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45-J Desel - Servce & Parts Manual

January 2022

Secton 27 - Optons

Option - 3��5kW Generator Sub-Assembly

Art_5603

ILLUSTRATION No.

45-J

SEE DETAIL B
FOR ITEMS 4 TO 3
MOUNTING DETAILS

SEE DETAIL A

FOR HOSE

CONNECTIONS

5 11

DETAIL B

GENERATOR MOUNTING

"T" PRESSURE OUT

TO HYDRAULIC TANK

LOAD

SENSE

LINE

"P" PRESSURE IN

FROM MAIN MAINFOLD

DETAIL A

BACKSIDE OF ITEM

3.5kW Generator Option Sub-Assembly, Part 1

Summary of Contents for 45-J Diesel

Page 1: ...Service Parts Manual Part 95090 January 2022 Serial Number Range 14700001 Up 45 J Diesel Art 5500...

Page 2: ...vision 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 info...

Page 3: ...ctrical 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...

Page 4: ...Messages 62 Section 18 Mechanical Components 65 Mechanical Components 65 Nordlock Washers 66 Platform Removal Installation 67 Platform Rotator 69 Jib Cylinder 71 Platform Level Cylinder 74 Boom Exten...

Page 5: ...ction 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...

Page 6: ...ilter 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...

Page 7: ...nd 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...

Page 8: ...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 fou...

Page 9: ...t 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...

Page 10: ...d 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 Eng...

Page 11: ...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...

Page 12: ...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...

Page 13: ...he 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...

Page 14: ...oom 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 th...

Page 15: ...etal 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...

Page 16: ...January 2022 Primary Machine Components SWING GATE PLATFORM CONTROLS JIB LIFT GATE PLATFORM BOOM CHASSIS Art 5505 TURRET ENGINE HYDRAULIC OIL TANK FUEL TANK LOWER CONTROL BOX Primary Machine Componen...

Page 17: ...h 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 fu...

Page 18: ...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 activat...

Page 19: ...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 befor...

Page 20: ...NE 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 HAZAR...

Page 21: ...SON ACTING AS A SPOTTER TO MAKE SURE THE PERSON LOADING THE MACHINE AVOIDS DANGEROUS SITUATIONS Driving Turn the Base Key Switch to PLATFORM Check that the Emergency Stop Switch is reset by turning it...

Page 22: ...are arranged so that they do not damage the machine ART_4742 Securing The Platform With the boom completely stowed raise the jib slightly then use the Platform Level function to lower the platform unt...

Page 23: ...9 Transporting and Lifting Instructions The boom of each machine should be full retracted Arrange the machines as shown Secure the chassis of each machine as previously instructed on page 16 Secure th...

Page 24: ...placement gear type Functions Pump mounted to the back of the piston pump As the engine turns the hydraulic pumps draw fluid from the reservoir and pump this fluid to the wheel motors and valve manifo...

Page 25: ...ic fluid to the Axle Cylinders the Brake Release function and the 2 Speed Pilot function through the use of electronically operated solenoid valves Platform Functions Manifold The Auxiliary Manifold p...

Page 26: ...e Boom Extend Cylinder One hydraulic cylinder extends and retracts the upper boom Platform Level Cylinder One hydraulic cylinder levels the platform as needed as the boom is raised and lowered Platfor...

Page 27: ...Recommended Hydraulic Fluid 30 F 0 C Chevron 1000THF 0 F 18 C 30 F 0 C Chevron Rando Premium MV 0 F 18 C Chevron Rando Premium MV System Flushing Procedure With boom fully lowered and retracted drain...

Page 28: ...ir The Hydraulic Fluid Reservoir Assembly consists of the reservoir a lockable filler cap with breather a drain plug a sight gauge and a bypass filter with a 10 micron filter element Check reservoir f...

Page 29: ...ll valve s on the Hydraulic Tank to prevent fluid loss when the hoses are removed Tag and disconnect hydraulic hoses and IMMEDIATELY cap or cover the openings to prevent contamination Remove the bolts...

Page 30: ...CHARGE FILTER INTERIOR SIDE DETAIL A B LS CD T CP EXTERIOR SIDE DETAIL P MA FE G MB Art_5510 Drive Pump The Drive Pump provides fluid to power the machine s Drive Function The Drive Pump must be fill...

Page 31: ...Page 25 45 J Diesel Service Parts Manual January 2022 Section 10 Hydraulic System Art_5706 ILLUSTRATION No...

Page 32: ...mp The pump creates only the oil flow necessary with the load sense signal determining pump demand The Functions Pump must be filled with fluid and all air bled out any time the pump is removed and re...

Page 33: ...removed Tag and disconnect the solenoid valve electrical leads Tag and disconnect hydraulic hoses Immediately cap the openings to prevent contamination Remove the bolts that hold the manifold to the m...

Page 34: ...each hydraulic function and check for leaks and for proper operation Adjust valve pressures Hydraulic Pressure Adjustment Before attempting to check and or adjust pressure relief valves operate the ma...

Page 35: ...f Valve Pressure 6 Park the machine on a firm level surface free from overhead obstructions Primary Manifold Pressure should be set to 3000 psi 207 bar Insert a 0 5000 psi gauge into the port GP of th...

Page 36: ...e is LOW adjust Valve 3 2 turn clockwise and recheck If pressure is HIGH adjust Valve 3 2 turn counterclockwise and recheck Tighten the lock nuts on the valves Boom Extend Relief 10 Park the machine o...

Page 37: ...luid Recommendations on page 21 Fill the reservoir with the appropriate hydraulic fluid as recommended in Fluid Recommendations on page 21 Always filter fluid through a 10 micron filter when pouring i...

Page 38: ...als Seals Piston Vent to Tank Return to Tank Barrel Pressure Piston Securing Nut Typical Single Acting Cylinder Removal Note Refer to Section 18 Mechanical Components for Remove and Replace instructio...

Page 39: ...llar and barrel using solvent rags and an air hose Inspect parts for scratches pits or polishing Check seal groves and sealing surfaces Scratches or pits deep enough to catch the fingernail are unacce...

Page 40: ...outside seals of the head and piston Reinstall the shaft into the barrel of the cylinder and push in until groove of the head lines up with the slot in the barrel Reinstall the cylinder retainer Insta...

Page 41: ...e set the controls have electrical power and the machine will operate When operating from the lower controls station only the lower Emergency Stop switch affects machine operation Activation of the lo...

Page 42: ...he processor should be ON If the LED is OFF or FLASHING refer to Section 19 Troubleshooting This section also contains instructions on the use of the EZ Cal diagnostic tool Starter Circuit Cutout ART_...

Page 43: ...ired to start the engine and to operate the electrical circuits An optional second may be present in machines to provide additional power for the Emergency Down power unit Battery Maintenance In Stora...

Page 44: ...ors will lead to shortened battery life Excessive water usage can indicate that a battery has been overcharged has been subjected to excessively high temperatures or is nearing the end of its service...

Page 45: ...Always disconnect the negative battery cable first Always connect the positive battery cable first To Remove A Battery Turn the Battery Disconnect switch to OFF Disconnect the battery cables and remov...

Page 46: ..._4824 17 18 16 13 12 10 9 14 15 3 2 4 5 1 8 7 6 ALWAYS CHECK OVER UNDER AND AROUND THE MACHINE FOR PERSONNEL STRUCTURES AND OBSTRUCTIONS BEFORE ACTIVATING ANY CONTROL FUNCTION AND CONTINUE TO WATCH FO...

Page 47: ...form downward 9 Overload Indicator Light Optional Overload Sensing System Only Light ON indicates too much weight on the platform An audible alarm will sound and all machine function will stop Remove...

Page 48: ...witch Move this switch up to activate glow plugs prior to cold starting the engine 5 Emergency Stop Switch Press the EMERGENCY STOP switch at any time to stop all machine functions Turn switch clockwi...

Page 49: ...on front of the control lever then push the control lever forward to lower the jib Platform Rotate Function Depress the enable bar on front of the control lever then push the control lever right to r...

