Mec 45-J Diesel Service & Parts Manual
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Mec 45-J Diesel Service & Parts Manual

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Service & Parts Manual
45-J Diesel
Art 5500
Serial Number Range
Part # 95090
14700001 - Up
January 2022

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Summary of Contents for Mec 45-J Diesel

  • Page 1 Service & Parts Manual 45-J Diesel Art 5500 Serial Number Range Part # 95090 14700001 - Up January 2022...
  • Page 2 May 2020 New Release August 2020 Added Boom Harness 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 January 2022 Battery Replacement ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ 39 Section 12 - Controls ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������...
  • Page 5 January 2022 Calbraton Related Messages������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Interlock Messages ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Other Messages ������...
  • Page 6 January 2022 Boom Extend Cylnder ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ Platform Level Cylnder ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������ ������...

  • 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 January 2022 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 January 2022 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 January 2022 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 January 2022 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 January 2022 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 January 2022 Primary Machine Components Primary Machine Components PLATFORM SWING GATE CONTROLS ENGINE LIFT PLATFORM GATE BOOM TURRET LOWER CONTROL FUEL TANK HYDRAULIC OIL TANK CHASSIS Art 5505 Page 10 45-J Desel - Servce & Parts Manual...

  • Page 17: Emergency Systems And Procedures

    Secton 8 - Emergency Systems And Procedures January 2022 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 January 2022 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 January 2022 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 January 2022 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 January 2022 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 January 2022 The boom of each machine should be full retracted. Arrange the machines as shown. Secure the chassis of each machine as previously instructed on page 16. Secure the platform of each machine as previously instructed on page 16. Page 17 45-J Desel - Servce &...

  • Page 24: HydraulC System - General

    Secton 10 - Hydraulc System January 2022 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 January 2022 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 January 2022 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 in sequence. 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 January 2022 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 January 2022 Hydraulic Pumps Note: Refer to Section 25 - Hydraulics. 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 45-J machines. Contact MEC for the nearest service provider. Page 24...
  • Page 31 Secton 10 - Hydraulc System January 2022 Page 25 45-J Desel - Servce & Parts Manual...
  • Page 32 Secton 10 - Hydraulc System January 2022 Functions Pump The Functions Pump is a variable-displacement open loop load sense pump. The pump creates only the oil flow necessary with the load sense signal determining pump demand. The Functions Pump must be filled with fluid and all air bled out any time the pump is removed and re-installed, or drained of fluid for any reason.

  • Page 33: HydraulC ManFolds

    Secton 10 - Hydraulc System January 2022 Hydraulic Manifolds Note: Refer to Section 25 - Hydraulics. 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 34 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 35: AdjustNg RelEf Valves

    Secton 10 - Hydraulc System January 2022 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 36 Secton 10 - Hydraulc System January 2022 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 37: 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 or drive pump. Contact MEC for the nearest service provider or replacement. Page 31...

  • Page 38: General CylNder RepaR

    Secton 10 - Hydraulc System January 2022 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 39 Secton 10 - Hydraulc System January 2022 Insert cylinder into vise. Do not over clamp the cylinder or damage will result. DO NOT overtighten the vise������ Overtightening may damage the cylinder������ Cylinder Disassembly Mark and remove solenoid valves or counterbalance valves, if the cylinder is equipped with them.
  • Page 40 Secton 10 - Hydraulc System January 2022 by slowly twisting the piston onto the threads of the shaft. Be very careful not to damage the inside seals. Reinstall the shaft nut. Torque 1 ½” nut to 160 ft. lbs. (216 N-m). On pistons with set screws, tighten the set screw.

  • Page 41: ElectrCal System - General

    Secton 11 - Electrcal System January 2022 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 42 Secton 11 - Electrcal System January 2022 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/GP500 Module located inside the lower control box.

  • Page 43: BatterEs

    Secton 11 - Electrcal System January 2022 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 44 Secton 11 - Electrcal System January 2022 Battery Maintenance (In Use) Check battery and surrounding area for signs of damage or corrosion. Check battery terminals for: • Corrosion: Regularly clean connections and apply a nonmetallic grease or protective spray to retard corrosion.

  • Page 45: Battery Replacement

    Secton 11 - Electrcal System January 2022 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 46: Section 12 - Controls

    Secton 12 - Controls January 2022 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 40 45-J Desel - Servce &...
  • Page 47 Secton 12 - Controls January 2022 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 48: Platform Controls

    Secton 12 - Controls January 2022 Platform Controls ART_4709 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 49 Secton 12 - Controls January 2022 13 -- Depending on the position of the turntable, the machine may move in unexpected directions when the Drive and Steer functions are activated. The color- and shape-coded arrows on the joystick decal correspond to similar arrow decals on the machine chassis. Be sure to check the arrows on the chassis before using the Drive or Steer functions.

  • Page 50: Section 13 - Sensors, Relays & Alarms

    Secton 13 - Sensors, Relays & Alarms January 2022 Sensors Sensors CAN-Tilt CAN-Tilt Proximity Load Cell* Switch Boom Retract Proximity EZ Fit Sensor Angle Sensor *Optional Overload Sensing System component ART_4889 Page 44 45-J Desel - Servce & Parts Manual...
  • Page 51 Secton 13 - Sensors, Relays & Alarms January 2022 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 52: Relays

    Secton 13 - Sensors, Relays & Alarms January 2022 Relays Throttle Solenoid Starter Relay Controller Glow Plug Relay Glow Plug Circuit ART_4890 Breaker Engine Relays The Engine Relays are located beside the engine on the exterior edge of the Engine Tray. These relays convert GP400/GP500 signals into engine operational functions (e.g., start and stop).

  • Page 53: Alarms

    Secton 13 - Sensors, Relays & Alarms January 2022 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 Lower Control Box).

  • Page 54: 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 55: Section 15 - Continuity Checks

    Secton 15 - Contnuty Checks January 2022 Continuity Checks Continuity Checks Selector Switch – On-Off • Disconnect wires. Normally Normally • Connect the first probe of the ohm meter to Common Open Closed terminal. • Connect the second probe to any Normally Open terminal. •...
  • Page 56 Secton 15 - Contnuty Checks January 2022 Toggle Momentary Switch • Disconnect wires. Normally Open • Connect the first probe of the ohm meter to Common Terminal. Common Test top position Normally Open • Connect second probe to top Normally Open terminal. •...

  • Page 57: Section 16 - Control System

    Secton 16 - Control System January 2022 Control System Control System The GP400/GP500 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 58: Gp400 CalBratOn

    Secton 16 - Control System January 2022 GP400 Calibration GP440 Module P1 P2 Upper Controls EZ-Cal Port EZ-Cal port on bottom, facing down GP440 ART_4891 Module The GP400 Module relies on angle sensors to monitor platform elevation at all times. These sensors send voltages signals to the GP400 that relate directly to their respective angle.

