Mec 45-J Diesel Guide

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

Page i 45-J Diesel - Service & Parts Manual
January 2022
Revision History
Date Reason for Update
May 2020 New Release
August 2020 Added Boom Harness
1401 S. Madera Avenue, Kerman, CA 93630 USA
Toll Free: 1 - 877 - 632 - 5438
Phone: 1 - 559 - 842 - 1500
Fax: 1 - 559 - 842 - 1520
[email protected]
www.MECawp.com
MEC Aerial Work Platforms

Page ii 45-J Diesel - Service & Parts Manual
January 2022
Table of Contents
Chapter 1 - Service . . . . . . . . . . . . . 1
Service Introduction ................1
Section 1 - MEC Operator Policy ............2
MEC Operator Policy . . . . . . . . . . . . . . . . . . . 2
Section 2 - Safety Symbols & General Safety Tips. . . . . . . . 3
Safety Symbols & General Safety Tips . . . . . . . . . . . . . . 3
Section 3 - Specifications . . . . . . . . . . . . . . 4
Specifications.....................4
Section 4 - Torque Specifications . . . . . . . . . . . . 5
Bolt Torque Specification - American Standard . . . . . . . . . . . . 5
Bolt Torque Specification - Metric Standard . . . . . . . . . . . . . 6
Hydraulic Components Torque Table . . . . . . . . . . . . . . . 7
Section 5 - Boom Support . . . . . . . . . . . . . . 8
BoomSupport.....................8
Section 6 - Hydraulic, Electrical & Total System . . . . . . . . 9
Hydraulic, Electrical and Total System . . . . . . . . . . . . . . 9
Section 7 - Primary Machine Components . . . . . . . . . . 10
Primary Machine Components . . . . . . . . . . . . . . . . 10
Section 8 - Emergency Systems And Procedures . . . . . . . . 11
Emergency Systems and Procedures . . . . . . . . . . . . . . . 11
Auxiliary Power System & Test . . . . . . . . . . . . . . . . 12
Section 9 - Transporting and Lifting Instructions . . . . . . . . 13
Lift and Support The Machine . . . . . . . . . . . . . . . . . 13
Transportation Instructions . . . . . . . . . . . . . . . . . 14
Driving or Winching onto or off of a Transport Vehicle. . . . . . . . . . . 15
Section 10 - Hydraulic System . . . . . . . . . . . . . 18
Hydraulic System – General . . . . . . . . . . . . . . . . . 18
Hydraulic Roadmap . . . . . . . . . . . . . . . . . . . 19
HydraulicFluid.....................21
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . . 23
Hydraulic Manifolds . . . . . . . . . . . . . . . . . . . 27
Adjusting Relief Valves . . . . . . . . . . . . . . . . . . 29
Wheel Motor Startup Procedure . . . . . . . . . . . . . . . . 31
General Cylinder Repair . . . . . . . . . . . . . . . . . . 32
Section 11 - Electrical System . . . . . . . . . . . . . 35
Electrical System - General . . . . . . . . . . . . . . . . . 35
Batteries......................37

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Battery Replacement . . . . . . . . . . . . . . . . . . . 39
Section 12 - Controls. . . . . . . . . . . . . . . . 40
LowerControls.....................40
Platform Controls ....................42
Section 13 - Sensors, Relays & Alarms. . . . . . . . . . . 44
Sensors......................44
Relays .......................46
Alarms.......................47
Section 14 - Deutsch Connectors . . . . . . . . . . . . 48
Deutsch Connectors . . . . . . . . . . . . . . . . . . . 48
Section 15 - Continuity Checks . . . . . . . . . . . . . 49
Continuity Checks . . . . . . . . . . . . . . . . . . . . 49
Section 16 - Control System. . . . . . . . . . . . . . 51
ControlSystem....................51
GP400 Calibration . . . . . . . . . . . . . . . . . . . . 52
GP400 Calibration Procedure . . . . . . . . . . . . . . . . . 53
Section 17 - Calibration Problems . . . . . . . . . . . . 57
Failure Messages . . . . . . . . . . . . . . . . . . . . 57
Information Messages . . . . . . . . . . . . . . . . . . . 62
Section 18 - Mechanical Components . . . . . . . . . . . 65
Mechanical Components . . . . . . . . . . . . . . . . . . 65
Nordlock Washers . . . . . . . . . . . . . . . . . . . . 66
Platform Removal & Installation . . . . . . . . . . . . . . . . 67
Platform Rotator . . . . . . . . . . . . . . . . . . . . 69
JibCylinder.....................71
Platform Level Cylinder . . . . . . . . . . . . . . . . . . 74
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . . 76
Boom Lift Cylinder/Boom Linkage . . . . . . . . . . . . . . . . 78
Main Boom Assembly . . . . . . . . . . . . . . . . . . . 81
Swing Bearing/Turntable Components . . . . . . . . . . . . . . 84
Drive Motors & Gear Hubs. . . . . . . . . . . . . . . . . . 88
Engine Maintenance . . . . . . . . . . . . . . . . . . . 90
Lubrication Points . . . . . . . . . . . . . . . . . . . . 93
General Troubleshooting Tips . . . . . . . . . . . . . . . . . 94
Section 19 - Troubleshooting . . . . . . . . . . . . . 95
Electrical System Troubleshooting. . . . . . . . . . . . . . . . 95
GP400Module.....................96
Valve Constant Current Module and Terminal Block Module . . . . . . . . . 97
GP440 Module.....................98
EZ-Cal Scan Tools. . . . . . . . . . . . . . . . . . . . 99
Using the EZ-Cal with the Flow Charts . . . . . . . . . . . . . 100
EZ-Cal Messages . . . . . . . . . . . . . . . . . . . 105
Can Bus Related Messages ................ 106

