve located on Lift Cylinder Platform will not lower or Lowering valve not shifting Clean debris, check for damage, replace...
Page 123 Secton 8 - Troubleshootng - 3084RT Models January 2019 Problem Possible Cause Remedy/Solution Check continuity through Speed Select switch with wires disconnected Speed/Torque switch inoperative terminals 2 & 1 No low speed (high Check for 12 volts and ground to valve torque Valve SV3 not functioning Check for faulty valve spool...
Page 124 Secton 8 - Troubleshootng - 3084RT Models January 2019 Problem Possible Cause Remedy/Solution Level (Auto and Manual) Check elevation status using the EZ-Cal (see ID# 2a-13) System senses platform elevation above Recalibration of Height may be necessary (see 10 feet (3.2m) Calibration section for instruction.
Page 125: HydraulC Pressure Adjustment - 3084Rt
Before attempting to check and/or adjust pressure relief valves, operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid. Insert a 0-5000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no. 8434 Model Main...
Page 126: Adjustments - 3084Rt
Excessive flow will result in severe engine loading and stalling. Reduced flow will result in slower functions with no engine loading. If you suspect that the setting is incorrect, please call MEC Product Support at (800) 387- 4575 for assistance.
Page 127 Secton 8 - Troubleshootng - 3084RT Models January 2019 The steering Relief valve is located on the lower left side of the valve manifold. It is necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE CAP WHILE THE ENGINE IS RUNNING WILL RESULT IN FLUID LEAKAGE.
Page 128: Component IllustratOns
Secton 8 - Troubleshootng - 3084RT Models January 2019 Component Illustrations TILT Light (ANSI) Upper Controls Overload Light (CE) Overload Alarm (CE) HIGH SPEED MID RANGE HIGH TORQUE LIFT Matrix Module DRIVE Micro-Switch EMERGENCY STOP Steer Right OFF / RUN / START Steer Left CHOKE / PREHEAT GENERATOR...
Page 129 Hydraulic fluid contaminated with debris - filter change interval neglected. Note:MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Use only the recommended hydraulic fluid. Substituting with a lower grade fluid will result in pump failure.
Page 130: ElectrCal System TroubleshootNg - 3084Es
Secton 9 - Troubleshootng - 3084ES Models January 2019 Electrical System Troubleshooting - 3084ES The electronic control system used on the 3084ES is designed for very low maintenance and long trouble free operation. The system consists of three electronic microprocessor controlled modules; the Matrix Module, P600 Motor Control Module and the GP400 Processor.
Page 131: Gp400 Module
Secton 9 - Troubleshootng - 3084ES Models January 2019 GP400 Module The GP400 module is “the brains” of the system. It receives and processes a variety of inputs both from the machine and the operator, then controls all the operative functions of the machine. It also has a feature that allows the technician to access and monitor all functionality of the system, along with a technician-friendly series of fault messages that can be accessed through the use of the EZ- Cal scan tool.
Page 132: MatrX Module & TermNal Block Module
Secton 9 - Troubleshootng - 3084ES Models January 2019 Matrix Module & Terminal Block Module Matrix Module The Matrix Module is the remote module located inside the upper control box. It received inputs from the operator and relays them to the GP400. P4-1 —...
Page 133: P600 Motor Control Module
Secton 9 - Troubleshootng - 3084ES Models January 2019 P600 Motor Control Module The Motor Control Module operates the electric pump motor with varied speeds depending on operator commands. Pulse-width Modulation provides smooth and controlled operation with maximum battery efficiency. The Motor Controller also converts battery voltage (48 volts DC) to the user-friendly 12 volts DC used throughout the rest of the system.
Page 134: Ez-Cal Scan Tool
January 2019 EZ-Cal Scan Tool 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 135: UsNg The Ez-Cal WTh The Flow Charts
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 136 Secton 9 - Troubleshootng - 3084ES Models January 2019 2684ERT, 3084ERT (SPEED LEVEL) EZ-Cal Flow Chart Adjustments & Setups EZ-CAL MENU Chart 1 of 2 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted RUN SYSTEM HELP...
Page 137 Secton 9 - Troubleshootng - 3084ES Models January 2019 XX84RT SERIES ANSI & CE EZ-Cal Flow Chart DIAGNOSTIC EZ-CAL MENU SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Use in conjunction with Menu and sub-menu DIAGNOSTICS Diagnostic tables for LEFT/RIGHT BUTTONS Thorough explanation Select menus and setting to be adjusted...
Page 138 Secton 9 - Troubleshootng - 3084ES Models January 2019 2684ERT, 3084ERT (SPEED LEVEL) EZ-Cal Flow Chart Adjustments & Setups EZ-CAL MENU Chart 1 of 2 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS Select menus and setting to be adjusted RUN SYSTEM HELP...
Page 139 Secton 9 - Troubleshootng - 3084ES Models January 2019 XX84RT SERIES ANSI & CE EZ-Cal Flow Chart DIAGNOSTIC EZ-CAL MENU SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Use in conjunction with Menu and sub-menu DIAGNOSTICS Diagnostic tables for LEFT/RIGHT BUTTONS Thorough explanation Select menus and setting to be adjusted...
Page 140: Ez-Cal Adjustment
Secton 9 - Troubleshootng - 3084ES Models January 2019 EZ-Cal Adjustment Refer to “EZ-Cal Scan Tool” on page 127. Adjustments possible in Access Level 1 Only. Before changing personalities, ensure that the correct customer and model have been selected in the SETUPS menu.
Page 141 Secton 9 - Troubleshootng - 3084ES Models January 2019 Operation Personality Factory Setting Explanation 5F-1 Outriggers 2 = drive i lock Outrigger program controls level operation 5F-2 Extend Maximum speed potential 5F-3 Level Extend speed after all legs touch down 5F-4 Retract Maximum speed potential...
Page 142: Ez-Cal Setup
Secton 9 - Troubleshootng - 3084ES Models January 2019 EZ-Cal Setup Refer to “EZ-Cal Scan Tool” on page 127. Operation Personality Factory Setting Explanation 6A-1 Customer 5=xx84ES Choose basic model and power source CHANGE 3 = 3084ES ANSI 6A-2 Model Select Choose model and certification DEFAULTS 4 = 3084ES CE...
Page 143 Secton 9 - Troubleshootng - 3084ES Models January 2019 EZ-Cal Diagnostics The EZ-Cal Diagnostics menu provides the ability to view and test individual circuits for irregularities. Whether diagnosing a failure or testing functions during preventative maintenance, the Diagnostics Menu provides a quick view at the inputs and outputs as registered by the GP400 Control Module and the P600 Motor Control Module in real time.
Page 144 Axle Lock Valves. ON= Valves activated (axles can oscillate) 2H-1 Cal Date Date of last calibration (height or load) 2H-2 Software MEC specific software 2H-3 Powered Accumulated time GP400 powered up (red LED on) Page 137 Speed Level Seres - Servce & Parts Manual...
Page 145 Secton 9 - Troubleshootng - 3084ES Models January 2019 EZ-Cal Retrieve Mode And Help Messages Note:It is important to understand that an error message will only be available if the red Diagnostic LED is flashing. If the machine is not operating properly and the red Diagnostic LED is not flashing, the trouble may lie with something not monitored by the electronic control system, i.e.
Page 146 Secton 9 - Troubleshootng - 3084ES Models January 2019 SHUTDOWN! • The system cannot operate – for example both the PLATFORM & GROUND inputs are active together. CHECK CANBUS • The system cannot operate – CANBUS communications is not successful (for example wire damage to the platform) PLATFORM, GROUND •...
Page 147 Secton 9 - Troubleshootng - 3084ES Models January 2019 LEFT LOCKED, RIGHT LOCKED • A platform steer function is selected but not allowed (for example, the switch was closed at power-on) UP LOCKED, DOWN LOCKED • A platform lift/lower function is selected but not allowed (for example, the switch was closed at power-on) CHECK DRIVE/LIFT •...
