Mec 2047ES Building instructions

CE SERVICE AND PARTS MANUAL
Part # 90972 R2
March 2008
2047ES / 2647ES / 3247ES
Serial Number Range
2047ES: 9801000 - Present
2647ES: 9901000 - Present
3247ES: 10001000 - 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
"2047ES / 2647ES / 3247ES" Service & Parts Manual - CE Specifications March 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 ................................................................ 1-6
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

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March 2008 "2047ES / 2647ES / 3247ES" 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
Pothole Circuit ................................................................................................... 4-9
Platform Removal ............................................................................................ 4-10
Lift Cylinder Removal and Installation ............................................................. 4-11
Scissor Beam Assembly.................................................................................. 4-12

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"2047ES / 2647ES / 3247ES" Service & Parts Manual - CE Specifications March 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
2047ES - Serial # 9801000 - 9801099
2647ES - Serial # 9901000 - 9901199
3247ES - Serial # 10001000 - 10001199 ..................................................... 6-2
2047ES - Serial # 9801100 - CURRENT
2647ES - Serial # 9901200 - CURRENT
3247ES - Serial # 10001200 - CURRENT ................................................... 6-4
Electric Schematics .............................................................................................. 6-9
2047ES - Serial # 9801000 - 9801099
2647ES - Serial # 9901000 - 9901199
3247ES - Serial # 10001000 - 10001199 ................................................... 6-10
2047ES - Serial # 9801100 - CURRENT
2647ES - Serial # 9901200 - CURRENT
3247ES - Serial # 10001200 - CURRENT ................................................. 6-12

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March 2008 "2047ES / 2647ES / 3247ES" 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

"2047ES / 2647ES / 3247ES" Service & Parts Manual - CE Specifications March 2008
Page 1-1
SECTION 1:
HYDRAULIC SYSTEM
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 .................................................................................................................. 1-6
Steering Circuit ....................................................................................................................................................... 1-8
Platform Lift Circuit ................................................................................................................................................ 1-9
Cylinder Repair ..................................................................................................................................................... 1-10
Hydraulic Manifold ............................................................................................................................................... 1-13

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HYDRAULIC FLUID
Handling Precautions
PERSONS IN REGULAR CONTACT WITH MINERAL-BASED
HYDRAULIC FLUID NEED TO BE AWARE OF THE IMPORTANCE OF
THOROUGH HYGIENE, AND THE PROPER METHODS FOR
HANDLING MINERAL OILS IN ORDER TO AVOID POTENTIAL
HAZARDS TO HEALTH.
If mineral-based hydraulic fluid is SPLASHED INTO THE EYES, it must be WASHED OUT
THOROUGHLY using abundant quantities of water. If irritation persists, medical advice should be
sought.
HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE AND
BURN SKIN, DAMAGE EYES, AND MAY CAUSE SERIOUS INJURY
OR BLINDNESS.
FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE.
Fluid Recommendations
MEC recommends the use of ISO Grade 32 hydraulic fluid. A 150SSU EQUIVALENT substitute
can be used if absolutely necessary. Mineral-based hydraulic fluids produced by different compa-
nies will USUALLY mix with each other satisfactorily, but this IS NOT RECOMMENDED. When in
doubt, consult with your supplier.
ISO Grade 32 has proven to be suitable for use in all climates. For continued operation in tem-
peratures below 32 °F (0 °C), use of an ATF hydraulic fluid is satisfactory.
The only exception to the above is to drain and fill the system with ATF fluid or its equivalent. This
will also start up at temperatures down to -20 °F (-29 °C). However, use of this fluid will give poor
performance at temperatures above 120 °F (49 °C).

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System Flushing Procedure
1. With platform fully down, drain hydraulic fluid from hydraulic reservoir into an, empty con-
tainer.
2. When the hydraulic reservoir is empty, remove suction strainer and hoses.
3. Remove return line on the hydraulic reservoir.
4. Remove the bypass filter and hose.
5. Flush the hoses with clean hydraulic fluid.
6. Discard old bypass filter element and replace.
7. Flush out the tank with hoses removed from the hydraulic reservoir.
8. Reinstall all hoses in the previous steps.
9. Fill hydraulic reservoir with filtered, fresh hydraulic fluid (refer to Lubrication Chart).
10. Loosen output hose fittings at pump to flood with hydraulic fluid. Tighten fittings.
11. Briefly operate all functions. Two or three lift cycles may be necessary to purge all air from
lift cylinder(s).
12. When the above procedures have been completed, fill hydraulic reservoir to full mark on
sight gauge.
13. Check all leaks and correct as necessary. Machine is now ready to be placed back into
operation.
NOTE: Avoid mixing petroleum and synthetic base fluids. It is not advisable to mix fluids
of different brands or types, except as recommended.

