Mec 60-J Diesel Guide

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

Page i 60-J Diesel - Service & Parts Manual
April 2019
Revision History
Date Reason for Update
September 2015 New Release
April 2016 CE Revision
March 2018 Continuous Improvement Update
April 2019 Added Bracket to Main Boom Component
1401 S. Madera Avenue, Kerman, CA93630 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 60-J Diesel - Service & Parts Manual
April 2019
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 . . . . . . . . . . . . . . . . . . . 25
Adjusting Relief Valves . . . . . . . . . . . . . . . . . . 27
Wheel Motor Startup Procedure . . . . . . . . . . . . . . . . 29
General Cylinder Repair . . . . . . . . . . . . . . . . . . 30
Section 11 - Electrical System . . . . . . . . . . . . . 33
Electrical System - General . . . . . . . . . . . . . . . . . 33
Batteries......................35

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April 2019
Battery Replacement . . . . . . . . . . . . . . . . . . . 37
Section 12 - Controls. . . . . . . . . . . . . . . . 38
LowerControls.....................38
Platform Controls ....................40
Section 13 - Sensors, Relays & Alarms. . . . . . . . . . . 42
Sensors......................42
Relays .......................44
Alarms.......................45
Section 14 - Deutsch Connectors . . . . . . . . . . . . 46
Deutsch Connectors . . . . . . . . . . . . . . . . . . . 46
Section 15 - Continuity Checks . . . . . . . . . . . . . 47
Continuity Checks . . . . . . . . . . . . . . . . . . . . 47
Section 16 - Control System. . . . . . . . . . . . . . 49
ControlSystem....................49
GP400 Calibration . . . . . . . . . . . . . . . . . . . . 50
GP400 Calibration Procedure . . . . . . . . . . . . . . . . . 51
Section 17 - Calibration Problems . . . . . . . . . . . . 55
Failure Messages . . . . . . . . . . . . . . . . . . . . 55
Information Messages . . . . . . . . . . . . . . . . . . . 60
Section 18 - Mechanical Components . . . . . . . . . . . 63
Mechanical Components . . . . . . . . . . . . . . . . . . 63
Nordlock Washers . . . . . . . . . . . . . . . . . . . . 64
Platform Removal & Installation . . . . . . . . . . . . . . . . 65
Platform Rotator . . . . . . . . . . . . . . . . . . . . 67
Jib Cylinder/Jib Components . . . . . . . . . . . . . . . . . 69
Platform Level Cylinder . . . . . . . . . . . . . . . . . . 72
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . . 74
Boom Lift Cylinders/Boom Linkage . . . . . . . . . . . . . . . 76
Main Boom Assembly . . . . . . . . . . . . . . . . . . . 80
Swing Bearing/Turntable Components . . . . . . . . . . . . . . 83
Drive Motors & Gear Hubs. . . . . . . . . . . . . . . . . . 89
Engine Maintenance . . . . . . . . . . . . . . . . . . . 91
Lubrication Points . . . . . . . . . . . . . . . . . . . . 94
Section 19 - Troubleshooting . . . . . . . . . . . . . 95
General Troubleshooting Tips . . . . . . . . . . . . . . . . . 95
Electrical System Troubleshooting. . . . . . . . . . . . . . . . 96
GP400Module.....................97
Valve Constant Current Module and Terminal Block Module . . . . . . . . . 98
GP440 Module.....................99
EZ-Cal Scan Tools. . . . . . . . . . . . . . . . . . . 100
Using The EZ-Cal With The Flow Charts . . . . . . . . . . . . . 101
EZ-Cal Messages . . . . . . . . . . . . . . . . . . . 104
Can Bus Related Messages ................ 105