  • Page 59: Gp400 CalBratOn Procedure

    The following procedures and additional tasks detailed in Section 19 - Troubleshooting 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...
  • Page 60 Secton 16 - Control System January 2022 Two calibrations must be performed for all versions of this machine: Level Sensor(s) Calibration Height Sensor Calibration Machines equipped with the optional Overload Sensing System 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 prevent full boom elevation.
  • Page 61 Secton 16 - Control System January 2022 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 62 Secton 16 - Control System January 2022 • (1) 227 kg (500 lbs) -- Machines equipped with optional Overload Sensing System. Press the right arrow until the display reads “PLATFORM EMPTY”. Remove all weight from the platform, then press ENTER. Once the calibration is complete, a screen should appear to enter the date.

  • Page 63: FaLure Messages

    Secton 17 - Calbraton Problems January 2022 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 64 Secton 17 - Calbraton Problems January 2022 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”...
  • Page 65 • 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”...
  • Page 66 Secton 17 - Calbraton Problems January 2022 • This message could also occur if the wrong pressure sensor was fitted (e.g.: a 5000psi sensor 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”...
  • Page 67 Secton 17 - Calbraton Problems January 2022 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 68: InformatOn Messages

    Secton 17 - Calbraton Problems January 2022 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 69 Secton 17 - Calbraton Problems January 2022 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 70 Secton 17 - Calbraton Problems January 2022 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 71: Section 18 - Mechanical Components

    OF THE EQUIPMENT������ ON MACHINES WHERE FOAM FILLED TIRES ARE 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 72: Nordlock Washers

    Secton 18 - Mechancal Components January 2022 Nordlock Washers Nord-Lock® style lock washers are used on many places in this machine. Nord-Lock® washers consist of a pair of washers with cams facing each other and spline gripping the mating surface. The use cam-geometry to effectively prevent the bolt from unbolting loose.
  • Page 73 Secton 18 - Mechancal Components January 2022 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 74 Secton 18 - Mechancal Components January 2022 Note: Load Cells are used on any machine equipped with the optional Overload Sensing System. The Spacer Plate is used only if the optional Overload Sensing System is not present. Assembly Assembly is the reverse of disassembly. Tighten all fasteners to proper torque as shown below. Location Torque Platform Rotator to Spacer/Load Cell...

  • Page 75: Platform Rotator

    Secton 18 - Mechancal Components January 2022 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 76 Secton 18 - Mechancal Components January 2022 Note: Load Cells are used on any machine equipped with the optional Overload Sensing System. The Spacer Plate is used only if the optional Overload Sensing System is not present. Assembly Assembly is the reverse of disassembly. Examine all pins for signs of wear, surface imperfections, cracks or gray dust in the pivot area.

  • Page 77: JB CylNder

    Secton 18 - Mechancal Components January 2022 Jib 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������ The Jib Cylinder is located within the Jib linkage assembly.
  • Page 78 Secton 18 - Mechancal Components January 2022 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 79 Secton 18 - Mechancal Components January 2022 Assembly Assembly is the reverse of disassembly. Examine all pins for signs of wear, surface imperfections, cracks or gray dust in the pivot area. Replace if any of the above conditions exist. 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 80: Platform Level CylNder

    Secton 18 - Mechancal Components January 2022 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 81 Secton 18 - Mechancal Components January 2022 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 82 Secton 18 - Mechancal Components January 2022 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 83 Secton 18 - Mechancal Components January 2022 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 84: Boom LFt CylNder/Boom LNkage

    Secton 18 - Mechancal Components January 2022 Boom Lift Cylinder/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 85 Secton 18 - Mechancal Components January 2022 Main Boom Assembly Rig slings and a spreader bar from the Main Boom Block Assembly to an overhead hoist as shown. Apply slight lifting pressure. ART_4934 Place a 4x4 inch (10x10 cm) block between the Lift Cylinder and turntable side sheets as shown.
  • Page 86 Secton 18 - Mechancal Components January 2022 Assembly Assembly is the reverse of disassembly. Examine all pins for signs of wear, surface imperfections, cracks or gray dust in the pivot area. Replace if any of the above conditions exist. Refer to Section 4 - Torque Specifications of this manual for torque specifications of fasteners. Page 80 45-J Desel - Servce &...

  • Page 87: MaN Boom Assembly

    Secton 18 - Mechancal Components January 2022 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 88 Secton 18 - Mechancal Components January 2022 Remove the side and the top inner wear pads and shims from the front of the boom’s Base Section. Apply slight lifting pressure. Wear Remove the bottom inner wear pad from the front of the Pads boom’s Base Section.
  • Page 89 Secton 18 - Mechancal Components January 2022 Bolts & Washers 50033 Bolt, M10-25 Lg 50034 Bolt, M10-30 Lg 50332 Bolt, M10-35 Lg 50035 Bolt, M10-40 Lg 50036 Bolt, M10-50 Lg 50021 Bolt, M10-55 Lg 50006 Washer, M10 Nordlock Use an overhead hoist or forklift to position the End Section of the boom in front of the Base Section.
  • Page 90 Secton 18 - Mechancal Components January 2022 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 91 Note: Swing Drive and Swing Bearing Mass: 210 LBS 95 KG ART_4946 THE WASHERS USED ON THESE BOLTS ARE HARDENED STRUCTURAL WASHERS������ REPLACE LOST OR DAMAGED WASHERS WITH MEC PART #50582 ONLY������ Page 85 45-J Desel - Servce & Parts Manual...
  • 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: 200 LBS...
  • Page 93 Secton 18 - Mechancal Components January 2022 Swing Bearing/ Swing Drive Installation Install the Swing Bearing with the motor axis parallel to the chassis side sheet. The swing bearing drive motor should be towards/facing the front axle. Painted Swing Bearing ART_5515 Use an alternating criss-cross pattern to tighten the bolts securing the Swing...

  • Page 94: DrVe Motors & Gear Hubs

    Secton 18 - Mechancal Components January 2022 Drive Motors & Gear Hubs Note: See Section 24 - Axles & Section 25 - Hydraulics 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 95 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 96: EngNe MaNtenance

    Secton 18 - Mechancal Components January 2022 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 97 Secton 18 - Mechancal Components January 2022 Air Filter Element Clean the air filter housing before opening. Remove the cap to the air filter canister. Remove old filter and replace with a new filter. Replace the cap to the air filter canister. Out to Fuel Filter Fuel...
  • Page 98 Secton 18 - Mechancal Components January 2022 Front Of Idle Speed Engine Screw Throttle Lever Throttle Adjustment Clevis & Throttle Link Throttle Solenoid Idle Speed Adjustment Adjustment Bring engine to operating temperature. Jam Nut Throttle Slow engine to complete idle. Solenoid Adjust the Idle Speed Screw until the RPM is 1800.

  • Page 99: LubrCatOn PoNts

    Secton 18 - Mechancal Components January 2022 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 100: General TroubleshootNg TPs

    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 101 Secton 19 - Troubleshootng January 2022 Electrical System Troubleshooting 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 Module, located in the lower controls box. They communicate through a low voltage digital signal called CAN-Bus communication.

  • Page 102: Gp400 Module

    Secton 19 - Troubleshootng January 2022 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 the 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 103: Valve Constant Current Module And TermNal Block Module

    Secton 19 - Troubleshootng January 2022 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 104: Gp440 Module

    Secton 19 - Troubleshootng January 2022 GP440 Module The GP440 Module is the remote module located inside the upper control box. It receives inputs from the operator and relays the inputs to the GP400. YELLOW LAMP-LOW FUEL INDICATOR P5-1 P7-1 JIB UP/DOWN SIGNAL BOOM UP/DOWN SIGNAL P5-2...