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January 2022
Calibration Related Messages. . . . . . . . . . . . . . . . 107
Interlock Messages .................. 108
Other Messages ....................110
Troubleshooting Chart . . . . . . . . . . . . . . . . . . .112
Section 20 - Schematics . . . . . . . . . . . . . . . 118
Hydraulic Schematics . . . . . . . . . . . . . . . . . . .118
Hydraulic Schematics with Weld Ready Option . . . . . . . . . . . .119
Electric Schematic, Lower Control Box, To Serial #14700199 . . . . . . . 120
Electric Schematic, Chassis, To Serial #14700199 . . . . . . . . . . 121
Electric Schematic, Upper Controls Box, To Serial #14700199 . . . . . . . 122
Electric Schematic, Lower Control Box, From Serial #14700200 . . . . . . . 123
Electric Schematic, Chassis, From Serial #14700200. . . . . . . . . . 124
Electric Schematic, Upper Controls Box, From Serial #14700200 . . . . . . 125
Chapter 2 - Parts . . . . . . . . . . . . . . 127
Parts Introduction ................127
Section 21 - Controls................128
Upper Controls Box, Part 1 . . . . . . . . . . . . . . . . 128
Upper Controls Box, Part 2 . . . . . . . . . . . . . . . . 130
Lower Controls Box . . . . . . . . . . . . . . . . . . 132
Section 22 - Platform. . . . . . . . . . . . . . . . 134
Platform Sub-Assembly, Part 1 . . . . . . . . . . . . . . . 134
Platform Sub-Assembly, Part 2 . . . . . . . . . . . . . . . 136
Section 23 - Elevating Assembly . . . . . . . . . . . . 138
Base Boom Sub-Assembly, Part 1. . . . . . . . . . . . . . . 138
Base Boom Sub-Assembly, Part 2. . . . . . . . . . . . . . . 140
Boom Sub-Assembly . . . . . . . . . . . . . . . . . . 142
Tip Boom Sub-Assembly . . . . . . . . . . . . . . . . . 144
Jib Components . . . . . . . . . . . . . . . . . . . 146
Platform Rotator . . . . . . . . . . . . . . . . . . . 148
Section 24 - Axles . . . . . . . . . . . . . . . . 150
Wheel and Tire Assembly . . . . . . . . . . . . . . . . . 150
Front Axle Sub-Assembly, Part 1 ............... 152
Front Axle Sub-Assembly, Part 2 . . . . . . . . . . . . . . . 154
Section 25 - Hydraulics . . . . . . . . . . . . . . . 156
Main Manifold Assembly . . . . . . . . . . . . . . . . . 156
Main Functions Manifold Block Components . . . . . . . . . . . . 158
Platform Functions Manifold . . . . . . . . . . . . . . . . 160
Brake/Axle/2-Speed Manifold . . . . . . . . . . . . . . . . 162
Rotary Manifold Sub-Assembly . . . . . . . . . . . . . . . 164
Front Case Drain Manifold Assembly . . . . . . . . . . . . . . 166
Hydraulic Tank Sub-Assembly. . . . . . . . . . . . . . . . 168
Charge Filter Sub-Assembly . . . . . . . . . . . . . . . . 170
Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . 172