Page 148 Secton 9 - Troubleshootng - 3084ES Models January 2019 • The heatsink must be bolted to a significant metal panel of the vehicle, capable of dissipating heat to the environment. UNCALIBRATED • The height and/or pressure sensors have not been calibrated see CALIBRATION OF OVERLOAD SYSTEM (CE option only).
Page 149: Ez-Cal Help Messages
Secton 9 - Troubleshootng - 3084ES Models January 2019 EZ-Cal Help Messages In addition to the MODE messages detailed above, the GP400 provides a HELP message to identify failure modes. Some error messages may also be identified by counting the number of times the red LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible.
Page 150 Secton 9 - Troubleshootng - 3084ES Models January 2019 Function Active Messages The following HELP messages indicate that there is no problem with the GP400 but that a function is active – the vehicle should be moving as requested by the operator. DRIVING! _____________________________________________ (no flash code) LIFTING! ______________________________________________ (no flash code) LOWERING! ___________________________________________ (no flash code)
Page 151: Shutdown Help Messages
Secton 9 - Troubleshootng - 3084ES Models January 2019 Shutdown Help Messages This section lists “shutdown” HELP messages – functions can be shut down to prevent them being used: SHUTDOWN - CHECK EMS SWITCHES! ____________________ Flash Code: 2/1 • The Base/Platform selector switch position indicates the mode in which the system must operate if both are active together;...
Page 152 Secton 9 - Troubleshootng - 3084ES Models January 2019 • There is a problem with the platform drive/lift select switch – both modes are selected together. CHECK JOYSTICK SWITCHES! ___________________________ Flash Code: 2/2 • There is a problem with the platform joystick switches – both directions are selected together. RELEASE TRIGGER! ____________________________________ Flash Code: 2/2 •...
Page 153: P600 Temperature Messages
Secton 9 - Troubleshootng - 3084ES Models January 2019 P600 Temperature Messages This section lists “temperature” HELP messages – problems have been detected which are likely due to excessive duty cycling or poor heatsinking: FAULT: BAD INTERNAL TEMPERATURE SENSOR! ___________ Flash Code: 4/1 •...
Page 154: Sensor Messages Ce Models
Secton 9 - Troubleshootng - 3084ES Models January 2019 Sensor Messages CE Models The following are “sensor” HELP messages – problems have been detected which are likely due to sensor issues (CE models). FAULT: CHECK HEIGHT1 SENSOR _________________________ Flash Code: 6/1 FAULT: CHECK HEIGHT2 SENSOR _________________________ Flash Code: 6/1 •...
Page 155: Other Messages
Secton 9 - Troubleshootng - 3084ES Models January 2019 Other Messages The following are other HELP messages: SOME BIG BAD PROBLEM! ______________________________ Flash Code: 9/9 • This message should not occur! FACTORY OVERRIDE___________________________ Flash Code: (fast flashing) • When the controller is first shipped, prior to initial calibration, it is configured in a special “factory override”...
Page 156 Secton 9 - Troubleshootng - 3084ES Models January 2019 Troubleshooting Chart The following chart is a guide to help the technician find the area of a problem. In order to benefit from the information, you are advised to fully assess the symptoms by operating all machine functions.
Page 157 Secton 9 - Troubleshootng - 3084ES Models January 2019 Problem Possible Cause Remedy/Solution LIFT/LOWER Excessive weight on platform Reduce weight to rated platform capacity Lift Relief Valve RV-1 out of Adjust relief valve to rated platform capacity adjustment Platform will not Check wiring to lift valve.
Page 158 Secton 9 - Troubleshootng - 3084ES Models January 2019 Unit out of level Lower and re-position the machine. Will receive 4-4 or 7-7 flash on GP400. Clean, service No drive elevated and charge batteries. Batteries discharged Battery charger may not operate if battery voltage drops below 20 volts System interlock Check HELP messages using EZ-Cal...
Page 159 Secton 9 - Troubleshootng - 3084ES Models January 2019 Problem Possible Cause Remedy/Solution LIFT AND DRIVE Main Relief Valve RV-3 out of For test purposes, swap RV-3 with RV-2. adjustment No drive or lift Pump or pump coupler failure Inspect, replace as necessary operation motor operates Diverter Valve EC-1 malfunction...
Page 160: Section 10 - Schematics
Secton 9 - Troubleshootng - 3084ES Models January 2019 Problem Possible Cause Remedy/Solution LEVEL, AUTO & MANUAL Platform is in elevated position or is perceived to be in the elevated Use EZ-Cal to monitor platform state of elevation. position. See Diagnostic chart I.D. 2a13 for elevated status Elevation is monitored by a sensor and 2e1 for platform % of elevation input.
Page 161: Chapter 2 - Parts
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 un-switched AC power source if the machine is stored for long periods of time.
Page 162 Secton 9 - Troubleshootng - 3084ES Models January 2019 Battery Charger, HB1500-48 BATTERY CHARGER INDICATOR YELLOW 100% FAULT HSB1500-48 No AC power to charger INDUSTRIAL AUTO SELECTABLE DUAL AC INPUT 100 - 240V ~ 50/60 Hz 18A BATTERY CHARGER Normal operation, charger is charging Normal, battery is over 80% charged Normal, battery is 100% charged STATUS...
Page 163 Secton 9 - Troubleshootng - 3084ES Models January 2019 Problem Diagnosis The AC plug must be disconnected and reconnected to start the charger once it has turned-off from a charge cycle. Charger does not • Connect the AC supply cord securely to a live AC outlet (minimum 20-amp circuit) turn ON - no LEDs •...
Page 164 Before attempting to check and/or adjust pressure relief valves, operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid. Insert a 0-5000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no. 8434 Model Main...
Page 165 Secton 9 - Troubleshootng - 3084ES Models January 2019 • Hold the switch for 10 seconds to get an accurate reading on the pressure gauge. • If pressure is LOW, adjust main relief valve ¼ turn clockwise and recheck. • If pressure is HIGH, adjust main relief valve ¼...
Page 166: Section 11 - Controls
Secton 9 - Troubleshootng - 3084ES Models January 2019 Component Illustrations TILT Light (ANSI) Overload Light (CE) Upper Controls HIGH SPEED MID RANGE LIFT HIGH TORQUE DRIVE EMERGENCY STOP OFF / RUN Micro-Switches GP400 Steering HORN (Optional) Matrix Module AUTO LEVEL 9 1 8 Enable Switch MANUAL LEVEL...
Page 167: January
Secton 9 - Troubleshootng - 3084ES Models January 2019 Hydraulic Manifold 3084ES HIGH SPEED HIGH TORQUE 213 - YEL/WHT 313 - YEL/BLK DRIVE FORWARD DRIVE REVERSE 111 - GRY/RED 110 - GRY/BLK TO TANK LIFT HAND PUMP 204 - RED/BLU BRAKE RELEASE ORLS GAUGE PORT...
Page 168 Secton 9 - Troubleshootng - 3084ES Models January 2019 Hydraulic Manifold - Alternate Configuration 3084ES HIGH SPEED HIGH TORQUE 213 - YEL/WHT 313 - YEL/BLK DRIVE FORWARD DRIVE REVERSE 111 - GRY/RED 110 - GRY/BLK TO TANK LIFT HAND PUMP 204 - RED/BLU BRAKE RELEASE ORLS...
Page 169 Secton 10 - Schematcs January 2019 3084RT - Diesel/Dual Fuel Models 3084RT - Diesel/Dual Fuel Models Hydraulic - 3084RT The following table applies to page 163 - 165. Callout Description Callout Description MA-1 MAIN MANIFOLD STEERING COMPONENTS CBV1 Counter Balance Valve, Drive CYL1 Steer Cylinder, Right CBV2...
Page 170 Secton 10 - Schematcs January 2019 3084RT - Hydraulic Schematic OSCILLATING AXLE LOCK CYLINDERS CYL6 CYL7 CYL4 CYL5 2500 2500 LC1A LC1B LC2A LC2B MA-2 ORF4 ORF5 2500 2500 ø.040 ø.040 TILT TILT CYLINDER CYLINDER FRONT/REAR SIDE/SIDE MA-3 ø.067 ORF3 CYL3 STEERING CYL1...
Page 171 Secton 10 - Schematcs January 2019 3084RT - Hydraulic Manifold Main M1 BOTTOM PLG4 PLG4 PLG4 PLG6 PLG6 FRONT BACK PLG4 PLG4 PLG4 PLG4 SV4 CL1 SVD1 SV3 CL1 PLG4 ORLS SV2 CL1 CL1 LEFT RIGHT PLG4 OPL3 PLG4 OPL2 SP3 CL3 CBV1 PLG4...