  • Page 105: 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 106: 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 107 OVERLOAD 5F-5 NOT USED 5H-5 USED ON 5D-7 FROM ON I/C STARTER DELAY MACHINES GEN MAX MAX DRIVE 10 SEC POWERED MEC AERIALS WITH 101% 100% UNITS 5F-6 OVERLOAD 5D-8 AUTO GLOW SENSING SLOW DOWN 10 SEC OPTION ONLY RISER...
  • Page 108 Secton 19 - Troubleshootng January 2022 To Serial #14700199 45JD 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...
  • Page 109 NOT USED 2.2 SEC 1.5 SEC NOT USED NOT USED 0.5 SEC PRIOR AUTHORIZATION 4A-9 4D-9 4F-9 4G-9 FROM MEC AERIALS STOP DECEL DECEL P5-14 DOWN CW MAX 4A-10A 0.7% 0.7 SEC NOT USED * YOUR PLATFORM LEVEL ANGLE DELAY+...
  • Page 110 Secton 19 - Troubleshootng January 2022 From Serial #14700200 EZ-Cal Flow Chart DIAGNOSTIC 45JD BOOM Chart 2 of 2 SERIAL FROM 14700200 SYMBOL KEY FUNCTIONS ESC/ENTER BUTTONS To move back and forth between Menu and sub-menu LEFT/RIGHT BUTTONS DIAGNOSTICS Select menus and setting to be adjusted UP/DOWN BUTTONS Adjust setting values ENTER...

  • Page 111: Ez-Cal Messages

    Secton 19 - Troubleshootng January 2022 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 112: Can Bus Related Messages

