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Mec 60-J Diesel Service & Parts Manual

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Service & Parts Manual
60-J Diesel
ART_4883
Serial Number Range
Part # 94047 R2
14400001 - Up
April 2018

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Summary of Contents for Mec 60-J Diesel

  • Page 1 Service & Parts Manual 60-J Diesel ART_4883 Serial Number Range Part # 94047 R2 14400001 - Up April 2018...
  • Page 2 Continuous Improvement Update April 2019 Added Bracket to Main Boom Component MEC Aerial Work Platforms 1401 S. Madera Avenue, Kerman, CA 93630 USA Toll Free: 1 - 877 - 632 - 5438 Phone: 1 - 559 - 842 - 1500 Fax: 1 - 559 - 842 - 1520 info@MECawp.com...

  • Page 3: Table Of Contents

    Service Introduction ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Section 1 - MEC Operator Policy ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ MEC Operator Polcy ������ ������ ������...
  • Page 4 Aprl 2019 Battery Replacement ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ 37 Section 12 - Controls ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������...
  • Page 5 Aprl 2019 Calbraton Related Messages������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Interlock Messages ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Other Messages ������...
  • Page 6 Aprl 2019 Man Functons Manfold Fttngs -- Seral #14400127~ ������ ������ ������ ������ ������ ������ ������ ������ ������ Man Functons Manfold Block Components -- Seral #14400127~ ������ ������ ������ ������ ������ ������ Brake/Axle/2-Speed Manfold ������ ������ ������ ������ ������ ������ ������...

  • Page 7: Chapter 1 - Service

    All parts represented here are manufactured and supplied in accordance with MEC quality standards. We recommend that you use genuine MEC parts to ensure proper operation and reliable performance. To obtain maximum benefits from your MEC Aerial Work Platforms, always follow the proper operating and maintenance procedures.

  • Page 8: Section 1 - Mec Operator Policy

    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.

  • Page 9: Section 2 - Safety Symbols & General Safety Tips

    Safety Symbols & General Safety Tips Safety Symbols & General Safety Tips MEC manuals and decals use symbols, colors and signal words to help you recognize important safety, operation and maintenance information. RED and the word DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury������...

  • Page 10: Section 3 - Specifications

    Meets applicable requirements of ANSI A92.5-2006 and CSA B354.4-2002. Allowable ambient temperature range: -20° F to 120° F (-29° C to 49°C). Consult with MEC for operation outside of this range. *Working Height adds 6 feet (2 m) to platform height.

  • Page 11: Section 4 - Torque Specifications

    Secton 4 - Torque Specfcatons Aprl 2019 Bolt Torque Specification - American Standard Bolt Torque Specification - American Standard Use the following values to apply torque unless a specific torque value is called out for the part being used. American Standard Cap Screws SAE Grade Cap Screw Torque...

  • Page 12: Bolt Torque SpecFCatOn - MetrC Standard

    Secton 4 - Torque Specfcatons Aprl 2019 Bolt Torque Specification - Metric Standard Use the following values to apply torque unless a specific torque value is called out for the part being used Metric Cap Screws Metric Grade 8������ 8 10������...

  • Page 13: HydraulC Components Torque Table

    Secton 4 - Torque Specfcatons Aprl 2019 Hydraulic Components Torque Table 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.

  • Page 14: Section 5 - Boom Support

    Secton 5 - Boom Support Aprl 2019 Boom Support Boom Support Supporting The Boom Assembly NEVER PERFORM WORK UNDER THE BOOM ASSEMBLY WITH THE PLATFORM ELEVATED WITHOUT FIRST SUPPORTING THE BOOM ASSEMBLY������ DO NOT work beneath the boom assembly with the platform elevated unless the boom assembly is properly supported.

  • Page 15: Section 6 - Hydraulic, Electrical & Total System

    Secton 6 - Hydraulc, Electrcal & Total System Aprl 2019 Hydraulic, Electrical and Total System Hydraulic, Electrical and Total System 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������...

  • Page 16: Section 7 - Primary Machine Components

    Secton 7 - Prmary Machne Components Aprl 2019 Primary Machine Components Primary Machine Components Platform Platform Controls Swing Gate Boom Lift Gate Engine Module Engine Controls Module Fuel Tank Turntable Hydraulic Tank Base Controls Chassis ART_4708 Page 10 60-J Desel - Servce & Parts Manual...

  • Page 17: Emergency Systems And Procedures

    Secton 8 - Emergency Systems And Procedures Aprl 2019 Emergency Systems And Procedures 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 ELEVATING ASSEMBLY������...
  • Page 18 Secton 8 - Emergency Systems And Procedures Aprl 2019 Auxiliary Power System & Test IF PRIMARY POWER FAILS WHILE THE PLATFORM IS ELEVATED, USE THE AUXILIARY POWER SYSTEM TO SAFELY LOWER THE PLATFORM������ DO NOT CLIMB DOWN THE BOOM ASSEMBLY OR EXIT THE PLATFORM WHILE ELEVATED������...

  • Page 19: LFt And Support The MachNe

    Secton 9 - Transportng and Lftng Instructons Aprl 2019 Lift And Support The Machine Lift And Support The Machine 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������...

  • Page 20: TransportatOn InstructOns

    THIS SECTION IS PROVIDED FOR REFERENCE AND DOES NOT SUPERSEDE ANY GOVERNMENT OR COMPANY POLICY REGARDING THE LOADING, TRANSPORT OR LIFTING OF MEC MACHINERY������ TRUCK DRIVERS ARE RESPONSIBLE FOR LOADING AND SECURING MACHINES, AND SHOULD BE PROPERLY TRAINED AND AUTHORIZED TO OPERATE MEC MACHINERY������...

  • Page 21: DrVNg Or WNchNg Onto Or Off Of A Transport VehCle

    Secton 9 - Transportng and Lftng Instructons Aprl 2019 Driving Or Winching Onto Or Off Of A Transport Vehicle Before loading the machine, orient the turntable so that the platform is over the nonsteering wheels so that the Rotation Lock may be engaged later in the loading process. ONLY PROPERLY TRAINED AND QUALIFIED OPERATORS SHALL LOAD AND UNLOAD THIS MACHINE������...
  • Page 22 Secton 9 - Transportng and Lftng Instructons Aprl 2019 Securing To Truck Or Trailer For Transport • Turn the key Selector Key Switch to OFF and remove the key before transport. • Turn the Battery Disconnect Switch to OFF before transport. •...
  • Page 23 Secton 9 - Transportng and Lftng Instructons Aprl 2019 Loading Two Machines Two machines may be loaded onto a single trailer by rotating the turntable of each machine and rotating the platforms as shown below. ART_4748 Extend the boom of each machine approximately 15 inches (38 cm). Arrange the machines as shown.

  • Page 24: HydraulC System - General

    Secton 10 - Hydraulc System Aprl 2019 Hydraulic System – General Hydraulic System – General The hydraulic system is designed to control all or part of machine functions by integrating various hydraulic cartridge valves into three manifolds to provide directional, pressure, flow, and load control. The hydraulic system is a feedback, load-sensing type.
  • Page 25 Secton 10 - Hydraulc System Aprl 2019 Hydraulic Roadmap Hydraulic Reservoir • Hydraulic fluid is held in the reservoir for delivery to the pumps and is returned to the reservoir after use. Returning hydraulic fluid is routed through a filter before entering the reservoir. The reservoir also serves as the oil cooling device.
  • Page 26 Secton 10 - Hydraulc System Aprl 2019 Steer Cylinders • This machine has two Steer Cylinders that control the angle of the steerable wheels. • Steering is not self-centering. Boom Lift Cylinders • Two hydraulic lift cylinders raise and lower the boom assembly. Boom Extend Cylinder •...

  • Page 27: HydraulC FluD

    FLUID LEAKS UNDER PRESSURE MAY NOT ALWAYS BE VISIBLE������ Fluid Recommendations MEC recommends only the use of the Chevron hydraulic fluids listed in the chart below, and each only in the operating temperatures listed in the chart. Do not substitute other fluids as pump damage may result, and use only the fluid appropriate to the ambient operating temperature.
  • Page 28 Secton 10 - Hydraulc System Aprl 2019 complete cycles may be necessary to purge all air from Boom Lift and Boom Extend cylinder(s). When the above procedures have been completed, lower the platform to the stowed position, then fill hydraulic reservoir to the full mark on sight gauge. Check for leaks and correct as necessary.

  • Page 29: HydraulC Pumps

    Secton 10 - Hydraulc System Aprl 2019 Hydraulic Pumps Note: Refer to Parts Section 25. An internal combustion engine drives the Drive and Functions Pumps. The Drive Pump is a variable displacement axial piston pump that provides hydraulic power to the Drive Motors.
  • Page 30 To prime the pump, loosen the output hose fittings at the hydraulic pumps to flood with hydraulic fluid. Tighten fittings. Drive Pump Service MEC does not recommend end-user maintenance or repair of the Drive Pump on the 60-J machines. Contact MEC or Rexroth for the nearest service provider. Functions Pump The Functions Pump is a fixed-displacement gear pump.

  • Page 31: HydraulC ManFolds

    Secton 10 - Hydraulc System Aprl 2019 Hydraulic Manifolds Note: Refer to Parts Section 25. This machine has three hydraulic valve manifolds: the Main Functions Manifold, the Brake/Axle/2- Speed Manifold and the Boom Functions Manifold. Additional hydraulic manifolds include the Brake and Steering junction blocks at the steering end of the chassis and the Rotary Manifold provides hydraulic connection between the turntable and chassis and allows continuous rotation of the turntable.
  • Page 32 Before attempting to check and/or adjust pressure relief valves, operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid to normal operating temperature. Insert a 0-5000 psi gauge onto the appropriate pressure test port GP using gauge adapter fitting MEC part no. 50974...

  • Page 33: AdjustNg RelEf Valves

    Secton 10 - Hydraulc System Aprl 2019 Adjusting Relief Valves Gauge Port Boom Extend Relief Valve 10 Steering Cross Port Steering Cross Port Relief Valve 3.2 Relief Valve 3.1 Main Relief Valve 6 ART_4888 System pressures should be checked and adjusted during routine maintenance to ensure proper machine performance Counterbalance Valves The counterbalance valves located on many of the cylinders are set by the manufacturer and should...
  • Page 34 Secton 10 - Hydraulc System Aprl 2019 The Steering Cross Port Relief Valves (3.1 and 3.2) should be set to 1500 psi (103 bar). • Insert a 0-5000 psi gauge into the port GP of the Main Functions Manifold. • Loosen the lock nuts on Steering Cross Port Relief Valves 3.1 and 3.2 on the Main Functions Manifold.