Page 50: ...ts Manual January 2022 Sensors ART_4889 CAN Tilt 163 CAN Tilt 161 Jib Proximity Switch Load Cell EZ Fit Angle Sensor Boom Retract Proximity Sensor Optional Overload Sensing System component Sensors Se...

Page 51: ...keep the platform level during boom operation CAN Tilt Angle Transducers are not interchangeable Each is identified by number for communication with the GP400 GP500 Module If removed be sure that eac...

Page 52: ...edge of the Engine Tray These relays convert GP400 GP500 signals into engine operational functions e g start and stop Refer to the Section 20 Schematics for relay functions and interconnect Start Rela...

Page 53: ...itioning the platform Overload Alarm On machines equipped with the optional Overload Sensing System the Overload Alarm is a dual tone alarm that sounds at the Base Controls Box when the control system...

Page 54: ...ng Wedge from the connector Replace worn or damaged parts Replace or re crimp wires and contacts Locking Fingers Remove the Locking Wedge as outlined above Using the Removal Tool or a flat blade screw...

Page 55: ...he first probe of the ohm meter to Common terminal Connect the second probe to top Normally Open terminal With toggle DOWN there should be no reading With the toggle UP there should be a low resistanc...

Page 56: ...Normally Open Normally Open Common Normally Open Normally Open Common ART_2564 Momentary Button Switch Disconnect wires Connect one probe of ohm meter to each terminal With the button in the neutral...

Page 57: ...ls Box Valve Current Control Module VCCM Inside Lower Controls Box GP440 Module Inside Upper Control Box ART_4892 GP400 Module Lower Controls Box Terminal Block Module VCCM Module EZ Cal Diagnostic Po...

Page 58: ...vation has a variable output between 1 00 and 4 00 Vdc as the Jib Boom Platform rotates through 140 degrees During calibration the GP400 calculates that 1 80 Vdc is the fully lowered condition and 3 6...

Page 59: ...EDURE In the event of a GP400 replacement the GP400 must be calibrated before it will operate properly The following procedures and additional tasks detailed in Section 19 Troubleshooting can only be...

Page 60: ...platform fore and aft After the platform has been confirmed to be absolutely level proceed to the Level Sensor s Calibration instructions The sensors used on the this machine are very sensitive and ca...

Page 61: ...arrow and right arrow to enter the day s date Once the CAL DATE has been entered calibration is complete Press ESC 3 times and or turn off the machine Height calibration is complete The following cal...

Page 62: ...the date that the machine was successfully calibrated and hit ENTER You should now see FINISHED appear on the screen The machine is now calibrated and ready to be used Alternative Load Calibration An...

Page 63: ...message is given if the height sensor output P8 2 and P8 6 is out of range at the start of calibration The height sensor output must be between 1 0V and 4 0V Check DIAGNOSTICS SENSORS to see the outpu...

Page 64: ...ed too early when the platform is not fully raised F14 BAD HEIGHT1 This message occurs if EZfit 1 output is out of range during the DYNAMIC LIFT The height sensor output must be between 1 00V and 4 00...

Page 65: ...message occurs if too many static measurements are taken during a calibration step In the rare event that this occurs please call MEC for assistance F27 BAD HEIGHT This message indicates a problem wi...

Page 66: ...iring error Check DIAGNOSTICS SENSORS to check the pressure F44 LOW PRESSURE This message indicates that the pressure is too low 0 50V or less at a STATIC measurement point This message would occur if...

Page 67: ...cified order A Redo prompt will appear before each sequence Answer NO if there is no reason to repeat or YES if the phase must be completed F60 BAD EXTENSION Extension has not been calibrated or is fa...

Page 68: ...rs if the DOWN switch is released during either STATIC lowering phase when more measurements are needed before the platform is fully lowered GO UP MORE This message occurs if the UP switch is released...

Page 69: ...mpty Press ENTER to confirm when the platform is empty PLATFORM LOADED This message is prompting for confirmation that the platform is loaded to rated load For the standard version of this machine thi...

Page 70: ...replaced it will be necessary to redo the EMPTY phase REDO LOADED This message is displayed if the LOADED phase of load calibration has previously been completed Press ENTER when NO is displayed if th...

Page 71: ...PERSONAL INJURY REPLACE TIRES WITH THE CORRECT TIRES TO MAINTAIN THE RATING OF THE EQUIPMENT ON MACHINES WHERE FOAM FILLED TIRES ARE FITTED AS ORIGINAL EQUIPMENT TIRES MUST BE REPLACED WITH EQUIVALENT...

Page 72: ...and spline gripping the mating surface The use cam geometry to effectively prevent the bolt from unbolting loose Nord Lock style washers must be used anywhere they were originally installed on this m...

Page 73: ...is procedure Disassembly Park the machine on a firm level surface Position the platform on a pallet so that the bottom of the through bolt is off the ground Strap the platform to the pallet Disconnect...

Page 74: ...if the optional Overload Sensing System is not present Assembly Assembly is the reverse of disassembly Tighten all fasteners to proper torque as shown below Location Torque Platform Rotator to Spacer...

Page 75: ...g them Immediately plug and cap all openings to prevent contamination Tag electrical connections before disconnecting them Position the platform on a pallet so that the bottom of the through bolt is o...

Page 76: ...ssembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace if any of the above conditions exist Tighten all fasteners to proper torque as shown belo...

Page 77: ...ediately plug and cap all openings to prevent contamination Tag electrical connections before disconnecting them Lower the boom to the stowed position so that the boom rests on the turntable Using the...

Page 78: ...as shown 8 ART_4911 Remove bolt and pin retainer for the lower pin at the front lower pivot point of the bell crank weldment Support the Jib Cylinder and the lower jib link that are hanging straight d...

Page 79: ...ace imperfections cracks or gray dust in the pivot area Replace if any of the above conditions exist Re connect the hydraulic lines after the barrel end of the Jib Cylinder is secured Use the Jib Lift...

Page 80: ...to raise the boom slightly Use the Jib Lift Lower function to lower the jib completely Use the Boom Extend Retract function to extend the boom approximately 5 feet 1 5 m Use the Boom Lift Lower funct...

Page 81: ...hen remove bolts and pin retainer plates that secure the upper Platform Level Cylinder pin Remove the pin then remove the Platform Level Cylinder 15 16 ART_4916 Assembly Assembly is the reverse of dis...

Page 82: ...re disconnecting them Lower the boom to the stowed position so that the boom rests on the turntable Use the Boom Extend Retract function to extend the boom approximately 5 feet 1 5 m to expose the rod...

Page 83: ...fully extract the cylinder completely from the boom 11 12 ART_4933 Cylinder Foot IMPORTANT Measure and record the length of the slightly extended cylinder for easier reassembly Assembly Assembly is th...

Page 84: ...ns and tag all hoses for proper reassembly before disconnecting them Immediately plug and cap all openings to prevent contamination Tag electrical connections before disconnecting them Remove the Plat...

Page 85: ...wn Remove the pin and the rod end of the Lift Cylinder Remove the pivot pin at the base of the Main Boom Assembly Remove the Main Boom Assembly 9 10 11 12 ART_4934 Block Pin Main Boom Assembly ART_493...

Page 86: ...s Assembly Assembly is the reverse of disassembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace if any of the above conditions exist Refer to S...

Page 87: ...e disconnecting them Immediately plug and cap all openings to prevent contamination Tag electrical connections before disconnecting them Remove the Platform Jib Assembly and Platform Level Cylinder as...

Page 88: ...eral times to properly identify the tightest point of travel and to adjust the number of shims After the proper number of shims has been determined tighten the mounting bolts for that set of wear pads...

Page 89: ...1 End Section External Wear Pads Base Section End Section With the hoist still attached to the boom End Section install the Base Section Internal Wear pads and shims Use the hoist to position the End...

Page 90: ...reassembly before disconnecting them Immediately plug and cap all openings to prevent contamination Tag electrical connections before disconnecting them Remove the Platform Jib assembly as described i...

Page 91: ...st as shown Use a separate sling for each lift point Apply slight lifting pressure 12 ART_4945 Remove the bolts and washers holding the Turntable Assembly to the Swing Bearing Note Swing Drive and Swi...

