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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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

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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
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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

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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

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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