MAINTENANCE LIFT Property of American Airlines · Maintaining proper hydraulic oil level is...

MAINTENANCE LIFT Maintenance Manual

Manufactured by

TISl:D TE co EQUIPMENT LLCCoral Springs, Florida

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2-ContentsPage 1

Page

ML50-30 MAINTENANCE LIFT TESCO EQUIPMENT LLC

TABLE OF CONTENTS

CHAPTER 2: MAINTENANCE

Section 1: ServicingPERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CHECKING HYDRAULIC OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FILLING HYDRAULIC OIL RESERVOIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Oil Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Section 2: Hydraulic System AdjustmentsHYDRAULIC ADJUSTMENTS - HYDRAULIC POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HYDRAULIC ADJUSTMENTS - TRAVERSING PLATFORM VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 4

Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

COUNTER BALANCE/HOLDING VALVE-HOLD PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . 5

LIFT DOWN FLOW CONTROL VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Section 3: TroubleshootingGENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Troubleshooting Chart - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Section 4: RepairsINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

STRUCTURAL REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Scissor arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Scissor frame or van body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Surface rust or scratches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 5: System SchematicsHYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 Stabilizers & 12VDC Pump with Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1 . . . . 1

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2-ContentsPage 2

TESCO EQUIPMENT LLC ML50-30 MAINTENANCE LIFT

ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How to Read This Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2 . . . . . 1Electrical Schematic, Engine & Chassis - Sheet 1 of 9 . . . . . . . . . . . . . . . . . . . . Figure 3 . . . . . 1Electrical Schematic, Lighting - Sheet 2 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4 . . . . . 1Electrical Schematic, Lift & Stab. Control - Sheet 3 of 9 . . . . . . . . . . . . . . . . . . . Figure 5 . . . . . 1Electrical Schematic, Lift & Stab. Control - Sheet 4 of 9 . . . . . . . . . . . . . . . . . . . Figure 6 . . . . . 1Electrical Schematic, Options - Sheet 5 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7 . . . . . 1Electrical Schematic, Options - Sheet 6 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8 . . . . . 1Electrical Schematic, Options - Sheet 7 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9 . . . . . 1Electrical Schematic, Tables of Veh. Connections - Sheet 8 of 9 . . . . . . . . . . . . Figure 10 . . . . 1Electrical Schematic, Tables of Veh. Connections

DPDT & SPDT Relay Wiring - Sheet 9 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11 . . . . 1

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2-FiguresPage 1


LIST OF FIGURES


Section 1: Servicing

2-1 Figure 1 HYDRAULIC OIL FILL POINT......................................................................... Page 3

2-1 Figure 2 GREASE POINTS DIAGRAM ......................................................................... Page 5

2-1 Figure 3 GREASE POINTS - LIFT CYLINDERS UPPER.............................................. Page 6

2-1 Figure 4 GREASE POINTS - LIFT CYLINDERS BOTTOM........................................... Page 7

2-1 Figure 5 GREASE POINTS - STABILIZERS................................................................. Page 7

2-1 Figure 6 GREASE POINTS - TRAVERSING CYLINDER AND ROLLERS................... Page 8

2-1 Figure 7 GREASE POINTS - SCISSOR ROLLERS AND PINS.................................... Page 9

2-1 Figure 8 GREASE POINT - LOWER BOOSTER ARM.................................................. Page 10

2-1 Figure 9 GREASE POINTS - TRACKS AND BOOSTER ARM UPPER LIP ................. Page 10

2-1 Figure 10 OIL POINTS .................................................................................................... Page 11

Section 2: Hydraulic System Adjustments

2-2 Figure 1 HYDRAULIC SYSTEM.................................................................................... Page 3

2-2 Figure 2 TRAVERSING PLATFORM VALVE................................................................ Page 4

2-2 Figure 3 COUNTER BALANCE/HOLDING VALVE....................................................... Page 5

2-2 Figure 4 LIFT DOWN FLOW CONTROL VALVE ADJUSTMENT................................. Page 6

Section 3: Troubleshooting

Section 4: Repairs

Section 5: System Schematics

2-5 Figure 1 HYDRAULIC SCHEMATIC - 4 STABILIZERS & 12V PUMPWITH RETURN FILTER.................................................................................. Page 2

2-5 Figure 2 HOW TO READ THIS SCHEMATIC ............................................................... Page 5

2-5 Figure 3 ELECTRICAL SCHEMATIC, ENGINE & CHASSIS - SHEET 1 OF 9 ............. Page 6

2-5 Figure 4 ELECTRICAL SCHEMATIC, LIGHTING - SHEET 2 OF 9 .............................. Page 7

2-5 Figure 5 ELECTRICAL SCHEMATIC, LIFT & STAB. CONTROL - SHEET 3 OF 9 ...... Page 8

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2-FiguresPage 2


2-5 Figure 6 ELECTRICAL SCHEMATIC, LIFT & STAB. CONTROL - SHEET 4 OF 9 ...... Page 9

2-5 Figure 7 ELECTRICAL SCHEMATIC, OPTIONS - SHEET 5 OF 9............................... Page 10



2-5 Figure 10 ELECTRICAL SCHEMATIC, TABLES OF VEH. CONNECTIONS - SHEET 8 OF 9 ............................................................................................. Page 13