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April 2019
Calibration Related Messages. . . . . . . . . . . . . . . . 106
Interlock Messages .................. 107
Other Messages ................... 109
Troubleshooting Chart . . . . . . . . . . . . . . . . . . .111
Section 20 - Schematics . . . . . . . . . . . . . . . 117
Hydraulic Schematics ~Serial #14400126, Part 1. . . . . . . . . . . .117
Hydraulic Schematics ~Serial #14400126, Part 2. . . . . . . . . . . .118
Primary Functions Manifold, ~Serial #14400126, Part 1 . . . . . . . . . .119
Primary Functions Manifold, ~Serial #14400126, Part 2 . . . . . . . . . 120
Hydraulic Schematic, Serial #14400127~, Part 1 . . . . . . . . . . . 121
Hydraulic Schematic, Serial #14400127~, Part 2 . . . . . . . . . . . 122
Primary Functions Manifold, Serial #14400127~, Part 1 . . . . . . . . . 123
Primary Functions Manifold, Serial #14400127~, Part 2 . . . . . . . . . 124
Electric Schematic, Lower Control Box, Standard Machines . . . . . . . . 125
Electric Schematic, Chassis, Standard Machines . . . . . . . . . . . 126
Electric Schematic, Lower Control Box, Optional Overload Sensing System . . . . 127
Electric Schematic, Chassis, Optional Overload Sensing System . . . . . . 128
Electric Schematic, Upper Controls Box, All Machines . . . . . . . . . 129
Chapter 2 - Parts . . . . . . . . . . . . . . 131
Parts Introduction ................131
Section 21 - Controls................132
Upper Controls Box, Part 1 . . . . . . . . . . . . . . . . 132
Upper Controls Box, Part 2 . . . . . . . . . . . . . . . . 134
Lower Controls Box . . . . . . . . . . . . . . . . . . 136
Section 22 - Platform. . . . . . . . . . . . . . . . 138
Platform Entries . . . . . . . . . . . . . . . . . . . 138
Platform Components . . . . . . . . . . . . . . . . . . 140
JibConnection.................... 142
Platform Options . . . . . . . . . . . . . . . . . . . 144
Section 23 - Elevating Assembly . . . . . . . . . . . . 146
Boom/Chassis Installation . . . . . . . . . . . . . . . . . 146
Boom&Riser.................... 148
Main Boom Components . . . . . . . . . . . . . . . . . 150
Jib Components . . . . . . . . . . . . . . . . . . . 152
Section 24 - Axles . . . . . . . . . . . . . . . . 154
Front Axle Installation . . . . . . . . . . . . . . . . . . 154
Rear Axle Installation - To Serial #14400260 . . . . . . . . . . . . 156
Front Axle Components . . . . . . . . . . . . . . . . . 158
Rear Axle Components . . . . . . . . . . . . . . . . . 160
Section 25 - Hydraulics . . . . . . . . . . . . . . . 162
Hydraulic Components . . . . . . . . . . . . . . . . . 162
Main Functions Manifold Fittings -- ~Serial #14400126 . . . . . . . . . 164
Main Functions Manifold Block Components -- ~Serial #14400126 . . . . . . 166