  • Page 35: Wheel Motor Startup Procedure

    Start the engine and allow it to run for one minute, then test the Drive Function for proper operation. Repair MEC does not recommend end-user maintenance or repair of the drive motors. Contact MEC for the nearest service provider or replacement. Page 29...

  • Page 36: General CylNder RepaR

    Secton 10 - Hydraulc System Aprl 2019 General Cylinder Repair WHEN REMOVING ANY HYDRAULIC CYLINDER, ENSURE THAT THE COMPONENTS IT SUPPORTS ARE THEMSELVES SECURELY SUPPORTED PRIOR TO BEGINNING ANY REMOVAL������ CYLINDERS ARE HEAVY������ SUPPORT CYLINDERS BEFORE REMOVING HARDWARE THAT SECURES THE CYLINDER TO THE MACHINE������ Return to Tank Piston Seals...
  • Page 37 Secton 10 - Hydraulc System Aprl 2019 DO NOT overtighten the vise������ Overtightening may damage the cylinder������ Cylinder Disassembly Remove solenoid valves or counterbalance valves, if the cylinder is equipped with them. Remove the head from the cylinder body. Remove the shaft assembly from the barrel, pulling in a straight line, so as not to scar the internal parts.
  • Page 38 Secton 10 - Hydraulc System Aprl 2019 On pistons with set screws, tighten the set screw. Grease the outside seals of the head and piston. 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.

  • Page 39: ElectrCal System - General

    Secton 11 - Electrcal System Aprl 2019 Electrical System - General Electrical System - General The electrical control system consists of lower controls located on the machine base and upper controls located on the machine platform. Emergency lowering controls are located at each control station.
  • Page 40 Secton 11 - Electrcal System Aprl 2019 Note: The Auxiliary Power System is disabled when the engine is running. The Auxiliary Power switch serves as an enable switch. It is not necessary to use the primary function enable switch. Diagnostic LED & EZ-Cal Diagnostic Tool If the machine fails to operate, inspect the GP400 Module located inside the control box.

  • Page 41: BatterEs

    Secton 11 - Electrcal System Aprl 2019 Batteries Discharged batteries can freeze, causing damage to the battery and/or battery case������ A broken battery case will allow electrolyte to leak out������ BATTERIES UNDER CHARGE CREATE EXPLOSIVE HYDROGEN GAS������ KEEP SPARKS, FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES������...
  • Page 42 Secton 11 - Electrcal System Aprl 2019 Check battery terminals for: • Corrosion: Regularly clean connections and apply a nonmetallic grease or protective spray to retard corrosion. • Loose connections: Be sure all cable connections are tightly secured, and that good contact is made with terminals.

  • Page 43: Battery Replacement

    Secton 11 - Electrcal System Aprl 2019 Battery Replacement TURN OFF THE BATTERY DISCONNECT SWITCH BEFORE REMOVING ANY BATTERY FROM THE MACHINE������ Prevent damage to the battery and/or electrical system; • Always disconnect the negative battery cable first������ • Always connect the positive battery cable first������ To Remove A Battery: Turn the Battery Disconnect switch to OFF.

  • Page 44: Section 12 - Controls

    Secton 12 - Controls Aprl 2019 Lower Controls Lower Controls ART_4824 ALWAYS CHECK OVER, UNDER AND AROUND THE MACHINE FOR PERSONNEL, STRUCTURES AND OBSTRUCTIONS BEFORE ACTIVATING ANY CONTROL FUNCTION AND CONTINUE TO WATCH FOR HAZARDS WHILE OPERATING THE MACHINE Page 38 60-J Desel - Servce &...
  • Page 45 Secton 12 - Controls Aprl 2019 CONTROL DESCRIPTION Hour Meter Indicates total elapsed time of machine operation. PLATFORM Select to operate from the platform control panel. Selector Switch BASE Select to operate from the base control panel. Select to stop operation from either control panel. Start/Stop Switch Push switch up to start engine.

  • Page 46: Platform Controls

    Secton 12 - Controls Aprl 2019 Platform Controls ART_4822 ALWAYS CHECK OVER, UNDER AND AROUND THE MACHINE FOR PERSONNEL, STRUCTURES AND OBSTRUCTIONS BEFORE ACTIVATING ANY CONTROL FUNCTION AND CONTINUE TO WATCH FOR HAZARDS WHILE OPERATING THE MACHINE Control Description Function Enable Press and hold this button to enable boom and platform operations.
  • Page 47 Secton 12 - Controls Aprl 2019 Green light illuminates when the High Capacity setting is properly engaged. To engage the High Capacity setting, retract the boom, then move the switch to the down High Capacity position. Indicator Light If the green light does not illuminate, move the switch up, retract the boom completely, (Optional) then move the switch down.

  • Page 48: Section 13 - Sensors, Relays & Alarms

    Secton 13 - Sensors, Relays & Alarms Aprl 2019 Sensors Sensors CAN-Tilt CAN-Tilt Proximity Load Cell* Switch Boom Boom Extention Retract Proximity Proximity EZ Fit Sensors** Sensor Angle Sensor EZ Fit Angle Sensor CAN-Tilt 162* CAN-Tilt 164* *Optional Overload Sensing System component **Optional High Capacity component ART_4889 Page 42...
  • Page 49 Secton 13 - Sensors, Relays & Alarms Aprl 2019 Platform Load Cell On machines equipped with the optional Overload Sensing System, there is one Load Cell sensor located between the platform mounting bracket and the platform rotator. The Load Cell senses the weight of the platform contents and stops operation of the machine if the platform is overloaded.

  • Page 50: Relays

    Secton 13 - Sensors, Relays & Alarms Aprl 2019 Relays Throttle Solenoid Starter Relay Controller Glow Plug Relay Circuit Breaker ART_4890 Engine Relays The Engine Relays are located beside the engine on the rear wall of the Engine Module. These relays reduce the current flow supplied by the GP400 Control Module.

  • Page 51: Alarms

    Secton 13 - Sensors, Relays & Alarms Aprl 2019 Alarms Tilt Alarm The Tilt Alarm is a dual-tone alarm that sounds at the Base Controls Box when the angle of the platform is outside of acceptable levels of operation (as measured by the GP400 inside the Base Controls).

  • Page 52: Deutsch Connectors

    Deutsch Connectors Deutsch Connectors Deutsch connectors used on MEC equipment are designed so that individual parts may be replaced without replacing the entire component. Special tools and detailed instructions are provided in Deutsch Connector field kits, MEC part no. 84091.

  • Page 53: Section 15 - Continuity Checks

    Secton 15 - Contnuty Checks Aprl 2019 Continuity Checks Continuity Checks Selector Switch – On-Off • Disconnect wires. Normally Normally • Connect first probe of ohm meter to common terminal. Open Closed • Connect second probe to any normally open terminal. •...
  • Page 54 Secton 15 - Contnuty Checks Aprl 2019 Toggle Momentary Switch • Disconnect wires. Normally Open • Connect first probe of ohm meter to common terminal. Common Normally Open Test top position • Connect second probe to top normally open terminal. Normally Open •...

  • Page 55: Section 16 - Control System

    Secton 16 - Control System Aprl 2019 Control System Control System The GP400 Control System uses a variety of components and sensors to maintain proper and safe operation of the machine. This machine may be sold into many different countries that require a variety of monitoring equipment.
  • Page 56 Secton 16 - Control System Aprl 2019 GP400 Calibration GP440 Module P1 P2 Upper Controls EZ-Cal Port EZ-Cal port on bottom, facing down GP440 ART_4891 Module The GP400 processor relies on angle sensor(s) to monitor platform elevation at all times. These sensors send varied voltages to the GP400 that relate directly to their respective position.

  • Page 57: Gp400 CalBratOn Procedure

    The following procedures and additional tasks detailed in Section 19 can only be performed using an EZ-Cal scan tool or optional on-board diagnostic display. If you do not have an EZ-Cal, please contact MEC to obtain one. Calibrator GP400 Control Module...
  • Page 58 Secton 16 - Control System Aprl 2019 Two calibrations must be performed for all versions of this machine: Level Sensor Calibration Height Sensor Calibration Machines equipped with the optional Overload Sensing System or optional High Capacity package must perform the following calibration: Load Calibration Pre-Calibration Setup Park the machine on an absolute flat and level surface free from overhead obstructions that will...
  • Page 59 Secton 16 - Control System Aprl 2019 Level calibration is complete. Proceed to Height Calibration. Height Sensor Calibration If not already done, perform Pre-Calibration Set-up as described in the beginning of these instructions and the Level Sensors Calibration before proceeding. With the EZ-Cal menu remaining in the Level Calibration, press ESC once until the display reads”...
  • Page 60 Secton 16 - Control System Aprl 2019 should now read “ACCESS LEVEL 2” Press the right arrow twice until the display reads “SETUPS”. Press ENTER. Press the right arrow until the display reads “LOAD SETUPS”. Press ENTER. Press the right arrow until the display reads “CALIBRATE LOAD”. Press ENTER. Follow the instructions on the EZ-Cal display through a series of lift lower cycles.

  • Page 61: FaLure Messages

    Secton 17 - Calbraton Problems Aprl 2019 Failure Messages Failure Messages Various problems can be detected by the EZ-Cal that prevent successful calibration. These problems are reported with a flashing message including an “F” code. The following descriptions are helpful in solving the problem.
  • Page 62 Secton 17 - Calbraton Problems Aprl 2019 F10:BAD HEIGHT1 F10:BAD HEIGHT2 • This message is given if the height sensor output (P8-2) is out of range at the end of the DYNAMIC lift. The height sensor output must be between 1.0V and 4.0V. Check DIAGNOSTICS/ SENSORS to see the output.
  • Page 63 • This message occurs if too many static measurements are taken during a calibration step. • In the rare event that this occurs, please call MEC for assistance. F27:BAD HEIGHT • This message indicates a problem with the height sensor output (P8-2) during the STATIC calibration phases.
  • Page 64 Secton 17 - Calbraton Problems Aprl 2019 when a 3000psi one is needed). • Check CALIBRATIONS / HEIGHT CALS; the “Height” indicates the first height at which there was insufficient difference and the “Up” and “Down” values show the loaded pressure (first) and the difference between loaded and empty pressure (second).
  • Page 65 Secton 17 - Calbraton Problems Aprl 2019 F52:NOT CALIBRATED • This message is a catch-all code which indicates an improper calibration sequence or that one of the phases of calibration was not completed. The skipped phase must be completed or the calibration sequence must be passed through in proper sequence before this message will clear.