Page 172 Secton 10 - Schematcs January 2019 3084 All Models - Hydraulic Manifold Tilt M2 FRONT BOTTOM CL1 CL1 CL1 CL1 PLG8 ORF5 PLG4 PLG4 ORF4 LC1A LC2A LC1B LC2B LEFT RIGHT 3084 All Models ART_3111 Page 165 Speed Level Seres - Servce & Parts Manual...
Page 173 Secton 10 - Schematcs January 2019 3084RT - Upper Controls Electric Schematic 3084RT SCHEMATIC Model: / Serial # 3084RT | 11800025- UP Upper Controls GP400: 21 510 411 B– HORN Reference Art #: none Publication Art #: ART_3112 (option) PLATFORM UNDERSIDE P31-1 P31-2 P31-3...
Page 174 Secton 10 - Schematcs January 2019 3084RT - Upper Controls Components 3084RT Toggle Switches TILT Light HIGH SPEED ANSI MID RANGE Matrix Module HIGH TORQUE LIFT DRIVE Micro-Switch EMERGENCY STOP Steer Right OFF / RUN / START Steer Left Toggle Switches CHOKE / GLOW GENERATOR Enable Switch...
Page 175 Secton 10 - Schematcs January 2019 3084RT Dual Fuel - Lower Control Box Electric Schematic 3084RT DUAL FUEL SCHEMATIC SCHEMATIC Model: / Serial # Model: / Serial # 3084 | Serial #11800025 - UP Lower Control Box - Dual Fuel Reference Art #: Publication Art #: none...
Page 176 Secton 10 - Schematcs January 2019 3084RT Dual Fuel - Base Electric Schematic SCHEMATIC SCHEMATIC ENGINE Model: / Serial # Model: / Serial # 3084 | Serial #11800025 - UP Base - Dual Fuel THROTTLE CHOKE COIL Reference Art #: Publication Art #: none ART_3196...
Page 177 Secton 10 - Schematcs January 2019 3084RT Diesel - Lower Control Box Electric Schematic 3084RT DIESEL SCHEMATIC SCHEMATIC Model: / Serial # Model: / Serial # 3084 | Serial #11800025 - UP Lower Control Box - Diesel Reference Art #: Publication Art #: none ART_3197...
Page 178 Secton 10 - Schematcs January 2019 3084RT Diesel - Base Electric Schematic SCHEMATIC SCHEMATIC GLOW ENGINE Model: / Serial # Model: / Serial # 3084 | Serial #11800025 - UP Base - Diesel Reference Art #: Publication Art #: none ART_3198 3084RT DIESEL THROTTLE...
Page 179 Secton 10 - Schematcs January 2019 3084RT - Lower Controls Components RAISE EMERGENCY STOP HOUR METER GP400 (Green) Module CHOKE LOWER (Green) START DELAY Master START Terminal Disconnect Block 15 AMP Switch BREAKER Module PLATFORM 91854 BASE EMERGENCY LOWERING PROPANE / GASOLINE 3084RT Selector Dual Fuel - ANSI...
Page 180 Secton 10 - Schematcs January 2019 3084ES - Electric Model Hydraulic - 3084ES The following table applies to page 174 - 176. Callout Description Callout Description MA-1 MAIN MANIFOLD STEERING COMPONENTS CBV1 Counter Balance Valve, Drive CYL1 Steer Cylinder, Right CBV2 Counter Balance Valve, Drive CYL2...
Page 181 Secton 10 - Schematcs January 2019 3084ES - Hydraulic Schematic OSCILLATING AXLE LOCK CYLINDERS CYL6 CYL7 CYL4 CYL5 2500 2500 LC1A LC1B LC2A LC2B MA-2 ORF4 ORF5 2500 2500 ø.040 ø.040 TILT TILT CYLINDER CYLINDER FRONT/REAR SIDE/SIDE MA-3 ø.067 ORF3 CYL3 STEERING CYL1...
Page 182 Secton 10 - Schematcs January 2019 3084ES - Hydraulic Manifold Main M1 BOTTOM PLG4 PLG4 PLG4 PLG6 PLG6 FRONT BACK PLG4 PLG4 PLG4 PLG4 SV4 CL3 SVD1 SV3 CL3 PLG2 PLG4 ORLS PLG4 CL1 CL1 LEFT RIGHT PLG4 OPL3 PLG4 OPL2 CBV1 PLG4 CBV2...
Page 183 Secton 10 - Schematcs January 2019 3084 All Models - Hydraulic Manifold Tilt M2 FRONT BOTTOM CL1 CL1 CL1 CL1 PLG8 ORF5 PLG4 PLG4 ORF4 LC1A LC2A LC1B LC2B LEFT RIGHT 3084 All Models ART_3111 Page 176 Speed Level Seres - Servce & Parts Manual...
Page 184 Secton 10 - Schematcs January 2019 3084ES - Upper Controls Electric Schematic 3084ES SCHEMATIC Model: / Serial # 3084ES | 11800025- UP Upper Controls B– GP400: 21 510 411 HORN (option) PLATFORM UNDERSIDE Reference Art #: none Publication Art #: ART_3287 P31-1 P31-2...
Page 185 Secton 10 - Schematcs January 2019 3084ES - Upper Controls Components 3084ES ANSI Toggle Switches TILT Light HIGH SPEED MID RANGE Matrix Module HIGH TORQUE LIFT DRIVE Micro-Switch EMERGENCY STOP Steer Right OFF / RUN Steer Left Enable Switch Toggle Switches 9 1 8 AUTO LEVEL Micro-Switch...
Page 186 Secton 10 - Schematcs January 2019 3084ES - Lower Control Box Electric Schematic 3084ES SCHEMATIC SCHEMATIC Model: / Serial # Model: / Serial # 3084ES | Serial #11800025- UP Lower Control Box - Electric Reference Art #: Publication Art #: ART_3217 none GP400...
Page 187 Secton 10 - Schematcs January 2019 3084ES - Base Electric Schematic 3084ES SCHEMATIC SCHEMATIC Model: / Serial # Model: / Serial # 3084ES | Serial #11800025- UP P600 PUMP MOTOR CONTROLLER Base - Electric 48 VDC TO 12 VDC CONVERTER P6-1 CAN BUS H P6-2...
Page 188 Secton 10 - Schematcs January 2019 3084ES - Lower Controls Components RAISE EMERGENCY STOP HOUR METER GP400 (Green) Module CHARGE LOWER INDICATOR PUSH FOR EMERGENCY STOP RAISE (Green) LOWER TWIST TO RESET PLATFORM Master Terminal Disconnect BASE Block 15 AMP Switch BREAKER Module...
Page 189 Secton 10 - Schematcs January 2019 XX84RT Model, Hydraulic Schematic with Hydrastatic Drive 2684RT - From Serial # 12800200 3084RT - From Serial # 11800400 Page 182 Speed Level Seres - Servce & Parts Manual...
Page 190 Secton 10 - Schematcs January 2019 XX84 RT Diesel Models - Electrical Schematic, Part 1 2684 RT - From Serial # 12800200 3084 RT - From Serial # 11800400 GP400 LOWER CONTROL BOX MICROPROCESSOR CAN BUS HI P1-1 P1-2 CAN BUS LO GROUND P1-3 CHOKE / PREHEAT...
Page 191 Secton 10 - Schematcs January 2019 XX84 RT Diesel Models - Electrical Schematic, Part 2 2684 RT - From Serial # 12800200 3084 RT - From Serial # 11800400 ENGINE GENERATOR GLOW STARTER OPTION THROTTLE FUEL PULL HOLD PRESSURE DEUTSCH ALTERNATOR 12 PIN GENERATOR...
Page 192 January 2019 Notes Page 185 Speed Level Seres - Servce & Parts Manual...
Page 193 This Parts sections consists of illustrated parts sections and is designed to provide you, the customer, with illustrations and the list of associated parts needed to properly maintain the MEC self-propelled aerial work platform. When used in conjunction with the Service section in this manual and the Operator’s Manual (provided separately), this manual will assist you in making necessary adjustments...
Page 194 Secton 11 - Controls January 2019 Upper Controls, ANSI Models, Early Style Upper Controls, ANSI Models, Early Style SPEED/ TILT INDICATOR LIFT/ DRIVE E-STOP START CHOKE/PREHEAT TORQUE SWITCH ST -- RT only GENERATOR OPTION RT Model Start Switch HORN BUTTON MATRIX ES Model MODULE...
Page 195 Secton 11 - Controls January 2019 Item Part Number Description Qty�� Fixed Control Box Assembly 83169 Assy, Upper Control Box, Without Options - 3084 ANSI ES 83170 Assy, Upper Control Box, With Horn Option - 3084 ANSI ES 83171 Assy, Upper Control Box, Without Options - 3084 ANSI DSL 83172 Assy, Upper Control Box, With Horn Option - 3084 ANSI DSL 83189...
Page 196 Secton 11 - Controls January 2019 Upper Controls, CE Models SPEED/ OVERLOAD LIFT/ DRIVE E-STOP CHOKE/PREHEAT START TORQUE INDICATOR SWITCH ST -- RT only OVERLOAD ALARM GENERATOR RT Model OPTION Start Switch MATRIX ES Model MODULE OFF-ON Switch HORN BUTTON AUTO LEVEL MANUAL LEVEL FRONT TO REAR...
Page 197 Secton 11 - Controls January 2019 Item Part Number Description Qty�� Removable Control Box Assembly 83169 Assy, Upper Control Box, Without Options - 3084 ANSI ES 83170 Assy, Upper Control Box, With Horn Option - 3084 ANSI ES 83171 Assy, Upper Control Box, Without Options - 3084 ANSI DSL 83172 Assy, Upper Control Box, With Horn Option - 3084 ANSI DSL 83189...
Page 198 Secton 11 - Controls January 2019 Upper Control Box Cover Assembly, Early Style TO CONTROL BOX Control Box Cover Assembly ART_2220 R3 Page 191 Speed Level Seres - Servce & Parts Manual...
Page 199 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 83076 Control Box Cover Assembly 92199 Joystick Assembly 3772 Cover 7875 Gasket 7882 O-Ring HDW3768 Washer, Flat 1008348 Pin, Hold Down 50155 Screw, 6–32 x 1/2 Inch 13502 Bracket, Centering 3763 Spacer, Step 13402...
