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

Page iii 45-J Diesel - Service & Parts Manual
January 2022
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

Page iv 45-J Diesel - Service & Parts Manual
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

Page v 45-J Diesel - Service & Parts Manual
January 2022
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . 174
Platform Level Cylinder . . . . . . . . . . . . . . . . . 176
JibCylinder.................... 178
Steer Cylinders . . . . . . . . . . . . . . . . . . . 180
Axle Cylinders . . . . . . . . . . . . . . . . . . . . 182
Auxiliary Power Unit . . . . . . . . . . . . . . . . . . 184
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . 186
Section 26 - Base. . . . . . . . . . . . . . . . . 190
Chassis Sub-Assembly . . . . . . . . . . . . . . . . . 190
Engine Hood Assembly . . . . . . . . . . . . . . . . . 192
Control Hood Assembly . . . . . . . . . . . . . . . . . 194
Engine Components . . . . . . . . . . . . . . . . . . 196
Engine Tray Assembly, Part 1 . . . . . . . . . . . . . . . . 198
Engine Tray Assembly, Part 2 . . . . . . . . . . . . . . . . 200
Engine Tray Assembly, Part 3 . . . . . . . . . . . . . . . . 202
Engine Tray Assembly, Part 4 . . . . . . . . . . . . . . . . 204
Power Plant Assembly, Engine Module . . . . . . . . . . . . . 206
Relay & Fuel Filter Sub-Assembly. . . . . . . . . . . . . . . 208
Solenoid Control Sub-Assembly . . . . . . . . . . . . . . . 210
Diesel Turret Sub-Assembly, Part 1 . . . . . . . . . . . . . . 212
Diesel Turret Sub-Assembly, Part 2 . . . . . . . . . . . . . . 214
Lower Control Box & Brackets Assembly . . . . . . . . . . . . . 216
Hood Stop Assembly . . . . . . . . . . . . . . . . . . 218
Fuel Tank, 16 Gal . . . . . . . . . . . . . . . . . . . 220
BoomHarness.................... 222
Section 27 - Options . . . . . . . . . . . . . . . . 224
Option - 7.5kW Generator Motor Sub-Assembly . . . . . . . . . . . 224
Option - 7.5kW Breaker Box . . . . . . . . . . . . . . . . 226
Option - 7.5kW Generator Sub-Assembly . . . . . . . . . . . . . 228
Option - 7.5kW Generator, Partial Manifold Sub-Assembly . . . . . . . . 232
Option - 3.5kW Generator Sub-Assembly . . . . . . . . . . . . . 234
Option - 3.5kW Generator Fitting Assembly . . . . . . . . . . . . 238
Option - Glazier Rack . . . . . . . . . . . . . . . . . . 240
Option - Portable Welder Bracket Platform . . . . . . . . . . . . 242
Option - Proactive Platform Safety System . . . . . . . . . . . . 244
Option - Upper Control Box Cover. . . . . . . . . . . . . . . 246
Section 28 - Decals . . . . . . . . . . . . . . . . 248
Decal Locations . . . . . . . . . . . . . . . . . . . 248

Page 1 45-J Diesel - Service & Parts Manual
January 2022
Service Introduction
This Service section is designed to provide you, the customer, with the instructions needed to
properly maintain the MEC self-propelled aerial work platform. When used in conjunction with the
illustrated Parts section in this manual and the Operator’s Manual (provided separately), this manual
will assist you in making necessary adjustments and repairs, and identifying and ordering the correct
replacement parts.
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. Only trained authorized personnel should be allowed to
operate or service this machine. Service personnel should read and study the Operator’s, and the
Service and Parts Manuals in order to gain a thorough understanding of the unit prior to making any
repairs.
Chapter 1 - Service