  • Page 66: InformatOn Messages

    Secton 17 - Calbraton Problems Aprl 2019 Information Messages During calibration the following messages will be displayed. They are informational prompts only and do not indicate a failure. BUILDING TABLES • This message indicates that the STATIC measurements are being used to build calibration data - the process should take no more than 5s.
  • Page 67 Secton 17 - Calbraton Problems Aprl 2019 MEASURING # • This message is displayed when the platform is stopped during either STATIC phase, when the GP400 takes a measurement. • There will be a short delay while the machine is allowed to stabilize after movement is stopped. MUST GO DOWN! •...
  • Page 68 Secton 17 - Calbraton Problems Aprl 2019 REDO EMPTY: • This message is displayed if the EMPTY phase of load calibration has previously been completed. • Press ENTER when “NO” is displayed if there is no need to redo the EMPTY phase. •...

  • Page 69: Section 18 - Mechanical Components

    OF THE EQUIPMENT������ ON MACHINES WHERE FOAM FILLED TIRES WERE FITTED AS ORIGINAL EQUIPMENT, TIRES MUST BE REPLACED WITH EQUIVALENT SPECIFICATION TIRES AND FOAM-FILL WEIGHT������ CONTACT MEC SERVICE������ Changing Tires Refer to “Lift and Support The Machine” in Section 9 for instructions and safety precautions.

  • Page 70: Nordlock Washers

    Secton 18 - Mechancal Components Aprl 2019 Nordlock Washers Nordlock-style lock washers are used in many places on this machine. These twopiece washers have a ramped surface in the center and a splined outer surface. Since the angle of the ramps is larger than the angle of a bolt’s thread, and since the splined surfaces grip the material around them, these washers provide excellent bolt-holding capabilities.
  • Page 71 Secton 18 - Mechancal Components Aprl 2019 Platform Removal & Installation THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 72 Secton 18 - Mechancal Components Aprl 2019 Note: Load Cells are used on any machine equipped with the optional Overload Sensing System and/or the optional High Capacity Package. The Spacer Plate is used only if neither option is present. Assembly Assembly is reverse of disassembly.

  • Page 73: Platform Rotator

    Secton 18 - Mechancal Components Aprl 2019 Platform Rotator THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������ The Platform Rotator is located between the Platform and the Jib.
  • Page 74 Secton 18 - Mechancal Components Aprl 2019 Note: Load Cells are used on any machine equipped with the optional Overload Sensing System and/or the optional High Capacity Package. The Spacer Plate is used only if neither option is present. Assembly Assembly is reverse of disassembly.

  • Page 75: JB CylNder/JB Components

    Secton 18 - Mechancal Components Aprl 2019 Jib Cylinder/Jib Components THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 76 Secton 18 - Mechancal Components Aprl 2019 Remove the bolts that secure the Jib Cylinder pin to the jib. Support the end of the Jib Cylinder, then remove the pin. ART_4910 Swing the Jib Cylinder out as shown. ART_4911 Remove bolt and pin retainer for the lower pin at the front lower pivot point of the bell crank weldment.
  • Page 77 Secton 18 - Mechancal Components Aprl 2019 Assembly Assembly is reverse of disassembly. Examine all pins for signs of wear, surface imperfections, cracks or gray dust in the pivot area. Replace as necessary. Re-connect the hydraulic lines after the barrel end of the Jib Cylinder is secured. Use the Jib Lift/ Lower function to extend or retract the cylinder to proper length for assembly.

  • Page 78: Platform Level CylNder

    Secton 18 - Mechancal Components Aprl 2019 Platform Level Cylinder THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 79 Secton 18 - Mechancal Components Aprl 2019 Use the Jib Extend/ Retract function to retract the boom away from the Platform/Jib Assembly. IMPORTANT! Be sure the plates that secure the Platform Level Cylinder pin are exposed. Disconnect the hydraulic hoses that supply the Platform Level Cylinder.

  • Page 80: Boom Extend CylNder

    Secton 18 - Mechancal Components Aprl 2019 Boom Extend Cylinder THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 81 Secton 18 - Mechancal Components Aprl 2019 Wrap a sling around the cylinder base, then pull the end of the cylinder approximately 5 feet (1.5 m) out of the boom. Be careful as the end of the cylinder comes out through the access hole. ART_4931 Attach a sling to the cylinder barrel and apply slight lifting pressure with a forklift or overhead crane.

  • Page 82: Boom LFt CylNders/Boom LNkage

    Secton 18 - Mechancal Components Aprl 2019 Boom Lift Cylinders/Boom Linkage THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 83 Secton 18 - Mechancal Components Aprl 2019 Main Boom Assembly Rig slings and a spreader bar from the Main Boom Assembly to an overhead hoist as shown. Apply Block slight lifting pressure. Place a 4x4 inch (10x10 cm) block between the ART_4934 Upper Lift Cylinder and Lower Boom as shown.
  • Page 84 Secton 18 - Mechancal Components Aprl 2019 Place a 4x4 inch (10x10 cm) block between the Tension Link and the upper portion of the turntable weldment. Rig a sling from the Upright Post to an overhead hoist Upright Post through the tear-drop shaped hole as shown. Apply slight lifting pressure.
  • Page 85 Secton 18 - Mechancal Components Aprl 2019 Lower Lift Cylinder Rig slings from the Lower Lift Cylinder to an overhead hoist as shown. Apply slight lifting pressure. Disconnect the hydraulic hoses and control wiring connected to the Upper Lift Cylinder. Remove the pin at the barrel end of the Lower Lift Cylinder.

  • Page 86: MaN Boom Assembly

    Secton 18 - Mechancal Components Aprl 2019 Main Boom Assembly THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 87 Secton 18 - Mechancal Components Aprl 2019 Assembly The boom must be properly shimmed to function correctly. Each boom section must be shimmed to a clearance no greater than 0.030” (0.762mm) at its tightest point of travel. It may be necessary to run each boom section in and out several times to properly identify the tightest point of travel, and to adjust the number of shims.
  • Page 88 Secton 18 - Mechancal Components Aprl 2019 Use an overhead hoist of forklift to position the End Section of the boom in front of the Base Section. Base Section With wearpads and shims in place, insert the End Section into the Base Section of the boom. End Section Keeping the sections as parallel as possible, slide External...
  • Page 89 Secton 18 - Mechancal Components Aprl 2019 Swing Bearing/Turntable Components THIS PROCESS REQUIRES SPECIFIC REPAIR SKILLS AND EXPERIENCE, APPROPRIATE LIFTING EQUIPMENT AND A PROPER WORKPLACE������ DEATH, SERIOUS INJURY OR SIGNIFICANT MACHINE DAMAGE COULD OCCUR IF YOU ATTEMPT THIS PROCESS WITHOUT THE APPROPRIATE SKILLS AND EQUIPMENT������...
  • Page 90 Secton 18 - Mechancal Components Aprl 2019 Disconnect the hydraulic hoses connected to the Swing Drive. Rig slings from the Swing Drive to an overhead hoist as shown. Swing Drive Remove the bolts securing the Swing Drive. Remove the Swing Drive from the Control Module. Note: Swing Drive Mass: 130 LBS 59 KG...
  • Page 91 Assembly to the Swing Bearing. ART_4946 THE WASHERS USED ON THESE BOLTS ARE HARDENED STRUCTURAL WASHERS������ REPLACE LOST OR DAMAGED WASHERS WITH MEC PART #50582 ONLY������ Carefully apply lifting pressure. Check the balance of the load before lifting and adjust the rigging as necessary.
  • Page 92 Bearing to the Chassis. THE WASHERS USED ON THESE BOLTS ARE HARDENED STRUCTURAL WASHERS������ REPLACE LOST OR DAMAGED WASHERS WITH MEC PART #50582 ONLY������ Remove the Swing Bearing and ring spacers from the Chassis. Note: Ring Bearing Mass: 121 LBS...
  • Page 93 Secton 18 - Mechancal Components Aprl 2019 Install the Swing Bearing with the painted teeth placed on the same side of the chassis as the Rotation Lock. Due to the placement of the mounting holes in the Chassis, the teeth will be slightly forward from straight sideways.
  • Page 94 Secton 18 - Mechancal Components Aprl 2019 Install the swing Drive Mounting Bolts finger tight. Ensure that the Swing Drive is engaging the painted teeth, then tighten the center Adjustment Bolt while manually moving the turntable back and forth to take out all play between the gears of the Swing Drive and the Swing Bearing.

  • Page 95: DrVe Motors & Gear Hubs

    Secton 18 - Mechancal Components Aprl 2019 Drive Motors & Gear Hubs Note: See Section 24 & Section 25 of the Parts portion of this manual for parts lists. There is one hydraulic drive wheel motor and one gear hub located at each wheel. Clean all fittings before disconnecting hoses������...
  • Page 96 Gear Hub Use grease to hold the O-ring in place during ART_4966 installation. Drive Motors MEC does not recommend end-user maintenance or repair of the drive motors. Contact MEC or for the nearest service provider. Gear Hubs Lubrication • Change the oil after the first 100 hours of operation •...

  • Page 97: EngNe MaNtenance

    Secton 18 - Mechancal Components Aprl 2019 Engine Maintenance For complete service information consult the engine manual that came with the machine. Always wear protective eye-wear when working with fuel and oil������ Engine should be OFF when replacing filter elements������ Do not run the engine with the air filter element removed������...
  • Page 98 Secton 18 - Mechancal Components Aprl 2019 Out to Fuel Filter Fuel Pump Turn OFF valve on bottom of fuel tank and clean the filter area before removing the filter. Place a suitable container beneath the fuel filter assembly to catch spilled fuel. In From Fuel Fuel Filter...
  • Page 99 Secton 18 - Mechancal Components Aprl 2019 Throttle Solenoid Adjustment IMPORTANT! This final adjustment must be made after all other throttle speed adjustments. The solenoid must be free to retract fully in order to turn OFF the High Amperage Pull Circuit.

  • Page 100: LubrCatOn PoNts

    Secton 18 - Mechancal Components Aprl 2019 Lubrication Points Boom Wear Pads With the boom in the stowed position, raise the jib and extend the boom completely. Spread a thin, even coat of lithium-based grease on the areas where the wear pads rub -- top, bottom and sides of the internal sections of the boom.
  • Page 101 Hydraulic fluid contaminated with debris - filter change interval neglected. Note: MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Use only the recommended hydraulic fluid. Substituting a lower grade fluid will cause the machine to operate incorrectly and may lead to pump and drive motor failure.