Page 200 Secton 11 - Controls January 2019 Upper Control Joystick, Early Style Connect Purple and Blue wires Purple together at #13 Blue Control Arm (Joystick) Reference: ART_188 ART_2221 R1 Page 193 Speed Level Seres - Servce & Parts Manual...
Page 201 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 92199 Joystick Assembly 8630 Joystick Assembly Without Control Arm (#6) 8750 Pin (Service Only) 8453 Switch Actuator (Service Only) HDW8455 Screw (Service Only) 8752 Grip, Top Half (Service Only) 8751 Grip, Bottom Half (Service Only) 13638...
Page 202 Secton 11 - Controls January 2019 Upper Control Box Assembly, Early Style ILLUSTRATION No. Speed Level Series Upper Control Box Assembly - J.R. Merrit Art_5392 Page 195 Speed Level Seres - Servce & Parts Manual...
Page 203 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 7875 Gasket 18660 Joystick Box Weldment 28542 Palm Rest Weldment 50191 THMS #10-32X00.50 ZP 50238 NNYL #10-32 05 Z 50330 THMS #10-32X01.00 ZP 90729 Decal, Upper Control Joystick Operations 94688 Single Axis Joystick W/Trig &...
Page 204 Secton 11 - Controls January 2019 Lower Controls, 3084ES Electric Models Raise (Green) Emergency Stop Hour Meter Lower (Green) Platform / Base Charge Indicator Selector Switch Circuit Breaker Emergency Lower Toggle Switch Alarm 18 x2 19 x2 20 x2 21 x2 GP400 18 x4 19 x4...
Page 205 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 83077 Lower Control Box Assembly, ES Models 9549 Switch, 3-Position, Keyed 91667 Switch, Button, Green 7800 Switch, Emergency Stop, Red 91704 Hour Meter 91744 Charge Indicator 7235 Circuit Breaker 7423 Switch Toggle 1 Pole 2 Position 3 8082...
Page 206 Secton 11 - Controls January 2019 Lower Controls, 3084RT Dual Fuel Models Emergency Stop Raise (Green) Hour Meter Lower (Green) 30 Sec Delay (Red) Platform / Base Selector Switch Choke (Black) Start (Green) Circuit Breaker Emergency Lower Toggle Switch Fuel Select Alarm 20 x2 22 x2...
Page 207 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 83078 Lower Control Box Assembly, DF Models 9549 Switch, 3-Position, Keyed 91667 Switch, Button, Green 91957 Switch, Button, Black 7800 Switch, Emergency Stop 91926 Switch, 2-Position 91704 Hour Meter 92254 Light, Red 7235...
Page 208 Secton 11 - Controls January 2019 Lower Controls, 3084RT Diesel Models Raise (Green) Emergency Stop Hour Meter Lower (Green) 30 Sec Delay (Red) Platform / Base Selector Switch Preheat (Black) Start (Green) Circuit Breaker Emergency Lower Toggle Switch Alarm 22 x2 23 x2 20 x2 GP400...
Page 209 Secton 11 - Controls January 2019 Item Part Number Description Qty�� 83079 Lower Control Box Assembly, Diesel Models 9549 Switch, 3-Position, Keyed 91667 Switch, Button, Green 91957 Switch, Button, Black 7800 Switch, Emergency Stop 91704 Hour Meter 92254 Light, Red 7235 Circuit Breaker 7423...
Page 210 Secton 12 - Platform and Rals January 2019 Platform Installation - To Serial #11800046 Platform Installation - To Serial #11800046 Side-Bolted Ladder Top-Bolted Ladder Typical Installation; 3084 Platform Shown Platfrom Installation Speed Level™ Sigma Lift ART_3114 Page 203 Speed Level Seres - Servce & Parts Manual...
Page 211: Section 13 - Boom
Secton 12 - Platform and Rals January 2019 Item Part Number Description Qty�� 83083 Boom Assembly 83080 / 83160 Platform Assembly, 3084 83097 Platform Assembly, 2684 19258 Ladder, Side-Bolted 19148 Ladder, Top-Bolted 50040 Bolt, M12 x 35, GR8.8 50003 Washer, 13.5 mm ID x 24mm OD 50054 Nut, M12, GR8.8 50039...
Page 212 Secton 12 - Platform and Rals January 2019 Platform & Rails, 3084 - To Serial # 11800046 16 17 23 x2 22 23 24 17 20 27 28 22 21 3084 Platform & Rails Speed Level™ Sigma Lift ART_3113 Page 205 Speed Level Seres - Servce &...
Page 213 Secton 12 - Platform and Rals January 2019 Item Part Number Description Qty�� 83080 Platform Assembly, 3084 19252 Platform Deck 19207 Entry Rail, RH 19221 Entry Rail, LH 19192 Gate 19216 Side Rail 19218 Front Rail 50182 Clip Fastener, 3/8 X 2 50183 Clip Fastener, 3/8 X 2.25 50186...
Page 214 Secton 12 - Platform and Rals January 2019 Platform & Rails, 3084 - From Serial # 11800047 ILLUSTRATION No. 3084 - Speed Level Series 3084 Platform Art_5374 Page 207 Speed Level Seres - Servce & Parts Manual...
Page 215 Secton 12 - Platform and Rals January 2019 Item Part Number Description Qty�� 50000 WSHR M06 ZP Standard Flat 50002 WSHR M10 ZP Standard Flat 50020 HHCS M10-1.50x050 08 ZP P 50021 HHCS M10-1.50x055 08 ZP P 50296 HHCS M06-1.00x16 08 ZP P 50047 NNYL M06x1.00 08 ZP Nylock 50049...
Page 216 Secton 12 - Platform and Rals January 2019 Platform & Rails, 2684 - Part 1 Guard Rail Detail 2684 Platform & Rails, 1 of 2 Speed Level™ Sigma Lift ART_3476 Page 209 Speed Level Seres - Servce & Parts Manual...
Page 217 Secton 12 - Platform and Rals January 2019 Item Part Number Description Qty�� 83097 Platform Assembly, 2684 19356 Platform Weldment 19377 Side Rail 19381 End Rail, Left 22366 Gate Weldment 22372 Gate Toeboard 16799 Gate Latch (Not Shown) 7408 Gate Latch (Not Shown) 50015 Bolt, 8 x 50 (Not Shown) 50001...
Page 218 Secton 12 - Platform and Rals January 2019 Platform & Rails, 2684 - Part 2 35 36 41 36 36 37 not shown 35 36 36 37 35 36 38 39 39 40 not shown 36 37 Guard Rail Detail 2684 Platform &...
Page 219 Secton 12 - Platform and Rals January 2019 Item Part Number Description Qty�� 83097 Platform Assembly, 2684 Screw, Countersink 91593 Bearing 19399 Roller 19398 Axle, Threaded 19131 Rail Wheel 50016 Bolt, M8 x 55 50001 Washer, M8 50048 Nut, M8 Nylock 50283 Bolt, M4 x 55 50284...
Page 220 Secton 13 - Boom January 2019 Boom Mount and Pivot Boom Mount and Pivot CYLINDER MOUNT DETAIL Boom Mount and Pivot Speed Level™ Sigma Lift ART_3115 Page 213 Speed Level Seres - Servce & Parts Manual...
Page 221 Secton 13 - Boom January 2019 Item Part Number Description Qty�� 83081 Chassis Assembly 19020 Chassis Weldment 19031 Boom Mount Weldment 19013 Level Pivot Weldment 19124 19123 18152 Pin Retainer 50023 Bolt, M12 x 50 19122 50119 Nut, Nylock 1-1/4” 19081 Cylinder, Level 50039...
Page 222 Chassis Planetary Drive Assembly 2684RT - From Serial # 12800107 / 2684ES - From Serial # 12700041 3084RT - From Serial # 11800400 / 3084ES - From Serial # 11700089 ILLUSTRATION No. Speed Level Series Chassis Planetary Drive Assembly Art_5386 Page 215...
Page 223 Secton 13 - Boom January 2019 Item Part Number Description Qty�� 7292 Bearing, Sleeve, Bronze, .625 X .500 LG 18074 Pin, 1.250 X 8.00 18151 Keeper Pin 18152 1/2” Pin Retainer 18165 Keeper Pin .375 x 2.20 19087 Axle Lock Cylinder 19103 Module Mount 19104...
Page 224 Secton 13 - Boom January 2019 Side Port Assembly FRONT LEFT FRONT RIGHT REAR RIGHT REAR LEFT ILLUSTRATION No. Speed Level Series Side Port Assembly Art_5385 Page 217 Speed Level Seres - Servce & Parts Manual...
Page 225 Secton 13 - Boom January 2019 Item Part Number Description Qty�� 93710 Omni Gear VB04 WHL DRV Planetary 93965 129CC HYD Motor Side Ports 94756 O-Ring AS 568A-046 Page 218 Speed Level Seres - Servce & Parts Manual...
Page 226: Lower Boom Assembly
Secton 13 - Boom January 2019 Lower Boom Assembly 2 each side 32 33 22 24 ANSI -- Qty 1 CE -- Qty 2 Lower Linkage Installation Speed Level™ Sigma Lift ART_3116 Page 219 Speed Level Seres - Servce & Parts Manual...
Page 227 Secton 13 - Boom January 2019 Item Part Number Description Qty�� 83082 3084 -- Lower Boom Assembly 83095 2684 -- Lower Boom Assembly 19034 3084 -- Lower Boom Weldment 19327 2684 -- Lower Boom Weldment 19049 3084 -- Lower Tension Weldment 19329 2684 -- Lower Tension Weldment 19118...
Page 228: Upper Boom Assembly
Secton 13 - Boom January 2019 Upper Boom Assembly Boom Assembly Speed Level™ Sigma Lift ART_3117 Page 221 Speed Level Seres - Servce & Parts Manual...
Page 229 Secton 13 - Boom January 2019 Item Part Number Description Qty�� 83083 3084 -- Upper Boom Assembly 83096 2684 -- Upper Boom Assembly 19068 Platform Pivot Weldment 19073 3084 -- Upper Boom Weldment 19332 2684 -- Upper Boom Weldment 19058 3084 -- Upper Tension Weldment 19334 2684 -- Upper Tension Weldment...