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HYDRAULIC SYSTEM COMPONENTS
Hydraulic Fluid Reservoir
This consists of the tank, a filler cap with breather, a drain plug, and a bypass filler with a
10 micron filter element.
Perform the following steps weekly:
• Check tank for signs of leakage.
• Inspect tank securing bolts for tightness.
Hydraulic Filter
All machines are produced with a filter. It is a 10 micron spin-on, bypassing filter. When the filter is
clogged, hydraulic flow bypasses the filter element. The filter element must be changed every 6
months or 500 hours. Extremely dirty conditions may require that the filter be replaced more
often.
Beware of hot fluid. Contact with hot fluid may cause burns.
Hydraulic Pump
An electric motor drives the fixed displacement, gear pump. The pump provides hydraulic fluid
flow to operate the machine functions at 3 g.p.m. There are no adjustments on the pump. The
pump provides power for the lift, drive, brake and steering functions.
ART_2170
Fluid Level
Sight Gauge
Early Models are equipped with
a Welded Steel Hydraulic Reservoior
Late Models are equipped
with a Translucent Plastic
Hydraulic Reservoior
Return
Filter
Fluid Level
Indicator
Plastic
Hydraulic
Reservoior Hydraulic Pump
and Motor
Filler Cap
with Strainer

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ART_2171
Brake
2047ES / 2647ES / 3247ES
Braking Circuit
Rear brakes are
released whenever
the machine is
commanded to
drive.
ART_2165
Wheel Drive Circuit
There are two (2) hydrau-
lic, fixed-displacement
gear wheel motors to
provide power to two (2)
front wheels.

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PARKING BRAKE AND TOWING CIRCUIT
Note: Refer to Parts Section E for hose routing.
Machine can be winched or moved short distances in case of power failure at speeds not to
exceed 5 m.p.h. (8.05 km/h).
PRIOR TO MANUALLY RELEASING BRAKES, INSURE WHEELS ARE
CHOCKED TO PREVENT MACHINE FROM MOVING.
Release Brakes Before Towing:
• Open the tow valve by turning counter-clockwise.
• Push in the manual Brake Release valve located on the main manifold.
• Using the hand pump on the manifold, pump valve until pressure is built.
• Machine is now ready for towing.
AFTER RELEASING THE BRAKES, THERE IS NOTHING TO STOP
THE MACHINE’S TRAVEL. MACHINE WILL ROLL FREELY ON
SLOPES. BE ON GUARD AGAINST RUNAWAY.
To Reset Brakes:
• Close the tow valve by turning clockwise.
• Brakes will reset when drive function is activated or reset by pulling on manual brake re-
lease valve.
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 SCISSOR ASSEMBLY.
BEFORE LOWERING PLATFORM, RETRACT THE DECK EXTENSION.

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Emergency Lowering - 2047ES and 2647ES
(current models)
Emergency Down system is used to lower the platform in
case of power or valve failure. To lower the platform, pull the
red “T” handle located at the rear of the machine. Lowering
stops when you release the “T” handle.
Emergency Lowering - 3247ES (all models)
The Emergency Down System is used to lower the platform
in case of power or valve failure. To lower the platform, per-
form the following steps:
1. Push down on the toggle switch and hold it to lower
the platform to the desired height.
2. Once the platform is fully lowered, release the toggle switch to close the valve
ART_2172
2047ES / 2647ES
ART_2173
90918
EMERGENCY LOWERING
ACTUATE SWITCH TO
LOWER PLATORM
90918
3247ES
ART_2249
EMERGENCY DOWN PROCEDURE
LOCK OPEN VALVE ON LIFT
CYLINDER ABOVE.
PULL MANUALACTIVATOR BELOW
TO LOWER PLATFORM.
TO RETURN TO NORMAL OPERATION
RESET LIFT CYLINDER VALVE.
90727
CYLINDER
VALVE
MANUAL
ACTIVATOR
8599
90727
8599
Emergency Lowering
- 2047ES and 2647ES
(early models)
The Emergency Down System is used
to lower the platform in case of power
or valve failure. To lower the platform,
perform the following steps:
1. Pull and turn knurled knob on
lift cylinder counterclockwise to
lock the valve in open position.
2. Pull manual activator (override
valve) on main manifold to
lower platform to
desired height.
3. To return to normal operation,
turn knurled knob on lift cylin-
der clockwise. Valve will automatically lock.