    Secton 19 - Troubleshootng January 2022 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 113 Secton 19 - Troubleshootng January 2022 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 114 Secton 19 - Troubleshootng January 2022 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 115 Secton 19 - Troubleshootng January 2022 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 116 Secton 19 - Troubleshootng January 2022 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 117 Secton 19 - Troubleshootng January 2022 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 118 Secton 19 - Troubleshootng January 2022 Troubleshooting Chart The following chart describes the possible causes for inoperable 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. The majority of electrical troubleshooting on this model will require the use of the onboard EZ-Cal scan tool, located inside the lower control box door.
  • Page 119 Secton 19 - Troubleshootng January 2022 Problem Possible Cause Remedy/Solution Engine Related Issues Indicates an attempt to start was 7-7 Flash code on GP400 sent by the GP400 but the oil Check all the above pressure switch did not close. Low fuel reservoir Check/fill fuel reservoir.
  • Page 120 Secton 19 - Troubleshootng January 2022 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 function...
  • Page 121 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 122 Secton 19 - Troubleshootng January 2022 Problem Possible Cause Remedy/Solution Drive 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...
  • Page 123 Secton 19 - Troubleshootng January 2022 Problem Possible Cause Remedy/Solution Steer Check continuity through micro-switch inside joystick handle using wires Joystick rocker switch inoperative 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 124 Secton 20 - Schematcs January 2022 Hydraulic Schematics Page 118 45-J Desel - Servce & Parts Manual...
  • Page 125 Secton 20 - Schematcs January 2022 Hydraulic Schematics with Weld Ready Option Page 119 45-J Desel - Servce & Parts Manual...
  • Page 126 Secton 20 - Schematcs January 2022 Electric Schematic, Lower Control Box, To Serial #14700199 T O T UR NT AB LE S C HE MAT IC P AG E 2 V ALV E C ONS T ANT C UR R E NT MODULE G P 400 MIC OR P R OC E S S OR (VC C M) (95)
  • Page 127 Secton 20 - Schematcs January 2022 Electric Schematic, Chassis, To Serial #14700199 ANG LE T R ANS DUC E R #1 (143) (15) OR G (15) B OOM R E T R AC T OR G /B LK (15) P R OX S WIT C H B LK (95) B OOM...
  • Page 128 Secton 20 - Schematcs January 2022 Electric Schematic, Upper Controls Box, To Serial #14700199 Page 122 45-J Desel - Servce & Parts Manual...
  • Page 129 Secton 20 - Schematcs January 2022 Electric Schematic, Lower Control Box, From Serial #14700200 TO TURNTABLE SCHEMATIC PAGE 2 GP 500 MICORPROCESSOR (414) (15) P1-1 CAN-BUS HI (95) (413) P1-2 CAN-BUS LO (412) (96) P1-3 GROUND (216) (217) (130) (217) JIB DOWN P4-1 (111)
  • Page 130 Secton 20 - Schematcs January 2022 Electric Schematic, Chassis, From Serial #14700200 ANGLE TRANSDUCER (DUAL CIRCUIT) (143) (43) (15) (15) (G BUS) ORG/BLK (15) (95) BOOM MANIFOLD (96) BOOM RETRACT WHT/BLK (15) PROX SWITCH BLK/WHT LEVEL UP LEVEL DOWN (216) BLU/WHT (15) JIB UP...
  • Page 131 Secton 20 - Schematcs January 2022 Electric Schematic, Upper Controls Box, From Serial #14700200 TO TURNTABLE SCHEMATIC PAGE 2 GP 442 MICORPROCESSOR PP1-1 PP1-2 PP1-3 PP1-4 LOAD CELL PP2-1 PP2-2 S+ CH2 PP2-3 S- CH2 PP2-3 S+ CH1 S4-1 S- CH1 S4-2 100µF MISC.
  • Page 132 January 2022 Notes Page 126 45-J Desel - Servce & Parts Manual...
  • Page 133 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 134 Upper Controls Box, Part 1 Upper Controls Box, Part 1 Horn Drive Speed Tilt Idle Speed Emergency Stop Glow Plug Engine Start/Stop Function Enable Aux Power Platform Level Upper Controls 45-J Diesel ART_4840 Page 128 45-J Desel - Servce & Parts Manual...
  • Page 135 Secton 21 - Controls January 2022 Item Part Number Description Qty������ 94685 PQ Controls - Boom Control Handle 94686 PQ Controls - Platform Control Handle 94687 PQ Controls - Drive Control Handle 28581 Palm Rest 7423 Switch, 2 Position Momentary 92422 Enable Button 92427...
  • Page 136 Secton 21 - Controls January 2022 Upper Controls Box, Part 2 Upper Controls 45-J Diesel ART_4841 Page 130 45-J Desel - Servce & Parts Manual...
  • Page 137 Secton 21 - Controls January 2022 Item Part Number Description Qty������ 28781 Upper Controls Enclosure 90714 Switch Base 8082 Contact Block, Normally Closed 8083 Contact Block, Normally Open 28779 Bracket 50191 THMS #10-32X00.50 ZP 92027 GP440 Module (Up To Serial #14700199) 95236 GP442 Module (From Serial #14700200) 50330...
  • Page 138 Secton 21 - Controls January 2022 Lower Controls Box Lower Controls 45-J Diesel ART_4842 Page 132 45-J Desel - Servce & Parts Manual...
  • Page 139 Secton 21 - Controls January 2022 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 93687 Decal, Lower Controls, 60J-D 7800 Emergency Stop Button 93900...
  • Page 140 Secton 22 - Platform January 2022 Platform Sub-Assembly, Part 1 Platform Sub-Assembly, Part 1 16 4X 10 2X 8 3X SEE DETAIL A FOR UNDERSIDE VIEW OF ITEM MOUNTING 16 8X DETAIL A ILLUSTRATION No. 65-J Platform Sub-Assembly, Part 1 Art_5520 Page 134 45-J Desel - Servce &...
  • Page 141 Secton 22 - Platform January 2022 Item Part Number Description Qty������ 31890 Platform Sub-Assembly 8909 Enclosure Service Manual 28521 Platform, Entry Slide Tube 28520 Platform, Swing Gate Weldment 28528 Platform, Swing Gate Latch Cable Assembly 28916 Upper Control Box (Refer to Pages 122 and 124) 31160 Weldment, Platform, 90”...
  • Page 142 Secton 22 - Platform January 2022 Platform Sub-Assembly, Part 2 11 8X 29 2X 13 8X 12 8X ILLUSTRATION No. 65-J Platform Sub-Assembly, Part 2 Art_5520 Page 136 45-J Desel - Servce & Parts Manual...
  • Page 143 Secton 22 - Platform January 2022 Item Part Number Description Qty������ 31890 Platform Sub-Assembly 28520 Platform, Swing Gate Weldment 28698 Spacer, Load Ring Plate w/o Overload 93868 Spacer, Load Ring Plate w/ Overload 28916 Upper Control Box (Refer to Pages 122 and 124) 31160 Weldment, Platform, 90”...
  • Page 144 Secton 23 - Elevatng Assembly January 2022 Base Boom Sub-Assembly, Part 1 Base Boom Sub-Assembly, Part 1 ILLUSTRATION No. 45-J Base Boom Sub-Assembly, Part 1 Art_5554 Page 138 45-J Desel - Servce & Parts Manual...
