Mec 65-J Diesel Page 128 Service & Parts Manual Download

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Page 122

65-J Desel - Servce & Parts Manual

February 2021

Secton 20 - Schematcs

Electric Schematic, Upper Controls Box, All Machines

SCHEMA

TIC -- Lower Controls

ALL MACHINES -- Upper Controls Box

Publication Art #:

T_4921

Reference Art #: 28872

ENABLE

HALL EFFECT

JIB PROPORTIONAL

CONTROL HANDLE

GP440

MICROPROCESSOR

(392)

LOW FUEL

P14 P14-1

P14-2

P14-9

P14-10

P14-11

P14-12

P14-13

P14-14

TELESCOPE OUT

TELESCOPE IN

.
.
.
.

MANUAL PLATFORM LEVEL UP

MANUAL PLATFORM LEVEL DOWN

AUXILLIARY POWER SIGNAL

GENERATOR SIGNAL

P10 P10-1

P10-4

P10-6

P10-7

P10-8

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

P7 P7-1

P7-2

P7-3

P7-4

P7-5

P7-6
P7-8

BOOM UP/DOWN SIGNAL

SWING LEFT/RIGHT SIGNAL

ENABLE

BOOM HALL EFFECT SUPPLY

BOOM HALL EFFECT GROUND

P6-2

P6-3

P6-4

P6-5

P6-6

JIB UP/DOWN SIGNAL

PLATFORM ROTATE L/R SIGNAL

JIB/ROTATE ENABLE

PLATFORM HALL EFFECT SUPPLY

PLATFORM JOYSTICK ENABLE SUPPLY

PLATFORM HALL EFFECT GROUND

P5 P5-1

P5-2

P5-3

P5-4

P5-7

YELLOW LAMP-LOW FUEL INDICATOR

ALARM TILT/OVERLOAD

12 V SUPPLY

RED LAMP-TILT INDICATOR

GROUND SUPPLY

GLOW/CHOKE

PLATFORM

LEVEL UP/DOWN

GENERATOR

HI SPEED

HORN

ENGINE

START/STOP

ALARM

EMERGENCY STOP

TILT

(427)
(417)
(1)
(74)

(15)

(402)
(403)
(276)
(50)
(277)

(398)
(399)
(278)
(50)

(51)

(50)
(51)
(8)
(7)
(3)
(30)

(394)
(395)
(242)
(71)

(450)

(419)
(24)
(420)

(73)

AUXILIARY

POWER

PLATFORM

LEVEL ENABLE

(427)

(417)

(74)

(394)

(395)

(71)

(450)

(419)

(24)

(420)

(73)

(15)

BUS

CONNECTION

(POSITIVE)

(1)

(15)

(BLUE)

(GREY)

(BLACK)

(ORANGE)

(RED)

(GREEN)

(BLUE)

(GREY)

(BLACK)

(ORANGE)

(GREEN)

(GREY)

(RED)

(BLACK)

(GREY)

(RED)

(1)

(515)

(415)

(515)

(1)

BUS

CONNECTION

(NEGATIVE)

UPPER CONTROL

BOX CONNECTOR

P12 P12-1

P12-2

ENABLE

HALL EFFECT

BOOM PROPORTIONAL

CONTROL HANDLE

CAN BUS HI

CAN BUS LO

HALL EFFECT

DRIVE PROPORTIONAL

CONTROL HANDLE

ENABLE

STEER

P1-3

P1-6

P1-4&12

P1-5

P2-1&3

P2-2&4

P2-5&8

A
B
C
D
E
F
G
H

K
L

M
N

P
U
V

TO CONTROL

CABLE

(SEE PAGE 3)

J11

P4-1

OVERLOAD

(OPTION)

(74)

RED LAMP-OVERLOAD INDICATOR

(74)

(414)

(413)

TELE

P15

P15-1

P15-2

P15-3

P15-4

P15-5

P15-6

P15-7

P15-8

P15-9

START

PLAT LEVEL ENABLE

GLOW PLUG/CHOKE

HIGH SPEED

HORN

JIB SLOW DOWN

AUX HYDRAULIC POWER

DRIVING LIGHTS

DRIVING LTS

AUX HYDRAULICS

(97)

(15)

(1)

EMERGENCY STOP SWITCH

750 LBS

(268)

750 LBS

CHANNEL 1 S+

P+

CHANNEL 1 S-
CHANNEL 2 S+

P1-1
P1-2
P1-3

P1-4

P+

CHANNEL 2 S-

P2-1
P2-2
P2-3

P2-4

1
2
3
4
5
6

LOAD CELL

CONNECTOR

LAOD CELL FOR CE AND 750

LBS OPTIONS ONLY

LAOD CELL FOR CE AND 750

LBS OPTIONS ONLY

750 LED OK INDICATOR

P5-5

750 LBS

OPTION

(267)

65-J Diesel - From Serial #14800000

Summary of Contents for 65-J Diesel

Page 1: ...Part 95105 February 2021 Serial Number Range 14800000 Up Service Parts Manual 65 J Diesel ART_4883 ...

Page 2: ...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 info MECawp com www MECawp com MEC Aerial Work Platforms ...

Page 3: ...ulic 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 ...

Page 4: ...es 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 T...

Page 5: ...24 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 Jib Connection 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 C...

Page 6: ...ing Drive 183 Boom Lift Cylinders 184 Boom Extend Cylinder 186 Platform Level Cylinder 188 Jib Cylinder 190 Steer Cylinders 191 Axle Cylinders 192 Hydraulic Hoses 194 Section 26 Base 196 Chassis 196 Module Doors 198 Engine Module 200 Engine Assembly 202 Engine Components 204 Controls Module 206 Controls Module 2 208 Turntable Components 210 Boom Harness 212 Section 27 Decals 213 Decal Locations 21...

Page 7: ... 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 sho...

Page 8: ...s 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 saf...

Page 9: ...ant 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 agai...

Page 10: ...ed 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 ...

Page 11: ...1 698 7 8 14 407 448 551 607 543 597 736 809 1 8 537 592 728 802 716 790 970 1070 1 14 670 740 908 1003 894 987 1211 1137 Torque values apply to fasteners as received from the supplier dry or when lubricated with normal engine oil If special graphite grease molydisulphide grease or other extreme pressure lubricants are used these torque values do not apply Specific Torque Values for Selected Faste...

Page 12: ...17 1488 M30 3 00 872 1066 1181 1444 1224 1496 1658 2027 Torque values apply to fasteners as received from the supplier dry or when lubricated with normal engine oil If special graphite grease molydisulphide grease or other extreme pressure lubricants are used these torque values do not apply Specific Torque Values for Selected Fasteners Location Torque Lug Nuts 150 lb ft 203 Nm Torque Hubs to Yoke...

Page 13: ...n the Hydraulic Components Torque Table Parts drawings and service instructions in this manual Packaging and instruction sheets provided with new parts Instruction manuals provided by the manufacturer of the component being serviced Type SAE Port Series Cartridge Poppet Fittings Hoses Ft lbs Nm Ft lbs Nm In lbs Nm 4 N A N A N A N A 135 145 15 16 6 N A N A 10 20 14 27 215 245 24 28 8 25 30 31 41 25...

Page 14: ...ath the boom assembly with the platform elevated unless the boom assembly is properly supported Use two slings and overhead hoist rated for 3 tons 2700 kg or more Thread the sling through the opening in the boom post as shown below Connect it to the overhead hoist then lift enough that the weight of the boom assembly is being supported by the hoist ART_4745 Supporting The Boom Assembly Section 5 B...

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 IS REMOVED WHILE THE COOLANT IS AT NORMAL OPERATING TEMPERATURE PRESSURE WITHIN THE COOLANT SYSTEM WILL FORCE HOT LIQUID OUT THROUGH THE FILLER OPENING AND MAY CAUSE SEVERE SCALDING Failure to perfor...

Page 16: ...21 Primary Machine Components ART_4708 Controls Module Platform Controls Jib Platform Chassis Turntable Boom Fuel Tank Engine Hydraulic Tank Base Controls Lift Gate Swing Gate Engine Module Primary Machine Components Section 7 Primary Machine Components ...

Page 17: ...ch on both control panels Press the EMERGENCY STOP switch at any time to stop all machine functions Turn switch clockwise to reset Selector Switch Set To Platform Either switch will stop all machine functions Both switches must be reset or machine will not operate Selector Switch Is Set To Base The upper controls are locked out The lower controls switch must be reset or the machine will not operat...

Page 18: ...s Upper Auxiliary Power Switch Lower Auxiliary Power Switch Auxiliary Power Switch The Auxiliary Power System is used to lower the platform in case of primary power failure To lower the platform activate the Auxiliary Power Switch to run the auxiliary hydraulic pump This function uses battery power from the auxiliary battery to lower the platform Push and hold the Auxiliary Power Switch then use t...

Page 19: ...m level surface capable of supporting the weight of the machine Chock the tires on the end of machine opposite the end to be raised If wheel is to be removed break loose but do not remove lug nuts before raising the machine Position a jack at the end of the machine to be lifted under a solid lifting point in the center of the frame Raise the machine and place two 2 suitable jack stands under solid...

Page 20: ...HINE SEE THE SERIAL NUMBER PLATE FOR MACHINE WEIGHT ONLY PROPERLY TRAINED AND QUALIFIED OPERATORS SHALL LOAD AND UNLOAD THIS MACHINE Loading Free Wheel Configuration For Winching Or Towing RUNAWAY HAZARD AFTER RELEASING THE BRAKES THERE IS NOTHING TO STOP MACHINE TRAVEL MACHINE WILL ROLL FREELY ON SLOPES ALWAYS CHOCK THE WHEELS BEFORE MANUALLY RELEASING THE BRAKES The machine can be winched or tow...

Page 21: ...ERSON 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 clockwise Enter the platform and reset the Platform Emergency Stop Switch Test platform control functions Raise the jib slightly for platform ground clearance Carefully drive the machine off or on ...

Page 22: ...ing holes aligns with the Rotation Lock located on the chassis The lock holes are located on the bottom of the Controls Module The Rotation Lock is located on the chassis behind the left front wheel Lift the Rotation Lock using the attached pin then rotate to the right and lower it into the shallow depression to engage See illustration Disengage the Rotation Lock before operation Steering Wheels A...