Page 2 45-J Diesel - Service & Parts Manual
January 2022
MEC Operator Policy
Note:The best method to protect yourself and others from injury or death is to use common sense. If
you are unsure of any operation, don’t start until you are satisfied that it is safe to proceed and
have discussed the situation with your supervisor.
Service personnel and machine operators must understand and comply with all warnings and
instructional decals on the body of the machine, at the ground controls, and platform control console.
MODIFICATIONS OF THIS MACHINE FROM THE ORIGINAL DESIGN AND
SPECIFICATIONS WITHOUT WRITTEN PERMISSION FROM MEC ARE
STRICTLY FORBIDDEN. A MODIFICATION MAY COMPROMISE THE
SAFETY OF THE MACHINE, SUBJECTING OPERATOR(S) TO SERIOUS
INJURY OR DEATH.
MEC’s policies and procedures demonstrate our commitment to Quality and our relentless ongoing
efforts towards Continuous Improvement, due to which product specifications are subject to change
without notice.
Any procedures not found within this manual must be evaluated by the individual to assure oneself
that they are “proper and safe.”
Your MEC Aerial Work Platform has been designed, built, and tested to provide many years of safe,
dependable service. Only trained, authorized personnel should be allowed to operate or service the
machine.
MEC, as manufacturer, has no direct control over machine application and operation. Proper safety
practices are the responsibility of the user and all operating personnel.
If there is a question on application and/or operation, contact MEC Aerial Work 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
[email protected]
www.MECawp.com
MEC Aerial Work Platforms
MEC Operator Policy
Section 1 - MEC Operator Policy

Page 3 45-J Diesel - Service & Parts Manual
January 2022
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.
ORANGE and the word WARNING – Indicates a potentially hazardous
situation which, if not avoided, could result in death or serious injury.
YELLOW with alert symbol and the word CAUTION – Indicates a
potentially hazardous situation which, if not avoided, may result in minor
or moderate injury.
YELLOW without alert symbol and the word CAUTION – Indicates a
potentially hazardous situation which, if not avoided, may result in
property damage.
GREEN and the word NOTICE – Indicates operation or maintenance
information.
Regular inspection and constant maintenance is the key to efficient economical operation of your
aerial work platform. It will help to assure that your equipment will perform satisfactorily with a
minimum of service and repair.
The actual operating environment of the machine governs the inspection schedule. Correct lubrication
is an essential part of the preventative maintenance to minimize wear on working parts and ensure
against premature failure. By maintaining correct lubrication, the possibility of mechanical failure and
resulting downtime is reduced to a minimum.
Never leave hydraulic components or hoses open. They must be protected from contamination
(including rain) at all times.
Never open a hydraulic system when there are contaminants in the air.
Always clean the surrounding area before opening hydraulic systems.
Use only recommended lubricants. Improper lubricants or incompatible lubricants may be as
harmful as no lubrication.
Watch for makeshift “fixes” which can jeopardize safety as well as lead to more costly repair.
•
•
•
•
•
Safety Symbols & General Safety Tips
Section 2 - Safety Symbols & General Safety Tips

Page 4 45-J Diesel - Service & Parts Manual
January 2022
Specifications
Work Height* 50 ft 3 in 15.5 m
Platform Height 44 ft 3 in 13.5 m
Maximum Drive Height Full Height
Maximum Outreach 38 ft 11.6 m
Turntable Swing Continuous
Jib Range Of Motion 135°
Platform Rotation 180° (90° Each Side)
Machine Weight** (Unloaded) 13,650 lb 6,190 kg
Lift Capacity 500 lb 227 kg
Maximum Occupants 2
Stowed Height 95 in 2.4 m
Overall Length 28 ft 8.5 m
Overall Width 96 in 2.44 m
Tailswing 35 in 0.9 m
Platform Details
Width 90 in 2.3 m
Depth 40 in 1 m
Entry 1 End Swing Gate
2 Slide Bar Entries
Turning Radius, Inside 6 ft 6 in 2 m
Ground Clearance 13.5 in 34 cm
Lift Speed 40 sec
Extend Speed 20 sec
Jib Lift Speed 15 sec
Drive Speed
(Proportional) Stowed 0-3.5 mph 0-5.5 km/h
Raised or Extended 0-0.5 mph 0-0.8 km/h
Gradeability Stowed, Downhill 40%/22°
Stowed, Uphill 40%/22°
Breakover Angle 40%/22°
Axle Oscillation 10° (5° Each Side)
Maximum Allowable Operating Wind
Speed 28 mph 12.5 m/sec (45 km/h)
Engine Kubota V1505 - Tier 4 Final
Fuel Type Diesel
Fuel Capacity 16 gal 60 liter
Hydraulic Fluid Capacity 40 gal 150 liter Sound Pressure At Workstation 80 dB(A)
Maximum Vibration Does not exceed 8.2 ft/sec2
(2.5 m/sec2) at operator’s position Sound Power Level 86 dB @ 1m
Ambient Operating Range -20° F min
120° F max -29° C min 49° C max Ground Pressure/Wheel (Maximum) 69 psi 4.86 kg/cm2
Wheel Lug Nut Torque 150 Lb-ft 203 N-m Maximum Wheel Load 5869 lb 2662 kg
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.
**Weight may increase with certain options.
Specifications
Section 3 - Specifications