  • Page 145 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 16788 Slide Bumper 18151 Keeper Pin 18152 1/2" Pin Retainer 22541 M10 × 1.50 Insert 28748 Bracket, Boom Cable Tube Slide Guide 28765 Inner Tube Slide Block, High Load 28772 Offset, Thin Side Wear Pad 31222...
  • Page 146 Secton 23 - Elevatng Assembly January 2022 Base Boom Sub-Assembly, Part 2 ILLUSTRATION No. 45-J Base Boom Sub-Assembly, Part 2 Art_5554 Page 140 45-J Desel - Servce & Parts Manual...
  • Page 147 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 24379 Hose Wrap Forming 28634 Bracket, Boom Prox Switch 28694 Bracket, Platform Manifold Cover 50001 WSHR M08 ZP Standard Flat 50002 WSHR M10 ZP Standard Flat 50048 NNYL M08 × 1.25 08 ZP Nylon 50049 NNYL M10 ×...
  • Page 148 Secton 23 - Elevatng Assembly January 2022 Boom Sub-Assembly ILLUSTRATION No. 45-J Boom Sub-Assembly Art_5555 Page 142 45-J Desel - Servce & Parts Manual...
  • Page 149 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 28643 Wear Pad, Extend Cylinder Rest 28749 Bracket, Boom Cable Tube To Cable Track Connector 31032 Extend Cylinder 31227 Tube, Cable Track, 45J 31868 Base Boom Sub-Assembly (Refer to Pages 132 and 134) 31869 Tip Boom Sub-Assembly (Refer to Page 138) 50001...
  • Page 150 Secton 23 - Elevatng Assembly January 2022 Tip Boom Sub-Assembly ILLUSTRATION No. 45-J Tip Boom Sub-Assembly Art_5577 Page 144 45-J Desel - Servce & Parts Manual...
  • Page 151 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 22541 M10 × 1.50 Insert 28765 Inner Tube Slide Block, High Load 31086 Weldment, Tip Boom 31219 Pin, Platform 31221 Pin, Extend Cylinder, Tip Boom 28644 Retainer, Tip Boom Level Cyl Pin 50006 WSHR M10 ZP Nordlock 50414...
  • Page 152 Secton 23 - Elevatng Assembly January 2022 Jib Components 11 12 13 11 12 13 Jib Components 60-J ART_4849 Page 146 45-J Desel - Servce & Parts Manual...
  • Page 153 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 28400 Jib Tube Weldment 92032 Proximity Sensor 28646 Hose/Cable Cover 92360 Bearing Jib Cylinder (Refer to Page 168) 93740 Bearing 28420 Jib Linkage Weldment 28608 Pin, Jib Cylinder 28410 Compression Link 28607...
  • Page 154 Secton 23 - Elevatng Assembly January 2022 Platform Rotator Platform Rotator 60-J ART_4874 Page 148 45-J Desel - Servce & Parts Manual...
  • Page 155 Secton 23 - Elevatng Assembly January 2022 Item Part Number Description Qty������ 93830 Platform Rotator 50675 Fitting, MFFOR-MB45-4-4 94403 Manifold Assy Page 149 45-J Desel - Servce & Parts Manual...
  • Page 156 Secton 24 - Axles January 2022 Wheel and Tire Assembly Wheel and Tire Assembly 9X PER WHEEL ILLUSTRATION No. 45-J Wheel and Tire Assembly Art_5578 Page 150 45-J Desel - Servce & Parts Manual...
  • Page 157 Secton 24 - Axles January 2022 Item Part Number Description Qty������ 31098 Wheel & Tire, 33×12-20 RH, Solid 31099 Wheel & Tire, 33×12-20 LH, Solid 50266 Nut, Lug, 5/8-18 UNF Page 151 45-J Desel - Servce & Parts Manual...
  • Page 158 Secton 24 - Axles January 2022 Front Axle Sub-Assembly, Part 1 ILLUSTRATION No. 45-J Front Axle Sub-Assembly, Part 1 Art_5562 Page 152 45-J Desel - Servce & Parts Manual...
  • Page 159 Secton 24 - Axles January 2022 Item Part Number Description Qty������ 18051 Pin, 1.250 × 4.25 18070 Cylinder, Steering 18151 Keeper Pin 18165 Keeper Pin .375 × 2.20 31021 Weldment, Yoke, Right Side 31029 Weldment, Yoke, Left Side 31045 Weldment, Tie Rod 31236 Pin, 31.75mm ×...
  • Page 160 Secton 24 - Axles January 2022 Front Axle Sub-Assembly, Part 2 ILLUSTRATION No. 45-J Front Axle Sub-Assembly, Part 2 Art_5562 Page 154 45-J Desel - Servce & Parts Manual...
  • Page 161 Secton 24 - Axles January 2022 Item Part Number Description Qty������ 18151 Keeper Pin 18152 1/2" Pin Retainer 22209 Hose Guard 22210 Hose Guard 31021 Weldment, Yoke, Right Side 31034 Weldment, Front Axle 31216 Pin, 38.10mm × 180mm LG 31218 Pin, 50.80mm ×...
  • Page 162 Secton 25 - Hydraulcs January 2022 Main Manifold Assembly Main Manifold Assembly ILLUSTRATION No. 45-J Main Manifold Assembly Art_5571 Page 156 45-J Desel - Servce & Parts Manual...
  • Page 163 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31128 Bracket, Main 50002 WSHR M10 ZP Standard Flat 50006 WSHR M10 ZP Nordlock 50033 HHCS M10-1.50 × 25 08 ZP F 50049 NNYL M10 × 1.50 08 ZP Nylon Inse 50671 HYFT MFFOR-FFORX90-04-04 50674...
  • Page 164 Secton 25 - Hydraulcs January 2022 Main Functions Manifold Block Components 2 21 behind valve *Orifices located beneath plugs Main Functions Manifold 60-J ART_5002 Page 158 45-J Desel - Servce & Parts Manual...
  • Page 165 Secton 25 - Hydraulcs January 2022 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 166 Secton 25 - Hydraulcs January 2022 Platform Functions Manifold 11 12 Later Style Block Designation Platform Functions Manifold 60-J ART_4867 Page 160 45-J Desel - Servce & Parts Manual...
  • Page 167 Secton 25 - Hydraulcs January 2022 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 168 Secton 25 - Hydraulcs January 2022 Brake/Axle/2-Speed Manifold Brake/Axle/2-Speed Manifold 60-J Diesel ART_4865 Page 162 45-J Desel - Servce & Parts Manual...
  • Page 169 Secton 25 - Hydraulcs January 2022 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 170 Secton 25 - Hydraulcs January 2022 Rotary Manifold Sub-Assembly ILLUSTRATION No. 45-J Rotary Manifold Sub-Assembly Art_5575 Page 164 45-J Desel - Servce & Parts Manual...
  • Page 171 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 28621 Stop, Hydraulic Rotary Manifold 31263 Support, Rotary Manifold 50002 WSHR M10 ZP Standard Flat 50035 HHCS M10-1.50 × 40 08 ZP F 50049 NNYL M10 × 1.50 08 ZP Nylon Inse 50421 HHCS M10-1.50 ×...
  • Page 172 Secton 25 - Hydraulcs January 2022 Front Case Drain Manifold Assembly ILLUSTRATION No. 45-J Front Case Drain Manifold Assembly Art_5563 Page 166 45-J Desel - Servce & Parts Manual...
  • Page 173 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 50000 WSHR M06 ZP Standard Flat 50047 NNYL M06 × 1.00 08 ZP Nylock 50134 HHCS M06-1.00 × 60 08 ZP F 50656 HYFT MFFOR-MB90-04-06 50835 HYFT MFFOR-MB-6-6 ; FS6400-06-06-O 50836 HYFT MFFOR-MB-6-8 ;...
  • Page 174 Secton 25 - Hydraulcs January 2022 Hydraulic Tank Sub-Assembly ILLUSTRATION No. 45-J Hydraulic Tank Sub-Assembly Art_5568 Page 168 45-J Desel - Servce & Parts Manual...
  • Page 175 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31100 Weldment, Hydraulic Tank 50001 WSHR M08 ZP Standard Flat 50007 WSHR M12 ZP Nordlock 50014 HHCS M08-1.25 × 40 08 ZP P 50039 HHCS M12-1.75 × 30 08 ZP F 50981 HYFT MJ-MP-08-08 ;...