Page 230: Section 14 - Axles
Secton 14 - Axles January 2019 Front Axle Assembly Front Axle Assembly 24 27 Drive Ports Hydraulic Wheel Motor Case Drain Front Axle Assembly Speed Level™ Sigma Lift ART_3118 Page 223 Speed Level Seres - Servce & Parts Manual...
Page 231 Secton 14 - Axles January 2019 Item Part Number Description Qty�� 83084 Front Axle Assembly 19008 Front Axle Weldment 91019 Cylinder, Steering 90990 Seal Kit, Steer Cylinder (Not Shown) 50172 Pin, Clevis, ½ DIA. X 1 3/8” LG 50178 Pin, Cotter, .12 DIA. X 1” LG 19079 Rod, Tie Steering 50154...
Page 232 Secton 14 - Axles January 2019 Axle Installation, Front Front Axle Installation Speed Level™ Sigma Lift ART_3119 Page 225 Speed Level Seres - Servce & Parts Manual...
Page 233 Secton 14 - Axles January 2019 Item Part Number Description Qty�� 91166 Wheel/Tire Assy, LH - 10 PLY - Pneumatic (ANSI Standard) 91168 Wheel/Tire Assy, LH - 10 PLY - Foam (ANSI Option) (CE Standard) 91578 Wheel/Tire Assy, LH - Non-Marking Pneumatic (ANSI Option) 91580 Wheel/Tire Assy, LH - Non-Marking Foam (ANSI, CE Option) 91581...
Page 234 Secton 14 - Axles January 2019 Axle Installation, Rear Drive Ports Case Drain Rear Hydraulic Wheel Motor Brake Port with Brake Rear Axle Installation Speed Level™ Sigma Lift ART_3120 Page 227 Speed Level Seres - Servce & Parts Manual...
Page 235 Secton 14 - Axles January 2019 Item Part Number Description Qty�� 91166 Wheel/Tire Assy, LH - 10 PLY - Pneumatic (ANSI Standard) 91168 Wheel/Tire Assy, LH - 10 PLY - Foam (ANSI Option) (CE Standard) 91578 Wheel/Tire Assy, LH - Non-Marking Pneumatic (ANSI Option) 91580 Wheel/Tire Assy, LH - Non-Marking Foam (ANSI, CE Option) 91581...
Page 236: Wheel Motor, Rear
Secton 14 - Axles January 2019 Wheel Motor, Rear Assembly Bolts (7) Endcover Piston Commutator Spring Assembly Capscrews (8) Spacer I.D. Tag Shims (1–3) Assembly Shaft Bearing Drive Endcover Piston Link Piston Spacer Rear Housing Manifold Rotor Springs (25) Assembly Drive Link Shaft Key...
Page 237 Secton 14 - Axles January 2019 Item Part Number Description Qty�� 91319 Wheel Motor W/Brake 9781 Seal Kit Incl Dust Seal Incl Metal Backup Shim Incl Backup Seal Incl Shaft Seal Incl Small Piston O-Ring Seal Incl Small Piston Seal Incl Large Piston O-Ring Seal Incl...
Page 238: Wheel Motor, Front
Secton 14 - Axles January 2019 Wheel Motor, Front Endcover Assembly Bolts (7) Endcover Piston Commutator Assembly I.D. Tag Assembly Manifold Piston Spring Rear Housing Bearing Drive Link Shaft Key Rotor Assembly Divider Plate Thrust Shaft Washers (2) Housing Bearing Thrust Spacer Bearing...
Page 239 Secton 14 - Axles January 2019 Item Part Number Description Qty�� 7300P Motor Wheel Hyd Painted 90592 Seal Kit Incl Dust Seal Incl High Pressure Seal Incl Metal Backup Shim Incl Teflon Back Up Seal Incl Shaft Seal Incl Housing Seal Incl Body Seals Incl...
Page 240 Secton 15 - Hydraulcs January 2019 Main Manifold Assembly, Electric Models - Part 1 Main Manifold Assembly, Electric Models - Part 1 ES MODELS R I G F R O L E F 2 19 Sheet 1 of 2 ES Manifold Assembly ART_3170 Page 233 Speed Level Seres - Servce &...
Page 241 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 83072 Manifold Assembly, ES Models 91743 Manifold W/ Valves, No Fittings, ES Models 91144 Valve, Drive, 4 way 3 Position 91146 Valve, Steer, 4 Way 3 Position 91145 Valve, Lift Spool, 3 Way 91147 Valve, Series Parallel Spool, 4 Way 3 Position 91150...
Page 242 Secton 15 - Hydraulcs January 2019 Main Manifold Assembly, Electric Models - Part 2 ES MODELS R I G F R O L E F 39 40 39 43 Sheet 2 of 2 ES Manifold Assembly ART_3171 Page 235 Speed Level Seres - Servce & Parts Manual...
Page 243 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 50796 Elbow, 90°, Male, ½”, O-Ring, Male, ½”, MB-MJ90LL-8-8 50792 Elbow, 90°, Male, ½”, O-Ring, Male, ½”, MB-MJ90-8-8 50770 Fitting, Orifice 1/16” (Electric Only) 50794 Elbow, 90°, Male ¼” O-Ring, Male ¼”, MB-MJ90LL-4-4 50647 Elbow, 90°, Male ¼”...
Page 244 Secton 15 - Hydraulcs January 2019 Main Manifold Assembly, RT Models - Part 1 RT MODELS R I G F R O L E F 3 20 Sheet 1 of 2 RT Manifold Assembly ART_3172 Page 237 Speed Level Seres - Servce & Parts Manual...
Page 245 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 83071 Manifold Assembly, RT Models 91140 Manifold W/ Valves, No Fittings, RT Models 91144 Valve, Drive, 4 Way 3 Position 91145 Valve, Lift Spool, 3 Way 91146 Valve, Steer, 4 Way 3 Position 91147 Valve, Series Parallel Spool, 4 Way 3 Position 91148...
Page 246 Secton 15 - Hydraulcs January 2019 Main Manifold Assembly, RT Models - Part 2 RT MODELS R I G F R O L E F Sheet 2 of 2 RT Manifold Assembly ART_3173 Page 239 Speed Level Seres - Servce & Parts Manual...
Page 247 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 50796 Elbow, 90°, Male, ½”, O-Ring, Male, ½”, MB-MJ90LL-8-8 50792 Elbow, 90°, Male, ½”, O-Ring, Male, ½”, MB-MJ90-8-8 50794 Elbow, 90°, Male ¼” O-Ring, Male ¼”, MB-MJ90LL-4-4 50647 Elbow, 90°, Male ¼” O-Ring, Male ¼”, MB-MJ90L-4-4 50763 Elbow, 90°, Male ¾”...
Page 248 Secton 15 - Hydraulcs January 2019 Leveling Manifold Assembly FRONT BOTTOM LEFT RIGHT Leveling Manifold Speed Level™ Sigma Lift ART_3205 Page 241 Speed Level Seres - Servce & Parts Manual...
Page 249 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 83093 Leveling Manifold Assembly W/ Fittings 19300 Leveling Manifold Assembly W/o Fittings 92123 Valve 91143 Coil 91473 Check Valve 50661 Fitting, MB-MJ-90LL-6-4 (MB-MJ-90-4-4) 50660 Fitting, MB-MJ-90-6-4 50775 MB-MJ-6-4 50763 MB-MJ-12-12 50821 MB-MJ-90LL-12-12...
Page 250 RT Manifold Assembly 2684RT - From Serial # 12800107 / 2684ES - From Serial # 12700041 3084RT - From Serial # 11800400 / 3084ES - From Serial # 11700089 ILLUSTRATION No. Speed Level Series RT Manifold Assembly Art_5384 Page 243...
Page 251 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 94070 Valve, 4 Way/3 Pos Solenoid Operated, WK08J-01-C-N-0 HYDAC 2610215 94082 Coil 12DN-32-1329 HYDAC 2610149 94083 Coil 12DN-40-1836 HYDAC 3012600 94087 Valve 3W2P SO WK06C-01-C-N-0 HYDAC 2610183 94452 XX92 Main Manifold (Alt For 17950) HYDAC 7510113 94754 Line Body -08SIZE 4 Way SAE#6 Ports FH084-AS6 HYDAC 3011404 94760...
Page 252 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, RT Models: Steer, Brake, Case Drain Early Style 2684RT - From Serial # 12800107 / 2684ES - From Serial # 12700041 3084RT - From Serial # 11800400 / 3084ES - From Serial # 11700089 RIGHT RT MODELS FRONT...
Page 253 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19340 Hose Assy, 1/4” x 65”, 4G4FJX-4G4FJX 19358 Hose Assy, 1/4” x 15”, 4G4FJX-4G4FJX90S 19359 Hose Assy, 1/4” x 86”, 4G4FJX-4G4FJX90S 19361 Hose Assy, 1/4” x 73”, 4G4FJX-4G4FJX90S 19362 Hose Assy, 1/4”...
Page 254 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, RT Models: Lift, Pump RIGHT RT MODELS FRONT LEFT ORLS GSTR BACK ORLS FRONT LOAD SENSE PUMP LC1A LC2A CASE LC1B LC2B DRAIN LEFT RIGHT SUCTION BOTTOM PRESSURE Hydraulic Hose Routing: Lift and Pump Speed Level™...
Page 255 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19341 Hose Assy, 3/8” x 132”, 6G6FJX90S-6G6FJX 91265 Hose Assy, 1” x 22”, 16G16FJX-16G16FJX 19342 Hose Assy, 3/8” x 118”, 6G6FJX-6G6FJX 19369 Hose Assy, 1/4” x 28”, 4G4FJX-4G4FJX45 19370 Hose Assy, 1/4”...
Page 256 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, RT Models: Platform Level, Axle Float RIGHT RT MODELS LC2A LC2B FRONT LC1B LC1A LEFT GSTR BACK LC2A LC2B LC1A LC1B ORLS FRONT LC1A LC2A LC1B LC2B LEFT RIGHT BOTTOM Hydraulic Hose Routing: Level and Axle Float Speed Level™...
Page 257 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19349 Hose Assy, 1/4” x 120”, 4G4FJX-4G4FJX 90316 Hose Assy, 1/4” x 21”, 4G4FJX-4G4FJX 19361 Hose Assy, 1/4” x 73”, 4G4FJX-4G4FJX90S 19340 Hose Assy, 1/4” x 65”, 4G4FJX-4G4FJX 50927 Tee, MJT-4 Page 250 Speed Level Seres - Servce &...