Page 5 45-J Diesel - Service & Parts Manual
January 2022
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 5 8
Cap Screw
Size (inches) Torque Torque
Ft-lbs N-m Ft-lbs N-m
Min Max Min Max Min Max Min Max
1/4 - 20 6.25 7.25 8.5 10 8.25 9.5 11 13
1/4 - 28 8 9 11 12 10.5 12 14 16
5/16 - 18 14 15 19 20 18.5 20 25 27
5/16 - 24 17.5 19 12 26 23 25 31 34
3/8 - 16 26 28 35 38 35 37 47.5 50
3/8 - 24 31 34 42 46 41 45 55.5 61
7/16- 14 41 45 55.5 61 55 60 74.5 81
7/16 - 20 51 55 69 74.5 68 75 92 102
1/2 - 13 65 72 88 97.5 86 96 116 130
1/2 - 20 76 84 103 114 102 112 138 152
9/16 - 12 95 105 129 142 127 140 172 190
9/16 - 18 111 123 150 167 148 164 200 222
5/8 - 11 126 139 171 188 168 185 228 251
5/8 - 18 152 168 206 228 203 224 275 304
3/4 - 10 238 262 322 255 318 350 431 474
3/4 - 16 274 302 371 409 365 402 495 544
7/8 - 9 350 386 474 523 466 515 631 698
7/8 - 14 407 448 551 607 543 597 736 809
1- 8 537 592 728 802 716 790 970 1070
1 - 14 670 740 908 1003 894 987 1211 1137
Torque values apply to fasteners as received from the supplier, dry or when lubricated with
normal engine oil.
If special graphite grease, molydisulphide grease, or other extreme pressure lubricants are
used, these torque values do not apply.
Specific Torque Values for Selected Fasteners
Location Torque Location Torque
Lug Nuts 150 Lb-ft 203 N-m Engine Tray / Battery Tray 140 Lb-ft 190 N-m
Torque Hubs to Yokes, Front 180 Lb-ft 244 N-m Boom Wear Pads 30 Lb-ft 41 N-m
Torque Hubs to Rear Axle, Rear 180 Lb-ft 244 N-m Level Cylinder Pin Retainer 20 Lb-ft 27 N-m
Drive Motor to Torque Hub Bolts 60 Lb-ft 81 N-m Platform Rotator to Spacer/Load Cell 55 Lb-ft 75 N-m
Swing Bearing Bolts on Chassis 180 Lb-ft 244 N-m Spacer/Load Cell to Platform Mount
Weldment 95 Lb-ft 129 N-m
Swing Bearing Bolts on Turret 180 Lb-ft 244 N-m Platform Rotator Through Bolt & Nut 420-450 Lb-ft 569-610 N-m
Swing Drive Bolts 320 Lb-ft 434 N-m Platform Mount Weldment Bolts & Nuts 250-270 Lb-ft 339-366 N-m
Section 4 - Torque Specifications
Bolt Torque Specification - American Standard

Page 6 45-J Diesel - Service & Parts Manual
January 2022Section 4 - Torque Specifications
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 10.9
Cap Screw Size
(Millimeters)
8.8
9.01
Torque Torque
Ft-lbs N-m Ft-lbs N-m
Min Max Min Max Min Max Min Max
M6 × 1.00 6 8 8 11 9 11 12 15
M8 × 1.25 16 20 21.5 27 23 27 31 36.5
M10 × 1.50 29 35 39 47 42 52 57 70
M12 × 1.75 52 62 70 84 75 91 102 123
M14 × 2.00 85 103 115 139 120 146 163 198
M16 × 2.50 130 158 176 214 176 216 238 293
M18 × 2.50 172 210 233 284 240 294 325 398
M20 × 2.50 247 301 335 408 343 426 465 577
M22 × 2.50 332 404 450 547 472 576 639 780
M24 × 3.00 423 517 573 700 599 732 812 992
M27 × 3.00 637 779 863 1055 898 1098 1217 1488
M30 × 3.00 872 1066 1181 1444 1224 1496 1658 2027
Torque values apply to fasteners as received from the supplier, dry or when lubricated with
normal engine oil.
If special graphite grease, molydisulphide grease, or other extreme pressure lubricants are
used, these torque values do not apply.
Specific Torque Values for Selected Fasteners
Location Torque
Lug Nuts 150 Lb-ft 203 N-m
Torque Hubs to Yokes, Front 180 Lb-ft 244 N-m
Torque Hubs to Rear Axle, Rear 180 Lb-ft 244 N-m
Drive Motor to Torque Hub Bolts 60 Lb-ft 81 N-m
Swing Bearing Bolts on Chassis 180 Lb-ft 244 N-m
Swing Bearing Bolts on Turret 180 Lb-ft 244 N-m
Swing Drive Bolts 320 Lb-ft 434 N-m
Engine Tray / Battery Tray 140 Lb-ft 190 N-m
Boom Wear Pads 30 Lb-ft 41 N-m
Level Cylinder Pin Retainer 20 Lb-ft 27 N-m
Platform Rotator to Spacer/Load Cell 55 Lb-ft 75 N-m
Spacer/Load Cell to Platform Mount Weldment 95 Lb-ft 129 N-m
Platform Rotator Through Bolt & Nut 420-450 Lb-ft 569-610 N-m
Platform Mount Weldment Bolts & Nuts 250-270 Lb-ft 339-366 N-m

