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Mec 2633ES User Manual

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SERVICE AND PARTS MANUAL
Part # 90769 R4
October 2008
2033ES / 2633ES
Serial Number Range
2033ES: 8804000 - Present
2633ES: 11100000 - Present

Table of Contents

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Mec 2633ES Specifications

General IconGeneral
DriveElectric
Max. Platform Height26 ft
Drive Motor24V DC
Overall Width33 in
Platform Width33 in
Tire TypeNon-marking

Summary

Service And Parts Manual MEC 2033ES 2633ES

Introduction

General Safety Tips

Essential guidelines for safe operation and maintenance of the scissor lift.

Section 1: Hydraulic System

Section 3: Mechanical

Torque Specifications

Recommended torque values for fasteners and hydraulic components during assembly.

Section 4: Troubleshooting

General Troubleshooting Tips

Basic guidelines and common causes for system malfunctions and troubleshooting steps.

Hydraulic Pressure Adjustment Procedures

Steps for checking and adjusting hydraulic pressure relief valves for optimal performance.

Sevcon Motor Speed Controller

Information on the Sevcon controller, including flash codes and diagnostic definitions.

Troubleshooting Battery Charger

Guide to diagnosing and resolving issues with the battery charger unit.

Section 5: Schematics

Hydraulic Schematics

Diagrams illustrating the hydraulic systems for different serial number ranges and models.

Electric Schematics

Diagrams showing the electrical wiring and connections for the machine's systems.

Section A: Control Boxes

Introduction Safety Signals and Warnings

DANGER Warning

Explanation of the DANGER signal indicating an imminently hazardous situation.

WARNING Warning

Explanation of the WARNING signal indicating a potentially hazardous situation.

CAUTION Warning

Explanation of the CAUTION signal indicating a potentially hazardous situation or property damage.

General Safety Tips

Critical Maintenance Safety

Essential safety instruction to always use the maintenance lock when the platform is elevated.

Hydraulic System Warnings

Hydraulic Fluid Pressure Hazard

Warning about the dangers of high-pressure hydraulic fluid penetrating skin or causing eye injury.

Electrical System Safety

Battery Connection Safety

Precautions for connecting and disconnecting battery cables to prevent sparks and explosions.

Machine Specifications

Primary Machine Components

Lubrication

Hydraulic Fluid

Hydraulic System Components

Parking Brake and Towing Circuit

Release Brakes Before Towing

Step-by-step instructions for releasing the parking brakes to allow towing the machine.

To Reset Brakes

Procedure for resetting the parking brakes after towing or releasing them.

Emergency Systems and Procedures

Emergency Lowering - Early Models

Steps for lowering the platform using the emergency system on early model units.

Emergency Lowering - Current Models

Procedure for operating the emergency down system on current model units.

Steering Circuit

Platform Lift Circuit

Cylinder Repair

Hydraulic Manifold

Section 2: Electrical System

Batteries

Information on the battery system, maintenance, charging, and replacement procedures.

Alarms and Switches

Description of various alarms, switches, and controls on the machine, including emergency stops and selectors.

Electrical System - General

Deutsch Connectors

Batteries

Battery Maintenance (in storage)

Procedures for maintaining batteries when the machine is not in use, including cleaning and charging.

Battery Maintenance (in use)

Battery Preventative Maintenance

Steps for performing preventative maintenance on batteries in use, including checking specific gravity.

Battery Charging

Main Electrical Power

Guidelines for connecting the charger to AC power and understanding its automatic operation.

Charging State & LED Display

Explanation of the LED indicators that display the battery charging status and identify potential faults.

Battery Replacement

Main Electrical Power

Safety procedures for disconnecting power and removing/installing batteries from the machine.

Alarms and Switches

Emergency Stop Button

Location and function of emergency stop buttons on both control stations and their operation.

Selector Switch

Movement Alarm

Operation of the movement alarm, which activates when the joystick is moved from the neutral position.

Tilt Alarm

Tilt Alarm Visual

Warning light on the platform console indicating an unsafe angle for the machine.

Tilt Alarm Test

Procedure for testing the tilt alarm's functionality using the "Push-To-Test" feature.

Tilt Alarm Sensor Adjustment

Steps for adjusting the tilt sensor to ensure the chassis is level for accurate readings.

Limit Switch

Continuity Checks

Diode Board

Sevcon Motor Speed Controller

Cable Connection Identification

Identification and description of the cables connected to the Sevcon motor speed controller.

J5 Plug Pin Identification

Pinout and function details for the J5 plug on the Sevcon motor speed controller.

Section 3: Mechanical Components

Torque Specifications

Fasteners Torque Values

Torque values for various SAE and Metric cap screws used in assembly and maintenance.

Hydraulic Components Torque Values

Torque values for installing hydraulic fittings and hoses, with lubrication advice.

Mechanical Components

Raising the Machine

To Raise the Machine

Detailed steps for safely raising the machine using a jack and jack stands.

To Lower the Machine

Instructions for safely lowering the machine after it has been raised for maintenance.

Tires/Wheels

Changing Tires/Wheels

Step-by-step procedure for safely changing tires/wheels, including loosening lug nuts and torque specifications.