2-5 Figure 11 ELECTRICAL SCHEMATIC, TABLES OF VEH. CONNECTIONS DPDT & SPDT RELAY WIRING - SHEET 9 OF 9 ........................................... Page 14

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SERVICING 2-1Page 1



Section 1: Servicing

1. PERIODIC MAINTENANCE

Regular maintenance is required to ensure optimum performance and long life for machine components.Maintain the unit by performing periodic maintenance at the intervals listed in the Periodic MaintenanceChart below.

If the unit is being operated in severe weather conditions such as extreme heat or cold, or in sandy,dusty, or snowy areas, increase the frequency of periodic maintenance as necessary.

NOTE: Refer to the chassis manufacturer’s manual for service requirements to the chassis.

PERIODIC MAINTENANCE CHART

PROCEDUREPERIOD (HOURS)

8 250 OTHER

Perform walk-around inspection and check for damage, missing parts and fluid leaks.

X

Check spotlights, indicator lights, and beacon lights. X

Check hydraulic oil level. X

Check condition of all handrails and mounting brackets. X

Check condition of operator’s boarding steps. X

Check fire extinguisher levels. Make sure they are secured in their mounting brackets.

X

Inspect pivot pins on platform cylinders for wear. X

Check scissors pivot pins and rollers for wear. X

Inspect condition of all hydraulic hoses and fittings and check for leakage.

X

Inspect all hydraulic components for fluid leakage. X

Inspect all wiring harnesses for damage and security. X

Check condition of bumpers. X

Check operation of the platform mounted pendant control station. X

Check condition of Hi-Lift/scissors structure. Check for stress cracks, physical damage, or corrosion.

X

Check platform under structure for cracked welds or corrosion. X

Check condition of placards and safety warning decals. X

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MAINTENANCE2-1Page 2


CAUTION

AFTER PERFORMING MAINTENANCE ON THE HI-LIFT, DISPOSE OF ANY ENVIRONMENTALLY SENSITIVE MATERIALS ACCORDING TO LOCAL ENVIRONMENTAL REGULATIONS. EXAMPLES OF SUCH MATERIALS INCLUDE: BATTERIES, RUBBER BELTS, LUBRICANTS (MOTOR OILS AND GREASE), AND HYDRAULIC OIL.

2. HYDRAULIC OIL RECOMMENDATIONS

The hydraulic oil reservoir is factory filled with ISO 15 hydraulic oil at the time of shipping.

SEVERE CLIMATE OPERATION

• If platform lowering becomes too slow in severe cold weather operations, a lower viscosity fluid may be substituted.

3. CHECKING HYDRAULIC OIL LEVEL

Maintaining proper hydraulic oil level is important. DO NOT overfill the hydraulic oil reservoir. Hydraulicoil expands when heated.

1. The hydraulic oil reservoir is equipped with a sight gauge. Ensure that the Hi-Lift is fully lowered and stabilizers must be in stowed position when checking hydraulic oil level using the sight gauge. The oil level should be near the “High” mark and must not be below the “Low” mark.

Replace return filter 6 mos.

Check that all wiring terminals are secure. 6 mos.

Replace corrosion inhibitor in main electrical control box. Annually

Drain hydraulic reservoir and clean. Annually

Check hoist rollers for wear X No more than1/4” wear

OIL OPERATING TEMPERATURE RANGE

RECOMMENDEDGRADE OF

HYDRAULIC FLUIDCLIMATE AMBIENT

TEMPERATURE

MAXIMUM BULK OIL(RESERVOIR

TEMP.)

ISO 32 Hot Above 60° F (15° C) 180° F (82° C)

ISO 15 Moderate 20° F (-7° C) -100° F (38° C) 165° F (74° C)

ISO 5 Cold Below 32° F (0° C) 150° F (60° C)

PERIODIC MAINTENANCE CHART

PROCEDUREPERIOD (HOURS)

8 250 OTHER

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SERVICING 2-1Page 3


4. FILLING HYDRAULIC OIL RESERVOIR

1. Check hydraulic oil level as described above.

2. Determine the amount of oil to be added: 2.5 gallons of oil will raise the level in the reservoir about 1 inch.

3. Raise the work platform if necessary to access the reservoir filler cap. Support platform with the maintenance stand.

4. Clean the area around the filler/breather cap.

5. Remove cap and check strainer screen for any foreign material.

6. Clean thoroughly before putting hydraulic oil into the reservoir.

7. Use only clean, uncontaminated oil, filtered to 10M. Add the quantity of oil determined in step 2.

8. Secure cap when finished.

9. Recheck hydraulic oil level.

Figure 1HYDRAULIC OIL FILL POINT

5. LUBRICATION

A. Grease Points

NOTE: Use any commercially available “MP” multipurpose grease which meets NLGI Grade 1 or 2 standards.