  • Page 102: ElectrCal System TroubleshootNg

    Secton 19 - Troubleshootng Aprl 2019 Electrical System Troubleshooting The electronic control system used on this machine was designed for low maintenance and long, trouble-free operation. The system consists of two microprocessor based modules: the GP440 Module in the upper controls box and the GP400 Processor, located in the lower controls box. They communicate through a low voltage digital signal called CAN-Bus communication.

  • Page 103: Gp400 Module

    Secton 19 - Troubleshootng Aprl 2019 GP400 Module The GP400 module is “the brains” of the system. It receives and processes a variety of inputs both from the machine and the operator, then controls all the operative functions of the machine. It also has a feature that allows the technician to access and monitor all functionality of the system, along with a technician-friendly series of fault messages that can be accessed through the use of the onboard EZ-Cal scan tool.

  • Page 104: Valve Constant Current Module And TermNal Block Module

    Secton 19 - Troubleshootng Aprl 2019 Valve Constant Current Module and Terminal Block Module P12-1 P12-1 CAN HI CAN HI P12-2 P12-2 CAN LO CAN LO P12-3 P12-3 SHIELD SHIELD P6-1 DRIVE REV P6-2 DRIVE REV GROUND P5-1 DRIVE FWD Valve Constant Current Modules (VCCM) P5-2 DRIVE FWD GROUND...

  • Page 105: Gp440 Module

    Secton 19 - Troubleshootng Aprl 2019 GP440 Module The GP440 Module is the remote module located inside the upper control box. It received inputs from the operator and relays them to the GP400. YELLOW LAMP-LOW FUEL INDICATOR P5-1 P7-1 JIB UP/DOWN SIGNAL BOOM UP/DOWN SIGNAL P5-2 P6-2...

  • Page 106: Ez-Cal Scan Tools

    Handheld P1 P2 Scan Tool P/N 90888 The handheld EZ-Cal is not provided with the machine and is available from the MEC parts department (part #90888). Upper Controls To use and operate the handheld EZ-Cal at the upper controls station: •...

  • Page 107: UsNg The Ez-Cal WTh The Flow Charts

    ACCESS LEVEL 1 PROVIDES ACCESS TO CHANGE PERSONALITIES NORMALLY PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS������ PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION AS LISTED IN THE FOLLOWING TABLES������...
  • Page 108 1= X+ OUTPUTS 5D-6 PRIOR PUMP DELAY LOAD SETUPS 0.0 SEC MAX LIFT AUTHORIZATION & OVERLOAD 5F-5 5D-7 USE ON FROM MEC STARTER DELAY MAX DRIVE MACHINES 10 SEC AERIALS WITH 5D-8 OVERLOAD SLOW DOWN SENSING OPTION ONLY UPPER GROUND...
  • Page 109 Secton 19 - Troubleshootng Aprl 2019 60JD BOOM EZ-Cal Flow Chart DIAGNOSTIC EZ-CAL MENU Chart 2 of 2 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Use in conjunction with Menu and sub-menu DIAGNOSTICS Diagnostic tables for LEFT/RIGHT BUTTONS Thorough explanation Select menus and setting to be adjusted...

  • Page 110: Ez-Cal Messages

    Secton 19 - Troubleshootng Aprl 2019 EZ-Cal Messages “Help Messages” will appear on the EZ-Cal scan tool as a means of explaining operating and non- operating function(s) and system errors or interruptions that are accompanied by flash codes. It can also be used for verifying system operation.