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ART_2167
Bearing
Shaft Plate
Shaft Plate
Bearing
Steering Shaft
Steering Link
Steering Cylinder
Steering Link
Bearing
Spacer
Washer
Washer
Cylinder Mount Bolts 102 - 112 138 - 152
Shaft Plate Bolts 86 - 96 113 - 130
Steering Link Bolts 26 - 28 35 - 38
TORQUE Ft. lbs. Nm
STEERING CIRCUIT
Note: Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure .
Refer to Section 3 for Remove and Replace instructions.
Refer to Parts Section E for hose routing.
The steering system consists of the following components:
• Each wheel motor housings has a pivot and chain sprocket on the top.
• A hydraulic steering cylinder is mechanically linked via tie rods to two (2) chain-and-
sprocket assemblies (one [1] for each motor housing).
• Steering is accomplished
hydraulically by using
one (1) double-acting cylin-
der, and a 4-way 3-position
solenoid-operated, hydrau-
lic directional control car-
tridge valve.
Steer Cylinder
There is one (1) cylinder utilized in
the steering system. This cylinder is
a double acting double sided type
which requires fluid flow to operate
the cylinder rod in both directions.
Directing fluid forces the piston to
travel to one side or the other,
thereby extending one rod end and
retracting the other.
Refer to the Mechanical Section of
this manual for cylinder disassem-
bly, or replacement.

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PLATFORM LIFT CIRCUIT
Note: Refer to Hydraulic Manifold and Relief Pressure Adjustment Procedure .
Refer to
Section 3 for Remove and Replace instructions.
• The lift system uses the hydraulic pump to obtain proportional lifting function controlled by
the lift valve and pump speed.
• Lowering is single speed controlled by the holding valves on the lift cylinder(s) and regu-
lated by a fixed orifice located on the lift cylinder(s).
• Platform capacity is limited by a hydraulic relief valve in the lift circuit. (Refer to Machine
Specifications or the Hydraulic Schematic for proper setting).
Lift Cylinder
Note: Refer to Cylinder Repair .
2047ES / 2647ES
One (1) single acting type hydraulic cylinder.
The cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for hold-
ing the platform in position.
The valve is also externally actuated for manually lowering the platform. Early models use a pull-
to-release knob at the cylinder, while current models use a cable release with a pull handle lo-
cated near the ladder (see Emergency Systems and Procedures ).
3247ES
Two (2) single acting type hydraulic cylinders.
Each cylinder has an integrated 2-position, 2-way solenoid operated platform lower valve for
holding the platform in position (see Emergency Systems and Procedures ).
The valves are also externally actuated via a toggle switch for manually lowering the platform.
The normally closed holding valve prevents retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and its related control valve.

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CYLINDER REPAIR
CYLINDERS ARE HEAVY. SUPPORT CYLINDERS BEFORE
REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE
MACHINE.
ART_2232
Pressure
and
Return
Piston
Seals
Seals Seals
Rod
Seals Seals
Typical Dual Acting Double Ended Cylinder
Barrel
Head
Piston Securing Nut
Rod
Head
Seals Seals Piston Vent to Tank
Return to Tank
Barrel Pressure
Piston Securing Nut
Typical Single Acting Cylinder
Removal
Note: Refer to Section 3 for Remove and Replace instructions, and the Parts Section for a
list of hardware specific to the cylinder being repaired.
1. Tag hoses for proper reassembly.
2. Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination.
3. Remove cylinder from the machine as described in Section 3 .