Page 23: ...w 8 6 44 0 ART_4748 Extend the boom of each machine approximately 15 inches 38 cm Arrange the machines as shown The distance between the ends of the counterweights should be 44ft 45ft 13 4m 13 7m Secure the chassis of each machine as previously instructed on page 16 Engage the Rotation Lock of each machine as previously instructed on page 16 using one of the side turntable locking holes Secure the...

Page 24: ... 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 manifolds Each function has a maximum pressure control limit set by pressure relief valves ART_4884 Jib Cylinder Wheel Motor each wheel Platform Level Cylinder Boom Extend Cylinder Upper Boom Lift Cylinder Lower Boom Lift Cylinder Platform ...

Page 25: ... hydraulic 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 Platform Functions Manifold provides hydraulic control to the Platform Level Platform Rotate and Jib functions Turntable Rotator One hydraulic motor turns the turntable boom and platform in relation to the chassi...

Page 26: ...om 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 Platform Rotator One rotary hydraulic actuator rotates the platform 90 either side of the centered position Jib Cylinder One hydraulic cylinder raises and lowers the jib Auxiliary Power Unit The Auxiliary Power ...

Page 27: ...re 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 hydraulic fluid from hydraulic reservoir into a clean empty container When the hydraulic reservoir is empty remove suction strainer and hoses Remove the filter elements Flush the hoses with clean h...

Page 28: ...voir 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 for signs of leakage weekly Hydraulic Filters BEWARE OF HOT FLUID CONTACT WITH HOT FLUID MAY CAUSE SEVERE BURNS The Hydraulic Fluid Reservoir contains a return filter Additionally all machines have a Charge Filter Assembly attach...

Page 29: ...lose the ball valve 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 that secure the Functions Pump Remove the pump Remove the bolts that hold the Drive Pump to the engine Remove the pump Installation is reverse of removal Apply one 1 drop of Loctite 242 or e...

Page 30: ...ith fluid and all air bleed out any time the pump is removed and re installed or drained of fluid for any reason To prime the pump loosen the output hose fittings at the hydraulic pumps to flood with hydraulic fluid Tighten fittings Drive Pump Service MEC does not recommend end user maintenance or repair of the Drive Pump on the 65 J machines Contact MEC or Rexroth for the nearest service provider...

Page 31: ...ves on the Hydraulic Tank to prevent fluid loss when the hoses are 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 mounting bracket Remove the manifold block Disassembly Remove coils from solenoid valves Mark and remove valves Mark and remove fittin...

Page 32: ...sult in damage to the pumps Connect the battery Operate 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 machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid to normal operating temperature Insert a 0 5000 psi gauge onto the ...

Page 33: ... Main Relief 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 the Main Functions Manifold Loosen the lock nut on the Main Relief Valve on the Main Functions Manifold With no load on platform use the Boom Retract function to retract the boom completely P...

Page 34: ...re 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 on a firm level surface free from overhead obstructions The Boom Extend Relief Valve 10 should be set to 1500 psi 107 bar Insert a 0 5000 psi gauge into the port GP1 of the Functions Manifold Loosen t...

Page 35: ...he reservoir with the appropriate hydraulic fluid as recommended in Fluid Recommendations on page 21 Always filter fluid through a 10 micron filter when pouring into the reservoir Never reuse hydraulic fluid unless it was filtered upon removal stored in a clean container and then filtered upon refill Fill the inlet line leading from the pump to the reservoir Check the inlet line for properly tight...

Page 36: ...ston 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 instructions and the Parts Manual for a list of hardware specific to the cylinder being repaired Tag hoses for proper reassembly Disconnect hoses and IMMEDIATELY cap the openings to prevent contamination Remove cylinder fr...

Page 37: ...or pits deep enough to catch the fingernail are unacceptable replace the cylinder Polishing is a sign of uneven loading Check for roundness If a polished surface is not round within 007 in 0 18 mm replace the cylinder Cylinder Assembly To ensure a quality repair cylinder parts must be thoroughly cleaned dry and free of solvents and assembly must be performed in a clean area free of dust and contam...

Page 38: ...cylinder and push in until groove of the head lines up with the slot in the barrel Reinstall the cylinder retainer Installation is reverse of removal Reinstall any solenoid valves or counterbalance valve removed during disassembly Cycle the cylinder using air to check for proper operation Note Keep all parts clean when working with hydraulic cylinders Even one small piece of dirt or grit can damag...

Page 39: ...hes are 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 lower Emergency Stop switch in this situation will immediately cut electrical power to all controls and stopping all machine functions When operating from the upper controls activation of either E...

Page 40: ...cessor 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_3342 This light has 2 functions To protect the starter motor power cuts off to the starter circuit when the starter motor has run continuously for 10 seconds without starting the engine The Starter Circuit ...

Page 41: ...ectrical circuits An optional second may be present in machines to provide additional power for the Emergency Down power unit Battery Maintenance In Storage Follow these procedures for maintenance of battery on a machine not in use Keep battery clean Electrolyte of batteries should be checked regularly and kept at proper level Never stack one battery directly on top of another because post or cont...

Page 42: ...ive 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 life Battery Preventative Maintenance During quarterly maintenance after battery has been charged check the specific gravity of two or more cells A fully charged battery should indicate 1 28 specific gravity If low readings are noted check the fo...

Page 43: ...m 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 remove battery hold down hardware Lift the battery from the compartment put the battery aside and dispose of properly To Install A Battery Position the battery in the compartment and secure with hold dow...

Page 44: ...T_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 FOR HAZARDS WHILE OPERATING THE MACHINE Section 12 Controls Lower Controls ...

Page 45: ...rear of the platform 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 weight from the platform to restore function and continue 10 Tilt Indicator Light This light illuminates and an alarm sounds when the machine is not level Follow the instructions in th...

Page 46: ...his switch up to activate glow plugs prior to cold starting the engine Only for machines with V1505 T 5 Emergency Stop Switch Press the EMERGENCY STOP switch at any time to stop all machine functions Turn switch clockwise to reset 6 Generator Switch Optional Turn switch ON to engage optional AC generator Generator switches off when any other function is enabled 7 Engine Speed Select Switch Use thi...

Page 47: ...r backward to lift the jib Depress the enable bar 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 rotate the platform counterclockwise Depress the enable bar on front of the control lever then push the control lever left to rotate the platform clockw...

Page 48: ...anual February 2021 Sensors ART_4889 CAN Tilt 163 CAN Tilt 161 Jib Proximity Switch EZ Fit Angle Sensor Boom Retract Proximity Sensor EZ Fit Angle Sensor Optional Overload Sensing System component Section 13 Sensors Relays Alarms Sensors ...

Page 49: ...n with the GP400 Module If removed be sure that each returns to its original location If replaced be sure that the replacement has the same number as the original Jib Proximity Switch The Jib Proximity Switch senses when the jib is close to its fully lowered position and slows down jib motion EZfit Angle Sensors There are two EZfit Angle Sensors One is located at the base of the main boom while th...

Page 50: ...he rear wall of the Engine Module These relays reduce the current flow supplied by the GP400 Control Module Refer to the Section 20 Schematics for relay functions and interconnect Start Relay Provides power to the starter solenoid Glow Plug Relay Provides power to the diesel engine glow plugs Throttle Solenoid Controller Provides power to the electric throttle solenoid Glow Plug Circuit Breaker Pr...

Page 51: ... 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 senses an overload situation The Overload Alarm is installed on machines equipped with the optional Overload Sensing System To Correct Remove weight from the platform before operation can continue Alert Sounds The Platform Descent Alar...

Page 52: ...king 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 screwdriver push the Locking Fingers aside to release the contact Pull the wire and contact out of the connector Heavy Duty Plug Slide the removal tool along the wire to be replaced and push into the con...

Page 53: ...onnect first probe of ohm meter to common terminal Connect second probe to top normally open terminal With toggle DOWN there should be no reading With the toggle UP there should be a low resistance Move second probe to bottom normally open terminal With toggle UP there should be no reading With the toggle DOWN there should be a low resistance Common Normally Open Normally Open Common Normally Open...

Page 54: ...ormally Open Normally Open ART_2563 Common Normally Open Normally Open Normally Open Normally Open Common Normally Open Normally Open Common ART_2564 Momentary Button Switch Disconnect wires Connect one probe of ohm meter each terminal With the button in the neutral open position there should be no reading With the button pushed closed there should be a low resistance Common Normally Open Common N...

Page 55: ... equipment Components Locations GP400 Control Module processor Lower Controls Box GP440 Module Upper Controls Box Valve Current Control Module VCCM inside Lower Controls Box Terminal Block Module Inside Lower Control Box Diagnostic information can be found in Section 19 Troubleshooting Wiring information can be found in Section 20 Schematics ART_4892 GP400 Module Lower Controls Box Terminal Block ...

Page 56: ...n varies its output between 1 and 4 volts through 140 degrees of rotation During calibration the GP400 may learn that 1 8 volts fictional number used for explanation represents the fully lowered position and 3 6 volts represents the fully elevated position and therefore voltages between those figures relate to various heights in between All machines are calibrated at the factory and should not req...

Page 57: ...CEDURE 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 performed using an EZ Cal scan tool or optional on board diagnostic display If you do not have an EZ Cal please contact MEC to obtain one ART_4893 SYMBOL KEY FUNCTIONS ESC ENTER BUTTONS To move back ...

Page 58: ... side of the platform toe boards Use the Platform Level toggle function to level the platform fore and aft After the platform has been confirmed to be absolutely level proceed to the Level Sensors Calibration instructions The sensors used on the this machine are very sensitive and can detect even the slightest movement of the parts that they monitor Therefore it is it is absolutely mandatory that ...

Page 59: ... instructions on the display exactly and operate lift and lower only when the display instructs to do so DO NOT interrupt lifting or lowering during calibration as doing so will result in a bad calibration or possible fault You will be instructed to operate Boom Up to full elevation then back down to fully stowed position When the boom reaches full elevation and stops you must release the toggle s...

Page 60: ...s 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 output A reading of 0V or 5V is probably due to a wiring problem F06 CHECK ELEV This message is given if the elevation switch P7 5 is open at the start of calibration when the operator has confirmed the ...