  • Page 111: Can Bus Related Messages

    Secton 19 - Troubleshootng Aprl 2019 Can Bus Related Messages CAN bus communication system is the network by which the control modules and CAN Tilt modules communicate with the GP400. NO DATA FROM CAN TILT #1______________________ Flash Code: None • CAN Tilt module mounted to front of main boom (located behind panel, Left Module) has malfunctioned or wiring is damaged.
  • Page 112 Secton 19 - Troubleshootng Aprl 2019 Calibration Related Messages The following messages appear when the GP400 microprocessor has not been calibrated or was improperly calibrated. FACTORY OVERRIDE_________________________________ FAST FLASH • GP400 is shipped in this condition to allow temporary operation of the machine without interruption from the safety system so that calibration procedures can be performed.
  • Page 113 Secton 19 - Troubleshootng Aprl 2019 Interlock Messages The following messages appear as result of perceived improper operation, machine positioning, or other incorrect operation. Interlock messages may be the result of a part failure if the part in question provides incorrect information to the GP400. FUNCTIONS LOCKED - LIMIT REACHED________________ Flash Code: 2/2 •...
  • Page 114 Secton 19 - Troubleshootng Aprl 2019 CHECK PLATFORM SWITCHES_______________________ Flash Code 2/2 • Platform Rotate/slide joystick or toggle switch movement without enable or during power up. Check joystick analog output and switch digital outputs using the EZ-Cal. CHECK TELE SWITCHES_____________________________ Flash Code 2/2 •...
  • Page 115 Secton 19 - Troubleshootng Aprl 2019 Other Messages The following messages are the result of various possible failures or occurrences which may result in machine interruption. FUNCTIONS LOCKED - NO VALVE SUPPLY!____________ Flash Code 2/3 • GP400 detects no power on P7-1 of the GP400. Check wiring to plug connection; possible GP400 internal failure.
  • Page 116 Secton 19 - Troubleshootng Aprl 2019 FAULT: CHECK HEIGHT SENSORS!____________________ Flash Code 6/1 • Voltage from Height sensors out of range, should be .5 volts to 4.5 volts FAULT: CHECK PRESSURE SENSOR!___________________ Flash Code 6/2 • Voltage from Pressure sensor out of range, should be .5 to 4.5 volts (Overload option only). FAULT: CHECK ELEVATION SWITCH!___________________ Flash Code 6/3 •...
  • Page 117 Secton 19 - Troubleshootng Aprl 2019 Troubleshooting Chart The following chart describes the possible causes for inoperation of the different functions of this machine. The Causes and Solutions columns list various points of references that can be found in the Hydraulic, Electrical, Schematics and Troubleshooting sections of this manual.
  • Page 118 Secton 19 - Troubleshootng Aprl 2019 Indicates an attempt to start was 7-7 Flash code on sent by the GP400 but the oil Check all the above GP400 pressure switch did not close. Check/fill fuel reservoir. Fuel system requires air purge after loss of Low fuel reservoir fuel.
  • Page 119 Secton 19 - Troubleshootng Aprl 2019 Problem Possible Cause Remedy/Solution Boom Extend/Retract Excessive weight on platform Reduce weight to within platform capacity Level sensor out of level (platform Indicator light will be illuminated and alarm will sound off. elevated above 10’) Reposition machine to level ground Main relief valve (6) out of Adjust Main relief valve (6) to rated platform capacity located on...
  • Page 120 Refer to Adjustments Flow Chart column 4F for settings that will allow lowering platform (level Adjustments in GP400 incorrect leveling to be close then make slight changes until operating correctly. cylinder moving too slow Contact MEC Technical Support for assistance if needed. or fast) Pump faulty Test/replace pump Problem...
  • Page 121 Secton 19 - Troubleshootng Aprl 2019 Drive Valve (on drive pump) not Check Drive output from VCCM Module VP5 and VP6. energized Check for power at valve coils located on top of the drive pump. Drive Valve (on drive pump) not Check drive valve for contamination shifting Brakes not releasing (system...
  • Page 122 Secton 19 - Troubleshootng Aprl 2019 Problem Possible Cause Remedy/Solution Steer Check continuity through micro-switch inside joystick handle using Joystick rocker switch inoperative wires outside the handle. Check output (see EZ-Cal 2C2, P10-7 and P7-8). Check steering valve for power. Check for damage and contamination. Steering valve 5 inoperative Check output from GP400 (see EZ-Cal ID # 2E1 P5-2 and P5-3).
  • Page 123 Secton 20 - Schematcs Aprl 2019 Hydraulic Schematics ~Serial #14400126, Part 1 Hydraulic Schematics ~Serial #14400126, Part 1 AXLE CYLINDERS STEERING CYLINDERS JUNCTION BLOCK ROTARY MANIFOLD 22.1 22.2 22.3 2-SPD/BRK MANIFOLD 3000 psi DRIVE PUMP 60-J Boom, Diesel HYDRAULIC SCHEMATIC, 1 of 2 To Page 2 ~Serial #14400126 ART_4922...
  • Page 124 Secton 20 - Schematcs Aprl 2019 Hydraulic Schematics ~Serial #14400126, Part 2 UPPER BOOM CYLINDER PLATFORM LEVEL LOWER BOOM CYLINDER PLATFORM MANIFOLD 4.10 4.11 4.12 TELESCOPE CYLINDER 20.1 20.2 4.13 21.2 21.1 TURNTABLE ROTATOR 3K GENERATOR OPTION ECE SMA 1500 psi 1500 psi 1500 psi 3000 psi...
  • Page 125 Secton 20 - Schematcs Aprl 2019 Primary Functions Manifold, ~Serial #14400126, Part 1 Outward Faces Rearward Forward Bottom 60-J Boom, Diesel Functions Manifold Valves, 1 of 2 ~Serial #14400126 ART_4924 Page 119 60-J Desel - Servce & Parts Manual...
  • Page 126 Secton 20 - Schematcs Aprl 2019 Primary Functions Manifold, ~Serial #14400126, Part 2 BRAKE/2-SPEED MAIFOLD 22.1 S15 22.3 22.2 Shuttle Valve 22.1 - 22.3 Solenoid Valves Brake, Axle, 2 Spd 26, 27 Orifice 0.75mm S15 – S17 Coil 12 Volt PLATFORM MANIFOLD 20.1 4.10...
  • Page 127 Secton 20 - Schematcs Aprl 2019 Hydraulic Schematic, Serial #14400127~, Part 1 AXLE CYLINDERS STEERING CYLINDERS JUNCTION BLOCK ROTARY MANIFOLD 22.1 22.2 22.3 2-SPD/BRK MANIFOLD DRIVE PUMP 60-J Boom, Diesel HYDRAULIC SCHEMATIC, 1 of 2 To Page 2 Serial #14400127~ ART_5003 Page 121 60-J Desel - Servce &...
  • Page 128 Secton 20 - Schematcs Aprl 2019 Hydraulic Schematic, Serial #14400127~, Part 2 UPPER BOOM CYLINDER PLATFORM LEVEL LOWER BOOM CYLINDER 4.12 4.10 4.11 PLATFORM MANIFOLD 4.13 S13 S14 TELESCOPE CYLINDER 4.14 TURNTABLE ROTATOR 3K GENERATOR OPTION ECE SMA 1500 psi 1500 psi 1500 psi 18.1...
  • Page 129 Secton 20 - Schematcs Aprl 2019 Primary Functions Manifold, Serial #14400127~, Part 1 Outward Faces 18.1 19 Rearward Forward Bottom 60-J Boom, Diesel Functions Manifold Valves, 1 of 2 Serial #14400127~ ART_5005 Page 123 60-J Desel - Servce & Parts Manual...
  • Page 130 Secton 20 - Schematcs Aprl 2019 Primary Functions Manifold, Serial #14400127~, Part 2 Rearward Inward Faces 17.3 17.1 17.2 PRIORITY VALVE, STEER CHECK VALVE, AUX PUMP 3.1 – 3.2 CROSS PORT RELIEF VALVES, STEER 4.1 – 4.9 SHUTTLE VALVE, LOAD SENSE VALVE, 3-POS, 4 WAY, STEER RELIEF VALVE, MAIN FLOW SHARE VALVE...
  • Page 131 Secton 20 - Schematcs Aprl 2019 Electric Schematic, Lower Control Box, Standard Machines TO MAIN CHASSIS SCHEMATIC PAGE 2 GP400 MICROPROCESSOR VALVE CONSANT CURRENT MODULE (414) (VCCM) P1-1 CAN-BUS HI (95) (413) P1-2 (414) (133) CAN-BUS L0 PLATFORM LVL UP CAN HI (412) P1-3...
  • Page 132 Secton 20 - Schematcs Aprl 2019 Electric Schematic, Chassis, Standard Machines ANGLE TRANSDUCER HEIGHT1 REAR OF BOOM (15) ORG/BLK (143) 750 LBS OPTION (15) EXTEND 3 ONLY BOOM MANIFOLD (15) (95) (133) (BRN) WHT/BLK LEVEL UP (15) (BLU) (96) (86) BLK/WHT (BLK) BOOM RETRACT PROX SWITCH...
  • Page 133 Secton 20 - Schematcs Aprl 2019 Electric Schematic, Lower Control Box, Optional Overload Sensing System TO MAIN CHASSIS SCHEMATIC PAGE 2 GP400 MICROPROCESSOR VALVE CONSANT CURRENT MODULE (VCCM) (414) P1-1 (95) CAN-BUS HI (414) (133) (413) PLATFORM LVL UP P1-2 CAN HI CAN-BUS L0 (412)
  • Page 134 Secton 20 - Schematcs Aprl 2019 Electric Schematic, Chassis, Optional Overload Sensing System ANGLE TRANSDUCER HEIGHT1 REAR OF BOOM (15) ORG/BLK (143) 750 LBS OPTION (15) EXTEND 3 ONLY BOOM MANIFOLD (15) (95) (133) (BRN) WHT/BLK LEVEL UP (15) (BLU) (96) (86) BLK/WHT...
  • Page 135 Secton 20 - Schematcs Aprl 2019 Electric Schematic, Upper Controls Box, All Machines GP440 MICROPROCESSOR LOAD CELL CONNECTOR P1-1 CHANNEL 1 S+ LAOD CELL FOR CE AND 750 P1-2 LBS OPTIONS ONLY CHANNEL 1 S- P1-3 CHANNEL 2 S+ P1-4 P2-1 LAOD CELL FOR CE AND 750 P2-2...
  • Page 136 Aprl 2019 Notes Page 130 60-J Desel - Servce & Parts Manual...
  • Page 137 This Parts sections consists of illustrated parts sections and is designed to provide you, the customer, with illustrations and the list of associated parts needed to properly maintain the MEC self-propelled aerial work platform. When used in conjunction with the Service section in this manual and the Operator’s Manual (provided separately), this manual will assist you in making necessary adjustments...
  • Page 138 Overload (opt) Hi-Cap Indicator (opt) Tilt Hi-Cap Switch (opt) Low Fuel Idle Speed Generator (opt) Emergency Stop Glow Plug Engine Start/Stop Function Enable Aux Power Platform Level Upper Controls 60-J Diesel ART_4840 Page 132 60-J Desel - Servce & Parts Manual...
  • Page 139 Secton 21 - Controls Aprl 2019 Item Part Number Description Qty������ 93772 To Serial # 1440117 - J.R. Merritt - Boom Control Handle 94685 From Serial # 1440118 - PQ Controls - Boom Control Handle 28868 To Serial # 14400150 - Adapter Harness 93773 To Serial # 1440117 - J.R.
  • Page 140 Secton 21 - Controls Aprl 2019 Upper Controls Box, Part 2 Upper Controls 60-J Diesel ART_4841 Page 134 60-J Desel - Servce & Parts Manual...