Page 92: ...D ON THESE BOLTS ARE HARDENED STRUCTURAL WASHERS REPLACE LOST OR DAMAGED WASHERS WITH MEC PART 50582 ONLY Remove the Swing Bearing and ring spacers from the Chassis Note Ring Bearing Mass 200 LBS 91 K...

Page 93: ...ted Swing Bearing Use an alternating criss cross pattern to tighten the bolts securing the Swing Bearing to the chassis Tighten the bolts in three stages in numerical order as shown to the right Tight...

Page 94: ...mbly Remove the retaining pins that secure the steer cylinder and the tie rod to the motor hub housing Rotate the housing to access the drive motor Clean all hydraulic fittings then tag all hoses for...

Page 95: ...lace the O ring on the brake release port of the gear hub Take great care that this O ring is installed correctly Use grease to hold the O ring in place during installation 1 2 3 4 5 6 7 8 ART_4966 Ge...

Page 96: ...s of API classification CF or higher Oil used with this engine must have proper API and SAE Engine Oil classification according to ambient temperatures as shown below Above 77 F 25 C SAE30 SAE10W 30 o...

Page 97: ...stem as follows Fill fuel tank to the fullest extent Open valve on bottom of fuel tank Loosen Fuel Filter Bleed Screw on top of fuel filter housing a few turns Close the bleed screw when fuel flows st...

Page 98: ...de after Throttle Solenoid Replacement The solenoid must be free to retract fully in order to turn OFF the High Amperage Pull Circuit Improper adjustment will result in solenoid failure and may damage...

Page 99: ...on a standard grease gun then rotate swing bearing 45 Repeat this thru 180 of swing or 4 times Apply 325g approximately 80 pumps on a standard grease gun to the worm gear Do this thru 180 of motion w...

Page 100: ...patible hydraulic fluids mixed destroying the additives and causing varnish build up resulting in the valves sticking Water in the hydraulic fluid due to a damp climate Improper hydraulic fluid used V...

Page 101: ...failure or incorrect plug connections the modules are fully short circuit and reverse polarity protected All electrical plug connections are waterproof to promote longer trouble free operation and to...

Page 102: ...UND EZ CAL DIAGNOSTICS P4 4 P4 5 P4 6 P4 7 P4 8 P4 13 P4 14 P4 15 P4 JIB UP JIB DOWN AXLE LOCK SWING LEFT SWING RIGHT BRAKE DUMP VALVE DUMP VALVE MAIN MANIFOLD PLATFORM SUPPLY P5 1 P5 2 P5 3 P5 6 P5 7...

Page 103: ...EL DOWN PLATFORM LEVEL DOWN GROUND P3 P3 1 P3 2 BOOM UP BOOM UP GROUND P4 P4 1 P4 2 BOOM DOWN BOOM DOWN GROUND P5 P5 1 P5 2 DRIVE FWD DRIVE FWD GROUND P6 P6 1 P6 2 DRIVE REV DRIVE REV GROUND Terminal...

Page 104: ...P10 11 P10 12 FWD REV SIGNAL DRIVE HALL EFFECT SUPPLY DRIVE HALL EFFECT GROUND STEER LEFT STEER RIGHT DRIVE ENABLE SWITCH STEER DRIVE ENABLE SUPPLY P12 P12 2 CAN BUS HI CAN BUS LO 1 6 P P6 2 P6 3 P6...

Page 105: ...ble from the MEC Parts Department part 90888 To use and operate the handheld EZ Cal at the upper controls station Set the Base Platform Key Switch to Platform Open the lid to the Upper Controls Box Pl...

Page 106: ...ORMALLY PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION...

Page 107: ...D ADJUSTMENTS MUST NOT BE CHANGE WITHOUT PRIOR AUTHORIZATION FROM MEC AERIALS TEMPERATURE 5G 5G 1 FAN ON 65 DEG C ENTER STARTER DELAY 10 SEC 5F 5 TILT FILTER 4 4H 5 SET TO 0 FOR MODELS NOT EQUIPPED WI...

Page 108: ...SCOPE IN TELESCOPE OUT DRIVE FWD REV JSTK P5 3 P5 4 P5 6 P5 7 P5 9 P5 12 P6 4 P6 2 P6 9 STEER LEFT VALVE P4 1 P5 1 P5 2 P5 3 P5 4 P5 7 OVERLOAD LIGHT CE LOW FUEL INDICATOR LT TILT ALARM OVERLOAD 12 VO...

Page 109: ...CTIONS 5D 6 MAX LIFT 96 MAX DRIVE 101 THROTTLE HOLD FWD MAXHIGH 55 REV MAXHIGH 55 DECEL 2 2 SEC 4A 8 DRIVE ELEVATED 4A 11 STR MIN 50 4A 12C STR MAX 50 4A 12D INCLINED BRAKE DELAY 01 SEC 4A 13A LOW BAT...

Page 110: ...12 P6 13 P6 14 P6 15 DRIVE REVERSE VALVE JIB UP VALVE AXLE LOCK VALVE SWING LEFT VALVE SWING RIGHT VALVE BRAKE DUMP VALVE DUMP VALVE MAIN PLATFORM SUPPLY PLATFORM ROTATE LEFT STEER RIGHT VALVE PLATFOR...

Page 111: ...lt of normal operation and usually do not represent a problem EVERYTHING OK________________________________ Flash Code None All circuits performing properly no current operation performed GROUND MODE...

Page 112: ..._______________ Flash Code None CAN Tilt module mounted to Front axle has malfunctioned or wiring is damaged NO DATA FROM CAN TILT 3______________________ Flash Code None CAN Tilt module mounted to fr...

Page 113: ...rocessor has not been calibrated Operation will be restricted until calibration is completed Refer to GP400 Calibration Procedure for calibration information and instructions HEIGHT NOT CALIBRATED____...

Page 114: ..._____________Flash Code 2 2 Platform sensors indicate platform out of level level platform or chassis until alarm stops or re position machine FUNCTIONS LOCKED AUTO PLATFORM LEVEL_________Flash Code 2...

Page 115: ...ital outputs using the EZ Cal CHECK TELE SWITCHES_____________________________ Flash Code 2 2 Telescope joystick or toggle switch movement without enable or during power up Check joystick analog outpu...

Page 116: ...__ Flash Code 4 1 Oil pressure switch opened during operation or time out Check oil pressure pressure switch wiring Message will appear if engine stops running for reasons other then normal shut down...

Page 117: ...sensor out of range should be 5 to 4 5 volts Overload option only FAULT CHECK ELEVATION SWITCH ___________________ Flash Code 6 3 Check for incorrect GP 400 part FAULT LOW OIL PRESSURE ______________...

Page 118: ...he key switch Check for loose terminals Terminal 4 is Common power from Circuit breaker Terminals 1 and 2 are signals to close the relay No operation from upper or lower control station Module LEDs on...

Page 119: ...to level ground Main relief valve 6 out of adjustment Adjust main relief valve 6 to rated platform capacity located on function manifold See Section 10 Hydraulic System Lift valve 8 1 not energized Ch...

Page 120: ...m retract Main relief valve 6 out of adjustment Adjust main relief valve 6 to rated platform capacity located on function manifold See Section 10 Hydraulic System Foreign debris stuck in boom slide pa...

Page 121: ...r System interlock Check EZ Cal HELP messages for interlock Turntable will rotate in one direction only Rotate valve 11 not energizing Check wiring to valve Rotate valve 11 not shifting Clean debris C...

Page 122: ...ate drive continuously until drive begins to operate Boom Retract proximity switch failure Check for power ground signal output to Proximity Switch located inside the rear of boom Also check EZ Cal 2C...

Page 123: ...HELP messages for interlock Steer in one direction only Joystick rocker switch inoperative Check continuity through micro switch inside joystick handle using wires outside the handle Check output see...

Page 124: ...M EMERGENCY POWER AUX 5 STA STB T P GP 20 7 1 4 1 1500 psi 3 1 1500 psi 3 2 4 2 S9 S8 1 2 1 18 1 18 2 19 3300 psi 21 PLATFORM LEVEL PLATFORM ROTATE JIB BOOM CYLINDER P LD LU RR RL SF SR 8 3 3 2 4 10 6...