Wipe grease fittings clean and apply grease. Before coating tracks with grease, clean surfaces toremove dirt and foreign material (ref. Figure 2 thru Figure 8).

B. Oil Points

NOTE: Use SAE 5W-30W oil or other adequate Lubricants with brush or oil can as appropriate (ref. Figure 9).

Lift Cylinder Rods - Apply oil to reduce cylinder noise as needed which may be caused by dryseals.

HYDRAULIC FILL POINT(HYDRAULIC OIL ONLY)

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NOTE: The scissors lift must be raised to access the grease points. Make sure to put maintenance prop up.

NOTE: Check at intervals listed and lubricate as required. In unusual weather conditions, check at more frequent intervals.

GREASE POINTS

ITEM COMPONENT TOTALFITTINGS INTERVAL

1 Scissor pivot pins (Upper/Middle/Lower) 12 6 mos.

2 Scissor Arm End Pins 4 6 mos.

3 Scissor roller (Upper/Lower) 8 6 mos.

4 Traversing roller pins 4 6 mos.

5 Lift cylinder (Upper/Lower) 8 6 mos.

6 Traversing cylinder rod ends 2 6 mos.

7 Booster arm pivot 1 6 mos.

8 Stabilizers 16 6 mos.

9 Roller Tracks 3 mos.

GREASE

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SERVICING 2-1Page 5


WARNING

THE SCISSOR LIFT MUST BE SECURED WITH THE MAINTENANCE PROP BEFORE ACCESSING THE GREASE POINTS.

Figure 2GREASE POINTS DIAGRAM

Ref. Figure 7

Ref. Figure 8

Ref. Figure 7

Ref. Figure 6

Ref. Figure 3

1

3 6

7

15

1

3

2

4

5Ref. Figure 3& Figure 4

Ref. Figure 6

Ref. Figure 7

Ref. Figure 7

Ref. Figure 7

Ref. Figure 7

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Figure 3GREASE POINTS - LIFT CYLINDERS UPPER

TOP LIFT CYLINDER

BOTTOM LIFT CYLINDER

1. Set the maintenance prop. Refer to Chapter 1-2.

2. Raise or lower the lift to access all grease points of upper lift cylinder rollers (4).

GREASE POINT

GREASE POINT

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SERVICING 2-1Page 7


Figure 4GREASE POINTS - LIFT CYLINDERS BOTTOM

Figure 5GREASE POINTS - STABILIZERS

TOP LIFT CYLINDER

BOTTOM LIFT CYLINDER

GREASE POINTGREASE POINT

GREASE POINT - 4 PER LEG

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Figure 6GREASE POINTS - TRAVERSING CYLINDER AND ROLLERS

GREASE POINT

TRAVERSING CYLINDER ROD ENDS - BOTH ENDS

GREASE POINT - BOTH ENDS

TRAVERSING ROLLER PINS - 8 PLCS

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SERVICING 2-1Page 9


Figure 7GREASE POINTS - SCISSOR ROLLERS AND PINS

SCISSOR PIVOT PINS - BOTH SIDES& UPPER AND LOWER

SCISSOR ARM END PINS - 4 PLCS

SCISSOR CENTER PINS - BOTH SIDES

UPPER AND LOWER

UPPER SCISSOR ROLLERS - BOTH SIDES

SCISSOR LOWER ROLLER PINS - BOTH SIDES

NOTE: To grease lower scissor rollers, lift must be down.

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Figure 8GREASE POINT - LOWER BOOSTER ARM

Figure 9GREASE POINTS - TRACKS AND BOOSTER ARM UPPER LIP

GREASE POINT

GREASE W/BRUSH

SCISSOR ROLLER TRACKS - BOTH SIDES& UPPER AND LOWER

BOOSTER ARM LIP

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SERVICING 2-1Page 11


Figure 10OIL POINTS

OIL POINTS

ITEM COMPONENT TOTALPLCS INTERVAL

1 Lift Cylinder Rods 4 6 mos.

2 Platform entry swing gate hinge points & Lock 3 1 mos.

3 Platform Ext. Segments Pocket & Locking Bar 1 mos.

OIL

NOTE: Use SAE 5W-30W oil or other adequateLubricants with brush or oil can as appropriate.