Page 61: ...t 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 0V and 4 0V Check DIAGNOSTICS SENSORS to see the output A reading of 0V or 5V is probably due to a wiring problem F15 CHECK ELEV This message is given if the elevation switch P7 5 is open when the platform has been fully lowered after the DYNAMIC l...

Page 62: ...ep In the rare event that this occurs please call MEC for assistance F27 BAD HEIGHT This message indicates a problem with the height sensor output P8 2 during the STATIC calibration phases The height sensor output must be between 1 0V and 4 0V at all times Check DIAGNOSTICS SENSORS to see the output A reading of 0V or 5V is probably due to a wiring problem F30 BAD HEIGHTS This message indicates th...

Page 63: ... check the pressure F44 LOW PRESSURE This message indicates that the pressure is too low 0 5V or less at a STATIC measurement point This message would occur if the pressure sensor was disconnected or if there were some other wiring error Check DIAGNOSTICS SENSORS to check the pressure F45 HIGH PRESSURE This message indicates that the pressure is too high 4 5V or more at a STATIC measurement point ...

Page 64: ...pecified 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 faulty at the start of Load Calibration F61 BAD EXTENSION Extension is out of range at the start of Extension Calibration F62 BAD EXTENSION Extension is out of range at the start of Extension Calibrat...

Page 65: ...urs 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 during either STATIC lifting phase when more measurements are needed before the platform is fully raised LIFT EMPTY This message is displayed during the STATIC empty phase while the platform is bein...

Page 66: ...form 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 this is 500 lbs 227 kg See machine s the serial plate for platform capacity Press ENTER to confirm when the platform is loaded PLEASE LIFT This message is prompting for the platform to be raised The UP switch should be operated PLEASE LOWER Thi...

Page 67: ...Y 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 there is no need to redo the LOADED phase Press UP or DOWN to display YES then press ENTER if it is necessary to redo the LOADED phase If the previous LOADED calibration was in error or if the pressure sensor is replaced it will be necessary to red...

Page 68: ...PLACE TIRES WITH THE CORRECT TIRES TO MAINTAIN THE RATING OF THE EQUIPMENT ON MACHINES WHERE FOAM FILLED TIRES WERE FITTED AS ORIGINAL EQUIPMENT TIRES MUST BE REPLACED WITH EQUIVALENT SPECIFICATION TIRES AND FOAM FILL WEIGHT CONTACT MEC SERVICE Changing Tires Refer to Lift and Support The Machine in Section 9 Transporting and Lifting Instructions for instructions and safety precautions Always bloc...

Page 69: ... than the angle of a bolt s thread and since the splined surfaces grip the material around them these washers provide excellent bolt holding capabilities Nordlock style washers must be used anywhere they were originally installed on this machine Take care during disassembly to collect both parts of each washer for later reuse During installation be sure to assemble the pairs as shown with the ramp...

Page 70: ...e through bolt is off the ground Strap the platform to the pallet Disconnect the wiring harness from the Upper Controls box Carefully pull the wiring harness back to the jib Remove the center through bolt Remove the eight button head bolts that secure the platform mount weldment to the load cell spacer plate Use the forklift to move the platform and pallet away from the rest of the machine If nece...

Page 71: ...e of disassembly Tighten all fasteners to proper torque as shown below Location Torque Platform Rotator to Spacer Load Cell 55 lb ft 75 Nm Spacer Load Cell to Platform Mount Weldment 95 lb ft 129 Nm Platform Rotator Through Bolt Nut 420 450 lb ft 569 610 Nm Platform Mount Weldment Bolts Nuts 250 270 lb ft 339 366 Nm ...

Page 72: ...mbly before disconnecting 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 off the ground Strap the platform to the pallet Disconnect the wiring harness from the Upper Controls box Carefully pull the wiring harness back to the jib Disconnect all hydrau...

Page 73: ...of disassembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace as necessary Tighten all fasteners to proper torque as shown below Refer to Section 4 Torque Specifications for torque specifications of fasteners not listed below Location Torque Platform Rotator to Spacer Load Cell 55 lb ft 75 Nm Spacer Load Cell to Platform Mount Weldment 95 lb ...

Page 74: ...disconnecting them Immediately 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 Jib Lift function raise the jib high enough to position a pallet on the ground beneath the platform Lower the platform onto the pallet then strap the platform to the pallet Disc...

Page 75: ...t 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 down On the pin retainer side pull the pin out just far enough to release the link and the cylinder Remove the link and cylinder 9 ART_4912 IMPORTANT Leave the pin holding the nearer lower jib link i...

Page 76: ... signs of wear surface imperfections cracks or gray dust in the pivot area Replace as necessary Re connect the hydraulic lines after the barrel end of the Jib Cylinder is secured Use the Jib Lift Lower function to extend or retract the cylinder to proper length for assembly Refer to Section 4 Torque Specifications for torque specifications of fasteners ...

Page 77: ...oom Lift Lower function 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 function to lower the platform onto the pallet then strap the platform to the pallet Place 750 lbs 340 kg of weight on the platform floor 1 2 3 4 5 6 7 ART_4913 Note This will preven...

Page 78: ...atform Level Cylinder then 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 reverse of disassembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace as necessary Re connect the hydraulic lines to the Platform Level Cyl...

Page 79: ...onnections before 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 pins Disconnect all hydraulic hoses Immediately plug and cap all openings to prevent contamination At the base end of the main boom assembly tag and disconnect the wiring harness from ...

Page 80: ...orted by this foot Carefully 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 reverse of disassembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace as necessary Extend the cylinder to the length record...

Page 81: ... 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 Platform Jib assembly as described in steps 1 through 11 of the Platform Level Cylinder removal procedure on page 71 Use the Boom Lift Lower function to position the boom as shown at right Remove the hose and c...

Page 82: ...n and the rod end of the Upper 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_4935 Block Main Boom Assembly Rig slings from the Upper Lift Cylinder to an overhead hoist as shown Disconnect the hydraulic hoses and control wiring connected to the Upper Lift Cylinder Remove the pin at the barr...

Page 83: ...st Block Pin Place a 2x4 inch 5x10 cm block between the Tension Link and the lower portion of the turntable weldment A and in position to support the Lower Boom Cylinder then remove the 4x4 inch 10x10 cm block placed earlier and carefully rotate the Tension Link down Place a 4x4 inch 10x10 cm block between the Tension Link and the Lower Boom B Remove the pin from the rod end of the Lower Lift Cyli...

Page 84: ...ontrol wiring connected to the Upper Lift Cylinder Remove the pin at the barrel end of the Lower Lift Cylinder Remove the Lower Lift Cylinder 29 30 31 32 ART_4940 Lower Lift Cylinder Pin Assembly Assembly is reverse of disassembly Examine all pins for signs of wear surface imperfections cracks or gray dust in the pivot area Replace as necessary Refer to Section 4 Torque Specifications for torque s...

Page 85: ...m Assembly as described in steps 1 through 12 of the Boom Lift Cylinders Boom Linkage disassembly procedure on page 75 Set the Main Boom Assembly on stands for further disassembly Remove the cable track and associated machine parts from the boom Lay all cable and hoses out of the way to avoid damage Slide the End Section of the boom out approximately 6 feet 2 m Position an overhead hoist over the ...

Page 86: ...ifications Shims are not used on the larger square wearpads located on the top of the End section and bottom of the Base Section Standard Shims 22224 Shim 020 0 5 mm 11861977 Shim 040 1 mm 11861981 Shim 120 3 mm 11861982 Shim 200 5 mm 11861983 Shim 400 10 mm Wear pads use M10 1 5 bolts in varying lengths depending on shim use Use minimum bolt length needed to fully engage threaded insert Wear pad ...

Page 87: ...ached to the boom End Section install the Base Section Internal Wear pads and shims Use the hoist to position the End Section to provide clearance 5 ART_4962 Base Section Internal Wear Pads Base Section End Section DO NOT PLACE ANY PART OF YOUR BODY BETWEEN THE BOOM SECTIONS USE TOOLS TO POSITION SHIMS AND WEARPADS Keeping the sections as parallel as possible slide the End Section into and out of ...

Page 88: ...o perform this procedure unless stated Disassembly Park the machine on a firm level surface Throughout this procedure thoroughly clean all hydraulic connections 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 Platform Jib assembly as described in steps 1 ...

Page 89: ...ART_4943 Swing Drive Tag and disconnect the hydraulic lines from the top of the Rotary Manifold Tag and disconnect the hydraulic lines from the bottom of the Rotary Manifold Support the Rotary Manifold from below then remove the bolts securing the Rotary Manifold in place Remove the Rotary Manifold Note Rotary Manifold Mass 60 LBS 28 KG 12 13 14 15 ART_4944 Rotary Manifold Rig slings and a spreade...

Page 90: ... WASHERS USED ON THESE BOLTS ARE HARDENED STRUCTURAL WASHERS REPLACE LOST OR DAMAGED WASHERS WITH MEC PART 50582 ONLY Carefully apply lifting pressure Check the balance of the load before lifting and adjust the rigging as necessary Lift the Turntable Assembly off the Chassis Note Turntable Mass with Counterweight Swing Drive and Rotary Manifold removed 4350 LBS 1975 KG 18 19 ART_4947 ...

Page 91: ...h special instructions regarding Swing Bearing and Swing Drive installation below Tighten all fasteners to proper torque as shown below Refer to Section 4 Torque Specifications for torque specifications of fasteners not listed below Location Torque Swing Bearing Bolts on Chassis 180 lb ft 244 Nm Swing Bearing Bolts on Turret 180 lb ft 244 Nm Swing Drive Bolts 320 lb ft 434 Nm Swing Bearing Swing D...

Page 92: ... in three stages Tighten to 50 lb ft 68 Nm on the first pass Tighten to 100 lb ft 136 Nm on the second pass Tighten to 180 lb ft 244 Nm on the first pass Use the same pattern and stages later when securing the turntable to the Swing Bearing ART_5007 2 1 3 5 7 4 6 8 10 12 14 16 18 20 9 11 13 15 17 19 Set the Swing Drive in place after the Turntable is bolted down to the Swing Bearing Rotate the Tur...

Page 93: ...olt while manually moving the turntable back and forth to take out all play between the gears of the Swing Drive and the Swing Bearing Tighten the left and right Adjustment Bolts while continuing to move the Turntable back and forth Tighten the jam nuts on the Adjustment Bolts then tighten the Swing Drive Mounting Bolts to the torque listed at the beginning of the Assembly section ART_4954 Swing D...