Page 125: ...M EMERGENCY POWER AUX 7 5 KW GENERATOR WELD READY OPTION 1 2 3 4 2 TELESCOPE CYLINDER PLATFORM LEVEL PLATFORM ROTATE JIB P T GLS PLATFORM MANIFOLD 8 3 3 2 6 1 6 2 4 14 5 1 5 2 S10 S15 S14 S12 S13 LD...

Page 126: ...272 273 87 S WING LE FT S WITC H S WING R IGHT S WITC H P LATFOR M LE VE L UP S WITC H P15 1 P15 2 P15 3 P15 274 275 298 GLOW PLUG S WITC H IDLE E NABLE S WITC H P15 4 P15 5 24 289 PLATFOR M LE VE L D...

Page 127: ...P E R C ONT R OL B OX G R OUND B 1 C AN HIG H 2 C AN LOW 3 P OWE R B 4 G R OUND B 1 C AN HIG H 2 C AN LOW 3 4 G R OUND B 1 C AN HIG H 2 C AN LOW 3 P OWE R B 4 G R OUND B 1 C AN HIG H 2 C AN LOW 3 4 MA...

Page 128: ...Page 122 45 J Diesel Service Parts Manual January 2022 Section 20 Schematics Electric Schematic Upper Controls Box To Serial 14700199...

Page 129: ...KE 297 296 RIGHT LEFT PLATFORM ROTATE KEY ON 1 298 299 UP DOWN PLATFORM LEVEL INHIBIT 289 288 HIGH SPEED ENABLE IDLE 274 275 RIGHT LEFT TURRET SWING 36 272 273 UP DOWN JIB VALVE SUPPLY KEY SWITHCH BAS...

Page 130: ...IGH 2 CAN LOW 3 POWER B 4 GROUND B 1 CAN HIGH 2 CAN LOW 3 4 GROUND B 1 CAN HIGH 2 CAN LOW 3 POWER B 4 GROUND B 1 CAN HIGH 2 CAN LOW 3 4 MAIN DUMP VALVE SWING RIGHT SWING LEFT BOOM DOWN BOOM UP MANIFOL...

Page 131: ...4 11 394 MANUAL PLATFORM LEVEL DOWN AUXILLARY POWER SIGNAL PP14 12 PP14 13 242 GENERATOR SIGNAL PP14 14 071 395 FWD AND REV SIGNAL DRIVE HALL EFFECT SUPPLY DRIVE HALL EFFECT GROUND PP10 1 PP10 4 PP10...

Page 132: ...Page 126 45 J Diesel Service Parts Manual January 2022 Notes...

Page 133: ...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 repa...

Page 134: ...per Controls Box Part 1 ART_4840 Upper Controls 1 2 3 4 6 7 8 9 9 11 5 5 13 14 Aux Power Function Enable Engine Start Stop Glow Plug Emergency Stop Idle Speed Drive Speed 10 Horn Tilt Platform Level 4...

Page 135: ...tform Control Handle 1 3 94687 PQ Controls Drive Control Handle 1 4 28581 Palm Rest 1 5 7423 Switch 2 Position Momentary 2 6 92422 Enable Button 1 7 92427 Switch 3 Position Single Momentary 1 8 92408...

Page 136: ...Page 130 45 J Diesel Service Parts Manual January 2022 Section 21 Controls Upper Controls Box Part 2 ART_4841 Upper Controls 2 1 10 6 11 5 3 2 4 2 3 7 8 9 45 J Diesel...

Page 137: ...ck Normally Open 1 5 28779 Bracket 1 50191 THMS 10 32X00 50 ZP 4 6 92027 GP440 Module Up To Serial 14700199 1 95236 GP442 Module From Serial 14700200 1 50330 THMS 10 32X01 00 ZN Phillips Not Shown 4 5...

Page 138: ...132 45 J Diesel Service Parts Manual January 2022 Section 21 Controls Lower Controls Box ART_4842 Lower Controls 1 20 21 22 23 24 25 24 2 3 4 10 19 11 12 13 14 14 15 16 5 5 8 3 7 9 6 17 18 45 J Diese...

Page 139: ...Nut ZP 4 53325 THMS M05 0 80X025 ZP 4 11 91838 Terminal Block Module 1 50524 NNYL M05 0 80 Nylon Lock Nut ZP 2 53325 THMS M05 0 80X025 ZP 2 12 91950 VCCM Module 1 50524 NNYL M05 0 80 Nylon Lock Nut ZP...

Page 140: ...b Assembly Part 1 65 J Art_5520 ILLUSTRATION No DETAIL A 8 7 11 10 10 16 8X SEE DETAIL A FOR UNDERSIDE VIEW OF ITEM MOUNTING 8 32 30 1 31 4 21 10 2X 27 2 8 3X 3 28 2 27 6 11 10 18 16 4X 7 Platform Sub...

Page 141: ...Upper Control Box Refer to Pages 122 and 124 1 7 31160 Weldment Platform 90 1 8 31197 Decking Aluminum 90 3 9 31207 Weldment Platform To Jib Mount 45J 1 10 50000 WSHR M06 Standard Flat 52 11 50028 HH...

Page 142: ...e Parts Manual January 2022 Section 22 Platform Platform Sub Assembly Part 2 65 J Art_5520 ILLUSTRATION No 4X 3 7 16 10 10 11 8X 33 15 10 14 10 9 26 13 8X 22 12 8X 5 24 19 20 25 23 4X 29 2X 6 23 17 Pl...

Page 143: ...ib Mount 45J 1 10 50000 WSHR M06 Standard Flat 52 11 50028 HHCS M06 1 00 20 24 12 50006 WSHR M10 ZP Nordlock 8 13 50007 WSHR M12 ZP Nordlock 8 14 50028 HHCS M06 1 00 20 2 15 50047 NNYL M06 1 00 Nylock...

Page 144: ...bly Part 1 45 J Art_5554 ILLUSTRATION No 36 2 X 34 2 X 22 16 25 16 4X 14 2 18 27 13 3 19 21 4X 4 4 X 8 7 33 38 2 X 37 2 X 21 19 4X BOTH SIDES 2X 4X BOTH SIDES 9 2 X 33 19 32 1 16 22 3X Base Boom Sub A...

Page 145: ...in Side Wear Pad 2 13 31222 Pin 50 80mm 230mm LG 1 14 31226 Pin 31 75mm 300mm LG 1 16 50000 WSHR M06 ZP Standard Flat 11 18 50002 WSHR M10 ZP Standard Flat 24 19 50006 WSHR M10 ZP Nordlock 17 21 50033...

Page 146: ...l January 2022 Section 23 Elevating Assembly Base Boom Sub Assembly Part 2 45 J Art_5554 ILLUSTRATION No 23 17 2X 10 36 35 6 24 18 2X 4X 5 2X 31 18 18 24 29 18 18 24 15 29 18 18 24 4X 28 17 23 17 2X 2...

Page 147: ...10 28694 Bracket Platform Manifold Cover 1 17 50001 WSHR M08 ZP Standard Flat 6 18 50002 WSHR M10 ZP Standard Flat 24 23 50048 NNYL M08 1 25 08 ZP Nylon 4 24 50049 NNYL M10 1 50 08 ZP Nylon Inse 11 2...

Page 148: ...ary 2022 Section 23 Elevating Assembly Boom Sub Assembly Boom Sub Assembly 45 J Art_5555 ILLUSTRATION No SEE DETAIL A 3 5 14 6 4X 3 ALIGN PIN HOLES AND 4 13 7 10 7 DETAIL A 1 11 8 9 8 3 4X 4X DETAIL B...

Page 149: ...e Track 45J 1 5 31868 Base Boom Sub Assembly Refer to Pages 132 and 134 1 6 31869 Tip Boom Sub Assembly Refer to Page 138 1 7 50001 WSHR M08 ZP Standard Flat 8 8 50002 WSHR M10 ZP Standard Flat 24 9 5...