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THIS PAGE INTENTIONALLY LEFT BLANK

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HYDRAULIC SYSTEM ADJUSTMENTS 2-2Page 1


Section 2: Hydraulic System Adjustments

WARNING

BEFORE STARTING ANY ADJUSTMENT PROCEDURE THAT REQUIRES THE PLATFORM TO BE IN AN ELEVATED POSITION, MOVE THE MAINTENANCE STAND INTO POSITION AND LOWER THE PLATFORM FULLY AGAINST THE MAINTENANCE PROP.

WARNING

IT IS MANDATORY THAT EYE PROTECTION (SAFETY GOGGLES OR FACE SHIELD) BE WORN WHEN MAKING PRESSURE CHECKS AND/OR ADJUSTMENTS ON THE HYDRAULIC SYSTEM. HYDRAULIC OIL WILL CAUSE EYE INJURIES. IF HYDRAULIC OIL GETS ON THE SKIN, WASH AFFECTED AREA IMMEDIATELY TO AVOID IRRITATION.

WARNING

DRIVE WHEELS MUST BE CHOCKED TO PREVENT MOVEMENT OF THE UNIT IN EITHER DIRECTION.

WARNING

WHEN MAKING PRESSURE CHECKS OR ADJUSTMENTS, USE GAUGES WITH KNOWN ACCURACY. IMPROPER HYDRAULIC ADJUSTMENTS CAN CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.

WARNING

DO NOT REMOVE GAUGE PORT PLUGS OR GAUGES, OR LOOSEN HYDRAULIC CONNECTIONS WITH THE UNIT RUNNING. HYDRAULIC PRESSURE IN THE SYSTEMS COULD CAUSE HYDRAULIC OIL TO SPRAY ON PERSONNEL.

CAUTION

USE EXTREME CARE TO PREVENT CONTAMINATION OF HYDRAULIC SYSTEM WHEN INSTALLING GAUGES, FITTINGS, OR REPLACING A COMPONENT. CONTAMINATION CAN RESULT IN EQUIPMENT DAMAGE.

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CAUTION

WHENEVER AN ADJUSTABLE HYDRAULIC RELIEF VALVE OR PRESSURE REDUCING VALVE IS REPLACED, REDUCE THE PRESSURE SETTING PRIOR TO STARTING THE UNIT. ADJUST THE REPLACED COMPONENT TO SPECIFICATION AS OUTLINED IN THE ADJUSTMENT PROCEDURES.

CAUTION

WHEN MAKING HYDRAULIC SYSTEM ADJUSTMENTS, THE HYDRAULIC OIL MUST BE AT NORMAL OPERATING TEMPERATURE.

1. HYDRAULIC ADJUSTMENTS - HYDRAULIC POWER MODULE

ITEM FUNCTION SETTING PROCEDURE

A Pressure Gauge N/A Used for reading system pressures.

B Lift Down Speed Control

90 sec+/- 10

Raise lift fully. Activate lift down function and record the time it takes the lift to lower fully (not including stabilizer retract). Adjust valve to increase/decrease lift lower speed. Loosen locknut and turn valve clockwise to slow lift speed, counter-clockwise to increase lift speed. Tighten locknut when adjustment is complete.

C Main Relief 1800 psi+/- 25

With the engine running, extend the stabilizers to the maximum and hold control in “Extend”. Read the pressure at the gauge. To adjust the pressure, loosen the locknut on valve. Turn valve clockwise to increase pressure, counter-clockwise to lower pressure. Tighten locknut when pressure is set.

D Stabilizer SpeedControl(Left Rear Stab.)

N/A Make certain that left rear stabilizer is last to fully extend and last to fully retract. Loosen locknut and turn valve clockwise to slow stabilizer speed, counter-clockwise to increase stabilizer speed. Tighten locknut when adjustment is complete.

E Port Relief 1,200 psi+/- 25

Energize lift down function, read pressure at gauge. Turn valve clockwise to increase pressure, counter-clockwise to lower pressure.

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Figure 1HYDRAULIC SYSTEM

F

G

StabilizerPressure Reducing Valve

Stabilizer Pressure Switch(Left Rear)

N/A Fully retract lift and stabilizers. Turn valve fully clockwise and extend/retract stabilizers till all stabilizers operate smoothly and consistently with the left rear stabilizer last to extend and last to retract (See Adjustment D). Then turn valve counter-clockwise till chassis is lifted between 1 & 2 in. (2.54 am & 5.08 am). Fully retract stabilizers between adjustments. Chassis must be level +/- 1 in. (2.54 am) side to side.

Ensure Stabilizer Pressure Switch still just activates when stabilizers are extended. Screw in adjustment to increase the pressure needed to activate the switch. Screw out to decrease. Retract stabilizers and verify pressure switch deactivates.

H Compressor Pressure Relief

N/A Open the valve all the way counter clockwise. While the compressor is running continue to raise the lift. Adust valve (clockwise) until the lift operates smoothly. Turn valve clockwise to increase pressure, counter-clockwise to lower pressure.