Page 94: ... assembly 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 proper reassembly Disconnect all hydraulic hoses Immediately plug and cap all openings to prevent contamination Support the drive motor then remove the two bolts connecting the drive motor to the...

Page 95: ...eplace 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 Gear Hub Drive Motor O Rings Detail A Drive Motors MEC does not recommend end user maintenance or repair of the drive motors Contact MEC or for the nearest service provider Gear Hubs Lubrication Chang...

Page 96: ...ding to ambient temperatures as shown below Above 77 F 25 C SAE30 SAE10W 30 or SAE10W 40 32 77 F 0 25 C SAE20 SAE10W 30 or SAE10W 40 Below 32 F 0 C SAE10W SAE10W 30 or SAE10W 40 Use a suitable container to catch drained oil Remove the drain plug After oil has drained replace the drain plug Remove the old filter and wipe the filter seal contact surface with a clean towel Coat the seal on the new fi...

Page 97: ... engine for about 10 seconds then stop it or move the fuel feed pump lever by hand Start the engine Close the Fuel Injector Bleed Petcock when the engine idles smoothly 1 2 3 4 5 6 ART_4956 Out to Fuel Pump In From Fuel Tank Fuel Pump Lever beside pump Fuel Injector Bleed Petcock Fuel Pump In from Tank Return to Tank Fuel Filter Bleed Screw Fuel Filter Housing Fuel Filter Cartridge Turn To Remove ...

Page 98: ...cal system With the engine OFF disconnect the Clevis from the Throttle Lever Manually retract the Throttle Solenoid by grasping the piston just ahead of the boot and pull to the fully retracted position Note The solenoid must retract and extend smoothly Have a second person rotate the Throttle Lever as far as it will go With the Throttle Solenoid piston fully retracted adjust the Clevis until its ...

Page 99: ...sections of the boom Swing Bearing Gear Swing Bearing Gear Apply small amounts of lithium based grease to approximately every 3rd tooth of the ring gear Swing Bearing Open the Controls Module Locate the grease fitting at the front surface of the Auxiliary Power Unit mounting bracket 1 2 ART_4964 Grease Fitting Auxiliary Power Unit Controls Module Cabinet Latches And Hinges Apply spray lubricant to...

Page 100: ...c 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 Viscosity too high in cold climates Viscosity too low in warm climates Hydraulic fluid contaminated with debris filter change interval neglected Note MEC uses a multiple viscosity fluid that is light enough for cold c...

Page 101: ... CAN Bus communication To protect against part 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 increase terminal life NEVER ATTEMPT TO SUPPLY BATTERY POWER OR VOLTAGE HIGHER THAN 12 VOLTS TO ANY PART OR MODULE IN THIS SYSTEM AS CATASTROPHIC FAILURE...

Page 102: ...ROUND 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 P5 8 P5 9 P5 12 P5 P5 5 P5 4 PLAT ROTATE LEFT STEER RT STEER LT ALARM TELE EXTEND TELE RETRACT TWO SPEED TILT LIGHT PUMP CONT 1 INTERLOCK PLAT ROTATE RIGHT P6 P6 1 P6 2 P6 4 P6 6 P6 9 P6 10 P6 11 P...

Page 103: ...EVEL 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 Block Module TBM The Terminal Block Module TBM is a module inside the lower control box that provides terminal point connections for both positive and ground circuits A signal from the Emergency Sto...

Page 104: ...10 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 4 P6 5 P6 6 P6 P5 2 P5 1 P5 3 P5 4 P5 5 P5 7 P5 P7 2 P7 1 P7 3 P7 4 P7 6 P7 P15 P15 1 P15 3 P15 4 P15 5 P15 6 START PLAT LEVEL ENABLE CHOKE GLOW PLUG HI SPEED DRIVING LIGHTS P15 7 P15 8 AUX HYDRAULIC PO...

Page 105: ...able 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 Plug the EZ Cal into port P9 of the GP440 module This plug is on the right side of the module facing down ART_3709 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 1 4 1 4 1 3 1 3 1 4 1 4 1 4 1 4 7 1...

Page 106: ...NORMALLY 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 AS LISTED IN THE FOLLOWING TABLES Error Messages To obtain error messages from the EZ Cal access the EZ Cal as mentioned above The display will read HELP PRESS ENTER Press Enter to display the curre...

Page 107: ...ELAY TRIP 3 SEC 4H 7 SPEED 55 4J 1 DELAY CLEAR 0 3 SEC 4H 8 ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER CCW MAX 43 4G 11 L TO P STEP 17 4G 7 CW MIN 30 4G 8 ENTER ENTER CHANGE DEFAULTS 5A TILT SETUPS 5B HEIGHT SETUPS 5D LOAD SETUPS 5E INTERLOCKS 5F 5B 1 5B 2 5B 3 5D 1 ELEVATION 14 5D 2 5D 3 TRANSPORT 10 5D 4 5D 5 5A 1 MODEL 1 L60D 2 L60D CE 5A 2 CUSTOMER 1 L60D 5F 2 E TIME OUT 10 0 SEC 5F...

Page 108: ...LE BOOM SWING TELESCOPE IN TELESCOPE OUT DRIVE FWD REV JSTK P5 3 P5 4 P5 6 P5 7 P5 9 P5 12 P6 4 P6 1 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 VOLT SUPPLY TILT INDICATOR LT GROUND SUPPLY B TRANSPORT YES or NO 2A 14 CURTIS NOT USED 2A 15 P7 4 KEY SWITCH PLATFORM SEL P7 5 GENERATOR RUNNING 60JE P7 6 ENG START SWITCH MATRIX...

Page 109: ...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 ACTIVE__________________________ Flash Code None Base Platform selector switch set to base control station STARTUP_______________________________________ Flash Code None GP400 performing start up proc...

Page 110: ..._______________ 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 front of main boom located behind panel Right Module has malfunctioned or wiring is damaged NO DATA FROM CAN TILT 4_______________________ Flash Code None CAN Tilt module mounted to Rear axle has malfu...

Page 111: ...rocessor has not been calibrated Operation will be restricted until calibration is completed Refer to Set up procedures in this section for calibration information and instructions HEIGHT NOT CALIBRATED___________________________ Flash Code 1 1 The Height portion of the calibration has not been completed Operation will be restricted until calibration is completed Refer to Set up procedures in this...

Page 112: ..._______________ 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 2 Auto Platform Level operation running wait until completed to operate other functions FUNCTIONS LOCKED TOO HIGH_____________________ Flash Code 2 2 Elevation sensor indicating elevation beyond 9...

Page 113: ...gital 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 output and switch digital output using the EZ Cal RELEASE ENABLE SWITCH__________________________ Flash Code 2 2 One or more enable switches activated for extended period of time without corresponding fun...

Page 114: ...______________________ 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 FAULT BAD INTERNAL SLAVE ______________________ Flash Code 4 2 Malfunction within the GP400 possibly caused by a short circuit in the wiring or high voltage surge Replace GP400 FAU...

Page 115: ...ure 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 ____________________ _ Flash Code 7 7 Engine Start was pushed but engine did not start or oil pressure switch did not close Engine Oil Pressure is low Check oil level FAULT SOME BIG BAD PROBLEM _________________...

Page 116: ...naled by the 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 or flashing Flash codes are the GP400 s indication of a fault in the system Refer to flash code designation in this section of the manual or plug in an EZ Cal scan for more relevant informa...

Page 117: ...n relief valve 6 out of adjustment Adjust Main relief valve 6 to rated platform capacity located on function manifold see hydraulic section Lift valve 8 1 not energized Check wiring to lift valve Check for EZ Cal message or flash code Lift valve 8 1 not shifting Clean debris Check for damage replace Solenoid Valve 18 dump valve not energized Check wiring to valve Check EZ Cal ref P4 14 for output ...

Page 118: ... 8 2 not shifting completely Clean debris Check for damage replace Extend Speed adjustment reduced in GP400 Processor Use the EZ Cal and check adjust setting See ADJUSTMENTS TELESCOPE OUT MAX No boom retract Main relief valve 6 out of adjustment Adjust Main relief valve 6 to rated platform capacity located on function manifold see hydraulic section Foreign debris stuck in boom slide pads Inspect c...

Page 119: ...on Turntable Rotate joystick inoperative Check joystick output using EZ Cal See 2D2 P7 2 for signal Rotate Valve 11 not energizing Check wiring to valve Check GP400 output using EZ Cal See 2E1 P4 7 left and P4 8 right Rotate valve 11 not shifting Clean debris Check for damage replace Internal damage or failure of rotator Inspect clean repair System interlock Check EZ Cal HELP messages for interloc...

Page 120: ...HELP messages for interlock CE rated models Axles not parallel Reposition machine on flat ground Slow drive with platform in stowed position and boom retracted Slow speed enabled Check speed switch in platform box Check 2 speed valve located on the main manifold see hydraulic diagram Hydraulic oil incorrect for severe low temperatures Use hydraulic tank warmer if equipped Operate drive continuousl...

Page 121: ...ection 25 Hydraulics for correct connection Steer cross port relief valve s 3 1 and 3 2 set too low Set steer relief valves to 1500 PSI 103 bar See hydraulic diagram for relief valves location System interlock Check EZ Cal 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 h...

Page 122: ...RING CYLINDERS AF BR 2SP AXLE CYLINDERS T GCP CP A B 22 1 22 2 22 3 25 26 27 S17 S18 S19 ROTARY MANIFOLD I C PU1 DRIVE PUMP Fe Fa 1 2 4 5 3 6 JUNCTION BLOCK 2 SPD BRK MANIFOLD G 1 2 3 5 6 7 4 8 2 3 5 6 7 4 8 1 65 J Boom Diesel HYDRAULIC SCHEMATIC 1 of 2 From Serial 14800000 Section 20 Schematics Hydraulic Schematic Part 1 ...