Page 258 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, RT Models: Drive Motors RIGHT RT MODELS FRONT LEFT GSTR BACK ORLS FRONT LC1A LC2A LC1B LC2B LEFT RIGHT BOTTOM Hydraulic Hose Routing: Drive Motors Speed Level™ Sigma Lift ART_3202 Page 251 Speed Level Seres - Servce &...
Page 259 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19355 Hose Assy, 1/2” x 49”, 8M3K-8FJX-8FJX45 19357 Hose Assy, 1/2” x 102”, 8M3K-8FJX-8FJX45 19353 Hose Assy, 1/2” x 61”, 8M3K-8FJX-8FJX 19352 Hose Assy, 1/2” x 37”, 8M3K-8FJX-8FJX90S 19354 Hose Assy, 1/2”...
Page 260 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, ES Models: Steer, Brake, Case Drain ES MODELS GSTR ORLS FRONT LC1A LC1A LC2A LC2A LC1B LC1B LC2B LC2B LEFT RIGHT BOTTOM Hydraulic Hose Routing: Steer, Brake, Case Drain Speed Level™ Sigma Lift ART_3208 Page 253 Speed Level Seres - Servce &...
Page 261 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19340 Hose Assy, 1/4” x 65”, 4G4FJX-4G4FJX 19358 Hose Assy, 1/4” x 15”, 4G4FJX-4G4FJX90S 19359 Hose Assy, 1/4” x 86”, 4G4FJX-4G4FJX90S 19361 Hose Assy, 1/4” x 73”, 4G4FJX-4G4FJX90S 19362 Hose Assy, 1/4”...
Page 262 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, ES Models: Lift, Pump RIGHT RT MODELS FRONT LEFT ORLS GSTR BACK ORLS FRONT LOAD SENSE PUMP LC1A LC2A CASE LC1B LC2B DRAIN LEFT RIGHT SUCTION BOTTOM PRESSURE Hydraulic Hose Routing: Lift and Pump Speed Level™...
Page 263 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19341 Hose Assy, 3/8” x 132”, 6G6FJ90X - 6G6FJX 91698 Hose Assy, 3/4” x 35”, 12G12FJX - 12G12FJX 91909 Hose Assy, 3/8” x 150”, 6G6FJX - 6G6FJX 91879 Hose Assy, 3/4” x 16”, 12G12FJX - 12G12FJX 19347 Hose Assy, 3/4”...
Page 264 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, ES Models: Platform Level, Axle Float ES MODELS LC2A LC2B LC1B LC1A GSTR LC2A LC2B LC1A LC1B ORLS FRONT LC1A LC1A LC2A LC2A LC1B LC1B LC2B LC2B LEFT RIGHT BOTTOM Hydraulic Hose Routing: Level and Axle Float Speed Level™...
Page 265 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19349 Hose Assy, 1/4” x 120”, 4G4FJX-4G4FJX 90316 Hose Assy, 1/4” x 21”, 4G4FJX-4G4FJX 19361 Hose Assy, 1/4” x 73”, 4G4FJX-4G4FJX90S 19340 Hose Assy, 1/4” x 65”, 4G4FJX-4G4FJX 50927 Tee, MJT-4 Page 258 Speed Level Seres - Servce &...
Page 266 Secton 15 - Hydraulcs January 2019 Hydraulic Hose Routing, ES Models: Drive Motors ES MODELS GSTR ORLS FRONT LC1A LC1A LC2A LC2A LC1B LC1B LC2B LC2B LEFT RIGHT BOTTOM Hydraulic Hose Routing: Drive Motors Speed Level™ Sigma Lift ART_3211 Page 259 Speed Level Seres - Servce &...
Page 267 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19355 Hose Assy, 1/2” x 49”, 8M3K-8FJX-8FJX45 19357 Hose Assy, 1/2” x 102”, 8M3K-8FJX-8FJX45 19353 Hose Assy, 1/2” x 61”, 8M3K-8FJX-8FJX 19352 Hose Assy, 1/2” x 37”, 8M3K-8FJX-8FJX90S 19354 Hose Assy, 1/2”...
Page 268 Secton 15 - Hydraulcs January 2019 Lift Cylinder Lift Cylinder Sigma Level ART_3206 Page 261 Speed Level Seres - Servce & Parts Manual...
Page 269 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19084 Lift Cylinder 92077 Seal Kit 6669 Bearing 50776 Fitting, MB-MJ-6-6 50890 Fitting, MJ-FJX-90-6-6 91732 Orifice 91464 Valve, 2-Way, NC 91141 Coil, 12V 90845 Pressure Sensor (CE Only) Spring, Orifice Page 262 Speed Level Seres - Servce &...
Page 270 Secton 15 - Hydraulcs January 2019 Steering Cylinder SEAL KIT PISTON SEAL WEAR RING STATIC SEAL ROD SEAL ROD WIPER PISTON SEAL RETAINER X72 Steering Cylinder 91019 Steering Cylinder ART_2713 Page 263 Speed Level Seres - Servce & Parts Manual...
Page 271 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 91019 Steering Cylinder 90990 Seal Kit (Service) 50769 Adapter Male ¼” O-Ring-Male ¼” JIC 50962 Tee, MJ-MB-MJT-4 HDW5925 Jamnut 5/8-18 7293 Rod End 50665 Fitting, 90, MJ-FJX90-4-4 Page 264 Speed Level Seres - Servce &...
Page 272 Secton 15 - Hydraulcs January 2019 Level Cylinder Level Cylinder Sigma Level ART_3219 Page 265 Speed Level Seres - Servce & Parts Manual...
Page 273 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19081 Level Cylinder 92078 Seal Kit (Service) 92125 Counterbalance Valve 50665 Fitting, MB-MJ90-4-4 Page 266 Speed Level Seres - Servce & Parts Manual...
Page 274 Secton 15 - Hydraulcs January 2019 Axle Lock Cylinder Axle Lock Cylinder Sigma Level ART_3220 Page 267 Speed Level Seres - Servce & Parts Manual...
Page 275 Secton 15 - Hydraulcs January 2019 Item Part Number Description Qty�� 19087 Axle Lock Cylinder 92079 Seal Kit (Service) 7896 Bearing 92192 Valve 50665 Fitting, MB-MJ90-4-4 Page 268 Speed Level Seres - Servce & Parts Manual...
Page 276: Section 16 - Base
Secton 16 - Base January 2019 Module Installation Module Installation Module Installation Speed Level™ Sigma Lift ART_3121 Page 269 Speed Level Seres - Servce & Parts Manual...
Page 277: January
Secton 16 - Base January 2019 Item Part Number Description Qty�� 16978 Power Module Weldment, ES 16213 Power Module Weldment, RT 16984 Power Module Door, ES 16220 Power Module Door, RT 16989 Control Module, ES 16153 Control Module, RT 16985 Control Module Door, ES 16156 Control Module Door, RT...
Page 278 Secton 16 - Base January 2019 Control Module – ES, Drawing 1 of 2 2684ES To Serial #12700029 - 3084ES To Serial #11700042 ES MODELS 20 21 not shown 20 21 not shown 20 21 not shown 25 26 33 34 18 19 not shown 20 21...
Page 279 Secton 16 - Base January 2019 Item Part Number Description Qty�� Control Module Weldment -- See “Module Installation” On Page 270 16154 Bracket, Cross Support 14896 Block, Slide, Door 25429 16226 Bracket, Control Box 90749 Plug, Battery Charger Connection 16229 Bracket, Battery Disconnect 8841 Switch, Battery Disconnect...
Page 280 Secton 16 - Base January 2019 Control Module – ES, Drawing 2 of 2 2684ES To Serial #12700029 - 3084ES To Serial #11700042 ES MODELS 20 22 not shown S TO IS E IS T R IN P LA O FF not shown Control Module, Drawing 2 of 2 Speed Level™...
Page 281 Secton 16 - Base January 2019 Item Part Number Description Qty�� Control Module Weldment 83077 Control Box -- See Section 1 - Controls 91640 Electric Motor 91673 Pump, 10CC 83072 Hydraulic Manifold -- See Section 5 - Hydraulics HDW6727 Fitting, MP-MJ-4-4 90 6714 Filter Head 50916...
Page 282: Power Module – Es
Secton 16 - Base January 2019 Power Module – ES 2684ES To Serial #12700029 - 3084ES To Serial #11700042 ES MODELS 12 21 22 21 22 21 22 12 21 22 Power Module 3072ES - 3772ES - Sigma Level, ES ART_2719 Page 275 Speed Level Seres - Servce &...
Page 283 Secton 16 - Base January 2019 Item Part Number Description Qty�� Weldment, Battery Module -- See “Module Installation” On Page 270 16974 Panel, Battery Module 16977 Crossbar, Battery Module 14896 Block, Slide, Door 25429 16983 Battery Holddown 2987 Holddown Rod 6110 Wingnut 91641...
Page 284 Secton 16 - Base January 2019 Control Module RT, Drawing 1 of 2 2684RT To Serial #12800038 - 3084RT To Serial #11800078 RT MODELS 17 18 28 19 22 Control Module, Drawing 1 of 2 Speed Level™ Sigma Lift ART_3077 Page 277 Speed Level Seres - Servce &...
Page 285 Secton 16 - Base January 2019 Item Part Number Description Qty�� Control Module Weldment -- See “Module Installation” On Page 270 16154 Bracket, Cross Support 14896 Block, Slide, Door 25429 16226 Bracket, Control Box 16229 Bracket, Battery Disconnect 8841 Switch, Battery Disconnect 16152 Bulkhead 83071...
Page 286 Secton 16 - Base January 2019 Control Module, RT Drawing 2 of 2 2684RT To Serial #12800038 - 3084RT To Serial #11800078 RT MODELS Diesel 7 14 15 16 Dual Fuel 14 15 16 Control Module, Drawing 2 of 2 Speed Level™...
Page 287 Secton 16 - Base January 2019 Item Part Number Description Qty�� 91023 Fuel Tank, Plastic 91091 Fuel Tank Cap HDW91233 Plug (Dual Fuel) 1/8 NPT, 3/19 Hose Barb HDW91320 Adapter (Diesel) 6919 Fuel Shutoff HDW91279 Adapter, Male 1/8 NPT, 5/16 Hose Barb 7788 Clamp (Not Shown) 6458...
Page 288: Es Control Module Assembly
Secton 16 - Base January 2019 ES Control Module Assembly 2684ES From Serial #12700030 - 3084ES From Serial #11700043 ILLUSTRATION No. Speed Level Series ES Control Module Assembly Art_5387 Page 281 Speed Level Seres - Servce & Parts Manual...