ITEM FUNCTION SETTING PROCEDURE

A

C

B

DE

F

STABILIZER

G

H

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2. HYDRAULIC ADJUSTMENTS - TRAVERSING PLATFORM VALVE

A. Flow Control Valve

1. Loosen locknut (A).

2. Turn clockwise to to slow down and counter-clockwise to speed up.

3. Tigntened locknut.

Figure 2TRAVERSING PLATFORM VALVE

A

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3. COUNTER BALANCE/HOLDING VALVE-HOLD PRESSURE ADJUSTMENT

NOTE: The pressure on the counter balance holding valves is preset by TESCO at 1400 PSI. Adjustments are accomplished using an Allen wrench on the pressure adjuster and a standard open end wrench on the locknut.

NOTE: Counter Balance/Holding Valves should be pre-adjusted before installation by turning adjustment screw clockwise all the way and backing out one and three quarter (1 3/4) turns for 1400 PSI setting.

1. Extend stabilizer cylinders and partially raise lift. Install maintenance prop.

NOTE: Adjust one counterbalance valve at a time.

2. Loosen locknut.

3. Increase holding pressure by turning adjusting screw counter-clockwise direction. Each one eight (1/8) turn is equal to 100 PSI increase in holding pressure (ref. Figure 3).

4. Decrease holding pressure by turning adjusting screw clockwise direction. Each one eight (1/8) turn is equal to 100 PSI decrease in holding pressure.

5. Tighten locknut when adjustment is complete.

Figure 3COUNTER BALANCE/HOLDING VALVE

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4. LIFT DOWN FLOW CONTROL VALVE ADJUSTMENT

(Ref. Figure 4)

The flow control valve is used to restrict the amount of hydraulic oil being used to open the uppercounter balance valves. To have the upper cylinders work with the lower cylinders so that they can comedown together. The lowering speed may be adjusted to increase or decrease the hi-lift’s lowering speed.

1. Raise the scissor to the maximum height.

2. Activate lift down function and record the time it takes the lift to lower fully.

Lift Lower 90 sec +/-10

3. Loosen locknut and turn adjusting screw clockwise to slow lift speed, counter-clockwise to increase lift speed.

4. Tighten locknut when adjustment is complete.

Figure 4LIFT DOWN FLOW CONTROL VALVE ADJUSTMENT

LOCKNUT

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TROUBLESHOOTING 2-3Page 1


Section 3: Troubleshooting

1. GENERAL INFORMATION

WARNING

ONLY QUALIFIED TECHNICIANS, WHO HAVE BEEN TRAINED IN THE USE AND OPERATION OF THIS EQUIPMENT, SHOULD ATTEMPT ANY TROUBLESHOOTING. THE CHASSIS WHEELS MUST BE CHOCKED TO PREVENT THE HI-LIFT UNIT FROM MOVING IN EITHER DIRECTION. THE MAINTENANCE PROP MUST BE INSTALLED FOR SUPPORT WHENEVER THE PLATFORM IS RAISED FOR MAINTENANCE OR ADJUSTMENTS. FAILURE TO FOLLOW GOOD SAFETY PRACTICES DURING MAINTENANCE OR TROUBLESHOOTING COULD RESULT IN DEATH OR SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

The information contained in this section is provided as a guide to assist technical service personnel introubleshooting operational malfunctions in the ML5-30 Lift Unit hydraulic and electrical systems.

1. Before starting troubleshooting procedures, verify that the correct operating procedures were used. An incorrect operating procedure can cause apparent malfunctions.

2. The most important practice to observe when working on the hydraulic system is cleanliness. Serious damage can result quickly from foreign material in the hydraulic system. When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material and moisture-laden air from entering the system. DO NOT use Teflon tape or pipe compound on straight threads.

NOTE: Refer to the troubleshooting chapter in the chassis manufacturer’s manual for chassis troubleshooting instructions.

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1. INTRODUCTION

The Tesco ML50-30 Lift is a hydraulically operated, electrically controlled maintenance lift. Thehydraulic and electrical systems require a thorough understanding to determine the cause of amalfunction or failure of a component. System diagnosis is mandatory to locate a component that is outof adjustment or has failed.

2. HYDRAULIC SYSTEM

1. The hydraulic system is an open-center system.

2. The hydraulic system diagnosis is accomplished by observing the readings on the pressure gauge or timing a function when a particular hydraulic circuit is actuated. The hydraulic schematics and adjustment procedures indicate the correct setting for each pressure and flow adjustment.

3. The first step in diagnosing a malfunction is to isolate the malfunction to the hydraulic system or to the electrical control system.

NOTE: All solenoid actuated control valves in the hydraulic system are equipped with a manual override that can be used to actuate the valve should there be a loss of electrical current. The manual override shifts the valve spool and permits oil flow for the Hi-Lift function to operate. The pressure gauge can be observed for the correct pressure reading for the system in use.

