Mec 1532ES Building instructions

CE SERVICE AND PARTS MANUAL
Part # 90966 R2
February 2008
1532ES / 1932ES
Serial Number Range
1532ES CE: 9001000 - Present
1932ES CE: 9104000 - Present

1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: [phone]
E-mail:[e-mail] • Web:www.mecawp.com
Aerial Platform Sales Corp.

Table of Contents
"1532ES / 1932ES" Service & Parts Manual - CE Specifications February 2008
Page i
Service Manual
INTRODUCTION ............................................................................................... I
General Safety Tips ................................................................................................ III
Hydraulic System .............................................................................................. IV
Electrical System ............................................................................................... IV
Total System ...................................................................................................... IV
Machine Specifications ........................................................................................... V
Primary Machine Components ............................................................................. VII
LUBRICATION ....................................................................................................... VIII
SECTION 1
HYDRAULIC SYSTEM ............................................................................. 1-1
Hydraulic Fluid ...................................................................................................... 1-2
Hydraulic System Components........................................................................... 1-4
Parking Brake and Towing Circuit ....................................................................... 1-6
Emergency Systems And Procedures ................................................................ 1-7
Steering Circuit ..................................................................................................... 1-8
Platform Lift Circuit .............................................................................................. 1-9
Cylinder Repair ................................................................................................... 1-10
Hydraulic Manifold.............................................................................................. 1-13
SECTION 2
ELECTRICAL SYSTEM ........................................................................... 2-1
Electrical System - General ................................................................................. 2-2
Deutsch Connectors............................................................................................. 2-3
Batteries ................................................................................................................ 2-4
Alarms and Switches ........................................................................................... 2-8
Continuity Checks .............................................................................................. 2-11
Diode Board ........................................................................................................ 2-12
Sevcon Motor Speed Controller ........................................................................ 2-13
Load Sensing System ........................................................................................ 2-14

Table of Contents
February 2008 "1532ES / 1932ES" Service & Parts Manual - CE Specifications
Page ii
SECTION 3
PLATFORM OVERLOAD SYSTEM ......................................................... 3-1
General Description ............................................................................................. 3-2
Electrical Connections ......................................................................................... 3-3
Troubleshooting .................................................................................................... 3-4
GP102 - EZcal Help Messages ....................................................................... 3-4
GP102 LED Flash Codes ................................................................................ 3-7
Calibration ............................................................................................................. 3-8
CALIBRATION TROUBLESHOOTING; Failure Messages ............................ 3-11
CALIBRATION TROUBLESHOOTING; Information Messages ..................... 3-16
SECTION 4
MECHANICAL COMPONENTS ............................................................... 4-1
Torque Specifications .......................................................................................... 4-2
Mechanical Components ..................................................................................... 4-3
Base / Undercarriage ...................................................................................... 4-3
Hoses and Cables ........................................................................................... 4-3
Raising the Machine ........................................................................................ 4-4
Tires/Wheels ................................................................................................... 4-5
Front Drive Motors ........................................................................................... 4-6
Rear Wheel Brakes.......................................................................................... 4-7
Steer Cylinder .................................................................................................. 4-8
To replace steer cylinder: ................................................................................ 4-8
Pothole Circuit ................................................................................................. 4-9
Platform Removal .......................................................................................... 4-10
Lift Cylinder Removal and Installation ........................................................... 4-11
Scissor Beam Assembly ................................................................................ 4-12

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"1532ES / 1932ES" Service & Parts Manual - CE Specifications February 2008
Page iii
SECTION 5
TROUBLESHOOTING ............................................................................. 5-1
General Troubleshooting Tips .............................................................................. 5-2
Hydraulic Pressure Adjustment Procedures...................................................... 5-4
Troubleshooting .................................................................................................... 5-6
Sevcon Motor Speed Controller ........................................................................ 5-14
LED Diagnostics Definitions (Flash Codes) ................................................... 5-15
Sevcon Motor Speed Controller - Connections ............................................. 5-17
Troubleshooting Battery Charger ...................................................................... 5-19
SECTION 6
SCHEMATICS .......................................................................................... 6-1
Hydraulic Schematics .......................................................................................... 6-2
1532ES - Serial # 9001000 - 9001099
1932ES - Serial # 9104000 - 9104999 .......................................................... 6-2
1532ES - Serial # 9001100 - Current
1932ES - Serial # 9105000 - Current ............................................................ 6-4
Electric Schematics .............................................................................................. 6-9
1532ES, S/N 9000500 - 9001099
1932ES, S/N 9104000 - 9104999 .................................................................. 6-10
1532ES, S/N 9002000 - Current
1932ES, S/N 9105000 - Current .................................................................... 6-12

Table of Contents
February 2008 "1532ES / 1932ES" Service & Parts Manual - CE Specifications
Page iv
Parts Manual
SECTION A: CONTROL BOXES
SECTION B: PLATFORM AND RAILS
SECTION C: SCISSORS
SECTION D: HYDRAULICS
SECTION E: BASE
SECTION F: DECALS

