Mec 4069RT Building instructions

ART_4480
SERVICE AND PARTS MANUAL
4069RT
Serial Number Range
13500001 - Up Part # 93080
November 2013

1401 S. Madera Avenue • Kerman, CA 93630 USA
Ph: 1-800-387-4575 • 1-559-842-1500 • FAX [phone]
E-mail: [e-mail] • Web: www.mecAWP.com
93080 | 4069RT
Aerial Platform Sales Corp.
Revision History
Original Release Date: November 2013
Date Reason for Update
November
2013 New Release

“4069RT” Service and Parts Manual March 2014
Page i
Service Table of Contents
Introduction I Page
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II
MEC Operator Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
General Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Primary Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Emergency Systems and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Free-Wheel Configuration For Winching or Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI
Lift and Support the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII
Section 1: Hydraulic System Page
Hydraulic System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Roadmap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Fluid Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
System Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hydraulic Pump Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Functions Manifold & Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lift Vent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Front Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
Rear Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Brake Release Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Drive Case Drain Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
General Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Section 2: Electrical System Page
Electrical System – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Battery Maintenance (in storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

“4069RT” Service and Parts ManualMarch 2014
Page ii
Service Table of Contents
Battery Maintenance (in use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Lower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Upper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Alarms and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
GP400 Control Module Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
GP400 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Failure Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Information Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Section 3: Mechanical Components Page
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hoses and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Scissor Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Rear Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Front Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
DIESEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
DUAL FUEL Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Section 4: Troubleshooting Page
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
EZ-Cal Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Optional Onboard EZ-Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
EZ-Cal Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
EZ-Cal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
EZ-Cal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Ez-Cal Retrieve Mode And Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
MODE Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
OTHER Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

“4069RT” Service and Parts Manual March 2014
Page iii
Service Table of Contents
Section 5: Schematics Page
Hydraulic Schematics Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

“4069RT” Service and Parts ManualMarch 2014
Page iv
Service Table of Contents
N OTES :

“4069RT” Service and Parts Manual March 2014
Page I
INTRODUCTION
This manual consists of Service and Illustrated 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 aerial work platform. When used in conjunc-
tion with the Illustrated Parts Section and the Operators Manual (provided separately), this manual
will assist you in making necessary adjustments and repairs, and identifying and ordering the cor-
rect replacement parts.
All parts represented here are manufactured and supplied in accordance with MEC quality stan-
dards.
We recommend that you use genuine MEC parts to ensure proper operation and reliable perfor-
mance.
To obtain maximum benefits from your MEC Aerial Work Platform, always follow the proper oper-
ating and maintenance procedures. Only trained authorized personnel should be allowed to oper-
ate or service this machine. Service personnel should read and study the Operator’s, Service and
Parts Manuals in order to gain a thorough understanding of the unit prior to making any repairs.
C ONTENTS P AGE
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
MEC Operator Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
General Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Primary Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Emergency Systems and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Free-Wheel Configuration For Winching or Towing . . . . . . . . . . . . . . . . . . . . . . XI
Lift and Support the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII
F IGURES P AGE
Support Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

“4069RT” Service and Parts ManualMarch 2014
Page II
M ACHINE S PECIFICATIONS
4069RT
Working Height* 46 ft 14 m
Platform Height 40 ft 12 m
Maximum Drive Height 40 ft 12 m
Stowed Height Top Guardrail 95.5 in. 2.43 m
Rails Folded 64 in. 1.63 m
Platform Floor 51 in. 1.3 m
Guardrail Height 43.5 in. 1.11 m
Toeboard Height 6 in. 15 cm
Machine Weight** (Unloaded) 11,000 lb 4,990 kg
Lift Capacity Total 900 lb 410 kg
Platform 600 lb 274 kg
Sheet Material Rack 300 lb 136 kg
Deck Extension Capacity 1 Person / 250 lb (113 kg)
Maximum Occupants 2
Length-Stowed (Overall) 126 in. 3.2 m
Length-Stowed (Without Step) 125 in. 3.18 m
Length-Stowed, with optional Outriggers 145 in. 3.64 m
Platform Length (Extended) 166 in. 4.22 m
Platform Length (Retracted) 118 in. 3 m
Width (Overall) 69 in. 1.75 m
Platform Width (Outside) 59 in. 1.5 cm
Sheet Rack Width 7 in. 18 cm
Wheel Base 94.5 in 2.4 m
Turning Radius--Inside 79 in. 2 m
Ground Clearance 10 in 25 cm
Drive Speed (Proportional) Platform Stowed 0-3.4 mph 0-5.5 km/h
Platform Elevated† 0-.5 mph max.† 0-.8 km/h max.†
Gradability 40%/21.8°
Breakover Angle 42%/23°
Optional Outrigger Range Of Motion 10° side to side
Maximum Ground Pressure, Wheel 123 psi 8.6 kg/cm2
Maximum Ground Pressure, Outrigger Pad 56 psi 3.9 kg/cm2
Maximum Wheel Load 3540 lb 1605 kg
Maximum Operating Wind Speed 28 mph / 12.5 m/sec (45 km/h)
Tire Size 26" x 12" / 66 cm x 33 cm
Tire Pressure 55 psi
Wheel Bolt Torque 55 ft/lb 74.6 Nm
Hydraulic Pressure Drive System 3500 psi/ 240 bar
Lift System 3200 psi / 220 bar
Hydraulic Fluid Capacity 14 gal / 53 liter
System Voltage 12 Volt DC
Fuel Capacity 15 gal/ 57 liter
Battery Type 31 1000CCA
Engine Diesel -- Kubota D1105 24.8 HP (18.8 kW) Tier 4
Dual Fuel -- Kubota DF752, 20HP (14.9 kW)
Meets applicable requirements of ANSI A92.6-2006.
*Working Height adds 6 feet (2 m) to platform height. **Weight may increase with certain options.
†Drive speed while elevated is inversely proportional to platform height; the higher the platform is, the
lower the maximum elevated drive speed. The machine is driveable at full height.

“4069RT” Service and Parts Manual March 2014
Page III
MEC O PERATOR P OLICY
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 warn-
ings and instructional decals on the body of the machine, at the ground controls, and
platform control console.
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 relent-
less ongoing efforts towards Continuous Improvement, due to which product specifica-
tions are subject to change without notice.
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.
MEC, as manufacturer, has no direct control over machine application and opera-
tion. Proper safety practices are the responsibility of the user and all operating
personnel.
If there is a question on application and/or operation contact:
MEC Aerial Work Platform
1401 S. Madera Avenue
Kerman, CA 93630 USA
Ph: 1-800-387-4575
www.mecAWP.com

“4069RT” Service and Parts ManualMarch 2014
Page IV
S AFETY S YMBOLS
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” without alert symbol indicates a situation which, if not avoided, may
result in property damage.