NOTE: To obtain oil flow the PTO must be activated with the ENABLE switch. Alternatively, for test or emergency operation, the hand pump or optional electric auxiliary hydraulic pump may be used to provide hydraulic flow.

Press both UP switches simultaneously if not equipped with an ENABLE switch. In thiscase one of the UP switches function as the ENABLE switch.

3. ELECTRICAL SYSTEM

The Model ML50-30 has a 12-volt DC electrical system that controls all functions of the Hi-lift. Thecomponents of the electrical system are located in the lower control station, the upper control station,and the main electrical box. Limit switches in various locations sense a specific position of a mechanicalcomponent for the actuation and interlocking of electrical circuits. The electrical box is located below thevan body usally on the passenger’s side mounted on the hydraulic module. It consists of relays, diodes,circuit breakers, and terminal blocks. See Chapter 1, Section 2 for the location and function of each ofthe separate control stations.

4. TROUBLESHOOTING GUIDE

The following guide lists Hi-Lift malfunctions and some possible causes for those malfunctions. Whenthere is a problem or malfunction of the Hi-Lift, read through the list on the left side of the chart. Possiblecauses are listed to the right.

Hydraulic component problems are usually caused by oil contamination, and many components can bemade serviceable by a thorough cleaning. Hydraulic filter elements must be replaced when a systemhas been cleaned of contamination.

Hydraulic troubleshooting can be done using a pressure gauge and the hydraulic schematics.

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When a component is repaired or replaced, always check the hydraulic circuit for the correct indicatedpressure, correct actuator speeds, and correct hydraulic fluid level.

A. Troubleshooting Chart - General

TROUBLESHOOTING

TROUBLE PROBABLE CAUSE

Ground level controls will not operate with the vehicle’s engine running.

Vehicle not in lift mode (Parking brake off)

Emergency stop activated

Circuit breaker tripped or blown fuse

Defective solenoid coil or relay

Damaged or defective control switch

Damaged wiring or bad ground

Damaged Power Take Off (P.T.O.) or pump drive components

Stabilizers will not hold retracted or extended position.

Faulty check valve

Faulty cylinder

Stabilizers will not retract Vehicle not in lift mode (Parking brake off)

Hi-Lift not fully lowered or stowed


Defective relay

Defective Hi-Lift or stabilizer interlock switch


Defective valve cartridge



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Stabilizers will not extend. Vehicle not in lift mode (Parking brake off)






Defective valve cartridge


Emergency lowering handpump is not operating. Manual overrides not open

Upper controls will not operate with the vehicle's engine running.

Vehicle not in lift mode (Parking brake off)

Enable switch not depressed

Stabilizers not fully deployed




Defective enable relay




Vehicle’s engine will not turn off when the EMERGENCY STOP SWITCH on either control station is actuated.


TROUBLESHOOTING


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Platform mounted spotlight not operating. Burned fuse

Dead or low battery

Defective light bulb in spotlight

Corrosion build up on light bulb terminals

Faulty toggle switch on light assembly

Faulty ground at spotlight caused by corrosion

Faulty wiring harness

Hi-lift settles or does not hold position when control is released.

Air trapped in a lift cylinder

Misadjusted, faulty or sluggish counter balance hold valve on the lift cylinder

Defective lift cartridge valve

Hi-lift unit racked or twisted in one direction during raising or after reaching required height.

Exceeding maximum load capacity

Off center load on work platform

Air trapped in lift cylinder


Leak in one of the lift cylinder

Low hydraulic fluid level in reservoir

Faulty hi-lift scissors center pivot pin, attach pin, or roller axle

Hi-lift unit racks or twists during lowering. Off center load on work platform

Air trapped in lift cylinder


Uneven holding valve release pressure

TROUBLESHOOTING


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There is no hydraulic fluid flow or pressure from hydraulic oil pump when the engine is running.

Shut off valve closed

Clogged filter

Blockage on pump's suction port or collapsed suction hose

Damage to pump gears or wear plates

Pump does not respond to load immediately or fails to respond totally.

Low hydraulic oil level in reservoir

System relief valve pressure set too low

Pump worn or damaged

Overheated hydraulic oil. Hydraulic oil level too low

Hydraulic oil dirty and deteriorated

Hydraulic oil viscosity too light for climate

Hydraulic oil continuously flowing over relief valve

Relief valve pressure is set too low or too high

Worn pump or internal damage to pump

Hydraulic oil pump is noisy. Low hydraulic oil level

Hydraulic oil viscosity too heavy

Restricted hose or collapsed suction hose

Air leak in suction hose between suction outlet and pump’s inlet port

Hydraulic oil temperature too high

Pump pulling air through the input shaft’s seal when no load condition exists on pump

Hyd. oil foaming excessively Hydraulic oil level too low

Air leak on section hose between suction outlet and pump’s inlet port

Incorrect type or grade of hydraulic oil

TROUBLESHOOTING


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REPAIRS 2-4Page 1


Section 4: Repairs

WARNING

DO NOT ALLOW PERSONNEL UNDER THE HI-LIFT UNLESS THE MAINTENANCE PROPS ARE IN PLACE. FAILURE TO SUPPORT THE PLATFORM MAY ALLOW PLATFORM TO FALL, RESULTING IN DEATH OR INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.