Page 123: ... 2 16 4 7 PR 1500psi 10 4 1 GLS 1500 psi 3 1 1500 psi 3 2 4 2 4 4 4 6 4 8 14 13 9 4 5 15 17 1 17 2 S9 S8 S1 4 S 2 5 S S 3 S S6 S7 17 3 1 2 2 4 9 PLS ALS 12 2 1 18 1 18 2 19 8 3 3 2 4 10 6 1 6 2 4 11 4 12 4 13 4 14 5 1 5 2 S10 S11 S15 S12 S13 S14 3300psi 21 LOWER BOOM CYLINDER UPPER BOOM CYLINDER TELESCOPE CYLINDER PLATFORM LEVEL B I J E T A T O R M R O F T A L P PLATFORM MANIFOLD AUXILIARY POWER M...

Page 124: ...ruary 2021 Section 20 Schematics Primary Functions Manifold Part 1 ART_5005 Outward Faces 7 1 7 2 3 1 16 18 1 19 Forward 13 10 4 2 4 4 4 6 1 2 2 Rearward Bottom 20 2 1 4 8 Top 65 J Boom Diesel Functions Manifold Valves 1 of 2 From Serial 14800000 ...

Page 125: ...ALVE FLOW SHARE VALVE 3 POS 4 WAY VALVE BOOM UP DOWN 3 POS 4 WAY VALVE BOOM EXT RET SHUTTLE VALVE EXTEND REGENERATE 1 2 1 3 1 3 2 4 1 4 9 5 6 7 1 7 2 8 1 8 2 9 RELIEF VALVE BOOM EXTEND 10 VALVE 3 POS 4 WAY SWING CHECK VALVE PLATFORM RETURN FLOW COMPENSATOR VALVE ORIFICE 0 5MM LOAD SENSE DUMP VALVE MAIN FLOW SHARE VALVE ORIFICE 0 5MM FLOW SHARE 20 UNC CHECK VALVE PILOT OPERATED STEER PILOT PISTON S...

Page 126: ...LECT BOOM UP SWITCH KEY SWITCH PLAT SELECT AUXILIARY BATT SWITCH BOOM DOWN SWITCH TELE EXTEND SWITCH TELE RETRACT SWITCH ENGINE OIL PRES SWITCH ENGINE TEMP SWITCH LOW FUEL SWITCH P6 P7 P8 2 P8 3 P8 6 P8 7 P8 9 P8 13 P8 14 P8 15 P9 1 P9 2 P9 3 P9 4 P12 1 P12 2 P12 3 P14 1 P14 2 P14 10 UPPER BOOM ANGLE SENSOR UPPR BOOM ANGLE SENSOR 2 LOWER BOOM ANGLE SENSOR LOWR BOOM ANGLE SENSOR 2 CURRENT MEASURE G...

Page 127: ... 108 211 210 29 152 204G 205G 110 ALARM 37 HORN 73 BEACON 1 2 3 43 ANGLE TRANSDUCER HEIGHT 2 LOWER J3 1 15 1 131 415 515 BOOM MANIFOLD K J L M N P H F E B R S U 130 N M P G U V X D C E F W B CONTROL CABLE 21 PIN ROUND 414 413 412 15 1 15 15 1 133 96 134 216 217 PLATFORM ROTATE CCW PLATFORM ROTATE CW 130 131 BOOM MANIFOLD JIB DOWN JIB UP 216 217 LEVEL UP LEVEL DOWN 6 7 5 14 10 8 11 9 12 1 4 2 3 ORG...

Page 128: ...ENGINE START STOP 2 6 5 4 1 ALARM A B C EMERGENCY STOP TILT 427 417 1 74 15 402 403 276 50 277 398 399 278 50 51 50 51 8 7 3 30 394 395 242 71 450 419 24 420 73 AUXILIARY POWER 1 2 PLATFORM LEVEL ENABLE 3 4 427 417 74 394 395 71 450 419 24 420 73 1 2 15 15 15 15 15 BUS CONNECTION POSITIVE 1 1 1 1 1 15 15 BLUE GREY BLACK ORANGE RED GREEN BLUE GREY BLACK ORANGE GREEN GREY RED BLACK GREY GREY GREY RE...

Page 129: ...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 a...

Page 130: ...ntrols 60 J Diesel 1 2 3 4 6 7 8 9 9 9 10 9 11 5 5 12 13 13 14 Aux Power Function Enable Engine Start Stop Glow Plug Emergency Stop Generator opt Idle Speed Hi Cap Switch opt Hi Cap Indicator opt Drive Speed Horn Overload opt Tilt Low Fuel Platform Level Upper Controls Box Part 1 Section 21 Controls ...

Page 131: ...form Control Handle 1 3 94687 PQ Controls Drive Control Handle 1 4 18494 Palm Rest 1 5 7423 Switch 2 Position Momentary 2 6 92422 Enable Button 1 7 92427 Switch 3 Position Single Momentary 1 8 7800 Emergency Stop Button 1 9 6234 Switch 2 Position 4 10 90789 Light Green 1 11 92421 Horn Button 1 12 92254 Light Red 1 13 92253 Light Amber 2 14 91954 Switch 3 Position Momentary 1 ...

Page 132: ...Page 126 65 J Diesel Service Parts Manual February 2021 Section 21 Controls Upper Controls Box Part 2 ART_4841 Upper Controls 60 J Diesel 2 1 6 5 3 2 4 2 3 7 8 9 ...

Page 133: ...tem Part Number Description Qty 1 22208 Upper Controls Enclosure 1 2 90714 Switch Base 3 3 8082 Contact Block Normally Closed 2 4 8083 Contact Block Normally Open 1 5 22429 Bracket 1 6 92027 GP440 Module 1 7 92033 Buss Module 2 8 50191 Screw THMS 10 32 x 5 2 9 91881 Bus Mount 2 ...

Page 134: ...Page 128 65 J Diesel Service Parts Manual February 2021 Section 21 Controls Lower Controls Box ART_4842 Lower Controls 60 J Diesel 1 2 3 4 10 19 11 12 13 14 14 15 16 5 8 3 7 9 6 7 17 18 ...

Page 135: ...ch 3 Position Momentary 7 6 92253 Light Amber 1 7 92254 Light Red 2 8 92427 Switch 3 Position Single Momentary 1 9 7800 Emergency Stop Button 1 10 93900 GP400 Module 1 11 91838 Terminal Block Module 1 12 91950 VCCM Module 1 13 8082 Contact Block Normally Closed 2 14 90714 Switch Base 2 15 8083 Contact Block Normally Open 1 16 28696 Lower Controls Enclosure 1 17 92003 Diagnostic Display 1 18 26571 ...

Page 136: ...Sub 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 Assembly Part 1 Platform Sub Assembly Part 1 Section 22 Platform ...

Page 137: ...HR M10 ZP Nordlock 8 13 50007 WSHR M12 ZP Nordlock 8 14 50028 HHCS M06 1 00 020 2 15 50047 NNYL M06 1 00 Nylock 4 16 50047 NNYL M06 1 00 Nylock 24 17 50052 NNYL M20 2 50 4 18 50068 WSHR M06 Fender 4 19 50255 WSHR M06 Standard Flat 1 20 50256 NNYL M24 3 00 1 21 50327 HHCS M06 1 00 035 2 22 50378 SHCS M10 1 50 035 8 23 50489 WSHR M20 Thru Hardened 8 24 50593 HHCS M24 3 00 280 1 25 53002 HHCS M20 2 5...

Page 138: ...e Parts Manual February 2021 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 1 Platform Sub Assembly Part 2 ...

Page 139: ...00 020 24 12 50006 WSHR M10 ZP Nordlock 8 13 50007 WSHR M12 ZP Nordlock 8 14 50028 HHCS M06 1 00 020 2 15 50047 NNYL M06 1 00 Nylock 4 16 50047 NNYL M06 1 00 Nylock 24 17 50052 NNYL M20 2 50 4 18 50068 WSHR M06 Fender 4 19 50255 WSHR M06 Standard Flat 1 20 50256 NNYL M24 3 00 1 21 50327 HHCS M06 1 00 035 2 22 50378 SHCS M10 1 50 035 8 23 50489 WSHR M20 Thru Hardened 8 24 50593 HHCS M24 3 00 280 1 ...

Page 140: ...Page 134 65 J Diesel Service Parts Manual February 2021 Section 22 Platform Jib Connection ART_4894 Jib Connection 60 J 1 2 3 2 9 5 6 7 ...

Page 141: ...ty 1 50593 Bolt M24 x 280 1 2 50255 Washer M24 Flat 2 3 53013 Button Head Screw M12 x 35 8 50007 Washer M12 Nordlock 8 4 5 50256 Nut M24 Nylock 1 6 50378 Socket Head Screw M10 x 35 8 50006 Washer M10 Nordlock 8 All machines use only one of following 7 28698 Standard Machines Spacer Plate 1 9 93944 Grommet 1 ...

Page 142: ...Page 136 65 J Diesel Service Parts Manual February 2021 Section 22 Platform Platform Options ART_4845 Platform Options 60 J 1 4 3 5 6 2 ...

Page 143: ...lamp 5 16 x 1 3 8 2 50200 Washer M8 Nordlock 4 53020 Nut 5 16 Acorn 4 2 28950 Sheet Materials Rack Kit 3 28535 Guard Rail Pads 5 4 93963 Strap 1 5 28540 Sheet Materials Rack 1 6 93920 Decal Warning Sheet Material Rack Self Weight 4 28533 Bottom Wear Strip 1 28534 Front Wear Strip 1 50042 Bolt M12 x 35 8 50003 Washer M12 Std 16 50054 Nut M12 Nylock 8 ...

Page 144: ...Page 138 65 J Diesel Service Parts Manual February 2021 Boom Chassis Installation ART_4846 Boom Installation 60 J 1 2 3 4 5 6 7 8 1 10 11 Boom Chassis Installation Section 23 Elevating Assembly ...

Page 145: ... Part Number Description Qty 1 28915 Jib Assembly 1 2 REF Boom Assembly 3 28607 Pin 2 4 18151 Pin Retainer 2 5 50200 Washer M8 Nordlock 2 6 50032 Bolt M8 x 30 2 7 18152 Retainer Pin 3 8 50236 Bolt M12 x 40 3 9 50007 Washer M12 Nordlock 3 10 28601 Pin 3 11 REF Turntable Assembly REF Reference ...

Page 146: ...Page 140 65 J Diesel Service Parts Manual February 2021 Section 23 Elevating Assembly Boom Riser ART_4847 Boom Riser 60 J 1 2 3 4 2 3 4 2 3 4 8 6 12 11 10 9 16 15 14 13 11 10 9 7 5 ...