  • Page 176 Secton 25 - Hydraulcs January 2022 Charge Filter Sub-Assembly ILLUSTRATION No. 45-J Charge Filter Sub-Assembly Art_5556 Page 170 45-J Desel - Servce & Parts Manual...
  • Page 177 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31242 Bracket, Charge Filter 50006 WSHR M10 ZP Nordlock 50219 HHCS 03/08-16 × 0.75 05 ZP 50838 HYFT MFFOR-MB-8-12 ; FS6400-08-12-O 50849 HYFT MFFOR-MB90-8-12 ; FS6801-08-12-FG 92072 Filter Charge 725psi 92169 Filter Element Charge Page 171...
  • Page 178 Secton 25 - Hydraulcs January 2022 Boom Lift Cylinder Boom Lift Cylinder 45-J ART_5601 Page 172 45-J Desel - Servce & Parts Manual...
  • Page 179 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31030 Boom Lift Cylinder 50840 Fitting, MFFOR-MB-8-6 92622 Counterbalance valve 94033 Counterbalance valve 95382 Seal Kit Page 173 45-J Desel - Servce & Parts Manual...
  • Page 180 Secton 25 - Hydraulcs January 2022 Boom Extend Cylinder Boom Extend Cylinder 45-J ART_4877 Page 174 45-J Desel - Servce & Parts Manual...
  • Page 181 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31032 Extend Cylinder 50676 Fitting, MFFOR-MB45-6-6 28643 Wear Pad, Extend Cylinder Rest 50020 Bolt, M10 x 50 50053 Nut, M10 Nylock 50002 Washer, M10 Flat 92020 Counterbalance Valve 94536 Counterbalance Valve 95383 Seal Kit...
  • Page 182 Secton 25 - Hydraulcs January 2022 Platform Level Cylinder Platform Level Cylinder 45-J ART_4878 Page 176 45-J Desel - Servce & Parts Manual...
  • Page 183 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31033 Platform Level Cylinder 94527 Counterbalance Valve 95384 Seal Kit Page 177 45-J Desel - Servce & Parts Manual...
  • Page 184 Secton 25 - Hydraulcs January 2022 Jib Cylinder Jib Cylinder 45-J ART_5602 Page 178 45-J Desel - Servce & Parts Manual...
  • Page 185 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 28399 Jib Cylinder 50831 Fitting, MFFOR-MB-4-4 94630 Counterbalance Valve 94408 Counterbalance Valve 94327 Seal Kit Page 179 45-J Desel - Servce & Parts Manual...
  • Page 186 Secton 25 - Hydraulcs January 2022 Steer Cylinders Steer Cylinders 60-J ART_4873 Page 180 45-J Desel - Servce & Parts Manual...
  • Page 187 Secton 25 - Hydraulcs January 2022 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 181 45-J Desel - Servce & Parts Manual...
  • Page 188 Secton 25 - Hydraulcs January 2022 Axle Cylinders not shown Axle Cylinders 60-J ART_4880 Page 182 45-J Desel - Servce & Parts Manual...
  • Page 189 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 31031 Axle Cylinder 50676 Fitting, MFFOR-MB45-6-6 50675 Fitting, MFFOR-MB45-4-4 51167 Fitting, MP-MFFOR-4-4 95378 Counterbalance Valve 95385 Seal Kit Page 183 45-J Desel - Servce & Parts Manual...
  • Page 190 Secton 25 - Hydraulcs January 2022 Auxiliary Power Unit AUXILLARY POWER UNIT, 5592RT, 3392RT-T 92RT Series ART_3491 Page 184 45-J Desel - Servce & Parts Manual...
  • Page 191 Secton 25 - Hydraulcs January 2022 Item Part Number Description Qty������ 17973 Auxiliary Power Unit, Without Fittings 92534 Solenoid 50790 Fitting, MB-MJ90-6-6 Page 185 45-J Desel - Servce & Parts Manual...
  • Page 192 Secton 25 - Hydraulcs January 2022 Hydraulic Hoses Hose End A End A Fitting End B End B Fitting Hose Spec Hose Spec Length Fitting P/N Description Fitting P/N Description Description (mm) 52953 RFBRK - T 50667 4G-4FFORX 50679 4G-4FFORX 90 50627 4M-3K 1981...
  • Page 193 Secton 25 - Hydraulcs January 2022 LFB - 12G- 12M-4K 52982 50654 50704 12G-12FFORX 45 50730 1448 LBHUPER 12FFORX -MTF RFA - 12G- 12M-4K 52983 50654 50704 12G-12FFORX 45 50730 1448 RBHLOWER 12FFORX -MTF RFB - 12G- 12M-4K 52984 50654 50704 12G-12FFORX 45 50730...
  • Page 194 Secton 25 - Hydraulcs January 2022 B2SPEEDT- 56009 50666 6G-6FFORX 50685 6G-6FFORX 45 50629 6M-3K MMTOP EDOWNP- 56009 50666 6G-6FFORX 50687 6G-6FFORX 90 50629 6M-3K 1219 56010 PR - PMT 50698 8G-8FFORX 50698 8G-8FFORX 50630 8M-3K 3835 56010 CP-FET 50666 6G-6FFORX 50685 6G-6FFORX 45...
  • Page 195 Secton 25 - Hydraulcs January 2022 THIS PAGE IS INTENTIONALLY LEFT BLANK Page 189 45-J Desel - Servce & Parts Manual...
  • Page 196 Secton 26 - Base January 2022 Chassis Sub-Assembly Chassis Sub-Assembly ILLUSTRATION No. 45-J Chassis Sub-Assembly Art_5557 Page 190 45-J Desel - Servce & Parts Manual...
  • Page 197 Secton 26 - Base January 2022 Item Part Number Description Qty������ 18151 Keeper Pin 28617 Spacer, Swing Bearing 31000 Frame Weldment 31031 Axle Lock Cylinder 31055 Cover Plate, Chassis 31096 Plate, Cover, Rear Axle, 45J 31215 Pin, 38.1mm × 250mm LG 31238 Front Case Drain Manifold Assembly (Refer to Page 160) 31820...
  • Page 198 Secton 26 - Base January 2022 Engine Hood Assembly ILLUSTRATION No. 45-J Engine Hood Assembly Art_5560 Page 192 45-J Desel - Servce & Parts Manual...
  • Page 199 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31137 Weldment, Hood, Engine, 45J 31138 Hood Stop Assembly, 45J 31139 Mounting Bracket, Hood Hinge, 45J 93733-A Hinge Half 93733-B Hinge Half 93817 Flexible Molded Latch, Rubber, Stainless Steel 93821 Load Rated Pull Handle, 4-7/16"...
  • Page 200 Secton 26 - Base January 2022 Control Hood Assembly ILLUSTRATION No. 45-J Control Hood Assembly Art_5558 Page 194 45-J Desel - Servce & Parts Manual...
  • Page 201 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31138 Hood Stop Assembly (Refer to Page 210) 31139 Mounting Bracket, Hood Hinge, 45J 31151 Weldment, Hood, Control, 45J 31152 Assembly, Fuel Door 31231 Forming, Mount Fuel Door 50142 RHMS #06-32X00.375 ZP 50329 NNYL #06-32 ZP Nylon Inse...
  • Page 202 Secton 26 - Base January 2022 Engine Components See previous pages for Solenoid Mounting Bracket hardware. Engine Components 45-J Diesel ART_4858 Page 196 45-J Desel - Servce & Parts Manual...
  • Page 203 Secton 26 - Base January 2022 Item Part Number Description Qty������ 94038 94040 V-Belt 94038 Oil Plug 8665 Oil Filter 90227 Alternator 8413 Starter 94056 Oil Filler Cap 94058 Flywheel 91360 Ring Gear 94057 Fuel Solenoid 93619 Fuel Pump 31240 Mounting Bracket 92939 Throttle Pull Solenoid...
  • Page 204 Secton 26 - Base January 2022 Engine Tray Assembly, Part 1 ILLUSTRATION No. 45-J Engine Tray Assembly, Part 1 Art_5561 Page 198 45-J Desel - Servce & Parts Manual...
  • Page 205 Secton 26 - Base January 2022 Item Part Number Description Qty������ 6110 1/4"-20 Wing Nut 17966 Battery 950cca Group 31-STUD 22563 Battery Holdown 31109 Power Plant Assembly, Engine Module (Refer to Page 198) 31111 Engine Mount, LH, Engine Module 31112 Radiator Mount, Engine Module 31113 Mounting Bracket, Engine Module...