  • Page 141 Secton 21 - Controls Aprl 2019 Item Part Number Description Qty������ 22208 Upper Controls Enclosure 90714 Switch Base 8082 Contact Block, Normally Closed 8083 Contact Block, Normally Open 22429 Bracket 92027 GP440 Module 92033 Buss Module 50191 Screw, THMS #10-32 x .5 91881 Bus Mount Page 135...
  • Page 142 Secton 21 - Controls Aprl 2019 Lower Controls Box Lower Controls 60-J Diesel ART_4842 Page 136 60-J Desel - Servce & Parts Manual...
  • Page 143 Secton 21 - Controls Aprl 2019 Item Part Number Description Qty������ 91704 Hour Meter 9549 Key Switch 7423 Switch, 2 Position Momentary 7235 Circuit Breaker 91954 Switch, 3 Position Momentary 92253 Light, Amber 92254 Light, Red 92427 Switch, 3 Position, Single Momentary 7800 Emergency Stop Button 93900...
  • Page 144 Secton 22 - Platform Aprl 2019 Platform Entries Platform Entries Platform Entries 60-J ART_4843 Page 138 60-J Desel - Servce & Parts Manual...
  • Page 145 Secton 22 - Platform Aprl 2019 Item Part Number Description Qty������ 28528 Lanyard 28530 OPTION -- Gate Latch Handle, lanyard alternative 92302 Gate Latch 28520 Gate Weldment 91888 Hinge 28521 Sliding Lift Gate 52674 Rail Slide Hose Page 139 60-J Desel - Servce & Parts Manual...
  • Page 146 Secton 22 - Platform Aprl 2019 Platform Components Platform Components 60-J ART_4844 Page 140 60-J Desel - Servce & Parts Manual...
  • Page 147 Secton 22 - Platform Aprl 2019 Item Part Number Description Qty������ Upper Controls -- See Section 21 8909 Manuals Case 28697 Floor Panel 50028 Bolt, M6 x 20 50000 Washer, M6 Flat 50047 Nut, M6 Nylock 28500 Platform Weldment 53001 Bolt, M20 x 110 50005 Washer, M20 Std...
  • Page 148 Secton 22 - Platform Aprl 2019 Jib Connection Jib Connection 60-J ART_4894 Page 142 60-J Desel - Servce & Parts Manual...
  • Page 149 Secton 22 - Platform Aprl 2019 Item Part Number Description Qty������ 50593 Bolt, M24 x 280 50255 Washer, M24 Flat 53013 Button Head Screw, M12 x 35 50007 Washer, M12 Nordlock 50256 Nut, M24 Nylock 50378 Socket Head Screw, M10 x 35 50006 Washer M10 Nordlock All machines use only one of following:...
  • Page 150 Secton 22 - Platform Aprl 2019 Platform Options Platform Options 60-J ART_4845 Page 144 60-J Desel - Servce & Parts Manual...
  • Page 151 Secton 22 - Platform Aprl 2019 Item Part Number Description Qty������ 28960 Cover, Upper Controls 92665 U-Clamp, 5/16 x 1-3/8 50200 Washer, M8 Nordlock 53020 Nut, 5/16 Acorn 28950 Sheet Materials Rack Kit 28535 Guard Rail Pads 93963 Strap 28540 Sheet Materials Rack 93920 Decal, Warning, Sheet Material Rack Self Weight...
  • Page 152 Secton 23 - Elevatng Assembly Aprl 2019 Boom/Chassis Installation Boom/Chassis Installation Boom Installation 60-J ART_4846 Page 146 60-J Desel - Servce & Parts Manual...
  • Page 153 Secton 23 - Elevatng Assembly Aprl 2019 Item Part Number Description Qty������ 28915 Jib Assembly Boom Assembly 28607 18151 Pin Retainer 50200 Washer, M8 Nordlock 50032 Bolt, M8 x 30 18152 Retainer Pin 50236 Bolt, M12 x 40 50007 Washer, M12 Nordlock 28601 Turntable Assembly REF –...
  • Page 154 Secton 23 - Elevatng Assembly Aprl 2019 Boom & Riser Boom & Riser 60-J ART_4847 Page 148 60-J Desel - Servce & Parts Manual...
  • Page 155 Secton 23 - Elevatng Assembly Aprl 2019 Item Part Number Description Qty������ Main Boom 18152 Retainer Pin 50236 Bolt, M12 x 40 50007 Washer, M12 Nordlock 28604 Upper Lift Cylinder -- See Section 25 28300 Post Weldment 28603 50033 Bolt, M10 x 25 50006 Washer, M10 Nordlock 28647...
  • Page 156 Secton 23 - Elevatng Assembly Aprl 2019 Main Boom Components 20 21 22 12 13 Wear Pad Bolts Wear pads use M10-1.5 bolts in varying lengths, depending on shim use. Wear Pad Shim as needed to achieve .030” total clearance in both side-to-side and top-to-bottom directions.
  • Page 157 Secton 23 - Elevatng Assembly Aprl 2019 Item Part Number Description Qty������ 28642 Cable Track Tube 28749 Connector Plate 24379 Hose Wrap Forming 28641 Cable Track Forming 93658 Cable Track Platform Functions Manifold -- See Section 25 28694 Bracket 22386 Spacer 16788 Slide Bumper...
  • Page 158 Secton 23 - Elevatng Assembly Aprl 2019 Jib Components 11 12 13 11 12 13 Jib Components 60-J ART_4849 Page 152 60-J Desel - Servce & Parts Manual...
  • Page 159 Secton 23 - Elevatng Assembly Aprl 2019 Item Part Number Description Qty������ 28400 Jib Tube Weldment 92032 Proximity Sensor 28646 Hose/Cable Cover 92360 Bearing Jib Cylinder -- See Section 25 93740 Bearing 28420 Jib Linkage Weldment 28608 Pin, Jib Cylinder 28410 Compression Link 28607...
  • Page 160 Secton 24 - Axles Aprl 2019 Front Axle Installation Front Axle Installation Optional Overload Sensing System Only Front Axle Installation 60-J ART_4850 Page 154 60-J Desel - Servce & Parts Manual...
  • Page 161 Secton 24 - Axles Aprl 2019 Item Part Number Description Qty������ Axle Cylinder -- See Section 25 28600 18075 18151 Pin Retainer 50200 Washer, M8 Nordlock 50032 Bolt, M8 x 30 18152 Pin Retainer 50236 Bolt, M12 x 40 50007 Washer, M12 Nordlock (not shown) 18405 92039...
  • Page 162 Secton 24 - Axles Aprl 2019 Rear Axle Installation - To Serial #14400260 Rear Axle Installation 60-J ART_4851 Page 156 60-J Desel - Servce & Parts Manual...
  • Page 163 Secton 24 - Axles Aprl 2019 Item Part Number Description Qty������ 28612 Axle Stop Pad 50332 Bolt, M10 x 35 50006 Washer, M10 Nordlock 22225 Shim, .02 -- Equal numbers on each side until axle is tight against chassis As Req. 18152 Pin Retainer 50236...
  • Page 164 Secton 24 - Axles Aprl 2019 Front Axle Components Front Axle Components 60-J ART_4852 Page 158 60-J Desel - Servce & Parts Manual...
  • Page 165 Secton 24 - Axles Aprl 2019 Item Part Number Description Qty������ 28140 Tie Rod 22215 18151 Pin Retainer 50200 Washer, M8 Nordlock 50032 Bolt, M8 x 30 18051 18165 Pin Retainer Steering Cylinder 28110 Front Axle Weldment 92110 Bearing 19124 Yoke Pin 93559 Wheel/Tire Assembly, Right Side, Foam Filled...
  • Page 166 Secton 24 - Axles Aprl 2019 Rear Axle Components Rear Axle Components 60-J ART_4853 Page 160 60-J Desel - Servce & Parts Manual...
  • Page 167 Secton 24 - Axles Aprl 2019 Item Part Number Description Qty������ 93559 Wheel/Tire Assembly, Right Side, Foam Filled 93560 Wheel/Tire Assembly, Left Side, Foam Filled 28611 Cover Plate 92098 Clip Nut 93624 Planetary Gear Hub 92042 O-Ring, Brake Port 92166 O-Ring Wheel Motor -- See Section 25 28100...
  • Page 168 Secton 25 - Hydraulcs Aprl 2019 Hydraulic Components Hydraulic Components Hydraulic Components 60-J Diesel ART_4862 Page 162 60-J Desel - Servce & Parts Manual...
  • Page 169 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93830 Platform Rotator 93879 Jib Cylinder 28398 Platform Level Cylinder 28397 Boom Extend Cylinder 28396 Upper Boom Lift Cylinder Platform Functions Manifold 28395 Lower Boom Lift Cylinder 92072 Charge Filter Assembly 93339 Drive Pump 93232...
  • Page 170 Secton 25 - Hydraulcs Aprl 2019 Main Functions Manifold Fittings -- ~Serial #14400126 Main Functions Manifold -- Fittings ~Serial #14400126 60-J ART_4864 Page 164 60-J Desel - Servce & Parts Manual...
  • Page 171 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28920 Main Functions Manifold Assembly 93789 Main Functions Manifold, w/o fittings 50835 Fitting, MFFOR-MB-6-6 50676 Fitting, MFFOR-MB-8-8 50974 Fitting, TPO-4 50674 Fitting, MFFOR-MB90-6-6 50825 Fitting, MFFOR-MB-12-10 50656 Fitting, MFFOR-MB90-4-6 50676 Fitting, MFFOR-MB45-6-6 50816...
  • Page 172 Secton 25 - Hydraulcs Aprl 2019 Main Functions Manifold Block Components -- ~Serial #14400126 7 10 Main Functions Manifold -- Block Components ~Serial #14400126 60-J ART_4863 Page 166 60-J Desel - Servce & Parts Manual...
  • Page 173 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93789 Main Functions Manifold, w/o fittings, including parts listed below 94067 Check Valve 94081 Coil 94031 Solenoid Valve 94083 Coil 94080 Solenoid Valve, Directional Control 94077 Orifice, .6mm 94082 Coil 94036 Solenoid Valve...
  • Page 174 Secton 25 - Hydraulcs Aprl 2019 Main Functions Manifold Fittings -- Serial #14400127~ behind valves Main Functions Manifold -- Fittings Serial #14400127~ 60-J ART_5001 Page 168 60-J Desel - Servce & Parts Manual...
  • Page 175 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28928 Main Functions Manifold Assembly 93902 Main Functions Manifold, w/o fittings 50835 Fitting, MFFOR-MB-6-6 51091 Fitting, MFFOR-MB45-12-10 50671 Fitting, MFFOR-FFORX90- 4-4 50832 Fitting, MFFOR-MB-4-6 50814 Fitting, MFFOR-MB-10-8 50674 Fitting, MFFOR-MB90-6-6 50974 Fitting, TPO-4 50676...
  • Page 176 Secton 25 - Hydraulcs Aprl 2019 Main Functions Manifold Block Components -- Serial #14400127~ 2 21 behind valve *Orifices located beneath plugs Main Functions Manifold -- Block Components Serial #14400127~ 60-J ART_5000 Page 170 60-J Desel - Servce & Parts Manual...
  • Page 177 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93902 Main Functions Manifold, w/o fittings, including parts listed below 94081 Coil 94031 Solenoid Valve 94083 Coil 94080 Solenoid Valve, Directional Control 94223 Relief Valve 94082 Coil 94036 Solenoid Valve 94070 Solenoid Valve 94071...
  • Page 178 Secton 25 - Hydraulcs Aprl 2019 Brake/Axle/2-Speed Manifold Brake/Axle/2-Speed Manifold 60-J Diesel ART_4865 Page 172 60-J Desel - Servce & Parts Manual...
  • Page 179 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93779 Brake/Axle/2-Speed Manifold, complete, without fittings 50974 Fitting, TPO-4 50831 Fitting, MFFOR-MB-4-4 50673 Fitting, MFFOR-MB90- 4-4 50671 Fitting, MFFOR-FFORX90- 4-4 94087 Solenoid Valve 94082 Coil 51083 Fitting, MFFOR-MB90-6-4 94086 Valve 94088 Orifice, .75mm...