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April 2019
Main Functions Manifold Fittings -- Serial #14400127~ . . . . . . . . . 168
Main Functions Manifold Block Components -- Serial #14400127~ . . . . . . 170
Brake/Axle/2-Speed Manifold . . . . . . . . . . . . . . . . 172
Platform Functions Manifold -- ~Serial #14400126 . . . . . . . . . . 174
Platform Functions Manifold -- Serial #14400127~ . . . . . . . . . . 176
Chassis Blocks . . . . . . . . . . . . . . . . . . . 178
Rotary Manifold - To Serial # 14400334 . . . . . . . . . . . . . 180
Rotary Manifold - From Serial # 14400335 . . . . . . . . . . . . 182
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . 184
7.5kw Gen Assembly . . . . . . . . . . . . . . . . . . 186
7.5kw Gen Interim Assembly . . . . . . . . . . . . . . . . 188
7.5kw Gen Danfoss Assembly. . . . . . . . . . . . . . . . 190
Auxiliary Power Unit . . . . . . . . . . . . . . . . . . 192
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 194
Charge Filter Assembly . . . . . . . . . . . . . . . . . 196
Pressure Filter Assembly -- ~Serial #14400126 . . . . . . . . . . . 198
WheelMotors.................... 200
Platform Rotator - To Serial # 14400334 . . . . . . . . . . . . . 202
Platform Rotator - From Serial # 14400335 . . . . . . . . . . . . 204
SwingDrive.................... 205
Boom Lift Cylinders . . . . . . . . . . . . . . . . . . 206
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . 208
Platform Level Cylinder . . . . . . . . . . . . . . . . . 210
JibCylinder.................... 212
Steer Cylinders . . . . . . . . . . . . . . . . . . . 213
Axle Cylinders . . . . . . . . . . . . . . . . . . . . 214
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . 216
Section 26 - Base. . . . . . . . . . . . . . . . . 218
Chassis..................... 218
ModuleDoors.................... 220
EngineModule.................... 222
Engine Assembly . . . . . . . . . . . . . . . . . . . 224
Engine Components . . . . . . . . . . . . . . . . . . 226
Controls Module ................... 228
Controls Module #2 .................. 230
Turntable Components . . . . . . . . . . . . . . . . . 232
BoomHarness.................... 234
Section 27 - Decals, ANSI . . . . . . . . . . . . . . 235
Decals, 60-J Diesel ANSI . . . . . . . . . . . . . . . . . 235
Decals, 60-J Diesel ANSI, Platform . . . . . . . . . . . . . . 237
Decals, 60-J Diesel ANSI, Chassis & Turntable . . . . . . . . . . . 239
Section 28 - Decals, CE . . . . . . . . . . . . . . . 241
Decals, 60-J Diesel CE . . . . . . . . . . . . . . . . . 241
Decals, 60-J Diesel CE, Platform . . . . . . . . . . . . . . . 243
Decals, 60-J Diesel CE, Chassis & Turntable . . . . . . . . . . . . 245

Page 1 60-J Diesel - Service & Parts Manual
April 2019
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 60-J Diesel - Service & Parts Manual
April 2019
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, CA93630 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 60-J Diesel - Service & Parts Manual
April 2019
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 60-J Diesel - Service & Parts Manual
April 2019
Specifications
60-J Diesel
ART_4750
750 LBS
RESTRICTED
OPTION
500 LBS
UNRESTRICTED
0ft
0m
10ft
10ft
3m
20ft
6.1m
30ft
9.1m
40ft
12.2m
50ft
15.2m
10ft
3m
0ft
0m
3m
20ft
6.1m
30ft
9.1m
40ft
12.2m
50ft
15.2m
60ft
18.3m
70ft
21.3m
Working Height* 66 ft 20.1 m
Platform Height 60 ft 18.3 m
Maximum Drive Height 60 ft 18.3 m
Maximum Outreach 42 ft 8 in 13 m
Turntable Swing Continuous
Jib Range Of Motion 135°
Platform Rotation 180° (90° each side)
Machine Weight** (Unloaded) 17,900 lb 8,120 kg
Lift Capacity Unrestricted Standard 500 lb 227 kg
Restricted Option 750 lb 340 kg
Maximum Occupants 2
Stowed Height 100 in 2.54 m
Overall Length 30 ft 6 in 9.3 m
Overall Width 96 in 2.44 m
Tailswing 47 in 1.19 m
Wheel Base 101 in 2.56 m
Platform
Details
Width 96 in 2.44 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 50 sec
Extend Speed 20 sec
Jib Lift Speed 15 sec
Drive Speed
(Proportional) Stowed 0 - 4.0 mph 0 - 6.4 km/h
Raised or extended 0 - 0.5 mph 0 - 0.8 km/h
Gradeability Stowed, downhill 45%/24.2°
Stowed, uphill 45%/24.2°
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 V1505T 44 hp
Diesel
Fuel Type Diesel
Fuel Capacity 32 gal 120 liter
Hydraulic Fluid Capacity 40 gal 150 liter Sound Pressure At Workstation 80 dB(A)
Maximum Vibration Does not exceed 2.5 m/
sec2at operator’s position Sound Power Level 86 dB @ 1m
Ambient Operating Range -20° F min -29° C min Ground Pressure/Wheel
(Maximum) 4.86 kg/cm2
120° F max 49° C max
Wheel Lug Nut Torque 150 lb-ft 203 Nm Maximum Wheel Load 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