  • Page 206 Secton 26 - Base January 2022 Engine Tray Assembly, Part 2 ILLUSTRATION No. 45-J Engine Tray Assembly, Part 2 Art_5561 Page 200 45-J Desel - Servce & Parts Manual...
  • Page 207 Secton 26 - Base January 2022 Item Part Number Description Qty������ 17969 Motor Mount, Engine, 70 DR. 31110 Engine Mount, RH, Engine Module 31117 Weldment, Air Inlet, Engine Module 31265 Bracket, Radiator Mount, Top 31274 Weldment, Engine Pan 50002 WSHR M10 ZP Standard Flat 50003 WSHR M12 ZP Standard Flat 50006...
  • Page 208 Secton 26 - Base January 2022 Engine Tray Assembly, Part 3 ILLUSTRATION No. 45-J Hydraulic Hose Assemblies Attachment Points Art_5566 Page 202 45-J Desel - Servce & Parts Manual...
  • Page 209 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31241 Charge Filter Sub-Assembly (Refer to Page 164) 92169 Filter Charge Pump Element 92397 Filter Element In-tank Return Filter 50806 HYFT MFFOR-MB-16-12 50837 HYFT MFFOR-MB-8-10 51330 HYFT 04MFFOR-05MB 51083 HYFT MFFOR-MB90-06-04 50820 HYFT MFFOR-MB-6-4 ;...
  • Page 210 Secton 26 - Base January 2022 Engine Tray Assembly, Part 4 View A View A ILLUSTRATION No. 45-J Engine Tray Assembly, Part 4 Art_5561 Page 204 45-J Desel - Servce & Parts Manual...
  • Page 211 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31332 Weldment, Exhaust Tube 50200 M08 Nordlock Washer 50348 HHCS M08-1.25X25 08 ZP P 31257 Tube, Exhaust, End 92965 Exhaust Muffler, 6” Round, 1.5" ID Inlet, 1.5" ID Outlet 93267 1-5/8"...
  • Page 212 Secton 26 - Base January 2022 Power Plant Assembly, Engine Module ILLUSTRATION No. 45-J Power Plant Assembly, Engine Module Art_5573 Page 206 45-J Desel - Servce & Parts Manual...
  • Page 213 Secton 26 - Base January 2022 Item Part Number Description Qty������ 94746 Kubota Diesel Engine V1505 Tier 4, 1.5L, 4-Cyl 93470 D1105 SAE B-B Coupler (15T Spline) 50039 HHCS M12-1.75 × 30 08 ZP F 50003 WSHR M12 ZP Standard Flat 50007 WSHR M12 ZP Nordlock 94469...
  • Page 214 Secton 26 - Base January 2022 Relay & Fuel Filter Sub-Assembly ILLUSTRATION No. 45-J Relay & Fuel Filter Sub-Assembly Art_5574 Page 208 45-J Desel - Servce & Parts Manual...
  • Page 215 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31244 Bracket, Fuel Filter, Solenoid Controller, Relay 50000 WSHR M06 ZP Standard Flat 50001 WSHR M08 ZP Standard Flat 50031 HHCS M08-1.25 × 25 08 ZP F 50047 NNYL M06X1.00 08 ZP Nylock 50048 NNYL M08X1.25 08 ZP Nylon 50214...
  • Page 216 Secton 26 - Base January 2022 Solenoid Control Sub-Assembly ILLUSTRATION No. 45-J Solenoid Control Sub-Assembly Art_5576 Page 210 45-J Desel - Servce & Parts Manual...
  • Page 217 Secton 26 - Base January 2022 Item Part Number Description Qty������ 16347 Throttle Link 31240 Bracket, Throttle Solenoid 91117 Clevis, Throttle Linkage 92939 Throttle Pull Solenoid 50171 PCLV 0.310 × 0.50 ZP STL 50178 Cotter Pin, 1/8” × 1.00" 91588 WRFLAT 0.2500.7500 50006 WSHR M10 ZP Nordlock...
  • Page 218 Secton 26 - Base January 2022 Diesel Turret Sub-Assembly, Part 1 ILLUSTRATION No. 45-J Diesel Turret Sub-Assembly, Part 1 Art_5559 Page 212 45-J Desel - Servce & Parts Manual...
  • Page 219 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31020 Counterweight 31051 Weldment, Turret 31127 Main Manifold Assembly (Refer to Page 150) 31150 Control Hood Assembly (Refer to Page 188) 31250 Hydraulic Tank Sub-Assembly (Refer to Page 162) 31280 Fuel Tank, 16 Gal (Refer to Page 212) Page 213...
  • Page 220 Secton 26 - Base January 2022 Diesel Turret Sub-Assembly, Part 2 ILLUSTRATION No. 45-J Diesel Turret Sub-Assembly, Part 2 Art_5559 Page 214 45-J Desel - Servce & Parts Manual...
  • Page 221 Secton 26 - Base January 2022 Item Part Number Description Qty������ 17973 Auxiliary Pump, 12 VDC (Refer to Page 178) 18152 1/2" Pin Retainer 31107 Engine Tray Assembly (Refer to Pages 192 and 194 and 196) 31116 Front Mount, Gas Spring, Engine Module 31129 Lower Control Box &...
  • Page 222 Secton 26 - Base January 2022 Lower Control Box & Brackets Assembly ILLUSTRATION No. 45-J Lower Control Box & Brackets Assembly Art_5570 Page 216 45-J Desel - Servce & Parts Manual...
  • Page 223 Secton 26 - Base January 2022 Item Part Number Description Qty������ 28910 Lower Control Box (Refer to Page 126) 31130 Bracket, Control Box-To-Tank, 45J 31131 Bracket, Control Box-To-Frame, 45J 31132 Bracket, Accessories, Hood Latch, 45J 31278 Axle/2Spd/Brake Manifold Assembly (Refer to Page 156) 50000 WSHR M06 ZP Standard Flat 50002...
  • Page 224 Secton 26 - Base January 2022 Hood Stop Assembly ILLUSTRATION No. 45-J Hood Stop Assembly Art_5565 Page 218 45-J Desel - Servce & Parts Manual...
  • Page 225 Secton 26 - Base January 2022 Item Part Number Description Qty������ 31149 Bracket, Hood 50001 WSHR M08 ZP Standard Flat 50031 HHCS M08-1.25 × 25 08 ZP F 50048 NNYL M08 × 1.25 08 ZP Nylon 50203 NNYL 5/16-18, 05, ZP 93845 Load Rated Bumper Page 219...
  • Page 226 Secton 26 - Base January 2022 Fuel Tank, 16 Gal ILLUSTRATION No. 45-J Fuel Tank, 16 Gal Art_5564 Page 220 45-J Desel - Servce & Parts Manual...
  • Page 227 Secton 26 - Base January 2022 Item Part Number Description Qty������ 6919 Shut Off Valve 7789 SAE 4 Hose Clamp 8879 5/16" × 1/8" BARB 90 31285 Forming, Fuel Tank Mount, RH 31286 Forming, Fuel Tank Mount, LH 31281 Weldment, Fuel Tank 50000 WSHR M06 ZP Standard Flat 50002...
  • Page 228 Secton 26 - Base January 2022 Boom Harness Part Number Description 28853 Harness, Platform Valves 28854 Harness, Engine 28856 Harness, Power To Lower Box 28858 Harness, Main Function Block 28859 Harness, Engine Extension 28869 Harness, CAN Tilt Jumper 28883 Harness, COM To CAN Tilt 28884 Cable, Battery To Fuse (+) 28885...
  • Page 229 January 2022 THIS PAGE IS INTENTIONALLY LEFT BLANK Page 223 45-J Desel - Servce & Parts Manual...
  • Page 230 Secton 27 - Optons January 2022 Option - 7������ 5 kW Generator Motor Sub-Assembly Option - 7������ 5 kW Generator Motor Sub-Assembly ILLUSTRATION No. 45-J 7.5kW Generator Motor Sub-Assembly Art_5550 Page 224 45-J Desel - Servce & Parts Manual...
  • Page 231 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 31232 HYD Generator 7.5kW 208/120 60HZ 12cc (Cover) 94774 HYD Motor 50834 HYFT MFFOR-MB-6-10 ; FS6400-06-10-O 50842 HYFT MFFOR-MB90-12-10 ; FS6801-12-10-F 50832 HYFT MFFOR-MB-4-6 ; FS6400-04-06 50835 HYFT MFFOR-MB-6-6 51075 FFORX-MB90-06-06 FF6507-06-06 51199...