Page 150: ...rvice Parts Manual January 2022 Section 23 Elevating Assembly Tip Boom Sub Assembly Tip Boom Sub Assembly 45 J Art_5577 ILLUSTRATION No 12 4 BOTH SIDES X 1 12 2 X 1 2 1 16 X 9 16 X 7 16 X 11 4 X 5 2 X...

Page 151: ...igh Load 1 3 31086 Weldment Tip Boom 1 4 31219 Pin Platform 1 5 31221 Pin Extend Cylinder Tip Boom 2 6 28644 Retainer Tip Boom Level Cyl Pin 2 7 50006 WSHR M10 ZP Nordlock 16 8 50414 BHCS M08 1 25 30...

Page 152: ...Page 146 45 J Diesel Service Parts Manual January 2022 Section 23 Elevating Assembly Jib Components ART_4849 Jib Components 60 J 1 2 3 4 5 6 7 4 8 9 15 14 10 11 12 13 10 11 12 13 17 16...

Page 153: ...0 Bearing 4 5 REF Jib Cylinder Refer to Page 168 1 6 93740 Bearing 4 7 28420 Jib Linkage Weldment 1 8 28608 Pin Jib Cylinder 1 9 28410 Compression Link 2 10 28607 Pin Bell Crank Platform Rotator 4 11...

Page 154: ...Page 148 45 J Diesel Service Parts Manual January 2022 Section 23 Elevating Assembly Platform Rotator ART_4874 Platform Rotator 60 J 1 2 3 2...

Page 155: ...age 149 45 J Diesel Service Parts Manual January 2022 Section 23 Elevating Assembly Item Part Number Description Qty 1 93830 Platform Rotator 1 2 50675 Fitting MFFOR MB45 4 4 2 3 94403 Manifold Assy 1...

Page 156: ...Page 150 45 J Diesel Service Parts Manual January 2022 Wheel and Tire Assembly Wheel and Tire Assembly 45 J Art_5578 ILLUSTRATION No 1 9X PER WHEEL 2X 2X 3 2 Section 24 Axles Wheel and Tire Assembly...

Page 157: ...51 45 J Diesel Service Parts Manual January 2022 Section 24 Axles Item Part Number Description Qty 1 31098 Wheel Tire 33 12 20 RH Solid 2 2 31099 Wheel Tire 33 12 20 LH Solid 2 3 50266 Nut Lug 5 8 18...

Page 158: ...152 45 J Diesel Service Parts Manual January 2022 Section 24 Axles Front Axle Sub Assembly Part 1 45 J Art_5562 ILLUSTRATION No 15 5 17 22 1 3 17 33 1 5 20 29 11 25 17 2 8 9 Front Axle Sub Assembly Pa...

Page 159: ...4 5 18165 Keeper Pin 375 2 20 4 8 31021 Weldment Yoke Right Side 1 9 31029 Weldment Yoke Left Side 1 11 31045 Weldment Tie Rod 1 15 31236 Pin 31 75mm 130 2 17 50002 WSHR M10 ZP Standard Flat 12 20 50...

Page 160: ...rts Manual January 2022 Section 24 Axles Front Axle Sub Assembly Part 2 45 J Art_5562 ILLUSTRATION No 10 30 21 14 7 24 16 37 7 28 18 42 8 26 32 35 41 40 13 4 21 23 12 3 17 22 39 19 31 27 6 36 34 38 43...

Page 161: ...rdlock 13 22 50035 HHCS M10 1 50 40 08 ZP F 4 23 50039 HHCS M12 1 75 30 08 ZP F 1 24 50048 NNYL M08 1 25 08 ZP Nylon 4 26 50055 SHCS 7 16 14 1 5 GR 8 4 27 50056 SHCS 5 8 11 1 50 GR8 12 28 50133 HHCS M...

Page 162: ...vice Parts Manual January 2022 Main Manifold Assembly Main Manifold Assembly 45 J Art_5571 ILLUSTRATION No 12 18 11 6 19 8 9 9 8 12 12 13 10 1 15 11 6 2 5 3 4 1 3 4 4 3 16 7 14 17 Section 25 Hydraulic...

Page 163: ...04 2 7 50674 HYFT MFFOR MB90 06 06 1 8 50676 HYFT MFFOR MB45 06 06 2 9 50816 HYFT MFFOR MB45 6 8 FS6802 06 08 2 10 50831 HYFT MFFOR MB 4 4 FS6400 04 04 1 11 50832 HYFT MFFOR MB 4 6 FS6400 04 06 2 12...

Page 164: ...l January 2022 Section 25 Hydraulics Main Functions Manifold Block Components ART_5002 Main Functions Manifold 60 J 13 14 14 15 16 17 2 2 3 2 2 21 4 5 6 20 behind valve 7 7 8 4 4 9 10 11 20 12 20 18 2...

Page 165: ...Directional Control 1 6 94223 Relief Valve 1 7 94082 Coil 2 8 94036 Solenoid Valve 1 9 94070 Solenoid Valve 1 10 94071 Relief Valve 1 11 94217 Check Valve 1 12 94068 Relief Valve 2 13 94222 Check Val...

Page 166: ...iesel Service Parts Manual January 2022 Section 25 Hydraulics Platform Functions Manifold ART_4867 Platform Functions Manifold 60 J Later Style Block Designation 2 1 10 9 8 6 7 13 11 5 3 3 4 11 12 14...

Page 167: ...Fitting MFFOR MB 4 4 3 4 50673 Fitting MFFOR MB90 4 4 2 5 50671 Fitting MFFOR FFORX90 4 4 3 6 50832 Fitting MFFOR MB 4 6 1 7 50656 Fitting MFFOR MB90 4 6 1 8 50674 Fitting MFFOR MB90 06 06 1 9 50835...

Page 168: ...Page 162 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Brake Axle 2 Speed Manifold ART_4865 Brake Axle 2 Speed Manifold 60 J Diesel 1 2 4 6 7 2 8 10 9 3 4 5...

Page 169: ...Qty 1 93779 Brake Axle 2 Speed Manifold complete without fittings 1 2 50974 Fitting TPO 4 2 3 50831 Fitting MFFOR MB 4 4 1 4 50673 Fitting MFFOR MB90 4 4 4 5 50671 Fitting MFFOR FFORX90 4 4 1 6 94087...

Page 170: ...Manual January 2022 Section 25 Hydraulics Rotary Manifold Sub Assembly Rotary Manifold Sub Assembly 45 J Art_5575 ILLUSTRATION No 7 10 9 7 9 9 7 4X 2 13 8 9 4 3 4X 4X 6 3 3 5 4X 4X 4X 4X 2X 14 12 11...

Page 171: ...40 08 ZP F 6 5 50049 NNYL M10 1 50 08 ZP Nylon Inse 10 6 50421 HHCS M10 1 50 65 08 ZP P 4 7 50673 HYFT MFFOR MB90 4 4 7 8 50814 HYFT MFFOR MB 10 8 FD6400 10 08 1 9 50831 HYFT MFFOR MB 4 4 FS6400 04 04...

Page 172: ...Page 166 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Front Case Drain Manifold Assembly Front Case Drain Manifold Assembly 45 J Art_5563 ILLUSTRATION No 7 4 5 6 5 4 8 1 2 3...

Page 173: ...Description Qty 1 50000 WSHR M06 ZP Standard Flat 4 2 50047 NNYL M06 1 00 08 ZP Nylock 2 3 50134 HHCS M06 1 00 60 08 ZP F 2 4 50656 HYFT MFFOR MB90 04 06 2 5 50835 HYFT MFFOR MB 6 6 FS6400 06 06 O 2 6...

Page 174: ...el Service Parts Manual January 2022 Section 25 Hydraulics Hydraulic Tank Sub Assembly Hydraulic Tank Sub Assembly 45 J Art_5568 ILLUSTRATION No 9 13 12 14 15 19 2 X 16 1 17 3 4 X 3 X 3 X 11 8 5 4 X 2...

Page 175: ...911 HYFT MJ MP 24 24 2404 24 24 1 9 51257 HYFT MFFOR MB90 20 16 1 10 51261 HYFT MFFOR MP90 10 08 1 11 92111 Valve Ball Full Port 1 50 MPT FPT 1 12 92357 Hydraulic Tank Breather 3 4 NPT 1 13 92366 In T...