Page 147: ...6 4 50007 Washer M12 Nordlock 6 5 28604 Pin 1 6 REF Upper Lift Cylinder See Section 25 Hydraulics 7 28300 Post Weldment 1 8 28603 Pin 4 9 50033 Bolt M10 x 25 4 10 50006 Washer M10 Nordlock 4 11 28647 Retainer Plate 2 12 28602 Pin 1 13 28637 Hose Cable Cover 1 14 28370 Riser Boom Weldment 1 15 REF Lower Lift Cylinder See Section 25 Hydraulics 16 28380 Tension Link 1 REF Reference ...

Page 148: ...r Pad Threaded Insert M10 Nordlock Washer Bolt Shim as needed to achieve 030 total clearance in both side to side and top to bottom directions Use minimum bolt length needed to fully engage threaded insert Wear pads use M10 1 5 bolts in varying lengths depending on shim use 1 2 5 4 3 7 8 10 13 15 18 16 31 17 19 30 28 29 24 25 26 27 12 13 23 20 21 22 14 12 11 9 ...

Page 149: ... Req Wear Pad Bolts Wear pads use M10 1 5 bolts in varying lengths depending on shim use Use minimum bolt length needed to fully engage threaded insert Wear pad bolts must be installed with M10 Nordlock washers 50033 Bolt M10 x 25 50034 Bolt M10 x 30 50332 Bolt M10 x 35 50035 Bolt M10 x 40 50036 Bolt M10 x 50 50021 Bolt M10 x 55 50006 Washer M10 Nordlock 32 14 28765 Wearpad Wide 2 15 29105 Boom Ba...

Page 150: ...Page 144 65 J Diesel Service Parts Manual February 2021 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 151: ...ing 4 5 REF Jib Cylinder See Section 25 Hydraulics 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 18151 Pin Retainer 4 12 50200 Washer M8 Nordlock 4 13 50032 Bolt M8 x 30 4 14 REF Platform Rotator See Section 25 Hydraulics 1 15 28716 Roller Spacer 1 16 92201 CAN TILT 161 1 17 92203 CAN TILT 163 ...

Page 152: ...Page 146 65 J Diesel Service Parts Manual February 2021 Front Axle Installation ART_4850 Front Axle Installation 60 J 3 4 5 6 2 12 1 6 4 5 10 11 9 7 8 Front Axle Installation Section 24 Axles ...

Page 153: ...xle Cylinder See Section 25 Hydraulics 2 2 28600 Pin 2 3 18075 Pin 2 4 18151 Pin Retainer 4 5 50200 Washer M8 Nordlock 4 6 50032 Bolt M8 x 30 4 7 18152 Pin Retainer 1 8 50236 Bolt M12 x 40 1 9 50007 Washer M12 Nordlock not shown 1 10 18405 Pin 1 11 92039 Thrust washer 2 12 28903 Front Axle Assembly 1 REF Reference ...

Page 154: ...J Diesel Service Parts Manual February 2021 Section 24 Axles Front Axle Components ART_4852 Front Axle Components 60 J 2 11 12 13 10 9 1 2 8 7 4 5 6 3 4 5 5 3 4 19 14 20 21 22 24 18 17 16 19 20 21 23 15 24 17 18 16 ...

Page 155: ...olid Assemblies Serial 14800038 14800043 1 95023 Wheel Assembly RH 36 14 20 Solid From Serial 14800104 1 13 95107 Wheel Tire Assy LH 355 55 D625 Foam Serial 14800025 14800037 1 94975 Wheel Assembly LH 36 X 14 24 Solid Assemblies Serial 14800038 14800043 1 95024 Wheel Assembly LH 36 14 20 Solid From Serial 14800104 1 14 22209 Hose Guard Right Side 1 15 22210 Hose Guard Left Side 1 16 93624 Planetar...

Page 156: ...Page 150 65 J Diesel Service Parts Manual February 2021 Section 24 Axles Rear Axle Components ART_4853 Rear Axle Components 60 J 1 3 4 5 6 7 8 8 7 6 5 2 ...

Page 157: ...43 1 95023 Wheel Assembly RH 36 14 20 Solid From Serial 14800104 1 2 95107 Wheel Tire Assy LH 355 55 D625 Foam Serial 14800025 14800037 1 94975 Wheel Assembly LH 36 X 14 24 Solid Assemblies Serial 14800038 14800043 1 95024 Wheel Assembly LH 36 14 20 Solid From Serial 14800104 1 3 28021 Cover Plate 2 4 92098 Clip Nut 8 5 93624 Planetary Gear Hub 2 6 92042 O Ring Brake Port 2 7 92166 O Ring 2 8 REF ...

Page 158: ...5 J Diesel Service Parts Manual February 2021 Hydraulic Components ART_4862 Hydraulic Components 60 J Diesel 1 2 3 4 5 6 7 8 9 10 11 12 13 15 17 16 14 15 18 19 18 15 19 Hydraulic Components Section 25 Hydraulics ...

Page 159: ...rm Functions Manifold 1 7 28395 Lower Boom Lift Cylinder 1 8 92072 Charge Filter Assembly 1 9 93339 Drive Pump 1 10 93232 Main Functions Pump 1 11 28923 Brake Axle 2 Speed Manifold 1 12 93647 Turntable Rotator 1 13 17973 Auxiliary Power Unit 1 14 28909 Hydraulic Fluid Reservoir 1 15 92514 Wheel Motor 4 16 REF Main Functions Manifold 1 17 93651 Rotary Manifold 1 18 18070 Steer Cylinder 2 19 22315 A...

Page 160: ...154 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Main Functions Manifold Fittings ART_5001 Main Functions Manifold Fittings 65 J 1 2 3 4 8 9 10 9 2 11 12 13 6 7 8 5 4 5 behind valves ...

Page 161: ...o fittings 1 2 50835 Fitting MFFOR MB 6 6 3 3 51091 Fitting MFFOR MB45 12 10 1 4 50671 Fitting MFFOR FFORX90 4 4 2 5 50832 Fitting MFFOR MB 4 6 2 6 50814 Fitting MFFOR MB 10 8 1 7 50674 Fitting MFFOR MB90 6 6 1 8 50974 Fitting TPO 4 2 9 50676 Fitting MFFOR MB45 6 6 2 10 50816 Fitting MFFOR MB45 6 8 2 11 50840 Fitting MFFOR MB 8 6 1 12 50831 Fitting MFFOR MB 4 4 1 13 50961 Plug MB 4 1 ...

Page 162: ...ry 2021 Section 25 Hydraulics Main Functions Manifold Block Components ART_5002 Main Functions Manifold Block Components 65 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 22 19 12 Orifices located beneath plugs 1 ...

Page 163: ...0 Solenoid Valve 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 Valve 1 14 94067 Check Valve 2 15 94074 Pilot Valve 1 16 94221 Priority Flow Valve 1 17 94076 Pilot Valve 1 18 94072 Pilot Valve 1 19 94079 Pilot Valve 1 20 94218 Orifice 1 4 20 6mm 4 21 ...

Page 164: ...Page 158 65 J Diesel Service Parts Manual February 2021 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 165: ...n 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 Solenoid Valve 3 7 94082 Coil 3 8 51083 Fitting MFFOR MB90 6 4 2 9 94086 Valve 1 10 94088 Orifice 75mm 2 ...

Page 166: ...Service Parts Manual February 2021 Section 25 Hydraulics Platform Functions Manifold ART_4867 Platform Functions Manifold Later Style 60 J Later Style Block Designation 2 1 10 9 8 6 7 13 11 5 3 3 4 11 12 14 13 2 15 16 17 2 ...

Page 167: ...31 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 Fitting MFFOR MB 6 6 1 10 50672 Fitting MFFOR FFORX90 06 06 1 11 94081 Coil 2 12 94031 Solenoid Valve 1 13 94082 Coil 4 14 94036 Solenoid Valve 2 15 94084 Pilot Valve 1 16 94072 Pilot Valve 1 17 940...

Page 168: ...ice Parts Manual February 2021 Section 25 Hydraulics Chassis Blocks ART_4882 Chassis Blocks 60 J Steering Counterbalance Valves Case Drain Connections Brake Release Axle Extend Connections 1 2 3 1 6 7 3 x4 2 3 4 8 6 7 2 9 11 10 ...

Page 169: ...nnection Manifold 2 2 50835 Fitting MFFOR MB 6 6 4 3 50656 Fitting MFFOR MB90 4 6 6 4 51098 Fitting MB 8 Plug 1 5 93910 Counterbalance Valve 6 50832 Fitting MFFOR MB 4 6 2 7 50674 Fitting MFFOR MB90 6 6 2 8 50847 Fitting MFFOR MB90 6 8 1 9 50836 Fitting MFFOR MB 6 8 1 10 51180 Fitting FFORX MB 6 6 1 11 93864 Check Valve 1 ...

Page 170: ...Page 164 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Rotary Manifold Rotary Manifold Alternative 60 J Art_5304 ILLUSTRATION No ...

Page 171: ...Page 165 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Item Part Number Description Qty 94681 HYDRAULIC ROTARY SWIVEL MANIFOLD 8 PORT ALT FOR 93651 ...

Page 172: ...Page 166 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Hydraulic Pumps Hydraulic Pump 65 J Art_5522 ILLUSTRATION No 9 10 12 3 4 5 6 15 14 6 7 8 13 11 8 ...

Page 173: ...12 O 1 4 51066 HYFT MFFOR MB90 10 12 1 5 50837 HYFT MFFOR MB 8 10 1 6 50843 HYFT MFFOR MB90 12 12 2 7 50966 HYFT MFFOR MB 4 6 FS6400 04 06 1 8 50832 HYFT MFFOR MB 4 6 FS6400 04 06 2 9 50840 HYFT MFFOR MB 8 6 FS6400 08 06 O 2 10 50676 HYFT MFFOR MB45 06 06 1 11 50838 HYFT MFFOR MB 8 12 FS6400 08 12 O 1 12 50831 HYFT MFFOR MB 4 4 FS6400 04 04 1 13 50783 HYFT MB MJ90 12 16 6801 16 12 NWO 1 14 50007 W...