Page 7 45-J Diesel - Service & Parts Manual
January 2022Section 4 - Torque Specifications
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.
Parts drawings and service instructions in this manual.
Packaging and instruction sheets provided with new parts.
Instruction manuals provided by the manufacturer of the component being serviced.
Type: SAE Port Series Cartridge Poppet Fittings Hoses
Ft-lbs N-m Ft-lbs N-m Ft-lbs N-m
#4 N/A N/A N/A N/A 135 - 145 15 - 16
#6 N/A N/A 10 - 20 14 - 27 215 - 245 24 - 28
#8 25 - 30 31 - 41 25 - 30 34 - 41 430 - 470 49 - 53
#10 35 - 40 47 - 54 35 - 40 47 - 54 680 - 750 77 - 85
#12 85 - 90 115 - 122 85 - 90 115 - 122 950 - 1050 107 - 119
#16 130 - 140 176 - 190 130 - 140 176 - 190 1300 - 1368 147 - 155
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Page 8 45-J Diesel - Service & Parts Manual
January 2022
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.
Use a sling and overhead hoist rated for 3 tons (2,700 kg) or more.
Thread the sling around the boom as shown. Proper sling placement should have the sling up against
the cable slide-bracket.
Important: Sling should NOT wrap around the cable track tube, but between it and the boom.
Connect it to the overhead hoist, then lift enough that the weight of the boom assembly is being
supported by the hoist.
Art 5506
Art 5506
Boom Support
Section 5 - Boom Support

Page 9 45-J Diesel - Service & Parts Manual
January 2022
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.
Hydraulic fluid leaks under pressure may not always be visible. Check for
pin hole leaks with a piece of cardboard, not your hand.
Electrical System
To prevent damage to battery and/or electrical system:
Always disconnect the negative battery cable first.
Always connect the positive battery cable first.
•
•
When the negative cable is installed, a spark will occur if contact is made between the positive side
of the battery and a metal surface on the machine. This can cause electrical system damage, battery
explosion, and personal injury.
Total System
ENGINE COOLANT LEVEL MUST BE CHECKED ONLY AFTER ENGINE
HAS COOLED. IF RADIATOR CAP IS REMOVED WHILE THE COOLANT
IS AT NORMAL OPERATING TEMPERATURE, PRESSURE WITHIN THE
COOLANT SYSTEM WILL FORCE HOT LIQUID OUT THROUGH THE
FILLER OPENING AND MAY CAUSE SEVERE SCALDING.
Failure to perform preventive maintenance at recommended intervals
may result in the unit being operated with a defect that could result in
injury or death of the operator.
Immediately report to your supervisor any defect or malfunction.
Any defect shall be repaired prior to continued use of the aerial work
platform.
Inspection and maintenance should be performed by qualified personnel
familiar with the equipment.
Hydraulic, Electrical and Total System
Section 6 - Hydraulic, Electrical & Total System

Page 10 45-J Diesel - Service & Parts Manual
January 2022
Primary Machine Components
SWING GATE
PLATFORM
CONTROLS
JIB
LIFT
GATEPLATFORM
BOOM
CHASSIS
Art 5505
TURRET
ENGINE
HYDRAULIC
OIL TANK
FUEL TANK
LOWER CONTROL
BOX
Primary Machine Components
Section 7 - Primary Machine Components