  • Page 180 Secton 25 - Hydraulcs Aprl 2019 Platform Functions Manifold -- ~Serial #14400126 11 12 Early Style Block Designation Platform Functions Manifold -- Early Style 60-J ART_4866 Page 174 60-J Desel - Servce & Parts Manual...
  • Page 181 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93780 Platform Function Manifold -- Early Style, complete, without fittings 94069 Shuttle Valve 50831 Fitting, MFFOR-MB-4-4 50673 Fitting, MFFOR-MB90 4-4 50671 Fitting, MFFOR-FFORX90- 4-4 50832 Fitting, MFFOR-MB-4-6 50656 Fitting, MFFOR-MB90-4-6 50674 Fitting, MFFOR-MB90-06-06 50835...
  • Page 182 Secton 25 - Hydraulcs Aprl 2019 Platform Functions Manifold -- Serial #14400127~ 11 12 Later Style Block Designation Platform Functions Manifold -- Later Style 60-J ART_4867 Page 176 60-J Desel - Servce & Parts Manual...
  • Page 183 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93903 Platform Function Manifold -- Late Style, complete, without fittings 94069 Shuttle Valve 50831 Fitting, MFFOR-MB-4-4 50673 Fitting, MFFOR-MB90 4-4 50671 Fitting, MFFOR-FFORX90- 4-4 50832 Fitting, MFFOR-MB-4-6 50656 Fitting, MFFOR-MB90-4-6 50674 Fitting, MFFOR-MB90-06-06 50835...
  • Page 184 Secton 25 - Hydraulcs Aprl 2019 Chassis Blocks Steering Case Drain Counterbalance Connections Valves Brake Release/ Axle Extend Connections Chassis Blocks 60-J ART_4882 Page 178 60-J Desel - Servce & Parts Manual...
  • Page 185 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93863 Connection Manifold 50835 Fitting, MFFOR-MB-6-6 50656 Fitting, MFFOR-MB90-4-6 51098 Fitting, MB-8 Plug Serial #14400126 93932 Counterbalance Valve Assembly not used on later machines 93910 Counterbalance Valve 50832 Fitting, MFFOR-MB-4-6 50674 Fitting, MFFOR-MB90-6-6 50847...
  • Page 186 Secton 25 - Hydraulcs Aprl 2019 Rotary Manifold - To Serial # 14400334 Rotary Manifold 60-J ART_4868 Page 180 60-J Desel - Servce & Parts Manual...
  • Page 187 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93651 Rotary Manifold, without fittings 51063 Fitting, MFFOR-MB45-12-12 51101 Fitting, MB-FB-16-12 50673 Fitting, MFFOR-MB90 4-4 50816 Fitting, MFFOR-MB45-6-8 50831 Fitting, MFFOR-MB-4-4 50836 Fitting, MFFOR-MB-6-8 50979 Fitting, MFFOR-FFORX-MFFOR-12 50844 Fitting, MFFOR-MB90-12-16 Page 181 60-J Desel - Servce &...
  • Page 188 Secton 25 - Hydraulcs Aprl 2019 Rotary Manifold - From Serial # 14400335 ILLUSTRATION No. 60 - J Rotary Manifold - Alternative Art_5304 Page 182 60-J Desel - Servce & Parts Manual...
  • Page 189 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 94681 HYDRAULIC ROTARY / SWIVEL MANIFOLD, 8 PORT (ALT FOR 93651) Page 183 60-J Desel - Servce & Parts Manual...
  • Page 190 Secton 25 - Hydraulcs Aprl 2019 Hydraulic Pumps Hydraulic Pumps 60-J ART_4870 Page 184 60-J Desel - Servce & Parts Manual...
  • Page 191 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93232 Functions Pump 93339 Drive Pump, without fittings 50841 Fitting, MFFOR-MB-8-8 50782 Fitting, MB-MJ90-12-12 5004 Bolt, 3/8 x 1 50006 M10 Nordlock 51163 Fitting, FL-MFFOR90-12-12 51133 #12 Flange Kit -- include 2 flanges and 4 bolts 50837 Fitting, MB-MFFOR-10-8 50831...
  • Page 192 Secton 25 - Hydraulcs Aprl 2019 7������ 5 kw Gen Assembly REPLACE DW10Z-01-C-N-150 (94076) REPLACE WS10Y-01-C-N-12 DN (94503) MANIFOLD ASSEMBLY SHOWN FOR REFERENCE ONLY INSTALL ON "P" PORT FITTING ILLUSTRATION No. 60 - J 7.5kw Gen Assembly Art_5305 Page 186 60-J Desel - Servce &...
  • Page 193 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28295 7.5KW GEN COVER FORMING HOLE CUTOUTS 28847 7.5KW GEN MOUNT WELDMENT 28974 7.5KW GEN HYD TANK ASSEMBLY 28984 SUBASSEMBLY, OPTION, 7.5KW BREAKER BOX 28985 SUBASSEMBLY, OPTION, 7.5KW OUTLET BOXES 28993 7.5KW GENERATOR MANIFOLD ASSEMBLY 50007...
  • Page 194 Secton 25 - Hydraulcs Aprl 2019 7������ 5 kw Gen Interim Assembly 26 20 REPLACE WS10Y-01-C-N-12 DN (94503) REPLACE DW10Z-01-C-N-150 (94076) MANIFOLD ASSY SHOWN FOR REFERENCE ONLY 24 INSTALL ON "P" PORT FITTING ILLUSTRATION No. 60 - J 7.5kw Gen Interim Assembly Art_5306 Item Part Number...
  • Page 195 Secton 25 - Hydraulcs Aprl 2019 28847 7.5KW GEN MOUNT WELDMENT 28974 7.5KW GEN HYD TANK ASSEMBLY 28984 SUBASSEMBLY, OPTION, 7.5KW BREAKER BOX 28985 SUBASSEMBLY, OPTION, 7.5KW OUTLET BOXES 28993 7.5KW GENERATOR MANIFOLD ASSEMBLY 50007 WSHR M12 ZP NORDLOCK 50049 NNYL M10X1.50 08 ZP NYLON INSE 50215 HHCS M10-1.50X020 08 ZP F...
  • Page 196 Secton 25 - Hydraulcs Aprl 2019 7������ 5 kw Gen Danfoss Assembly INSTALL ON BOTTOM TANK RETURN PORT FITTING (MUST REMOVE CAP 50751 O-RING, 93318, GETS TRANFERED FROM THE 36 37 38 GEAR PUMP (SEE 28991 FOR DETAILS) CASE LINE MUST BE SIZED/ROUTED SUCH THAT A MAX CONTINUOUS/INTERMITTENT PRESSURE OF 7PSI/29PSI, RESPECTIVELY, IS ACHEIVED AUX PAD MOUNTING BOLT MUST NOT BOTTOM OUT!
  • Page 197 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28295 7.5KW GEN COVER FORMING HOLE CUTOUTS 28847 7.5KW GEN MOUNT WELDMENT 28984 SUBASSEMBLY, OPTION, 7.5KW BREAKER BOX 28985 SUBASSEMBLY, OPTION, 7.5KW OUTLET BOXES 28993 7.5KW GENERATOR MANIFOLD ASSEMBLY 50049 NNYL M10X1.50 08 ZP NYLON INSE 50215...
  • Page 198 Secton 25 - Hydraulcs Aprl 2019 Auxiliary Power Unit AUXILLARY POWER UNIT, 5592RT, 3392RT-T 92RT Series ART_3491 Page 192 60-J Desel - Servce & Parts Manual...
  • Page 199 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 17973 Auxiliary Power Unit, without fittings 92534 Solenoid 50790 Fitting, MB-MJ90-6-6 Page 193 60-J Desel - Servce & Parts Manual...
  • Page 200 Secton 25 - Hydraulcs Aprl 2019 Hydraulic Reservoir Hydraulic Reservoir 60-J ART_4869 Page 194 60-J Desel - Servce & Parts Manual...
  • Page 201 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 92366 Return Filter Assembly 92397 Filter Element 92357 Breather Cap 92478 Filler Cap 28660 Fuel Tank Weldment 9370 Sight Gauge 51161 Fitting, MFFOR-MP90-8-8 50876 Fitting, MFFOR-MP-8-8 93167 ~Serial #1440070 -- Suction Strainer 93706 Serial #1440071~ -- Suction Strainer 93605...
  • Page 202 Secton 25 - Hydraulcs Aprl 2019 Charge Filter Assembly Charge Filter Assembly TITAN BOOM 40-S ART_3656 Page 196 60-J Desel - Servce & Parts Manual...
  • Page 203 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 92072 Charge Filter Assembly, without fittings 92169 Filter Element 50849 Fitting, MFFOR-MB90-8-12 Page 197 60-J Desel - Servce & Parts Manual...
  • Page 204 Secton 25 - Hydraulcs Aprl 2019 Pressure Filter Assembly -- ~Serial #14400126 Pressure Filter Assembly 60-J ART_4872 Page 198 60-J Desel - Servce & Parts Manual...
  • Page 205 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 92785 High Pressure Filter 22657 Bracket 28796 Bracket, Long -- Used on early machines 50049 Nut, M10 Nylock 50034 Bolt, M10 x 30 50219 Bolt, 3/8 x .75 50006 Washer, M10 Nordlock 50849 Fitting, MFFOR-MB90-8-12...
  • Page 206 Secton 25 - Hydraulcs Aprl 2019 Wheel Motors Front (Steering) Wheels Planetary Gear Hub -- See Section D Rear Wheels Wheel Motors 60-J ART_4871 Page 200 60-J Desel - Servce & Parts Manual...
  • Page 207 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ Per Wheel Qty������ Per Machine 92514 Wheel Motor 92166 O-Ring 92042 O-Ring, Brake Port 50847 Fitting, MFFOR-MB90-6-8 50838 Fitting, MFFOR-MB-8-12 50656 Fitting, MFFOR-MB90-4-6 51086 Fitting, MFFOR-MB-4-4 50849 Fitting, MFFOR-MB90-12-8 50831 Fitting, MFFOR-MB-4-4 93360...
  • Page 208 Secton 25 - Hydraulcs Aprl 2019 Platform Rotator - To Serial # 14400334 Platform Rotator 60-J ART_4874 Page 202 60-J Desel - Servce & Parts Manual...
  • Page 209 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 93830 Platform Rotator 50675 Fitting, MFFOR-MB45-4-4 94403 Manifold Assy Page 203 60-J Desel - Servce & Parts Manual...
  • Page 210 Secton 25 - Hydraulcs Aprl 2019 Platform Rotator - From Serial # 14400335 ILLUSTRATION No. 60 - J Platform Rotator - Alternative Art_5308 Item Part Number Description Qty������ 94682 Hydraulic Rotator, Platform (ALT for 93830) Page 204 60-J Desel - Servce & Parts Manual...
  • Page 211 Secton 25 - Hydraulcs Aprl 2019 Swing Drive Swing Drive 60-J ART_4875 Item Part Number Description Qty������ 93647 Turntable Rotator 51007 Fitting, MFFOR-MB90-6-10 Page 205 60-J Desel - Servce & Parts Manual...
  • Page 212 Secton 25 - Hydraulcs Aprl 2019 Boom Lift Cylinders Boom Lift Cylinders 60-J ART_4876 Page 206 60-J Desel - Servce & Parts Manual...
  • Page 213 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28396 Upper Boom Lift Cylinder 50841 Fitting, MFFOR-MB-8-8 28395 Lower boom lift cylinder 94427 Counterbalance valve 94033 Counterbalance valve 94324 Seal kit 94323 Seal kit Page 207 60-J Desel - Servce & Parts Manual...
  • Page 214 Secton 25 - Hydraulcs Aprl 2019 Boom Extend Cylinder Boom Extend Cylinder 60-J ART_4877 Page 208 60-J Desel - Servce & Parts Manual...
  • Page 215 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28397 Extend Cylinder 50676 Fitting, MFFOR-MB45-6-6 28643 Pad, UHMW 50020 Bolt, M10 x 50 50053 Nut, M10 Nylock 50002 Washer, M10 Flat 92020 Counterbalance Valve 94536 Counterbalance Valve 94325 Seal Kit Page 209 60-J Desel - Servce &...
  • Page 216 Secton 25 - Hydraulcs Aprl 2019 Platform Level Cylinder Platform Level Cylinder 60-J ART_4878 Page 210 60-J Desel - Servce & Parts Manual...
  • Page 217 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 28398 Platform Level Cylinder 94527 Counterbalance Valve 94326 Seal Kit Page 211 60-J Desel - Servce & Parts Manual...
  • Page 218 Secton 25 - Hydraulcs Aprl 2019 Jib Cylinder Jib Cylinder 60-J ART_4879 Item Part Number Description Qty������ 28399 Jib Cylinder 50831 Fitting, MFFOR-MB-4-4 94408 Counterbalance Valve 94327 Seal Kit Page 212 60-J Desel - Servce & Parts Manual...