Page 176: ...Page 170 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Charge Filter Sub Assembly Charge Filter Sub Assembly 45 J Art_5556 ILLUSTRATION No 5 4 1 3 2 6...

Page 177: ...m Part Number Description Qty 1 31242 Bracket Charge Filter 1 2 50006 WSHR M10 ZP Nordlock 4 3 50219 HHCS 03 08 16 0 75 05 ZP 4 4 50838 HYFT MFFOR MB 8 12 FS6400 08 12 O 1 5 50849 HYFT MFFOR MB90 8 12...

Page 178: ...Page 172 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Boom Lift Cylinder ART_5601 Boom Lift Cylinder 45 J 1 3 4 2...

Page 179: ...vice Parts Manual January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 31030 Boom Lift Cylinder 1 2 50840 Fitting MFFOR MB 8 6 2 3 92622 Counterbalance valve 1 4 94033 Counterbalance...

Page 180: ...Page 174 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Boom Extend Cylinder ART_4877 Boom Extend Cylinder 45 J 1 4 5 3 2...

Page 181: ...tem Part Number Description Qty 1 31032 Extend Cylinder 1 2 50676 Fitting MFFOR MB45 6 6 2 3 28643 Wear Pad Extend Cylinder Rest 1 50020 Bolt M10 x 50 4 50053 Nut M10 Nylock 4 50002 Washer M10 Flat 4...

Page 182: ...Page 176 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Platform Level Cylinder ART_4878 Platform Level Cylinder 45 J 1 2...

Page 183: ...Page 177 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 31033 Platform Level Cylinder 1 2 94527 Counterbalance Valve 2 95384 Seal Kit 1...

Page 184: ...Page 178 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Jib Cylinder ART_5602 Jib Cylinder 45 J 1 3 4 2...

Page 185: ...Service Parts Manual January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 28399 Jib Cylinder 1 2 50831 Fitting MFFOR MB 4 4 2 3 94630 Counterbalance Valve 1 4 94408 Counterbalance Val...

Page 186: ...Page 180 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Steer Cylinders ART_4873 Steer Cylinders 60 J 1 2 1 3...

Page 187: ...Service Parts Manual January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 18070 Steer Cylinder Without Fittings 2 92616 Seal Kit 2 2 50858 Fitting MFFOR MB MFFORT 4 2 3 50673 Fitting...

Page 188: ...Page 182 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Axle Cylinders ART_4880 Axle Cylinders 60 J 1 2 3 5 6 4 not shown...

Page 189: ...l January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 31031 Axle Cylinder 1 2 50676 Fitting MFFOR MB45 6 6 1 3 50675 Fitting MFFOR MB45 4 4 1 4 51167 Fitting MP MFFOR 4 4 1 5 95378 C...

Page 190: ...Page 184 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Auxiliary Power Unit ART_3491 AUXILLARY POWER UNIT 5592RT 3392RT T 92RT Series 1 2 2...

Page 191: ...age 185 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics Item Part Number Description Qty 1 17973 Auxiliary Power Unit Without Fittings 1 92534 Solenoid 2 50790 Fitting MB MJ90 6 6...

Page 192: ...79 4G 4FFORX 90 50627 4M 3K 1880 52965 RM6 STRRET 50667 4G 4FFORX 50677 4G 4FFORX 45 50627 4M 3K 1803 52966 RM7 STREXT 50667 4G 4FFORX 50677 4G 4FFORX 45 50627 4M 3K 1803 52967 M8PORT RM8A 50667 4G 4F...

Page 193: ...4G 4FFORX 45 50627 4M 3K 940 52997 SRBH JIBRET 50667 4G 4FFORX 50677 4G 4FFORX 45 50627 4M 3K 940 52998 RLBH HP1 50667 4G 4FFORX 50677 4G 4FFORX 45 50627 4M 3K 940 52999 RRBH HP2 50667 4G 4FFORX 50677...

Page 194: ...432 56011 FET CFI 50698 8G 8FFORX 50622 8G 8FFORX 90 50630 8M 3K 432 56012 BV2T EDOWNT 50625 8G 8FJX 50698 8G 8FFORX 50630 8M 3K 1448 56012 DPCD TANK 50698 8G 8FFORX 50698 8G 8FFORX 50630 8M 3K 1321 5...

Page 195: ...Page 189 45 J Diesel Service Parts Manual January 2022 Section 25 Hydraulics THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 196: ...rts Manual January 2022 Chassis Sub Assembly Chassis Sub Assembly 45 J Art_5557 ILLUSTRATION No 6 13 10 2 28 4 3 26 27 16 19 22 9 7 1 10 14 25 21 23 10 10 17 18 11 20 12 5 24 A BREAK OUT VIEW 8 Chassi...

Page 197: ...tandard Flat 12 11 50004 WSHR M16 ZP Standard Flat 12 12 50006 WSHR M10 ZP Nordlock 4 13 50033 HHCS M10 1 50 25 08 ZP F 8 14 50035 HHCS M10 1 50 40 08 ZP F 2 15 50049 NNYL M10 1 50 08 ZP Nylon Inse 2...

Page 198: ...s Manual January 2022 Section 26 Base Engine Hood Assembly Engine Hood Assembly 45 J Art_5560 ILLUSTRATION No DETAIL A 10 9 1 8 8 21 11 19 11 19 1 2 SEE DETAIL A 3 4 5 17 16 4X 6 13 12 12 15 7 13 12 1...

Page 199: ...2 8 50002 WSHR M10 ZP Standard Flat 24 9 50034 HHCS M10 1 50 30 08 ZP F 6 10 50049 NNYL M10 1 50 08 ZP Nylon Inse 12 11 50203 NNYL 5 16 18 05 ZP 4 12 50284 WSHR M04 ZP Standard Flat 16 13 50285 NNYL...

Page 200: ...rts Manual January 2022 Section 26 Base Control Hood Assembly Control Hood Assembly 45 J Art_5558 ILLUSTRATION No A 2 8 9 11 3 20 1 5 19 12 12 18 18 4 3 5 1 DETAIL A 17 16 7 10 13 13 14 13 14 13 10 6...

Page 201: ...Steel Latch Catch 2 7 93821 Load Rated Pull Handle 4 7 16 Center To Center Aluminum 2 8 50002 WSHR M10 ZP Standard Flat 24 9 50034 HHCS M10 1 50 30 08 ZP F 6 10 53034 BHCS M04 0 70 12 10 ZP 8 11 50049...

Page 202: ...el Service Parts Manual January 2022 Section 26 Base Engine Components ART_4858 Engine Components 45 J Diesel 22 1 2 3 4 5 23 7 12 11 14 15 16 17 18 19 20 21 13 See previous pages for Solenoid Mountin...

Page 203: ...Cap 1 11 94058 Flywheel 1 91360 Ring Gear 1 12 94057 Fuel Solenoid 1 13 93619 Fuel Pump 1 14 31240 Mounting Bracket 1 15 92939 Throttle Pull Solenoid 1 16 91117 Throttle Link Clevis 1 50296 Bolt M6 x...

Page 204: ...ection 26 Base Engine Tray Assembly Part 1 45 J Art_5561 ILLUSTRATION No Engine Tray Assembly Part 1 6 1 17 16 46 20 19 15 50 75 76 21 9 17 17 26 36 32 26 26 36 8X 4 2X 56 7 77 13 35 30 38 2X 48 22 24...

Page 205: ...Mounting Bracket Fuse Holder 1 24 50000 WSHR M06 ZP Standard Flat 4 26 50002 WSHR M10 ZP Standard Flat 70 28 50006 WSHR M10 ZP Nordlock 24 30 50032 HHCS M08 1 25 30 ZP 2 32 50034 HHCS M10 1 50 30 08...

Page 206: ...al January 2022 Section 26 Base Engine Tray Assembly Part 2 45 J Art_5561 ILLUSTRATION No Engine Tray Assembly Part 2 5 4X 32 8X 44 4X 8 54 14 42 28 16X 36 29 26 26 2X 68 23 55 53 45 32 36 18 40 26 31...