Page 174: ...kw Gen Assembly 60 J Art_5305 ILLUSTRATION No 23 22 10 19 26 26 24 24 11 13 28 15 16 18 12 12 44 51 REPLACE DW10Z 01 C N 150 94076 27 INSTALL ON P PORT FITTING 50 REPLACE WS10Y 01 C N 12 DN 94503 MANIFOLD ASSEMBLY SHOWN FOR REFERENCE ONLY 5 4 2 1 3 49 48 29 14 17 12 17 14 20 30 52 25 21 47 6 27 51 50 ...

Page 175: ...5 51152 HYFT MFFOR MB 10 12 6400 10 12 1 26 51163 HYFT FL MFFOR90 12 12 Code 62 2 27 51198 HYFT MFFOR FFORX90 10 10 FF6500 10 10 1 28 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10 10 1 29 51208 HYFT MB MJ90 20 24 6801 24 20 1 30 51216 HYFT FFORX MB 12 12 1 31 52702 HOSE ASSEMBLY REL RET T FET CFI 35CCRRCD MIDTANKT 1 32 52772 HOSE ASSEMBLY GENINLET ALS 1 33 52773 HOSE ASSEMBLY 35CCRR GLS 1 34 52774 ...

Page 176: ...LUSTRATION No 47 24 46 5 4 2 1 3 45 49 26 13 16 11 16 13 18 27 48 22 19 44 6 12 25 14 15 17 11 11 41 26 20 13 16 23 23 21 21 10 40 7 46 REPLACE WS10Y 01 C N 12 DN 94503 47 REPLACE DW10Z 01 C N 150 94076 24 INSTALL ON P PORT FITTING MANIFOLD ASSY SHOWN FOR REFERENCE ONLY Item Part Number Description Qty 1 28295 7 5KW GEN COVER FORMING HOLE CUTOUTS 1 ...

Page 177: ... 10 FF6500 10 10 1 25 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10 10 1 26 51208 HYFT MB MJ90 20 24 6801 24 20 1 27 51216 HYFT FFORX MB 12 12 1 28 52702 HOSE ASSEMBLY REL RET T FET CFI 35CCRRCD MIDTANKT 1 29 52772 HOSE ASSEMBLY GENINLET ALS 1 30 52773 HOSE ASSEMBLY 35CCRR GLS 1 31 52774 HOSE ASSEMBLY GENCD MIDTANKT 1 32 52775 HOSE ASSEMBLY 35CCRR AUXMANIFOLDT 1 33 52776 HOSE ASSEMBLY AUXMANIFOLDPO...

Page 178: ...MOUNTING BOLT MUST NOT BOTTOM OUT LEAKING DAMAGE TO THE PUMP CAN RESULT THREADED BORE MAXIMUM DEPTH IS 21 4MM CASE LINE MUST BE SIZED ROUTED SUCH THAT A MAX CONTINUOUS INTERMITTENT PRESSURE OF 7PSI 29PSI RESPECTIVELY IS ACHEIVED 14 THIS ITEM 51066 GETS TRANFERED FROM THE GEAR PUMP SEE 28991 FOR DETAILS O RING 93318 GETS TRANFERED FROM THE GEAR PUMP SEE 28991 FOR DETAILS 40 REPLACE WS10Y 01 C N 12 ...

Page 179: ... 16 12 6410 16 12 O 1 21 51152 HYFT MFFOR MB 10 12 6400 10 12 1 22 51198 HYFT MFFOR FFORX90 10 10 FF6500 10 10 1 23 51199 HYFT MFFOR FFORX MFFOR 10 FF6602 10 10 10 1 24 51216 HYFT FFORX MB 12 12 1 26 52702 HOSE ASSEMBLY REL RET T FET CFI 35CCRRCD MIDTANKT 1 27 52772 HOSE ASSEMBLY GENINLET ALS 1 28 52773 HOSE ASSEMBLY 35CCRR GLS 1 29 52774 HOSE ASSEMBLY GENCD MIDTANKT 1 30 52775 HOSE ASSEMBLY 35CCR...

Page 180: ...Page 174 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Auxiliary Power Unit ART_3491 AUXILLARY POWER UNIT 5592RT 3392RT T 92RT Series 1 2 2 ...

Page 181: ...age 175 65 J Diesel Service Parts Manual February 2021 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 2 ...

Page 182: ...Page 176 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Hydraulic Reservoir ART_4869 Hydraulic Reservoir 60 J 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 183: ...ssembly 1 92397 Filter Element 2 92357 Breather Cap 1 3 92478 Filler Cap 1 4 28660 Fuel Tank Weldment 1 5 9370 Sight Gauge 1 6 51161 Fitting MFFOR MP90 8 8 1 7 50876 Fitting MFFOR MP 8 8 1 8 93706 Suction Strainer 1 9 93123 Ball Valve 1 1 10 51003 Plug 2 1 92508 OPTION Tank Heater 1 11 93706 Suction Strainer 1 12 93123 Ball Valve 1 1 ...

Page 184: ...Page 178 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Charge Filter Assembly ART_3656 Charge Filter Assembly TITAN BOOM 40 S 1 2 2 ...

Page 185: ...9 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Item Part Number Description Qty 1 92072 Charge Filter Assembly without fittings 1 92169 Filter Element 2 50849 Fitting MFFOR MB90 8 12 2 ...

Page 186: ...80 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Wheel Motors ART_4871 Wheel Motors 60 J 2 3 1 7 10 9 6 5 4 6 8 4 Front Steering Wheels Rear Wheels Planetary Gear Hub See Axles Section ...

Page 187: ... 95161 Hydraulic Drive Motor 2 Sp 45cc 17cc 1 4 2 92166 O Ring 1 4 3 92042 O Ring Brake Port 1 4 4 50847 Fitting MFFOR MB90 6 8 1 4 5 50838 Fitting MFFOR MB 8 12 2 4 6 50656 Fitting MFFOR MB90 4 6 1 4 7 51086 Fitting MFFOR MB 4 4 1 2 8 50849 Fitting MFFOR MB90 12 8 2 4 9 50831 Fitting MFFOR MB 4 4 1 4 10 93360 Gasket Motor Housing As Req ...

Page 188: ...sel Service Parts Manual February 2021 Section 25 Hydraulics Platform Rotator Platform Rotator Alternative 60 J Art_5308 ILLUSTRATION No Item Part Number Description Qty 94682 Hydraulic Rotator Platform ALT for 93830 1 ...

Page 189: ...83 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Swing Drive ART_4875 Swing Drive 60 J 1 2 Item Part Number Description Qty 1 93647 Turntable Rotator 1 2 51007 Fitting MFFOR MB90 6 10 2 ...

Page 190: ...Page 184 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Boom Lift Cylinders ART_4876 Boom Lift Cylinders 60 J 1 6 7 5 4 4 5 2 3 2 ...

Page 191: ... Section 25 Hydraulics Item Part Number Description Qty 1 28396 Upper Boom Lift Cylinder 1 2 50841 Fitting MFFOR MB 8 8 4 3 28395 Lower boom lift cylinder 1 4 94427 Counterbalance valve 2 5 94033 Counterbalance valve 2 6 94324 Seal kit 1 7 94323 Seal kit 1 ...

Page 192: ...Page 186 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Boom Extend Cylinder ART_4877 Boom Extend Cylinder 60 J 1 4 5 6 3 2 ...

Page 193: ...lics Item Part Number Description Qty 1 94973 Cylinder Boom Extend 65J 1 2 50676 Fitting MFFOR MB45 6 6 2 3 28643 Pad UHMW 1 50020 Bolt M10 x 50 4 50053 Nut M10 Nylock 4 50002 Washer M10 Flat 4 4 92020 Counterbalance Valve 1 5 94536 Counterbalance Valve 1 6 94325 Seal Kit 1 ...

Page 194: ...Page 188 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Platform Level Cylinder ART_4878 Platform Level Cylinder 60 J 1 3 2 ...

Page 195: ...Page 189 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Item Part Number Description Qty 1 28398 Platform Level Cylinder 1 2 94527 Counterbalance Valve 2 3 94326 Seal Kit 1 ...

Page 196: ...arts Manual February 2021 Section 25 Hydraulics Jib Cylinder ART_4879 Jib Cylinder 60 J 1 3 4 2 Item Part Number Description Qty 1 28399 Jib Cylinder 1 2 50831 Fitting MFFOR MB 4 4 2 3 94408 Counterbalance Valve 2 4 94327 Seal Kit 1 ...

Page 197: ...uary 2021 Section 25 Hydraulics Steer Cylinders ART_4873 Steer Cylinders 60 J 1 2 1 3 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 MFFOR MB90 04 04 2 ...

Page 198: ...Page 192 65 J Diesel Service Parts Manual February 2021 Section 25 Hydraulics Axle Cylinders ART_4880 Axle Cylinders 60 J 1 2 3 5 6 4 not shown ...

Page 199: ...l February 2021 Section 25 Hydraulics Item Part Number Description Qty 1 95108 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 92622 Counterbalance Valve 1 6 94328 Seal Kit 1 ...

Page 200: ... 1 4 x 14 04G 04FFORX x 4G 4FFORX 45 2 52560 AXLT 5 Hose Assembly 1 4 x 57 04G 04FFORX x 04G 04FFORX90S 1 52561 RRBRKT 8B Hose Assembly 1 4 x 89 04G 04FFORX x 04G 04FFORX90S 1 52562 RR2SPD 4B Hose Assembly 1 4 x 87 04G 04FFORX x 4G 4FFORX 45 1 52563 6 STRRET 7 STREXT Hose Assembly 1 4 x 77 04G 04FFORX x 4G 4FFORX 45 2 52564 CDABT 3A Hose Assembly 3 8 x 27 6G 6FFORX x 6G 6FFORX 1 52565 CDRRT 3B Hos...

Page 201: ...se Assembly 5 8 x 83 10G 10FFORX x 10G 10FFORX90L 1 52940 A MA B MB Hose Assembly 1 4 x 83 4G 4FFORX x 4G 4FFORX 45 2 52944 2SPDTPRT EDOWN Hose Assembly 3 8 x 40 6G 6FFORX x 6G 8FFORX 90 1 52945 EDOWNP AUX Hose Assembly 3 8 x 46 6G 6FFORX x 6G 6FFORX 90S 1 52946 CP AM3 Hose Assembly 3 8 x 85 6G 6FFORX x 6G 6FFORX 1 52592 G CFO Hose Assembly 1 2 x 24 8G 8FFORX x 8G 8FFORX 90L 1 52948 BV 3 4T EDOWN ...