Page 289 Secton 16 - Base January 2019 Item Part Number Description Qty�� 19471 Fuse Block 91709 Fuse, 300 Amp 8841 Switch, Battery 9370 Gauge Level Hyd Tank 19264 Control Module 19271 Bracket, Control Box 19274 Inverter Bracket Option 19276 Heat Sink 19441 Top Cover 19443...
Page 290: Rt Control Module Assembly
Secton 16 - Base January 2019 RT Control Module Assembly 2684RT From Serial #12800039 - 3084RT From Serial #11800079 ILLUSTRATION No. Speed Level Series RT Control Module Assembly Art_5388 Page 283 Speed Level Seres - Servce & Parts Manual...
Page 291 Secton 16 - Base January 2019 Item Part Number Description Qty�� 19264 Control Module 83107 Control Module Door Assem. 24146 Door Mount 19443 Wear Pad, Door 6854 Battery, 12 VDC 6860 Bracket, Tank Mount 3436 Hold Down Bar, Battery 2987 Rod, Hold Down 91550 Generator, 2000 Watt Optional...
Page 292: Power Module – Rt
Secton 16 - Base January 2019 Power Module – RT 2684RT To Serial #12800038 - 3084RT To Serial #11800078 RT MODELS Power Module 91RT - Speed Level™ RT ART_3478 Page 285 Speed Level Seres - Servce & Parts Manual...
Page 293 Secton 16 - Base January 2019 Item Part Number Description Qty�� 16213 Power Module Weldment 16247 Guard, Engine Module 25429 40620 Spacer, Insulator 14896 Slide Block, Door 14826 Bracket, Cross Support 50028 Screw, M6 x 20 50068 Washer, M6 Fender 50047 Nut, M6 Nylock HDW5724...
Page 294: Es Power Module Assembly
Secton 16 - Base January 2019 ES Power Module Assembly 2684ES From Serial #12700030 - 3084ES From Serial #11700043 ILLUSTRATION No. Speed Level Series ES Power Module Assembly Art_5389 Page 287 Speed Level Seres - Servce & Parts Manual...
Page 295 Secton 16 - Base January 2019 Item Part Number Description Qty�� 19281 Power Module 19443 Wear Pad, Door 19444 Top Cover 24146 Door Mount 92633 Rubber Door Bumper 19462 Battery Vent 19461 Intake Cover Plate 91641 X72ES Battery 90898 Emergency Down Battery 19438 Battery Bracket 19437...
Page 296 Secton 16 - Base January 2019 Diesel Power Module Assembly ILLUSTRATION No. Speed Level Series Diesel Power Module Assembly Art_5390 Page 289 Speed Level Seres - Servce & Parts Manual...
Page 297 Secton 16 - Base January 2019 Item Part Number Description Qty�� 19281 Power Module 19443 Wear Pad, Door 19444 Top Cover, Power Module 24146 Door Mount 92633 Rubber Door Stop 7736 Insulator, Rubber 16721 Bracket, Instake, Air Intake, Diesel 91023 Fuel Tank, Plastic 19293 Bulkhead, Power Module...
Page 298: Dual Fuel Power Module Assembly
Secton 16 - Base January 2019 Dual Fuel Power Module Assembly ILLUSTRATION No. Speed Level Series Dual Fuel Power Module Assembly Art_5391 Page 291 Speed Level Seres - Servce & Parts Manual...
Page 299 Secton 16 - Base January 2019 Item Part Number Description Qty�� 19281 Power Module 19443 Wear Pad, Door 19444 Top Cover 24146 Door Mount 92633 Rubber Door Stop 16295 Weldment, Intake 91023 Fuel Tank, Plastic 19293 Bulkhead 19316 Bracket, Fuel Tank 16211 Engine Mount, Dual Fuel 7736...
Page 300 Secton 16 - Base January 2019 Engine Mount – Dual Fuel DUAL FUEL MODELS Engine Mount, DF752 Dual Fuel ART_2126 R1 Page 293 Speed Level Seres - Servce & Parts Manual...
Page 301 Secton 16 - Base January 2019 Item Part Number Description Qty�� 16213 Power Module Weldment 16211 Engine Mount, Dual Fuel 16210 Spacer 91131 Radiator Bracket Kit 91127 Coolant Overflow Tank 50028 Screw, M6 x 20 50047 Nut, M6 Nylock 6458 Hose 3 ft.
Page 302 Secton 16 - Base January 2019 Engine Mount – Diesel DIESEL MODELS Engine Mount, D1105 Diesel ART_2127 R2 Page 295 Speed Level Seres - Servce & Parts Manual...
Page 303 Secton 16 - Base January 2019 Item Part Number Description Qty�� 16213 Power Module Weldment 16209 Engine Mount, Diesel 16210 Spacer 16207 Bracket, Solenoid Mount 16345 Bracket, Radiator Mount 91127 Coolant Overflow Tank 50028 Screw, M6 x 20 50047 Nut, M6 Nylock 6458 Hose 3 ft.
Page 304 Secton 16 - Base January 2019 Engine – Diesel DIESEL MODELS 43 44 Glow Plug Relay Throttle Relay Diesel Engine, Kubota D1105 ART_2130-R4 Page 297 Speed Level Seres - Servce & Parts Manual...
Page 305 Secton 16 - Base January 2019 Item Part Number Description Qty�� Additional attaching engine parts found earlier in this section 84036 Engine Subassembly, Diesel 91429 Engine Kit, D1105 91113 Radiator Kit 9831 Radiator 19405 Muffler Kit 92164 Gasket, Exhaust (Not Shown) 19458 Bracket Exhaust Mount 92533...
Page 306 Secton 16 - Base January 2019 Engine – Dual Fuel DUAL FUEL MODELS 42 43 38 39 44 45 Coil 19 20 Dual Fuel Engine, Kubota DF752 ART_2129-R4 Page 299 Speed Level Seres - Servce & Parts Manual...
Page 307 Secton 16 - Base January 2019 Item Part Number Description Qty. Item Part Number Description Additional attaching engine parts found earlier in this section Additional attaching engine parts found earlier in this section 91035 Engine Subassembly, Dual Fuel HDW91231 Jamnut, ¼–28 91125 Engine, Kubota DF752 50028...
Page 308: Lp Tank – Dual Fuel
Secton 16 - Base January 2019 LP Tank – Dual Fuel DUAL FUEL MODELS Control Module Dual Fuel LP Tank ART_2128 R2 Page 301 Speed Level Seres - Servce & Parts Manual...
Page 309 Secton 16 - Base January 2019 Item Part Number Description Qty�� 6859 LP Tank 6868 Quick Disconnect 6890 Hose Assembly, 30” 7406 Hose Assembly, 90” HDW6894 Elbow, Brass, NPT to SAE 45° 6861 Bulkhead Filter 6860 Bracket, Tank Mount 19102 Tank Support Weldment 50031 Screw, M8 x 25...
Page 310 Secton 16 - Base January 2019 Generator Option, RT - Old Style Upper Controls ROTATE 90° Control Module RT MODELS Generator Option ART_2135R1 Page 303 Speed Level Seres - Servce & Parts Manual...
Page 311 Secton 16 - Base January 2019 Item Part Number Description Qty�� Refer to Section 5 for Hose Kit 91550 Generator, 2000 Watt 7423 Switch Toggle 1 Pole 2 Position 3 91551 Valve, Solenoid, 2-Way, N.C. -- Included With Item #1 91002 Coil, 12V 10 Series -- Included With Item #1 91546...
Page 312 Secton 16 - Base January 2019 Wire Harness – Electric Models ES MODELS line to Lower Control Box not shown Wheel Motor Axle Lock Cylinder Lift Cylinder Axle Tilt To #7 Sensor Aux. Manifold Motor Control B+ M Axle Lock Cylinder Solenoid Fuse...
Page 313 Secton 16 - Base January 2019 Item Part Number Description Qty�� 92145 Harness, Main, Lower Control Box To Valve Manifold And Modules 92134 Harness, Main Harness To Level Manifold 92135 Harness, Main Harness To Down Valve, Axle Cylinders, Wheel Bypass 92137 Harness, Communication, Main Harness To Axle CAN-Tilt 92138...
Page 314 Secton 16 - Base January 2019 Wire Harness – RT Models RT MODELS Wheel Motor Axle Lock Cylinder Lift Cylinder Axle Tilt To #7 Sensor Aux. Manifold Axle Lock Cylinder Wheel Motor Main Manifold Control Module Main not to scale Disconnect 14 inside lower control box...
Page 315 Secton 16 - Base January 2019 Item Part Number Description Qty�� 92133 Harness, Main, Lower Control Box To Valve Manifold And Modules 92134 Harness, Main Harness To Level Manifold 92135 Harness, Main Harness To Down Valve, Axle Cylinders, Wheel Bypass 92136 Dual Fuel - Harness, Engine, Main Harness To Engine 92222...
Page 316: Section 17 - Decals, Ansi Models
Secton 17 - Decals, ANSI Models January 2019 Decals, ES Models, ANSI Specification - Part 1 Decals, ES Models, ANSI Specification - Part 1 ES MODELS - ANSI 3084ES 2684ES YOU MUST NOT OPERATE TIP-OVER HAZARDS THIS MACHINE: INSPECT MACHINE AND MAKE SURE THAT IT IS OPERATING PROPERLY, UNLESS YOU HAVE BEEN AUTHORIZED TO THAT ALL NAME PLATE AND SAFETY AND CONTROL DECALS ARE IN PLACE USE AND TRAINED IN THE SAFE OPERATION...
Page 317 Secton 17 - Decals, ANSI Models January 2019 Item Part Number Description Qty�� 90719 Decal, MEC Oval 91987 3084ES -- Decal, MEC 3084ES 92232 2684ES -- Decal, MEC 3084ES 8911 Decal, Manuals Inside 91869 Decal, Warning, Sheet Loading 91846 Decal, Warning Panel...