Page 207: ...50006 WSHR M10 ZP Nordlock 24 29 50020 HHCS M10 1 50 50 08 ZP P 2 31 50033 HHCS M10 1 50 25 08 ZP F 3 32 50034 HHCS M10 1 50 30 08 ZP F 22 36 50049 NNYL M10 1 50 08 ZP Nylon Inse 36 37 50050 NNYL M12...

Page 208: ...6 Base Engine Tray Assembly Part 3 Hydraulic Hose Assemblies Attachment Points 45 J Art_5566 ILLUSTRATION No SWING DRIVE DETAIL 64 64 CHARGE FILTER DETAIL 16 16 E DOWN PUMP DETAIL 71 72 EXTERIOR SIDE...

Page 209: ...n tank Return Filter 1 57 50806 HYFT MFFOR MB 16 12 2 59 50837 HYFT MFFOR MB 8 10 2 60 51330 HYFT 04MFFOR 05MB 2 62 51083 HYFT MFFOR MB90 06 04 1 63 50820 HYFT MFFOR MB 6 4 FS6400 06 04 O 1 64 51280 H...

Page 210: ...Page 204 45 J Diesel Service Parts Manual January 2022 Section 26 Base Engine Tray Assembly Part 4 45 J Art_5561 ILLUSTRATION No Engine Tray Assembly Part 4 1 View A 4 3 2 View A 5 6...

Page 211: ...Item Part Number Description Qty 1 31332 Weldment Exhaust Tube 1 2 50200 M08 Nordlock Washer 4 3 50348 HHCS M08 1 25X25 08 ZP P 4 4 31257 Tube Exhaust End 1 5 92965 Exhaust Muffler 6 Round 1 5 ID Inle...

Page 212: ...Page 206 45 J Diesel Service Parts Manual January 2022 Section 26 Base Power Plant Assembly Engine Module Power Plant Assembly Engine Module 45 J Art_5573 ILLUSTRATION No 1 2 8 6 3 5 4 3 5 7...

Page 213: ...n Qty 1 94746 Kubota Diesel Engine V1505 Tier 4 1 5L 4 Cyl 1 2 93470 D1105 SAE B B Coupler 15T Spline 1 3 50039 HHCS M12 1 75 30 08 ZP F 4 4 50003 WSHR M12 ZP Standard Flat 2 5 50007 WSHR M12 ZP Nordl...

Page 214: ...8 45 J Diesel Service Parts Manual January 2022 Section 26 Base Relay Fuel Filter Sub Assembly Relay Fuel Filter Sub Assembly 45 J Art_5574 ILLUSTRATION No 14 10 12 8 7 1 17 16 9 15 13 6 3 12 11 4 3 3...

Page 215: ...F 2 5 50047 NNYL M06X1 00 08 ZP Nylock 2 6 50048 NNYL M08X1 25 08 ZP Nylon 4 7 50214 HHCS M06 1 00 30 08 ZP P 2 8 50189 RHST 10 32 1 25 ZP 2 9 50191 THMS 10 32 0 50 ZP 2 10 50237 HHCS M08 1 25 100 08...

Page 216: ...Page 210 45 J Diesel Service Parts Manual January 2022 Section 26 Base Solenoid Control Sub Assembly Solenoid Control Sub Assembly 45 J Art_5576 ILLUSTRATION No 9 8 2 12 10 11 3 5 1 7 6 4...

Page 217: ...7 Clevis Throttle Linkage 1 4 92939 Throttle Pull Solenoid 1 5 50171 PCLV 0 310 0 50 ZP STL 1 6 50178 Cotter Pin 1 8 1 00 1 7 91588 WRFLAT 0 2500 7500 1 8 50006 WSHR M10 ZP Nordlock 4 9 50392 HHCS M10...

Page 218: ...Page 212 45 J Diesel Service Parts Manual January 2022 Section 26 Base Diesel Turret Sub Assembly Part 1 45 J Art_5559 ILLUSTRATION No 10 7 16 14 4 3 Diesel Turret Sub Assembly Part 1...

Page 219: ...t Number Description Qty 3 31020 Counterweight 1 4 31051 Weldment Turret 1 7 31127 Main Manifold Assembly Refer to Page 150 1 10 31150 Control Hood Assembly Refer to Page 188 1 14 31250 Hydraulic Tank...

Page 220: ...iesel Turret Sub Assembly Part 2 45 J Art_5559 ILLUSTRATION No 28 29 25 4X BROKEN OUT SECTION 15 15 EXHAUST SUB ASSEMBLY FLANGE MOUNT 27 9 5 1 11 2 21 19 2X 24 18 3X 12 6 8 13 30 22 2X 17 31 32 MOUNTS...

Page 221: ...13 31249 Support Block Boom 1 15 31251 Exhaust Sub Assembly 1 31332 Weldment Exhaust Tube 1 17 50001 WSHR M08 ZP Standard Flat 2 18 50002 WSHR M10 ZP Standard Flat 7 19 50007 WSHR M12 ZP Nordlock 2 2...

Page 222: ...45 J Diesel Service Parts Manual January 2022 Section 26 Base Lower Control Box Brackets Assembly Lower Control Box Brackets Assembly 45 J Art_5570 ILLUSTRATION No 5 1 8 6 10 7 7 9 11 7 7 9 3 4 2 12...

Page 223: ...Bracket Control Box To Frame 45J 1 4 31132 Bracket Accessories Hood Latch 45J 1 5 31278 Axle 2Spd Brake Manifold Assembly Refer to Page 156 1 6 50000 WSHR M06 ZP Standard Flat 8 7 50002 WSHR M10 ZP St...

Page 224: ...Page 218 45 J Diesel Service Parts Manual January 2022 Section 26 Base Hood Stop Assembly Hood Stop Assembly 45 J Art_5565 ILLUSTRATION No 6 1 5 3 2 4...

Page 225: ...uary 2022 Section 26 Base Item Part Number Description Qty 1 31149 Bracket Hood 1 2 50001 WSHR M08 ZP Standard Flat 2 3 50031 HHCS M08 1 25 25 08 ZP F 2 4 50048 NNYL M08 1 25 08 ZP Nylon 2 5 50203 NNY...

Page 226: ...Page 220 45 J Diesel Service Parts Manual January 2022 Section 26 Base Fuel Tank 16 Gal Fuel Tank 16 Gal 45 J Art_5564 ILLUSTRATION No 2 4 6 16 13 15 1 3 2 3 15 14...

Page 227: ...Forming Fuel Tank Mount LH 1 6 31281 Weldment Fuel Tank 1 7 50000 WSHR M06 ZP Standard Flat 8 8 50002 WSHR M10 ZP Standard Flat 12 9 50028 HHCS M06 1 00 20 08 ZP F 4 10 50047 NNYL M06 1 00 08 ZP Nylo...

Page 228: ...E Down 28886 Cable Battery To E Down 28889 Harness Flashing Beacon Light 28891 Harness Standard E Down Contactor 60 J Diesel 31159 Harness Sensor Temperature Hydro Stat 31205 Harness Platform Level To...

Page 229: ...Page 223 45 J Diesel Service Parts Manual January 2022 THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 230: ...al January 2022 Option 7 5kW Generator Motor Sub Assembly 7 5kW Generator Motor Sub Assembly 45 J Art_5550 ILLUSTRATION No BROKEN OUT SECTION VIEW 9 10 11 5 8 6 2 7 3 1 4 3 13 12 Option 7 5kW Generato...

Page 231: ...0842 HYFT MFFOR MB90 12 10 FS6801 12 10 F 2 4 50832 HYFT MFFOR MB 4 6 FS6400 04 06 1 5 50835 HYFT MFFOR MB 6 6 1 6 51075 FFORX MB90 06 06 FF6507 06 06 1 7 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10...

Page 232: ...TION No 7 5kW Breaker Box 17 16 67 FT 3 FT TO 7 5KW GENERATOR TO PLATFORM 10 1 4 11 15 2 7 8 2 PLCS 2 PLCS 3 6 5 9 2 PLCS CUT OUT DETAIL SEE DETAIL A FOR FRONT DECAL LOCATIONS 3 PLCS 15 18 B C D GROUN...