Page 11 45-J Diesel - Service & Parts Manual
January 2022
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.
Emergency Stop
ART_3353
The machine is equipped with an EMERGENCY STOP switch on both control
panels.
Press the EMERGENCY STOP switch at any time to stop all machine
functions.
Turn switch clockwise to reset.
Selector Switch Set To Platform
Either switch will stop all machine functions.
Both switches must be reset or machine will not operate.
Selector Switch Is Set To Base
The upper controls are locked out.
The lower controls switch must be reset or the machine will not operate.
The machine will operate from the lower controls if the upper controls
switch is tripped.
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Section 8 - Emergency Systems And Procedures
Emergency Systems and Procedures

Page 12 45-J Diesel - Service & Parts Manual
January 2022Section 8 - Emergency Systems And Procedures
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.
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
ART_4735
Base Controls
Platform Controls
Upper Auxiliary
Power Switch
Lower Auxiliary
Power Switch
Auxiliary
Power Switch
The Auxiliary Power System is used to lower the platform in case of primary power failure.
To lower the platform, activate the Auxiliary Power Switch to run the auxiliary hydraulic pump.
This function uses battery power from the auxiliary battery to lower the platform.
Push and hold the Auxiliary Power Switch, then use the Boom Extend/Retract function to retract
the boom.
Continue to hold the Auxiliary Power Switch, then use the Boom Lift/Lower function to lower the
boom.
Note: The Auxiliary Power System is disabled when the engine is running.
Note: The Auxiliary Power Switch serves as an enable switch. It is not necessary to use the primary
function enable switch.
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Page 13 45-J Diesel - Service & Parts Manual
January 2022
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.
BE SURE THAT THE SURFACE BENEATH THE MACHINE IS CAPABLE OF
SUPPORTING THE JACK AND JACK STANDS.
REMOVE ALL MATERIAL, TOOLS AND PERSONNEL FROM THE
PLATFORM BEFORE LIFTING.
The following are needed to safely lift and support the machine;
A jack with a lifting capacity of five (5) tons or more.
Jack stands with a rating of five (5) tons or more.
To Raise The Machine
Move machine to a firm level surface capable of supporting the weight of the machine.
Chock the tires on the end of machine opposite the end to be raised.
If wheel is to be removed, break loose but do not remove lug nuts before raising the machine.
Position a jack at the end of the machine to be lifted, under a solid lifting point in the center of
the frame.
Raise the machine and place two (2) suitable jack stands under solid support points at the outer
ends of the frame.
Lower the machine to rest on the jack stands and inspect for stability.
To Lower The Machine
Tighten lug nuts to hold the wheel snug to the hub. Do not torque the lug nuts at this time.
Raise machine slightly and remove jack stands.
Lower the machine and remove the jack.
Tighten lug nuts to proper torque (Refer to Specifications).
Remove chocks.
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1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
Section 9 - Transporting and Lifting Instructions
Lift and Support The Machine

Page 14 45-J Diesel - Service & Parts Manual
January 2022Section 9 - Transporting and Lifting Instructions
Transportation Instructions
Safety Information
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. DRIVERS ARE ALSO RESPONSIBLE
FOR SELECTING THE CORRECT AND APPROPRIATE TRAILER
ACCORDING TO GOVERNMENT REGULATIONS AND COMPANY POLICY.
DRIVERS MUST ENSURE THAT THE VEHICLE AND CHAINS ARE
STRONG ENOUGH TO HOLD THE WEIGHT OF THE MACHINE (SEE THE
SERIAL NUMBER PLATE FOR MACHINE WEIGHT).
ONLY PROPERLY TRAINED AND QUALIFIED OPERATORS SHALL LOAD
AND UNLOAD THIS MACHINE.
Loading
Free-Wheel Configuration For Winching Or Towing.
RUNAWAY HAZARD!
AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP
MACHINE TRAVEL. MACHINE WILL ROLL FREELY ON SLOPES.
ALWAYS CHOCK THE WHEELS BEFORE MANUALLY RELEASING THE
BRAKES.
The machine can be winched or towed short distances at speeds not to exceed 5 MPH (8 km/h).
Before towing or winching the machine, it is necessary to release the brakes. Reset the brakes after
towing or winching.
Disengage Brakes Before Towing Or Winching
Chock the wheels.
Remove the Torque Engage Cap and reinstall with the bump facing
inward on all four (4) hubs.
Engage Brakes Before Driving
Remove the Torque Engage Cap and reinstall with the bump facing
outward on all four (4) hubs.
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DISENGAGED
ENGAGED
ART_2848