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Preparation
Take care not to damage rod surface and guard against dirt or other
foreign objects entering system.
1. Drain all fluid from cylinder.
2. Clean all dirt and grit from outside of cylinder.
3. Insert cylinder into vise.
Cylinder Disassembly
1. Remove the head from the cylinder body.
2. Remove the shaft assembly from the barrel, pulling in a straight line, so as not to scar the
internal parts.
3. Insert shaft into a soft jawed vise so that the head and piston can be removed. Be sure
the shaft and vise are both clean before using.
4. Remove nut at the end of the shaft and pull head and piston off of the rod.
5. Remove all seals from the head and piston using a non-sharp seal tool. These tools are
available from various seal suppliers.
9. Clean all fluid and debris off of the head, piston, shaft, collar and barrel using solvent,
rags, and an air hose.
10. Inspect parts for scratches, pits or polishing. Check seal groves and sealing surfaces.
a. Scratches or pits deep enough to catch the fingernail are unacceptable; replace the
cylinder.
b. Polishing is a sign of uneven loading. Check for roundness. If a polished surface is not
round within .007 in (0.18 mm) replace the cylinder.

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Cylinder Assembly
CAUTION:
• To insure a quality repair, cylinder parts must be thoroughly cleaned, dry, and free of
solvents, and assembly must be performed in a clean area free of dust and
contamination.
• To avoid cutting the seals, do not use sharp edged tools during seal replacement. After
installing seals allow at least one hour for the seals to restore to their original shape
before assembling the cylinder.
• Torque all hardware according to the
Hydraulic Components Torque Table unless
otherwise specified.
1. Lubricate all components with clean hydraulic fluid.
2. Install new seal kit components. Install all seals on the head and piston using the non-
sharp seal tool.
3. Place a small amount of fluid on the inside seals of the head and reinstall it on the shaft,
by slipping head over the piston end of the shaft being very careful not to damage the
inside seals.
4. Place a small amount of fluid on the inside seals of the piston and reinstall it on the shaft
by slowly twisting the piston on over the threads of the shaft being very careful not to
damage the inside seals.
5. Reinstall the shaft nut; torque 1 ½” nut to 160 ft.-lbs.
6. Grease the outside seals of the head and piston.
7. Reinstall the shaft into the barrel of the cylinder and push in until groove of the head lines
up with the slot in the barrel.
17. Reinstall the cylinder retainer. Installation is reverse of removal.
18. Cycle the cylinder using air to check for proper operation.
NOTE: It is very important to keep all parts clean when working with hydraulic cylinders,
even one small piece of dirt or grit can damage the cylinder.

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Page 1-13
HYDRAULIC MANIFOLD
Note: Refer to Section 3 for Remove and Replace instructions, and the Parts Section for
a list of hardware.
Tag all components as they are removed so as not to confuse their location during
reassembly.
Hydraulic Manifold Removal
1. Disconnect the negative battery terminal.
2. Tag and disconnect the solenoid valve leads.
3. Tag and disconnect hydraulic hoses, and IMMEDIATELY cap the openings to prevent
contamination.
4. Remove the bolts that hold the manifold to the mounting bracket.
5. Remove the manifold block.
Disassembly
1. Remove coils from solenoid valves.
2. Remove valves.
3. Remove fittings, plugs, springs, balls, and orifices.
Cleaning and Inspection
1. Wash the manifold in cleaning solvent to remove built-up contaminants, then blow out all
passages with clean compressed air.
2. Inspect the manifold for cracks, thread damage and scoring where O-rings seal against
internal and external surfaces.
3. Wash and dry each component and check for thread damage, torn or cracked O-rings,
and proper operation.
4. Replace defective parts and O-rings.
Assembly
Note: Lubricate all O-rings before installation to prevent damage to the O-ring. Seat balls
in manifold block by lightly tapping on the ball with a brass drift punch.
1. Install fittings, plugs, springs, balls, and orifices. Use one drop of Locktite #424 or equiva-
lent thread locker on each screw-in orifice.
2. Install valves.
Installation
1. Attach manifold assembly to mounting plate with mounting bolts.
2. Connect solenoid leads (as previously tagged).
3. Connect hydraulic hoses (as previously tagged). Be certain to tighten hoses.
4. Connect the battery.
5. Operate each hydraulic function and check for proper operation and leaks.
6. Adjust valve pressures.

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