  • Page 232 Secton 27 - Optons January 2022 Option - 7������ 5 kW Breaker Box 2 PLCS 2 PLCS 67 FT TO PLATFORM CUT-OUT DETAIL TO 7.5KW GENERATOR 3 PLCS 3 FT 2 PLCS SEE DETAIL A GROUND JUNCTION BOX FOR FRONT DECAL LOCATIONS 3X CENTER ON DOOR APPROX.
  • Page 233 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 28849 Option, 7.5kW Generator DIN Rail 28894 Option, 7.5kW Back Panel Hole Cutout 31144 Option, 7.5kW Breaker Box Cutout 50191 THMS #10-32 × 0.50 ZP 50238 NNYL #10-32 05 Z 50337 WSHR #10-32 93095...
  • Page 234 Secton 27 - Optons January 2022 Option - 7������ 5 kW Generator Sub-Assembly PROPER CHECK VALVE ORIENTATION SEE DETAIL B FOR ITEM 34 TO ITEM MOUNTING SEE DETAIL D DETAIL C SEE DETAIL A FOR ITEM 34 TO ITEM MOUNTING 13 3 PLCS SEE NOTE 1 DETAIL B...
  • Page 235 Secton 27 - Optons January 2022 ILLUSTRATION No. 45-J 7.5kW Generator Option Sub-Assembly, Part 2 Art_5551 Page 229 45-J Desel - Servce & Parts Manual...
  • Page 236 Secton 27 - Optons January 2022 INSTALL 2X PROPER CHECK VALVE ORIENTATION DETAIL E ILLUSTRATION No. 45-J 7.5kW Generator Option Sub-Assembly, Part 3 Art_5551 Page 230 45-J Desel - Servce & Parts Manual...
  • Page 237 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 31085 Weldment, 7.5kW Gen 31134 Mounting Plate, 7.5kW Gen, 45J 31199 7.5kW Generator, Partial Manifold Sub-Assembly (Refer to Page 224) 28984 Option, 7.5kW Breaker Box Sub-Assembly (Refer to Page 218) 42871 Foot Plate Weldment 50002...
  • Page 238 Secton 27 - Optons January 2022 Option - 7������ 5 kW Generator, Partial Manifold Sub-Assembly ILLUSTRATION No. 45-J 7.5kW Generator, Partial Manifold Sub-Assembly Art_5552 Page 232 45-J Desel - Servce & Parts Manual...
  • Page 239 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 51066 HYFT MFFOR-MB90-10-12 51199 HYFT MFFOR-FFORX-MFFOR-10 FF6602-10-10-10 51217 HYFT MB-12 PLUG 94108 2 By 2 Parallel Body #12 93034 2 Way Proportional Valve NC 94410 Needle Valve 94109 Plug For 94108 91143 Coil 12V Page 233...
  • Page 240 Secton 27 - Optons January 2022 Option - 3������ 5 kW Generator Sub-Assembly "T" PRESSURE OUT "P" PRESSURE IN TO HYDRAULIC TANK FROM MAIN MAINFOLD DETAIL B DETAIL A GENERATOR MOUNTING BACKSIDE OF ITEM LOAD SENSE SEE DETAIL A LINE FOR HOSE CONNECTIONS SEE DETAIL B...
  • Page 241 Secton 27 - Optons January 2022 O.E.M. 10/3 CABLE TO PLATFORM UMBILICAL 10/3 CABLE FROM 10 DETAIL C ILLUSTRATION No. 45-J 3.5kW Generator Option Sub-Assembly, Part 2 Art_5603 Page 235 45-J Desel - Servce & Parts Manual...
  • Page 242 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 18667 Option, Generator Excite Harness Subassembly, Option, 7.5kW Outlet Boxes MKII 92271 Outlet, 120V 20A GFCI 92661 Terminal, Ring #10 Stud, 12-10 AWG 94414 3/4" Closure Plug 94741 Electrical Box, 1-Gang, Weatherproof, 5X 3/4 NPT Outlets, Alum 94748 Cover Weatherproof 1 Gang Vertical GFCI 94752...
  • Page 243 Secton 27 - Optons January 2022 THIS PAGE IS INTENTIONALLY LEFT BLANK Page 237 45-J Desel - Servce & Parts Manual...
  • Page 244 Secton 27 - Optons January 2022 Option - 3������ 5 kW Generator Fitting Assembly ILLUSTRATION No. 45-J 3.5kW Generator Fitting Assembly Art_5604 Page 238 45-J Desel - Servce & Parts Manual...
  • Page 245 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 93828 Generator, 3.5kW, 120V, 60 Hz 94764 Capacitor 14UF 93948 Check Valve Fitting 50961 HYFT MB-04-PLUG 50836 HYFT MFFOR-MB-6-8 ; FS6400-06-08-O 94506 Orifice Check Valve Fitting 50841 HYFT MFFOR-MB-8-8 ; FS6400-08-08-O 50850 HYFT MFFOR-MB90-8-8 ;...
  • Page 246 Secton 27 - Optons January 2022 Option - Glazier Rack ILLUSTRATION No. 45-J Option, Glazier Rack Art_5569 Page 240 45-J Desel - Servce & Parts Manual...
  • Page 247 NNYL M12X1.75 10 ZP Nylon 93920 Decal - Warning, Sheet Rack Self Weight 93963 Strap, Cam Buckle, 1”, 300# WL, Yellow, 10FT, W/ MEC Name 94393 Blind Rivot, Plastic, .157” Diameter, Yellow Zip Tie Yellow Zip Tie 15” Long X .30” Wide Page 241 45-J Desel - Servce &...
  • Page 248 Secton 27 - Optons January 2022 Option - Portable Welder Bracket Platform DETAIL A SCALE 1 : 6 ILLUSTRATION No. 45-J Option, Portable Welder Bracket Platform Art_5553 Page 242 45-J Desel - Servce & Parts Manual...
  • Page 249 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 28572 Portable Welder Bracket Assembly Option 31890 Assembly, Platform (Refer to Pages 128 & 130) 28571 Option, Welder Bracket Platform 94268 Clamp, Round Tube, 35 mm, Polyamide, Black 53205 PHMS M6-1.00 X 60MM Long ZP 94753 T-Bolt Clamp...
  • Page 250 Secton 27 - Optons January 2022 Option - Proactive Platform Safety System SECTION D-D SCALE 1 : 12 DETAIL M SCALE 1 : 8 ILLUSTRATION No. 45-J Option, Proactive Platform Safety System Art_5605 Page 244 45-J Desel - Servce & Parts Manual...
  • Page 251 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 28537 Bracket, Prox Switch Mount 28865 Harness, PPSS Extension 28866 Harness, PPSS Control 28890 Harness, PPSS Override 42386 Harness, PPSS Sensor Cable 90 Deg 50000 WSHR M06 ZP Standard Flat 50047 NNYL M06X1.00 08 ZP Nylock 50141...
  • Page 252 Secton 27 - Optons January 2022 Option - Upper Control Box Cover ILLUSTRATION No. 45-J Option, Upper Control Box Cover Art_5606 Page 246 45-J Desel - Servce & Parts Manual...
  • Page 253 Secton 27 - Optons January 2022 Item Part Number Description Qty������ 28780 Weldment, Upper Control Box Cover 53090 BHCS M06-1.00X070, 12.9, SS, F 53091 FHMS M03-0.50X008 SS 53092 NNYL M03-0.50 SS 53093 PHMS M03-0.50X008 92852 UHMW 1.25" X 5.5" C-Channel Wear Strip 94268 Clamp, Round Tube, 35 mm, Polyamide, Black 94486...
  • Page 254 Secton 28 - Decals January 2022 Decal Locations Decal Locations Page 248 45-J Desel - Servce & Parts Manual...
  • Page 255 Secton 28 - Decals January 2022 Inside S ID Opposite side of the chassis also Opposite side of the chassis also INSIDE CASE Page 249 45-J Desel - Servce & Parts Manual...
  • Page 256 Secton 28 - Decals January 2022 93182 Qty. - 1 94851 Qty. - 2 93801 Qty. - 2 93807 Qty. - 2 93755 Qty. - 2 93572 Qty. - 2 Qty. - 1 92117 Qty. - 1 9378 Qty. - 1 90732 Qty.
  • Page 257 January 2022 Notes Page 251 45-J Desel - Servce & Parts Manual...
  • Page 258 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 259 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 260 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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