WARNING

USE EYE PROTECTION AND PROTECTIVE CLOTHING RECOMMENDED BY THE MANUFACTURER OF THE WELDING EQUIPMENT THAT IS USED.

1. INTRODUCTION

All welded repairs must conform to the American Welding Society (AWS) Codes D1.1 2004, AWSD14.1-97 and to the Society of Automotive Engineers (SAE) ARP 1330A standards. Welders performingrepairs must be qualified to MIL.STD.-1595. Welded joint configuration and preparations must be inaccordance with existing AWS DD1.1 welding code for structural welding.

2. STRUCTURAL REPAIRS

A. Scissor arms

Welded repairs on scissor arm’s structural tubing are not permitted. Consult with Tesco forapproved methods or guidelines for conducting repairs.

B. Scissor frame or van body

Repair cracks or damage by welding or splicing as required except where the structural integrityof the unit is affected. Consult with Tesco for approved methods or guidelines for conductingrepairs on damaged area.

C. Handrails

Replace sections of damaged handrail with a new piece of metal. Weld into place.

D. Surface rust or scratches

Repair by sanding or cleaning rust with a wire brush. Prepare metal with metal etching chemicalbefore priming and painting.

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SYSTEM SCHEMATICS 2-5Page 1


Section 5: System Schematics

1. HYDRAULIC SCHEMATIC

A. 4 Stabilizers & 12VDC Pump with Return Filter Figure 1

2. ELECTRICAL SCHEMATIC

A. How to Read This Schematic Figure 2

B. Electrical Schematic, Engine & Chassis - Sheet 1 of 9 Figure 3

C. Electrical Schematic, Lighting - Sheet 2 of 9 Figure 4

D. Electrical Schematic, Lift & Stab. Control - Sheet 3 of 9 Figure 5

E. Electrical Schematic, Lift & Stab. Control - Sheet 4 of 9 Figure 6

F. Electrical Schematic, Options - Sheet 5 of 9 Figure 7

G. Electrical Schematic, Options - Sheet 6 of 9 Figure 8

H. Electrical Schematic, Options - Sheet 7 of 9 Figure 9

I. Electrical Schematic, Tables of Veh. Connections - Sheet 8 of 9 Figure 10

J. Electrical Schematic, Tables of Veh. ConnectionsDPDT & SPDT Relay Wiring - Sheet 9 of 9 Figure 11

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Figure 1HYDRAULIC SCHEMATIC - 4 STABILIZERS & 12V PUMP WITH RETURN FILTER

18 G

PM

@ L

O T

HR

OT

TLE

23 G

PM

@ H

I T

HR

OT

TLE

WIT

H O

N-D

EM

AN

D

EN

GA

GE

ME

NT

F

LO

WS

AV

AIL

AB

LE

: Z

ER

O (

DIS

EN

GA

GE

D)

DLD

A-D

HN

VA

LV

E

OR

XG

CA

-XX

N P

LU

G

T-1

3A

CA

VIT

Y

T-2

2A

CA

VIT

Y

T-5

A C

AV

ITY

T-1

6A

CA

VIT

Y

NF

DD

-LG

N

FD

EA

-LA

N

RV

ED

LA

N

CO

DE

61

-16

CO

DE

61

W/O

-RIN

G

W/O

-RIN

G

-32

(OP

TIO

NA

L)

RE

AR

LE

FT

SID

E

STA

BIL

IZE

R

FR

ON

T

RIG

HT

SID

E

STA

BIL

IZE

R

FR

ON

T

LE

FT

SID

E

STA

BIL

IZE

R

V1

V2

C2

C1

RE

AR

RIG

HT

SID

E

STA

BIL

IZE

R

V1

V2

C2

C1

V1

V2

C2

C1

V1

V2

C2

C1

A

FR

OM

MA

IN

MA

NIF

OLD

AU

X P

PO

RT

AIR

CO

MP

RE

SS

OR

- O

PT

ION

AL

HY

DR

AU

LIC

DR

IVE

N/C

OO

LE

D

TR

AV

ER

SE

C

YLIN

DE

R

FLO

WC

ON

TR

OL

PLA

TF

OR

M T

RA

VE

RS

E

VA

LV

E

DO

3 T

YP

E

VA

LV

E

N.C

. C

HE

CK

MA

IN M

AN

IFO

LD

ST

RA

INE

RS

-6-1

6-6

-81/8

NP

T

DO

5 T

YP

E

STA

BIL

IZE

R

VA

LV

E

SO

L3

750/3

000

T

P

SO

L4

PR

ES

SU

RE

RE

DU

CE

RP

RS

BLA

N

EN

GIN

E D

RIV

EN

PU

MP

M

CH

EC

KV

ALV

E

SO

L2

TA

NK

VA

LV

E

ISO

LA

TIO

N

RE

SE

RV

OIR

50 G

AL

-16

ALR

B2

AU

X P

-6A

1-1

2

-10

SY

ST

EM

RE

LIE

F

1800 P

SI N

OM

.

