Mec 65-J Diesel Guide

Part # 95105
February 2021
Serial Number Range
14800000 - Up
Service & Parts Manual
65-J Diesel
ART_4883

Page i 65-J Diesel - Service & Parts Manual
February 2021
Revision History
Date Reason for Update
August 2019 New Release
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 65-J Diesel - Service & Parts Manual
February 2021
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
Supporting The Boom Assembly . . . . . . . . . . . . . . . . 8
Section 6 - Hydraulic, Electrical and 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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February 2021
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 . . . . . . . . . . . . 54
Failure Messages . . . . . . . . . . . . . . . . . . . . 54
Information Messages . . . . . . . . . . . . . . . . . . . 59
Section 18 - Mechanical Components . . . . . . . . . . . 62
Mechanical Components . . . . . . . . . . . . . . . . . . 62
Nordlock Washers . . . . . . . . . . . . . . . . . . . . 63
Platform Removal & Installation . . . . . . . . . . . . . . . . 64
Platform Rotator . . . . . . . . . . . . . . . . . . . . 66
Jib Cylinder/Jib Components . . . . . . . . . . . . . . . . . 68
Platform Level Cylinder . . . . . . . . . . . . . . . . . . 71
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . . 73
Boom Lift Cylinders/Boom Linkage . . . . . . . . . . . . . . . 75
Main Boom Assembly . . . . . . . . . . . . . . . . . . . 79
Swing Bearing/Turntable Components . . . . . . . . . . . . . . 82
Drive Motors & Gear Hubs. . . . . . . . . . . . . . . . . . 88
Engine Maintenance . . . . . . . . . . . . . . . . . . . 90
Lubrication Points . . . . . . . . . . . . . . . . . . . . 93
Section 19 - Troubleshooting . . . . . . . . . . . . . 94
General Troubleshooting Tips . . . . . . . . . . . . . . . . . 94
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 . . . . . . . . . . . . . . . . . . . 103
Can Bus Related Messages ................ 104

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Calibration Related Messages. . . . . . . . . . . . . . . . 105
Interlock Messages .................. 106
Other Messages ................... 108
Troubleshooting Chart . . . . . . . . . . . . . . . . . . .110
Section 20 - Schematics . . . . . . . . . . . . . . . 116
Hydraulic Schematic, Part 1 . . . . . . . . . . . . . . . . .116
Hydraulic Schematic, Part 2 . . . . . . . . . . . . . . . . .117
Primary Functions Manifold, Part 1 . . . . . . . . . . . . . . .118
Primary Functions Manifold, Part 2 . . . . . . . . . . . . . . .119
Electric Schematic, Lower Control Box, Standard Machines . . . . . . . . 120
Electric Schematic, Chassis, Standard Machines . . . . . . . . . . . 121
Electric Schematic, Upper Controls Box, All Machines . . . . . . . . . 122
Chapter 2 - Parts . . . . . . . . . . . . . . 123
Parts Introduction ................123
Section 21 - Controls................124
Upper Controls Box, Part 1 . . . . . . . . . . . . . . . . 124
Upper Controls Box, Part 2 . . . . . . . . . . . . . . . . 126
Lower Controls Box . . . . . . . . . . . . . . . . . . 128
Section 22 - Platform. . . . . . . . . . . . . . . . 130
Platform Sub-Assembly, Part 1 . . . . . . . . . . . . . . . 130
Platform Sub-Assembly, Part 2 . . . . . . . . . . . . . . . 132
JibConnection.................... 134
Platform Options . . . . . . . . . . . . . . . . . . . 136
Section 23 - Elevating Assembly . . . . . . . . . . . . 138
Boom/Chassis Installation . . . . . . . . . . . . . . . . . 138
Boom&Riser.................... 140
Main Boom Components . . . . . . . . . . . . . . . . . 142
Jib Components . . . . . . . . . . . . . . . . . . . 144
Section 24 - Axles . . . . . . . . . . . . . . . . 146
Front Axle Installation . . . . . . . . . . . . . . . . . . 146
Front Axle Components ................. 148
Rear Axle Components ................. 150
Section 25 - Hydraulics . . . . . . . . . . . . . . . 152
Hydraulic Components . . . . . . . . . . . . . . . . . 152
Main Functions Manifold Fittings . . . . . . . . . . . . . . . 154
Main Functions Manifold Block Components . . . . . . . . . . . . 156
Brake/Axle/2-Speed Manifold . . . . . . . . . . . . . . . . 158
Platform Functions Manifold . . . . . . . . . . . . . . . . 160
Chassis Blocks . . . . . . . . . . . . . . . . . . . 162
Rotary Manifold . . . . . . . . . . . . . . . . . . . 164
Hydraulic Pumps . . . . . . . . . . . . . . . . . . . 166
7.5kw Gen Assembly . . . . . . . . . . . . . . . . . . 168
7.5kw Gen Interim Assembly . . . . . . . . . . . . . . . . 170

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February 2021
7.5kw Gen Danfoss Assembly. . . . . . . . . . . . . . . . 172
Auxiliary Power Unit . . . . . . . . . . . . . . . . . . 174
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 176
Charge Filter Assembly . . . . . . . . . . . . . . . . . 178
WheelMotors.................... 180
Platform Rotator . . . . . . . . . . . . . . . . . . . 182
SwingDrive.................... 183
Boom Lift Cylinders . . . . . . . . . . . . . . . . . . 184
Boom Extend Cylinder. . . . . . . . . . . . . . . . . . 186
Platform Level Cylinder . . . . . . . . . . . . . . . . . 188
JibCylinder.................... 190
Steer Cylinders . . . . . . . . . . . . . . . . . . . 191
Axle Cylinders . . . . . . . . . . . . . . . . . . . . 192
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . 194
Section 26 - Base. . . . . . . . . . . . . . . . . 196
Chassis..................... 196
ModuleDoors.................... 198
EngineModule.................... 200
Engine Assembly . . . . . . . . . . . . . . . . . . . 202
Engine Components . . . . . . . . . . . . . . . . . . 204
Controls Module . . . . . . . . . . . . . . . . . . . 206
Controls Module #2 . . . . . . . . . . . . . . . . . . 208
Turntable Components . . . . . . . . . . . . . . . . . 210
BoomHarness.................... 212
Section 27 - Decals . . . . . . . . . . . . . . . . 213
Decal Locations . . . . . . . . . . . . . . . . . . . 213

Page 1 65-J Diesel - Service & Parts Manual
February 2021
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 65-J Diesel - Service & Parts Manual
February 2021
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 65-J Diesel - Service & Parts Manual
February 2021
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 65-J Diesel - Service & Parts Manual
February 2021
Specifications
Work Height* 71 ft 21.6 m
Platform Height 65 ft 19.8 m
Maximum Drive Height Full Height
Maximum Outreach 47 ft 14.3 m
Turntable Swing Continuous
Jib Range Of Motion 135°
Platform Rotation 180° (90° Each Side)
Machine Weight** (Unloaded) 19,850 lb 9,000 kg
Lift Capacity 500 lb 227 kg
Maximum Occupants 2
Stowed Height 102 in 2.59 m
Overall Length 32 ft 9.8 m
Overall Width 98 in 2.49 m
Tailswing 54 in 1.37 m
Wheel Base 101 in 2.56 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 15 in 38 cm
Lift Speed 60 sec
Extend Speed 30 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 V1505-T
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 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 Nm 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.
Section 3 - Specifications Specifications