Front Drive Motors

Rear Wheel Brakes

Steer Cylinder

To Replace Steer Cylinder

Detailed instructions for replacing the steer cylinder, including disconnecting hoses and purging air.

Pothole Circuit

Platform Removal

Lift Cylinder Removal and Installation

CAUTION: Attach Lifting Device to Cylinder Body

Crucial safety warning regarding lifting the cylinder by its body to prevent rod extension.

Scissor Beam Assembly

General Troubleshooting Tips

Common Causes of Hydraulic System Malfunctions

Identifies common issues like fluid contamination, incorrect fluid, and water ingress affecting hydraulic performance.

Hydraulic Pressure Adjustment Procedures

Check and Adjust Pressure (except counterbalance)

Procedure for setting main system, lift, and steering pressures according to the specified table.

Setting Counterbalance Valves

Check and Adjust Pressure (counterbalance)

Procedure for checking and adjusting counterbalance valve pressure settings.

Troubleshooting

General Loss of Power

Common causes and solutions for complete loss of power to the control stations.

Lower Controls Functional, Upper Controls Not

Troubleshooting steps for issues where lower controls function but upper controls do not.

Lift Function Issues

Diagnostic guide for problems related to the lift function, including intermittent or partial lift.

Troubleshooting (continued)

Lift Function Issues (Continued)

Further troubleshooting for lift issues, including no lift with pump motor running or not operating.

Drive System Issues

Troubleshooting guide for drive system issues, including no drive, reduced speed, or sluggishness.

Platform Will Not Lower

Diagnostic steps for the platform not lowering, including maintenance lock and valve issues.

LED Diagnostics Definitions (Flash Codes)

LED Flashes 2-5

Diagnosis of LED flash codes from 2 to 5, indicating procedure, motor circuit, or contactor issues.

LED Diagnostics Definitions (continued)

LED Flashes 6-9

Diagnosis of LED flash codes from 6 to 9, covering accelerator, battery voltage, and thermal cutback issues.

Sevcon Motor Speed Controller - Connections

Sevcon Motor Speed Controller - Connections (continued)

Troubleshooting Battery Charger

Charger Safety Precautions

Important safety warnings regarding electrical shock, fire hazards, and disassembly of the charger.

Troubleshooting Battery Charger (continued)

LED Status Description

Table explaining the meaning of different LED blinking patterns on the battery charger indicating faults or warnings.

Charger does not turn ON

Potential causes and solutions when the battery charger fails to power on.

All 3 LEDs blink ONCE simultaneously

Diagnosis for output connection errors, including battery connections and polarity issues.

All 3 LEDs blink TWICE simultaneously

Troubleshooting steps for AC input voltage being outside the acceptable tolerance range.

All 3 LEDs blink THREE TIMES simultaneously

Diagnosis for charger overheating and recommended actions to correct the issue.

All 3 LEDs blink FOUR TIMES simultaneously

Troubleshooting for input or output over current conditions that may affect charger operation.

100% LED blinks while 50% and 75% LEDs are “OFF”

Diagnosis for the 18-hour timer elapsing and stopping charge, indicating weak batteries or incorrect pack size.

Hydraulic Schematics

Hydraulic Schematic

Hydraulic Manifold - early style

Hydraulic Manifold - current style

Electric Schematics

Electric Schematic

Component Locations

Controller Plug Pin Identification

J1 Plug Pin Identification

Diagram identifying the pins and functions of the J1 plug on the circuit board.

Parts Section Table of Contents

Section C: Scissors

Table of contents for the scissors section, covering scissor assemblies and lift cylinder components.

Section D: Hydraulics

Contents of the hydraulics section, including manifolds, reservoirs, and hoses.

Section E: Base

Table of contents for the base section, covering covers, ballast, brakes, and motors.

Section B: Platform and Rails

Section C: Scissors

Scissor Assembly, 2033ES

Scissor Assembly - 2033ES, Serial # Up to 8804199

Scissor Assembly - 2033ES, Serial # 8804200 - Up

Scissor Assembly, 2633ES

Scissor Assembly - 2633ES, Serial # Up to 11100999

Scissor Assembly - 2633ES, Serial # 11101000 -Up

Scissor Mounting Detail, X33ES

Cylinder Mounting Detail

90637 Hydraulic Cylinder

Lift Cylinder, 90637

90802 Hydraulic Clyinder

Lift Cylinder, 90802 Without Emergency Lowering Cable

Lift Cylinder with Emergency Lowering Cable and Bell Crank Assembly

Lift Cylinder and Emergency Lowering Cable w/ Bell Crank

Lift Cylinder with Emergency Lowering Cable

Lift Cylinder and Emergency Lowering Cable, w/o Bell Crank

Section D: Hydraulics

Brake Release Manifold, Early Models

Main Manifold Assembly, Early Models

Main Manifold Assembly, Late Models

Hydraulic Reservoir, Steel

Hydraulic Reservoir, Plastic

Hydraulic Hoses, Early Models

Hydraulic Hoses, Late Models

Section E: Base

Brake Assembly

Front Axle

Front Axle (Continued)

Steering Components

Hydraulic Pump Assembly

Pothole Assembly

Wheel Motor

Battery Installation

Battery Charger

Section F: Decals

Service Parts Order Form

Limited Owner Warranty

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