Page 318 TIRES MAY CAUSE MACHINE INSTABILITY. REFER TO SERVICE AND PARTS MANUAL FOR REPLACEMENT PART NUMBER. 90725 MFG. DATE MODEL NUMBER SERIAL NUMBER MODEL YEAR MEC AERIAL PLATFORM SALES CORP. XX/XX XXXXXX XXXXXXXXX 20XX ELECTRICAL VOLTAGE MAX. PLATFORM CAPACITY INCLUDING PERSONS XX VOLTS...
Page 319 Secton 17 - Decals, ANSI Models January 2019 Item Part Number Description Qty�� 91864 Decal, Lower Controls 91266 Decal, Quad Trax 4wd 91848 3084 -- Decal, Platform Capacity, Small 92122 2684 -- Decal, Platform Capacity, Small 9052 Decal, Battery Disconnect And Lock 8779 Warning, Battery, Explosive Gas 91774...
Page 320 Secton 17 - Decals, ANSI Models January 2019 Decals, ES Models, ANSI Specification - Part 3 ES MODELS - ANSI INSIDE CASE OPTION Decals Sigma Level ANSI Speed Level™ ES Models: Sheet 3 of 4 ART_3126 Page 313 Speed Level Seres - Servce & Parts Manual...
Page 321 Secton 17 - Decals, ANSI Models January 2019 Decals, ES Models, ANSI Specification - Part 4 ES MODELS - ANSI Decals Sigma Level ANSI Speed Level™ ES Models: Sheet 4 of 4 ART_3127 Page 314 Speed Level Seres - Servce & Parts Manual...
Page 322 Secton 17 - Decals, ANSI Models January 2019 Decals, RT Models, ANSI Specification - Part 1 RT MODELS - ANSI 3084RT 2684RT YOU MUST NOT OPERATE TIP-OVER HAZARDS THIS MACHINE: INSPECT MACHINE AND MAKE SURE THAT IT IS OPERATING PROPERLY, UNLESS YOU HAVE BEEN AUTHORIZED TO THAT ALL NAME PLATE AND SAFETY AND CONTROL DECALS ARE IN PLACE USE AND TRAINED IN THE SAFE OPERATION...
Page 323 Secton 17 - Decals, ANSI Models January 2019 Item Part Number Description Qty�� 90719 Decal, MEC Oval 91990 3084RT -- Decal, Speed Level 92231 2684RT -- Decal, Speed Level 8911 Decal, Manuals Inside 91869 Decal, Warning, Sheet Loading 91846 Decal, Warning Panel...
Page 324 REFER TO MAINTENANCE MANUAL FOR REPLACEMENT PART NUMBER. 8519 36 DUAL FUEL MFG. DATE MODEL NUMBER SERIAL NUMBER MODEL YEAR MEC AERIAL PLATFORM SALES CORP. XX/XX XXXXXX XXXXXXXXX 20XX ELECTRICAL VOLTAGE MAX. PLATFORM CAPACITY INCLUDING PERSONS XX VOLTS XXX kg = X PERSONS + XXX kg EQUIPMENT XXX kg = X PERSONS + XXX kg EQUIPMENT MAX.
Page 325 Secton 17 - Decals, ANSI Models January 2019 Item Part Number Description Qty�� 91930 Decal, Lower Controls Diesel 91854 Decal, Lower Controls Dual Fuel 91266 Decal, Quad Trax 4wd 91848 3084 -- Decal, Platform Capacity, Small 92122 2684 -- Decal, Platform Capacity, Small 9052 Decal, Battery Disconnect And Lock 6873...
Page 326 Secton 17 - Decals, ANSI Models January 2019 Decals, RT Models, ANSI Specification - Part 3 RT MODELS - ANSI INSIDE CASE OPTION Decals Sigma Level ANSI Speed Level™ RT Models: Sheet 3 of 4 ART_3130 Page 319 Speed Level Seres - Servce & Parts Manual...
Page 327 Secton 17 - Decals, ANSI Models January 2019 Decals, RT Models, ANSI Specification - Part 4 RT MODELS - ANSI 35 DUAL FUEL Decals Sigma Level ANSI Speed Level™ RT Models: Sheet 4 of 4 ART_3131 Page 320 Speed Level Seres - Servce & Parts Manual...
Page 328: Section 18 - Decals, Ce Models
Secton 18 - Decals, CE Models January 2019 Decals, ES Models, CE Specification - Part 1 Decals, ES Models, CE Specification - Part 1 ES MODELS - CE 3084ES 2684ES YOU MUST NOT OPERATE TIP-OVER HAZARDS THIS MACHINE: INSPECT MACHINE AND MAKE SURE THAT IT IS OPERATING PROPERLY, UNLESS YOU HAVE BEEN AUTHORIZED TO THAT ALL NAME PLATE AND SAFETY AND CONTROL DECALS ARE IN PLACE USE AND TRAINED IN THE SAFE OPERATION...
Page 329 Secton 18 - Decals, CE Models January 2019 Item Part Number Description Qty�� 90719 Decal, MEC Oval 91987 3084ES -- Decal, MEC 3084ES 92232 2684ES -- Decal, MEC 3084ES 8911 Decal, Manuals Inside 91869 Decal, Warning, Sheet Loading 91846 Decal, Warning Panel...
Page 330 OR SEE SERVICE MANUAL 8502 MFG. DATE MODEL NUMBER SERIAL NUMBER MODEL YEAR WARNING MEC AERIAL PLATFORM SALES CORP. XX/XX XXXXXX XXXXXXXXX 20XX ELECTRICAL VOLTAGE MAX. PLATFORM CAPACITY INCLUDING PERSONS XX VOLTS XXX kg = X PERSONS + XXX kg EQUIPMENT...
Page 331 Secton 18 - Decals, CE Models January 2019 Item Part Number Description Qty�� 91931 Decal, Lower Controls 91266 Decal, Quad Trax 4wd 91848 3084 - Decal, Platform Capacity, Small 92122 2684 - Decal, Platform Capacity, Small 9052 Decal, Battery Disconnect And Lock 8779 Warning, Battery, Explosive Gas 91774...
Page 332 Secton 18 - Decals, CE Models January 2019 Decals, ES Models, CE Specification - Part 3 ES MODELS - CE INSIDE CASE OPTION 41 Australia only Decals Sigma Level CE Speed Level™ ES Models: Sheet 3 of 4 ART_3400 Page 325 Speed Level Seres - Servce &...
Page 333 Secton 18 - Decals, CE Models January 2019 Decals, ES Models, CE Specification - Part 4 ES MODELS - CE Decals Sigma Level CE Speed Level™ ES Models: Sheet 4 of 4 ART_3401 Page 326 Speed Level Seres - Servce & Parts Manual...
Page 334 Secton 18 - Decals, CE Models January 2019 Decals, RT Models, CE Specification - Part 1 RT MODELS - CE 3084RT 2684RT YOU MUST NOT OPERATE TIP-OVER HAZARDS THIS MACHINE: INSPECT MACHINE AND MAKE SURE THAT IT IS OPERATING PROPERLY, UNLESS YOU HAVE BEEN AUTHORIZED TO THAT ALL NAME PLATE AND SAFETY AND CONTROL DECALS ARE IN PLACE USE AND TRAINED IN THE SAFE OPERATION...
Page 335 Secton 18 - Decals, CE Models January 2019 Item Part Number Description Qty�� 90719 Decal, MEC Oval 91990 3084RT -- Decal, Speed Level 92231 2684RT -- Decal, Speed Level 8911 Decal, Manuals Inside 91869 Decal, Warning, Sheet Loading 91846 Decal, Warning Panel...
Page 336 SPECIFICATIONS OR SEE SERVICE MANUAL 8502 MFG. DATE MODEL NUMBER SERIAL NUMBER MODEL YEAR 2684 MEC AERIAL PLATFORM SALES CORP. WARNING XX/XX XXXXXX XXXXXXXXX 20XX ELECTRICAL VOLTAGE MAX. PLATFORM CAPACITY INCLUDING PERSONS XX VOLTS XXX kg = X PERSONS + XXX kg EQUIPMENT...
Page 337 Secton 18 - Decals, CE Models January 2019 Item Part Number Description Qty�� 91930 Decal, Lower Controls 91266 Decal, Quad Trax 4wd 91848 3084 - Decal, Platform Capacity, Small 92122 2684 - Decal, Platform Capacity, Small 9052 Decal, Battery Disconnect And Lock 8779 Warning, Battery, Explosive Gas 11026730...
Page 338 Secton 18 - Decals, CE Models January 2019 Decals, RT Models, CE Specification - Part 3 RT MODELS - CE INSIDE CASE OPTION 41 Australia only Decals Sigma Level CE Speed Level™ RT Models: Sheet 3 of 4 ART_3404 Page 331 Speed Level Seres - Servce &...
Page 339 Secton 18 - Decals, CE Models January 2019 Decals, RT Models, CE Specification - Part 4 RT MODELS - CE Decals Sigma Level CE Speed Level™ RT Models: Sheet 4 of 4 ART_3405 Page 332 Speed Level Seres - Servce & Parts Manual...
Page 340 January 2019 Notes Page 333 Speed Level Seres - Servce & Parts Manual...
Page 341 January 2019 Notes Page 334 Speed Level Seres - Servce & Parts Manual...
Page 342 MEC Parts Order Form Phone: 559-842-1523 Fax: 559-400-6723 Email: Parts@mecawp�� c om Please fill out completely Date: Ordered By: Account: Your Fax No.: Ship to: Bill to: Purchase Order Number Ship VIA ** All orders MUST have a Purchase Order Number...
Page 343 MEC Aerial Platform Sales Corp. and is found upon inspection by MEC Aerial Platform Sales Corp. to be defective in material and/or workmanship. MEC Aerial Platform Sales Corp. shall not be liable for any consequential, incidental or contingent damages whatsoever.
Page 344 MEC Aerial Work Platforms 1401 S. Madera Avenue, Kerman, CA 93630 USA Toll Free: 1 - 877 - 632 - 5438 Phone: 1 - 559 - 842 - 1500 Fax: 1 - 559 - 842 - 1520 info@MECawp.com www.MECawp.com...

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2684rt 3084rt 2684es 3084es

Mec Speed Level Series Service & Parts Manual

Chapter 1 - Service

Service Introduction

Section 1 - MEC Operator Policy

Section 2 - Safety Symbols & General Safety Tips

Section 3 - Specifications

Section 4 - General Information

Section 10 - Schematics

Chapter 2 - Parts

Section 11 - Controls

Section 13 - Boom

Section 14 - Axles

Section 16 - Base

Section 17 - Decals, ANSI Models

Section 18 - Decals, CE Models

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