Page 233: ...Gland 1 2 9 93097 Locknut Cable Gland 1 2 10 94272 Ground Bar Kit 2 11 94397 ABB Miniature Circuit Breakers 1 12 94404 Electrical Equipment Marker 120 208 VOLTS 1 2 2 1 4 1 13 94405 Electrical Equipme...

Page 234: ...E DETAIL B FOR ITEM 2 MOUNTING 26 29 1 3 32 4 34 SEE DETAIL D 11 13 3 PLCS 25 23 27 30 28 17 29 14 10 7 4X 2X SEE NOTE 1 2 20 20 24 36 21 31 C DETAIL A 7 5KW GENERATOR MOUNTING IN BOARD SIDE 5 6 9 2 3...

Page 235: ...Page 229 45 J Diesel Service Parts Manual January 2022 Section 27 Options 45 J Art_5551 ILLUSTRATION No 3 26 4 32 28 17 7 5kW Generator Option Sub Assembly Part 2...

Page 236: ...el Service Parts Manual January 2022 Section 27 Options 45 J Art_5551 ILLUSTRATION No E 11 13 20 20 INSTALL 2X 25 23 12 9 6 6 26 2X DETAIL E PROPER CHECK VALVE ORIENTATION 36 7 5kW Generator Option Su...

Page 237: ...06 06 1 23 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10 10 2 24 51216 HYFT FFORX MB 12 12 1 25 51291 HYFT FFFOR MFFOR 10 04 D FF2406 10 04 1 26 56172 Hyd Hose Asy 6M 3K 1 27 56173 Hyd Hose Asy 4M 3K 1...

Page 238: ...J Diesel Service Parts Manual January 2022 Section 27 Options Option 7 5kW Generator Partial Manifold Sub Assembly 7 5kW Generator Partial Manifold Sub Assembly 45 J Art_5552 ILLUSTRATION No 8 5 2 1...

Page 239: ...Part Number Description Qty 1 51066 HYFT MFFOR MB90 10 12 2 2 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10 10 1 3 51217 HYFT MB 12 PLUG 2 4 94108 2 By 2 Parallel Body 12 1 5 93034 2 Way Proportional...

Page 240: ...45 J 17 13 2 15 2X 3 23 25 7 9 6 6 18 19 16 15 4 1 SEE DETAIL B FOR ITEMS 4 TO 3 MOUNTING DETAILS SEE DETAIL A FOR HOSE CONNECTIONS 3 8 3 5 11 2X DETAIL B GENERATOR MOUNTING 18 19 T PRESSURE OUT TO HY...

Page 241: ...rvice Parts Manual January 2022 Section 27 Options Art_5603 ILLUSTRATION No 45 J 3 5kW Generator Option Sub Assembly Part 2 15 10 19 12 4X DETAIL C 21 22 22 20 24 UMBILICAL 10 3 CABLE FROM 10 O E M 10...

Page 242: ...50332 HHCS M10 1 50 35 08 ZP P 2 12 50530 RHMS 10 32 3 4 ZP F 4 13 50809 HYFT MFFOR FFORX MFFOR 4 1 14 51198 HYFT MFFOR FFORX90 10 10 1 15 51199 HYFT MFFOR FFORX MFFOR 10 2 16 56200 Hyd Hose Assy CD T...

Page 243: ...Page 237 45 J Diesel Service Parts Manual January 2022 Section 27 Options THIS PAGE IS INTENTIONALLY LEFT BLANK...

Page 244: ...Page 238 45 J Diesel Service Parts Manual January 2022 Section 27 Options Option 3 5kW Generator Fitting Assembly 3 5kW Generator Fitting Assembly Art_5604 ILLUSTRATION No 45 J 5 7 6 2 3 4 8 9 10 11 1...

Page 245: ...heck Valve Fitting 1 3 50961 HYFT MB 04 PLUG 1 4 50836 HYFT MFFOR MB 6 8 FS6400 06 08 O 1 5 94506 Orifice Check Valve Fitting 1 6 50841 HYFT MFFOR MB 8 8 FS6400 08 08 O 1 7 50850 HYFT MFFOR MB90 8 8 F...

Page 246: ...Page 240 45 J Diesel Service Parts Manual January 2022 Section 27 Options Option Glazier Rack Option Glazier Rack 45 J Art_5569 ILLUSTRATION No 3 3 3 3 3 9 4 1 8 8 8 8 6 5 5 7 6 5 5 7 2...

Page 247: ...rip Small 1 3 28535 Bumper Foam Rubber 5 4 28540 Platform Material Rack Weldment 1 5 50003 WSHR M12 ZP Standard Flat 16 6 50042 HHCS M12 1 75 X 35 10 9 ZP 8 7 50054 NNYL M12X1 75 10 ZP Nylon 8 8 93920...

Page 248: ...45 J Diesel Service Parts Manual January 2022 Section 27 Options Option Portable Welder Bracket Platform Option Portable Welder Bracket Platform 45 J Art_5553 ILLUSTRATION No A DETAIL A SCALE 1 6 4 3...

Page 249: ...able Welder Bracket Assembly Option 1 1 31890 Assembly Platform Refer to Pages 128 130 REF 2 28571 Option Welder Bracket Platform 1 3 94268 Clamp Round Tube 35 mm Polyamide Black 3 4 53205 PHMS M6 1 0...

Page 250: ...anual January 2022 Section 27 Options Option Proactive Platform Safety System Option Proactive Platform Safety System 45 J Art_5605 ILLUSTRATION No M SECTION D D SCALE 1 12 2 3 9 8 4 DETAIL M SCALE 1...

Page 251: ...le 90 Deg 2 6 50000 WSHR M06 ZP Standard Flat 8 7 50047 NNYL M06X1 00 08 ZP Nylock 8 8 50141 THMS 06 32 X 3 4 ZP 2 9 50329 NNYL 06 32 ZP Nylon Inse 2 10 50524 NNYL M05 0 80 Nylon Lock Nut 4 11 53035 B...

Page 252: ...Page 246 45 J Diesel Service Parts Manual January 2022 Section 27 Options Option Upper Control Box Cover Option Upper Control Box Cover 45 J Art_5606 ILLUSTRATION No 1 2 7 8 10 5 3 4 4 6 9...

Page 253: ...1 2 53090 BHCS M06 1 00X070 12 9 SS F 4 3 53091 FHMS M03 0 50X008 SS 4 4 53092 NNYL M03 0 50 SS 8 5 53093 PHMS M03 0 50X008 4 6 92852 UHMW 1 25 X 5 5 C Channel Wear Strip 3 7 94268 Clamp Round Tube 3...

Page 254: ...Page 248 45 J Diesel Service Parts Manual January 2022 Decal Locations 1 2 2 3 3 6 7 14 24 25 26 33 12 4 5 37 Section 28 Decals Decal Locations...

Page 255: ...January 2022 Section 28 Decals INS IDE CA SE INSIDE CASE Opposite side of the chassis also Opposite side of the chassis also Inside 4 5 6 8 9 10 11 12 12 13 13 15 15 16 17 17 18 18 19 20 20 21 21 22...

Page 256: ...93804 Qty 2 14 95481 Qty 1 15 91973 Qty 8 16 93814 Qty 2 17 91971 Qty 2 18 91981 Qty 2 19 93815 Qty 2 20 91972 Qty 2 21 91982 Qty 2 22 93806 Qty 1 23 92119 Qty 1 24 90751 Qty 1 25 94850 Qty 1 26 92416...

Page 257: ...Page 251 45 J Diesel Service Parts Manual January 2022 Notes...

Page 258: ...ount number Part Number Description Quantity Price All back ordered parts will be shipped when available via the same ship method as original order unless noted below Ship complete order only No Backo...

Page 259: ...on MEC Aerial Platform Sales Corp s then current flat rate provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp and is found upon inspection by MEC Aerial Plat...

Page 260: ...1401 S Madera Avenue Kerman CA 93630 USA Toll Free 1 877 632 5438 Phone 1 559 842 1500 Fax 1 559 842 1520 info MECawp com www MECawp com MEC Aerial Work Platforms...

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