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.

“4069RT” Service and Parts Manual March 2014
Page V
G ENERAL S AFETY T IPS
Regular inspection and conscientious maintenance is the key to efficient economical oper-
ation of your aerial work platform. It will help to assure that your equipment will perform
satisfactorily with a minimum of service and repair.
The actual operating environment of the machine governs the inspection schedule. Cor-
rect lubrication 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 mechanical failure and resulting downtime is reduced to a minimum.
• Never leave hydraulic components or hoses open. They must be protected from contamina-
tion (including 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 lubricants 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.
M AINTENANCE L OCK
DEATH OR SERIOUS INJURY HAZARD!
NEVER PERFORM WORK OR INSPECTION ON THE MACHINE WITH THE
PLATFORM ELEVATED WITHOUT FIRST BLOCKING THE SCISSOR ASSEMBLY
WITH THE MAINTENANCE LOCK.
Figure 1-1: Support Platform
To set the Maintenance Lock, raise the
platform enough to allow the Maintenance
Lock to rotate to vertical. Carefully lower
the platform until the pin above rests
securely on the Maintenance Lock.
ART_4283

“4069RT” Service and Parts ManualMarch 2014
Page VI
H YDRAULIC S YSTEM
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.
E LECTRICAL S YSTEM
Prevent damage to battery and/or electrical system;
• Always disconnect the negative battery cable first.
• Always connect the positive battery cable first.
When the negative cable is installed, a spark will occur if contact is made between the
positive side of the battery and a metal surface on the machine. This can cause damage
to the electrical system, battery explosion, and personal injury.
T OTAL S YSTEM
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 AERIAL WORK PLATFORM.
INSPECTION AND MAINTENANCE SHOULD BE PERFORMED BY QUALIFIED
PERSONNEL FAMILIAR WITH THE EQUIPMENT.

“4069RT” Service and Parts Manual March 2014
Page VII
P RIMARY M ACHINE C OMPONENTS
Figure 1-2: Component Locations
ART_4403
Controls
Module
Module Coversremoved for clarity
Platform
Controls
Platform
Deck
Extension
Lift Cylinders
Chassis
Entry Gate
Hydraulic Tank
Lower Controls
Battery
Disconnect
Switch
Battery
Hydraulic Manifold
Entry Ladder
Engine
Air Filter
Hydraulic
Pump
Fuel
Tank
Maintenance
Lock
Sheet
Materials
Rack

“4069RT” Service and Parts ManualMarch 2014
Page VIII
T ORQUE S PECIFICATIONS
F ASTENERS
Use the following values to apply torque unless a specific torque value is called out for
the part being used.
H YDRAULIC C OMPONENTS T ORQUE T ABLE
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:
• parts drawings and service instructions in this manual.
• packaging and instruction sheets provided with new parts.
• instruction manuals provided by the manufacturer of the component being serviced.
SAE GRADE
TORQUE
FT. LBS
MIN MAX
TORQUE
Nm
MIN MAX
FT. LBS
MIN MAX
Nm
TORQUE
FT. LBS
TORQUE
Nm FT. LBS Nm
MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX
CAP SCREW
SIZE
- millimeters-
CAP SCREW
SIZE
- inches -
58 METRIC GRADE 8.8 10.9
8.8 10.9
1/4 - 20 6.25
8
14
17.5
26
31
41
51
65
76
95
111
126
152
238
274
350
407
537
670
7.25
9
15
19
28
34
45
55
72
84
105
123
139
168
262
302
386
448
592
740
8.5
11
19
23
35
42
55.5
69
88
103
129
150
171
206
322
371
474
551
728
908
10
12
20
26
38
46
61
74.5
97.5
114
142
167
188
228
255
409
523
607
802
1003
8.25
10.5
18.5
23
35
41
55
68
86
102
127
148
168
203
318
365
466
543
716
894
9.5
12
20
25
37
45
60
75
96
112
140
164
185
224
350
402
515
597
790
987
11
14
25
31
47.5
55.5
74.5
92
116
138
172
200
228
275
431
495
631
736
970
1211
13
16
27
34
50
61
81
102
130
152
190
222
251
304
474
544
698
809
1070
1137
M6 X 1.00
M8 X 1.25
M10 X 1.50
M12 X 1.75
M14 X 2.00
M16 X 2.50
M18 X 2.50
M20 X 2.50
M22 X 2.50
M24 X 3.00
M27 X 3.00
M3 X 3.00
6
16
29
52
85
130
172
247
332
423
637
872
8
20
35
62
103
158
210
301
404
517
779
1066
8
21.5
39
70
115
176
233
335
450
573
863
1181
11
27
47
84
139
214
284
408
547
700
1055
1444
9
23
42
75
120
176
240
343
472
599
898
1224
11
27
52
91
146
216
294
426
576
732
1098
1496
12
31
57
102
163
238
325
465
639
812
1217
1658
15
36.5
70
123
198
293
398
577
780
992
1488
2027
1/4 - 28
5/16 - 18
5/16 - 24
3/8 - 16
3/8 - 24
7/16 - 14
7/16 - 20
1/2 - 13
1/2 - 20
9/16 - 12
9/16 - 18
5/8 - 11
5/8 - 18
3/4 - 10
3/4 - 16
7/8 - 9
7/8 - 14
1 - 8
1 - 14
Torque valuesapply to fasteneersasreceived
from the supplier, dry or when lubricated with
normal engine oil.
If special graphite grease, molydisulphide
grease, or other extreme pressure lubricants
are used, these torque valuesdo not apply.
AMERICAN STANDARD CAP SCREWS METRIC CAP SCREWS
TYPE: SAE PORT SERIES CARTRIDGE POPPET FITTINGS HOSES
FT. LBS Nm
#4
#6
#8
#10
#12
#16
N/A
N/A
25 - 30
35 - 40
85 - 90
130 - 140
N/A
N/A
31 - 41
47 - 54
115 - 122
176 - 190
FT. LBS Nm
N/A
10 - 20
25 - 30
35 - 40
85 - 90
130 - 140
N/A
14 - 27
34 - 41
47 - 54
115 - 122
176 - 190
FT. LBS Nm
135 - 145
215 - 245
430 - 470
680 - 750
950 - 1050
1300 - 1368
15 - 16
24 - 28
49 - 53
77 - 85
107 - 119
147 - 155