"1532ES / 1932ES" Service & Parts Manual - CE Specifications February 2008
Page I
INTRODUCTION
This manual consists of Service and Parts sections.
The Service Section of this manual is designed to provide you, the customer, with the instructions
needed to properly maintain the MEC self-propelled scissor lift. When used in conjunction with
the illustrated Parts Section and the Operators Manual (provided separately), this manual will
assist you in making necessary adjustments, repairs, identifying, and ordering the correct re-
placement parts.
All parts represented here are manufactured and supplied in accordance with MEC’s quality
standards.
We recommend that you use Genuine MEC parts to insure proper OPERATION and reliable
PERFORMANCE.
To obtain maximum benefits from your MEC scissor lift, always follow the proper operating and
maintenance procedures. Only trained authorized personnel should be allowed to operate or
service this machine. Service personnel should read and study the Operator’s and Service and
Parts Manual in order to gain a thorough understanding of the unit prior to making any repairs.
To help you recognize important safety information, we have identified warnings and instructions
that directly impact on safety with the following signals:
“DANGER” INDICATES AN IMMINENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS
INJURY. THIS SIGNAL WORD IS LIMITED TO THE MOST EXTREME
SITUATIONS.
“WARNING” INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS
INJURY.
“CAUTION” INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE
PRACTICES. “CAUTION” IS USED FOR PROPERTY-DAMAGE ONLY
ACCIDENTS.

February 2008 "1532ES / 1932ES" Service & Parts Manual - CE Specifications
Page II
NOTE: The best method to protect yourself and others from injury or death is to use
common sense. If you are unsure of any operation, don’t start until you are
satisfied that it is safe to proceed and have discussed the situation with your
supervisor.
Service personnel and machine operators must understand and comply with all warnings and
instructional decals on the machine.
MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN
AND SPECIFICATIONS WITHOUT WRITTEN PERMISSION FROM
MEC ARE STRICTLY FORBIDDEN. A MODIFICATION MAY
COMPROMISE THE SAFETY OF THE MACHINE, SUBJECTING
OPERATOR(S) TO SERIOUS INJURY OR DEATH.
MEC’s policies and procedures demonstrate our commitment to Quality and our relentless ongo-
ing efforts towards Continuous Improvement, due to which product specifications are subject to
change without notice.
Any procedures not found within this manual must be evaluated by the individual to assure one-
self that they are “proper and safe.”
Your MEC Scissor Lift has been designed, built, and tested to provide many years of safe, de-
pendable service. Only trained, authorized personnel should be allowed to operate or service the
machine.
MEC, as manufacturer, has no direct control over machine application and operation. Proper
safety practices are the responsibility of the user and all operating personnel.
If There Is A Question On Application And/Or Operation Contact:
Aerial Platform Sales Corp.
1775 Park Street, Suite 77 • Selma, CA 93662 USA
Ph: 1-800-387-4575 • 559-891-2488 • Fax: [phone]
www.mecawp.com

"1532ES / 1932ES" Service & Parts Manual - CE Specifications February 2008
Page III
GENERAL SAFETY TIPS
Regular inspection and conscientious maintenance is the key to efficient economical operation of
your scissor lift. It will help to assure that your equipment will perform satisfactorily with a mini-
mum of service and repair.
The actual operating environment of the machine governs the inspection schedule. Correct lubri-
cation is an essential part of the preventative maintenance to minimize wear on working parts
and ensure against premature failure. By maintaining correct lubrication, the possibility of me-
chanical failure and resulting downtime is reduced to a minimum.
NEVER PERFORM SERVICE ON THE MACHINE (WITH THE
PLATFORM ELEVATED) WITHOUT FIRST BLOCKING THE SCISSOR
ASSEMBLY IN PLACE USING THE MAINTENANCE LOCK!
♦Block scissor assembly using Maintenance Lock if
machine is in the elevated/extended position.
♦Never leave hydraulic components or hoses open.
They must be protected from contamination (includ-
ing rain) at all times.
♦Never open a hydraulic system when there are
contaminants in the air.
♦Always clean the surrounding area before opening
hydraulic systems.
♦Use only recommended lubricants. Improper lubri-
cants or incompatible lubricants may be as harmful
as no lubrication.
♦Watch for makeshift “fixes” which can jeopardize
safety as well as lead to more costly repair.
ART_2152

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Page IV
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.
Electrical System
Prevent damage to battery and/or electrical system;
♦♦
♦♦
♦ Always disconnect the negative (–) battery cable first.
♦♦
♦♦
♦ Always connect the positive (+) battery cable first.
When connecting battery cables, connect the positive terminal first. If the negative cable is in-
stalled first, and contact is made between the positive side of the battery and a metal surface on
the machine while connecting the positive cable, a spark will occur. This can cause damage to
the electrical system, battery explosion, and personal injury.
Total System
Failure to perform preventive maintenance at recommended
intervals may result in the unit being operated with a defect that
could result in injury or death of the operator.
Immediately report to your supervisor any Defect or malfunction.
Any defect shall be repaired prior to continued use of the scissor
lift.
Inspection and maintenance should be performed by qualified
personnel familiar with the equipment.