Page 202: ...Page 196 65 J Diesel Service Parts Manual February 2021 Chassis ART_4854 Chassis 65 J See Axles Section of this manual for axle information 5 4 3 6 2 9 8 7 2 1 Chassis Section 26 Base ...

Page 203: ...r 1 50332 Bolt M10 x 35 8 50002 Washer M10 Flat 8 2 92098 Clip Nut 8 3 93646 Swing Bearing 1 4 28617 Spacer 2 5 50580 Bolt 5 8 x 3 1 4 20 50582 Washer 5 8 x 1 5 16 x 3 16 Hardened Structural 20 6 28616 Rear Chassis Cover 1 7 50493 Bolt M16 x 70 4 50597 Nut M16 Nylock 4 8 93862 Spring Pin 3 8 x 3 1 9 28730 Turret Lock Pin Weldment 1 ...

Page 204: ...Page 198 65 J Diesel Service Parts Manual February 2021 Section 26 Base Module Doors ART_4855 Module Doors 60 J 1 2 3 2 3 9 12 11 14 14 11 11 12 11 13 10 4 5 6 7 8 ...

Page 205: ...ols Side 1 2 93821 Door Handle 4 3 93817 Door Latch 4 93817 Door Hold Down Strap not shown 4 93733 Hinge 6 5 28236 Hinge Spacer 2 6 28225 Module Door Power Side 1 7 93845 Bumper 2 8 28728 Bracket 2 9 22400 Fuel Door 1 10 9221376 Hinge 1 11 93738 Ball Stud 8 12 94104 Gas Shock Locking 2 13 28719 Mount Plate 2 14 93952 Gas Spring 2 ...

Page 206: ...5 J Diesel Service Parts Manual February 2021 Section 26 Base Engine Module ART_4856 Engine Module 60 J Diesel 1 2 3 4 5 6 7 8 9 10 11 15 20 18 17 18 19 17 16 21 22 23 24 25 26 21 28 29 30 31 32 27 12 13 14 33 34 ...

Page 207: ... Assembly 1 93907 Filter Element 12 93757 Reducing Coupler 1 13 93756 Coupler 1 14 28665 Turbo Intake Tube 1 15 28663 Mount Plate 1 16 28672 Exhaust Tube 1 17 28664 Bracket 2 18 93267 Clamp 2 19 93832 Muffler 1 20 28669 Exhaust Tube Weldment 1 21 93728 Isolator 3 22 28662 Bracket 1 23 93644 Radiator 1 24 93794 Upper Radiator Hose 1 25 93793 Lower Radiator Hose 1 26 91127 Overflow Bottle 1 27 28661...

Page 208: ...e Parts Manual February 2021 Section 26 Base Engine Assembly ART_4857 Engine Assembly 3 4 5 6 7 8 9 10 A B 4 x 50116 4 x 50392 Longer bolt to mount Throttle Solenoid bracket at this location See next page A A A B 1 2 65 J Diesel ...

Page 209: ...ngine Bracket 2 8 17969 Engine Mount 4 9 28640 Engine Tray 1 10 28249 Door Latch Mount 1 REF Reference Hardware on this page Gear Pump to Piston Pump 5004 2 Bolt 3 8 x 1 50006 2 M10 Nordlock Piston Pump to Bell Housing 50069 2 Bolt 1 2 x 1 5 50007 2 Washer M12 Nordlock 50003 2 Washer M12 Flat Location A 50116 12 Bolt M10 x 25 50006 12 Washer M10 Nordlock Location B 50392 4 Bolt M10 x 30 50006 12 W...

Page 210: ...ervice Parts Manual February 2021 Section 26 Base Engine Components ART_4858 Engine Components 60 J Diesel 22 1 2 3 4 5 23 6 7 10 9 8 12 11 14 15 16 17 18 19 20 21 13 See previous pages for Solenoid Mounting Bracket hardware ...

Page 211: ...e Support 1 9 28776 Stud 1 10 53014 Nut M8 1 25 1 11 94058 Flywheel 1 91360 Ring Gear 1 12 94057 Fuel Solenoid 1 13 93619 Fuel Pump 1 14 28653 Mounting Bracket 1 15 92939 Throttle Pull Solenoid 1 16 91117 Throttle Link Clevis 1 50296 Bolt M6 x 15 4 50000 Washer M6 Std 4 50047 Nut M6 Nylock 4 17 91588 Washer 1 18 16347 Throttle Link 2 19 50178 Cotter Pin 1 20 50171 Clevis Pin 1 21 94059 Glow Plug 4...

Page 212: ...Page 206 65 J Diesel Service Parts Manual February 2021 Section 26 Base Controls Module ART_4859 Controls Module 60 J Diesel 1 2 3 4 5 6 7 8 9 10 11 12 13 1 18 20 19 21 22 23 24 15 16 17 ...

Page 213: ...Fitting MFFOR MP90 8 8 1 8 50876 Fitting MFFOR MP 8 8 1 9 93706 Suction Strainer 1 10 93123 Ball Valve 1 1 11 92508 Tank Heater 1 12 93706 Suction Strainer 1 13 93123 Ball Valve 1 1 14 15 22563 Battery Hold Down Bolt 2 16 17475 Battery Bracket 1 17 17966 Battery 950 CCA Group 31 1 18 REF Lower Controls Box See Section 21 Controls 1 19 28624 Controls Mounting Bracket 1 20 28627 Mounting Plate 1 21 ...

Page 214: ...Page 208 65 J Diesel Service Parts Manual February 2021 Section 26 Base Controls Module 2 ART_4860 Controls Module 60 J Diesel 1 2 3 4 5 6 7 8 9 10 ...

Page 215: ... 91745 Contactor 12V 1 4 93169 Series Parallel Switch 24v Auxiliary Power Option 1 5 28677 Mounting Plate 1 6 REF Functions Manifold See Section 25 Hydraulics 1 7 28622 Mounting Plate 1 8 REF Brake 2Spd Manifold See Section 25 Hydraulics 1 9 REF Swing Drive See Section 25 Hydraulics 1 10 REF Aux Power Pump See Section 25 Hydraulics 1 REF Reference ...

Page 216: ...Page 210 65 J Diesel Service Parts Manual February 2021 Section 26 Base Turntable Components ART_4861 Turntable Components 60 J 1 2 1 3 4 6 8 7 9 5 ...

Page 217: ...0054 Nut M12 Nylock 4 2 29100 Weldment Turret 1 3 28477 Counterweight 1 50585 Bolt M24 x 60 4 50586 Washer M24 Nordlock 4 50255 Washer M24 Flat 4 4 28680 Diesel Tray Support 1 5 50354 Bolt 5 8 x 2 5 20 6 50582 Washer 5 8 20 7 93646 Swing Bearing 1 8 28619 Spacer 4 9 REF Rotary Manifold See Section 25 Hydraulics 1 50209 Bolt M10 x 100 4 50006 Washer M10 Nordlock 4 REF Reference ...

Page 218: ...munication Jib To Upper Control Box 28853 Harness Platform Valves 28854 Harness Engine 28855 Harness Motor Control 28856 Harness Power To Lower Box 28857 Harness Inside Upper Control Box 28858 Harness Main Function Block 28859 Harness Engine Extension 28860 Harness Boom Swing Tele Joystick Update 28868 Harness Lower Tensioner Angle Transducer 28869 Harness CAN Tilt Jumper 28883 Harness Comm To CAN...

Page 219: ... Parts Manual February 2021 Decal Locations INSIDE CASE Front of turret Back of boom Front of turret Inside 1 2 2 3 3 4 4 5 6 5 7 12 12 13 13 24 25 26 27 27 27 28 28 29 31 32 33 35 30 6 9 14 23 34 Decal Locations Section 27 Decals ...

Page 220: ...Page 214 65 J Diesel Service Parts Manual February 2021 Section 27 Decals Each side of chassis Each side of chassis 1 22 15 15 20 20 11 16 17 17 18 18 19 21 21 8 10 ...

Page 221: ...Qty 2 P N 93806 Qty 1 P N 93803 Qty 3 P N 8911 Qty 1 P N 93801 Qty 2 P N 92117 Qty 1 P N 93804 Qty 2 P N 91981 Qty 2 P N 8606 Qty 1 P N 91970 Qty 2 P N 90719 Qty 1 P N 93807 Qty 2 P N 93855 Qty 1 P N 93851 Qty 1 P N 93815 Qty 2 P N 90751 Qty 1 P N 93688 Qty 1 P N 90718 Qty 1 P N 93755 Qty 2 P N 90732 Qty 1 P N 91973 Qty 8 P N 91972 Qty 2 P N 95059 Qty 1 P N 93754 Qty 1 6 7 8 9 10 11 12 13 14 15 16...

Page 222: ...l Plate 60 J Boom ANSI 1 15 91973 Decal Tie Down 8 16 93814 Decal Blue Arrows Small 2 17 91971 Decal Boom Blue Arrow Forward 2 18 91981 Decal Boom Blue Arrow Left 2 19 93815 Decal Yellow Arrows Small 2 20 91972 Decal Boom Yellow Arrow Reverse 2 21 91982 Decal Boom Yellow Arrow Right 2 22 93806 Decal Explosion Hazard Ether 1 23 8606 Decal Warning Lanyard Anchorage 1 24 90751 Decal Power To Platform...

Page 223: ...Page 217 65 J Diesel Service Parts Manual February 2021 Notes ...

Page 224: ...Page 218 65 J Diesel Service Parts Manual February 2021 Notes ...

Page 225: ...Page 219 65 J Diesel Service Parts Manual February 2021 Notes ...

Page 226: ...count 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 Backorders Ship all available parts and contact customer on disposition of back ordered parts Other Please specify MEC Parts Order Form Phone 559 842 1523 Fax 559 400 6723 Email Parts mecawp com ...

Page 227: ...d 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 Platform Sales Corp to be defective in material and or workmanship MEC Aerial Platform Sales Corp shall not be liable for any consequential incidental or contingent damages whatsoever Use of other than f...

Page 228: ...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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