“4069RT” Service and Parts Manual March 2014
Page IX
E MERGENCY S YSTEMS AND P ROCEDURES
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.
E MERGENCY S TOP
Figure 1-3: Emergency Stop Buttons
The machine is equipped with an EMERGENCY STOP
switch at the base controls and at the platform control box.
• Press the EMERGENCY STOP switch at any time to stop all
machine functions.
• Turn switch clockwise to reset.
S ELECTOR S WITCH SET TO PLATFORM
• Either switch will stop all machine functions.
• Both switches must be reset or machine will not operate.
S ELECTOR S WITCH IS SET TO BASE
• The upper controls are locked out.
• The lower controls switch must be reset or the machine will
not operate.
• The machine will not operate from the lower controls if the upper controls switch is tripped.
ART_3817
ART_3866

“4069RT” Service and Parts ManualMarch 2014
Page X
E MERGENCY L OWERING
IF THE CONTROL SYSTEM FAILS WHILE THE PLATFORM IS ELEVATED,
USE THE EMERGENCY LOWERING PROCEDURE TO SAFELY LOWER THE
PLATFORM.
DO NOT CLIMB DOWN THE ELEVATING ASSEMBLY OR EXIT THE PLATFORM.
Figure 1-4: Emergency Lowering
The Emergency Lowering
System is used to lower the
platform in case of power
failure.
To lower the platform, push
down on the Emergency
Lowering Switch, located
on the Base Control panel.
ART_4281

“4069RT” Service and Parts Manual March 2014
Page XI
F REE -W HEEL C ONFIGURATION F OR W INCHING OR T OWING
RUNAWAY HAZARD!
AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP MACHINE
TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES.
ALWAYS CHOCK THE WHEELS BEFORE MANUALLY RELEASING THE BRAKES.
The machine can be winched or towed short distances at speeds not to exceed 5 MPH
(8 km/h). Before towing or winching the machine, it is necessary to release the brakes.
Reset the brakes after towing or winching.
D ISENGAGE B RAKES BEFORE T OWING OR W INCHING
• Chock the wheels.
• Press and hold the Brake Release Valve, then slowly press the Hand Pump button on the
Functions Manifold repeatedly until the brakes release (normally 8-10 full pump strokes).
E NGAGE B RAKES BEFORE D RIVING
The brakes reset automatically when the motor is started.
The brakes may be manually applied by pulling the Brake Release Valve out.
BE SURE THAT THE BRAKES ARE ENGAGED BEFORE REMOVING THE WHEEL
CHOCKS.
ART_4293
Hand Pump
Release
Valve

“4069RT” Service and Parts ManualMarch 2014
Page XII
L IFT AND S UPPORT THE M ACHINE
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.
The following are needed to safely lift and support the machine;
• a jack with a lifting capacity of three (3) tons or more.
• jack stands with a rating of three (3) tons or more.
T O RAISE THE MACHINE
1. Move machine to a firm level surface capable of supporting the weight of the
machine.
2. Chock tires on one end of machine and raise the other end of machine.
3. If wheel is to be removed, break loose but do not remove the lug bolts before raising
the machine.
4. Position a jack at the end of the machine to be lifted, under a solid lifting point in the
center of the frame.
5. Raise the machine and place two (2) suitable jack stands under solid support points
at the outer ends of the frame.
6. Lower the machine to rest on the jack stands and inspect for stability.
T O LOWER THE MACHINE
1. Tighten lug bolts to proper torque (refer to machine specifications).
2. Raise machine slightly and remove jack stands.
3. Lower the machine and remove the jack.
4. Remove chocks.

“4069RT” Service and Parts Manual March 2014
Page 1-1
Section 1
H YDRAULIC S YSTEM
C ONTENTS P AGE
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

“4069RT” Service and Parts ManualMarch 2014
Page 1-2
F IGURES P AGE
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Hydraulic Pump Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Functions Manifold - Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Adjustable Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
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
Typical Cylinders, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25