  • Page 219 Secton 25 - Hydraulcs Aprl 2019 Steer Cylinders Steer Cylinders 60-J ART_4873 Item Part Number Description Qty������ 18070 Steer Cylinder, without fittings 92616 Seal Kit 50858 Fitting, MFFOR-MB-MFFORT-4 50673 Fitting, MFFOR-MB90-04-04 Page 213 60-J Desel - Servce & Parts Manual...
  • Page 220 Secton 25 - Hydraulcs Aprl 2019 Axle Cylinders not shown Axle Cylinders 60-J ART_4880 Page 214 60-J Desel - Servce & Parts Manual...
  • Page 221 Secton 25 - Hydraulcs Aprl 2019 Item Part Number Description Qty������ 22315 Axle Cylinder 50676 Fitting, MFFOR-MB45-6-6 50675 Fitting, MFFOR-MB45-4-4 51167 Fitting, MP-MFFOR-4-4 92622 Counterbalance Valve 94328 Seal Kit Page 215 60-J Desel - Servce & Parts Manual...
  • Page 222 Secton 25 - Hydraulcs Aprl 2019 Hydraulic Hoses Part Number Connections Description Qty������ 52546 BRK-8/AXLE-5 Hose, Assembly, 1/4" x 36", 04G-04FFORX 04G-04FFORX90S 52547 2SPD-4 Hose Assembly, 1/4" x 32", 04G-04FFORX x 04G-04FFORX90S 52548 STB-7 Hose Assembly, 1/4" x 38", 04G-04FFORX x 04G-04FFORX90S 52549 STA-6 Hose Assembly, 1/4"...
  • Page 223 Secton 25 - Hydraulcs Aprl 2019 52580 Various Hose Assembly, 1/2” x 57", 8G-8FFORX x 8G-8FFORX 52581 RBHLWR-PORT 2T Hose Assembly, 1/2” x 35", 8G-8FFORX x 8G-12FFORX90S 52582 LBHLWR-PORT 1T Hose Assembly, 1/2” x 30", 8G-8FFORX x 8G-12FFORX 52583 RT-FT Hose Assembly, 1/2”...
  • Page 224 Secton 26 - Base Aprl 2019 Chassis Chassis See Section D of this manual for axle information. Chassis 60-J ART_4854 Page 218 60-J Desel - Servce & Parts Manual...
  • Page 225 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 28615 Front Chassis Cover 50332 Bolt, M10 x 35 50002 Washer, M10 Flat 92098 Clip Nut 93646 Swing Bearing 28617 Spacer 50580 Bolt, 5/8 x 3-1/4 50582 Washer, 5/8 x 1-5/16 x 3/16 Hardened Structural 28616 Rear Chassis Cover 50493...
  • Page 226 Secton 26 - Base Aprl 2019 Module Doors Module Doors 60-J ART_4855 Page 220 60-J Desel - Servce & Parts Manual...
  • Page 227 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 28226 Module Door, Controls Side 93821 Door Handle 93817 Door Latch 93817 Door Hold Down Strap (not shown) 93733 Hinge 28236 Hinge Spacer 28225 Module Door, Power Side 93845 Bumper 28728 Bracket...
  • Page 228 Secton 26 - Base Aprl 2019 Engine Module 28 29 Engine Module 60-J Diesel ART_4856 Page 222 60-J Desel - Servce & Parts Manual...
  • Page 229 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 28670 Fuel Tank Weldment 93799 Sight Gauge HDW6727 Fitting 51098 Drain Plug 92480 Filler Cap 92967 Filler Screen 92699 Fitting, 92488 Fitting 28671 Tube Flange 93758 Intake Tube 93737 Air Filter Assembly 93907 Filter Element...
  • Page 230 Secton 26 - Base Aprl 2019 Engine Assembly 4 x #50116 4 x #50392 Longer bolt to mount Throttle Solenoid bracket at this location. See next page. Engine Assembly 60-J Diesel ART_4857 Page 224 60-J Desel - Servce & Parts Manual...
  • Page 231 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ Gear Pump -- See Section 25 Piston Pump -- See Section 25 93470 Bell Housing 93505 Engine Charge Filter Assembly -- See Section 25 28652 Engine Bracket 28659 Engine Bracket 17969 Engine Mount 28640...
  • Page 232 Secton 26 - Base Aprl 2019 Engine Components See previous pages for Solenoid Mounting Bracket hardware. Engine Components 60-J Diesel ART_4858 Page 226 60-J Desel - Servce & Parts Manual...
  • Page 233 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 94038 94040 V-Belt 94038 Oil Plug 8665 Oil Filter 90227 Alternator 8413 Starter 94060 Turbo 94056 Oil Filler Cap 93968 Turbo Tube Support 28776 Stud 53014 Nut, M8-1.25 94058 Flywheel 91360 Ring Gear...
  • Page 234 Secton 26 - Base Aprl 2019 Controls Module 10 11 Controls Module 60-J Diesel ART_4859 Page 228 60-J Desel - Servce & Parts Manual...
  • Page 235 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 28628 Bracket 92366 Return Filter Assembly 92397 Filter Element 92357 Breather Cap 92478 Filler Cap 28660 Fuel Tank Weldment 9370 Sight Gauge 51161 Fitting, MFFOR-MP90-8-8 50876 Fitting, MFFOR-MP-8-8 93167 ~Serial #1440070 -- Suction Strainer 93706 Serial #1440071~ -- Suction Strainer...
  • Page 236 Secton 26 - Base Aprl 2019 Controls Module #2 Controls Module 60-J Diesel ART_4860 Page 230 60-J Desel - Servce & Parts Manual...
  • Page 237 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 93173 Fuse, 400A 93172 Fuse Holder 91745 Contactor, 12V 93169 Series/Parallel Switch -- 24v Auxiliary Power Option 28677 Mounting Plate Functions Manifold -- See Section 25 28622 Mounting Plate Brake/2Spd Manifold -- See Section 25 Swing Drive -- See Section 25 Aux Power Pump -- See Section 25...
  • Page 238 Secton 26 - Base Aprl 2019 Turntable Components Turntable Components 60-J ART_4861 Page 232 60-J Desel - Servce & Parts Manual...
  • Page 239 Secton 26 - Base Aprl 2019 Item Part Number Description Qty������ 28343 Boom Rest Bumper 50025 Bolt, M12 x 60 50003 Washer, M12 Std 50054 Nut, M12 Nylock 28200 Turntable Weldment 18214 Counterweight 50585 Bolt, M24 x 60 50586 Washer, M24 Nordlock 50255 Washer, M24 Flat 28680...
  • Page 240 Secton 26 - Base Aprl 2019 Boom Harness Part Number Description 28850 Cable, Communication Lower Box To Jib 75’ 28851 Cable, Platform Manifold 35’ 28852 Cable, Communication, Jib To Upper Control Box 28853 Harness, Platform Valves 28854 Harness, Engine 28855 Harness, Motor Control 28856 Harness, Power To Lower Box...
  • Page 241 Secton 27 - Decals, ANSI Aprl 2019 Decals, 60-J Diesel ANSI Decals, 60-J Diesel ANSI Back of Boom Front of turret Front of turret 92416 93741 93745 QTY - 1 QTY - 1 QTY - 2 93801 QTY - 2...
  • Page 242 Secton 27 - Decals, ANSI Aprl 2019 Item Part Number Description Qty������ 92416 Decal, Website 93741 Decal, MEC Boom 60-J, Main Boom 93687 Decal, Lower Controls, 60J-D 93745 Decal, MEC Boom 60-J, Module Door 90751 Label, Power To Platform 93801 Decal, Compartment Access...
  • Page 243 Secton 27 - Decals, ANSI Aprl 2019 Decals, 60-J Diesel ANSI, Platform Inside INSIDE CASE 93802 - Standard 93911 - Option 94050 - Option 90718 8911 93754 QTY - 1 QTY - 1 QTY - 1 QTY - 1 QTY - 1...
  • Page 244 Decal, Boom Harness Attach Point 92236 Decal, EZ-Cal port 93688 Decal, Upper Controls, 60J-D 93859 Decal, Upper Controls, 60-J Diesel, High Capacity Option 93803 Decal, Platform Capacity Wide 93857 Decal, 60-J Platform Capacity, 600-LB option 94051 Decal, Dual Capacity Wide ANSI...
  • Page 245 Secton 27 - Decals, ANSI Aprl 2019 Decals, 60-J Diesel ANSI, Chassis & Turntable Each side of chassis Each side of chassis 91975 93806 91973 91972 QTY - 1 QTY - 1 QTY - 8 QTY - 2 91982 93815...
  • Page 246 Secton 27 - Decals, ANSI Aprl 2019 Item Part Number Description Qty������ 91975 Decal, Diesel 93806 Decal, Explosion Hazard 91973 Decal, Tie-Down Point 91972 Decal, Yellow Drive Arrow 91982 Decal, Yellow Turn Arrow 93815 Decal, Yellow Drive/Turn Arrows, Small 91971 Decal, Blue Drive Arrow 91981 Decal, Blue Turn Arrow...
  • Page 247 MAX. SIDE LOAD PRESSURE 93741 XXXXX XXXXX XXXX XXXXX XXXXX XXXXX 94042 MANUFACTURED BY MEC AERIAL WORK PLATFORMS, 1401 S. MADERA AVE, KERMAN, CA 93630 USA MULTIPLE PATENTS PENDING. 93804 2 places 93755 93742 93855 93745 2 places 91850 3 places...
  • Page 248 Decal, Serial Plate CE 93804 Decal, Crush Hazard 91850 Decal, Crush Hazard 93807 Decal, Tip Over Hazard 90719 Decal, MEC Oval 93755 Decal, Danger Panel 93687 Decal, Base Controls 93855 Decal, Rotation Lock Page 242 60-J Desel - Servce & Parts Manual...
  • Page 249 Secton 28 - Decals, CE Aprl 2019 Decals, 60-J Diesel CE, Platform Australia only inside S ID 8911 93754 93926 -- Std. Machine 94043 -- Standard 227 KG Capacity 93755 93927 -- with High Capacity option 3 places 3 Places...
  • Page 250 Secton 28 - Decals, CE Aprl 2019 Item Part Number Description Qty������ 8911 Decal, Manuals Case 93754 Decal, Instructions 94043 Decal, Platform Capacity Tall, Standard 227 KG 93052 Decal, Platform Capacity Tall, Option 227/340 KG 91325 Decal, Danger, Electrical -- Australia only 93755 Decal, Danger Panel 93807...
  • Page 251 Secton 28 - Decals, CE Aprl 2019 Decals, 60-J Diesel CE, Chassis & Turntable On Air Cleaner Housing Each side of chassis Each side of chassis Each end 2 places each 91975 2 places 91972 91971 92117 93805 93806 91982...
  • Page 252 Secton 28 - Decals, CE Aprl 2019 Item Part Number Description Qty������ 91975 Decal, Diesel 93806 Decal, Explosion Hazard 91973 Decal, Tie-Down Point 91972 Decal, Yellow Drive Arrow 91982 Decal, Yellow Turn Arrow 93815 Decal, Yellow Drive/Turn Arrows, Small 91971 Decal, Blue Drive Arrow 91981 Decal, Blue Turn Arrow...
  • Page 253 Aprl 2019 Notes Page 247 60-J Desel - Servce & Parts Manual...
  • Page 254 MEC Parts Order Form Phone: 559-842-1523 Fax: 559-400-6723 Email: Parts@mecawp������ c om Please fill out completely Date: Ordered By: Account: Your Fax No.: Ship to: Bill to: Purchase Order Number Ship VIA ** All orders MUST have a Purchase Order Number...
  • Page 255 MEC Aerial Platform Sales Corp. and is found upon inspection by MEC Aerial Platform Sales Corp. to be defective in material and/or workmanship. MEC Aerial Platform Sales Corp. shall not be liable for any consequential, incidental or contingent damages whatsoever.
  • Page 256 MEC Aerial Work Platforms 1401 S. Madera Avenue, Kerman, CA 93630 USA Toll Free: 1 - 877 - 632 - 5438 Phone: 1 - 559 - 842 - 1500 Fax: 1 - 559 - 842 - 1520 info@MECawp.com www.MECawp.com...

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