T

P

FLO

W C

ON

TR

OL

(NE

ED

LE

VA

LV

E)

LO

WE

RIN

GF

LO

W C

ON

TR

OL

AU

X P

G

1P

1

13

42

SO

L1

OP

TIO

NA

L

PB

U V

ALV

E

SA

ND

WIC

H

RE

LIE

F

-12

AU

X T

HA

ND

P2

PU

MP

SS

UC

TIO

N

D

G2

-04

(ALT

ER

NA

TIV

E T

O

RE

TU

RN

UP

TO

50 G

PM

RE

TU

RN

FIL

TE

R

PR

ES

S. F

ILT

ER

S)

BR

EA

TH

ER

T

LIF

T V

ALV

E

D05 T

YP

E

VA

LV

ES

LIF

T C

YLIN

DE

RS

SO

L5

CO

MP

RE

SS

OR

SO

LE

NO

ID

SO

L9

SO

L1

0

& R

ES

ER

VO

IR

PU

MP

12V

DC M

12 V

DC

EM

ER

GE

NC

Y P

UM

P

B1

-12

SO

L6

LO

WE

RIN

G

ML2 5

030 H

ydra

ulic

Syste

m w

ith F

PP

Retu

rn F

ilter

Manifold

s

1

2

511

5

12

9 9

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ITEM QTY TESCO NO PART NUMBER/DESCRIPTION NOTE

1 1 326-9110-490 • PUMP, 19 GPM

2 1 TR5012112NFHXNFXB • HYDRAULIC POWER MODULE

1 HYMS20046 •• CARTRIDGE, Systm Relief Valve

1 HYMS20047 •• CARTRIDGE, Stabilizer Flow Control Valve

1 HYMS20049 •• CARTRIDGE, Handpump Valve

1 HYMA10008 •• MANIFOLD, W/Return Filter Provision

1 HYVA10245 •• CARTRIDGE, Pressure Reducing500-3000 psi

4 HYMS20042 •• COIL, D05 12VDC Lift & Stabilizer

2 HYMS20041 •• VALVE, D05 3 Pos./4 Way Lift & Stabilizer

1 HYMS20055 •• MANIFOLD, Sandwitch, Port Relief

1 HYVA10247 •• CARTRIDGE, Port Relief

1 HYMS20048 •• CARTRIDGE, Lift Flow Control Valve

1 HYMS20045 •• GAUGE, 0-3000 PSI

1 HYMS20052 •• VALVE, Check, Inlet

1 HYFI10017 •• FILTER ELEMENT, Return

1 HYMS20051 •• PUMP, AUXILIARY 12VDC

1 HYVA10273 •• SANDWICH VALVE, Relief Lift

1 HYVA10149 •• CARTRIDGE, PBU Valve

5 4 HYVA10120 • CARTRIDGE, Counter Balance Valve

4 HYVA10121 • BODY, Counter Balance Valve

9 4 HYCY10027 • CYLINDER, Double Acting Stabilizer

11 2 HYCY10005 • CYLINDER, Single Acting Lift

12 2 HYCY10006 • CYLINDER, Single Acting Lift

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MAINTENANCE2-5Page 4Dec. 06

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Figure 2HOW TO READ THIS SCHEMATIC

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Figure 3ELECTRICAL SCHEMATIC, ENGINE & CHASSIS - SHEET 1 OF 9

6

BATTERY

BACKUPALARM

HOURMETER

+ -

112

LS3

102

104

203

CC1-A

IP

CC1-B

CC2 CC

EN

110

ENGINE STOP

ENGINERUNNING

IGN ON

CC

CC1-C

NEUTRAL200

203

IGNITION

12VDC

IGNITION SW.

100 -

101 -

102 -

103 -

104 -

105 -

106 -

107 -

108 -

109 -

112 -

110 -

111 -

ENGINECONTROLMODULE

HI THROTTLE

STARTER

BACKUP ALARMSTARTERREVERSE SWITCH

(CLOSED IN REVERSE)

HOUR METER STOP

113 -

114 -

115 -

116 -

117 -

TRANSMISSIONOIL PRESS.

(ENGINE RUNNING)

PS1

118 -

119 -

120 -

121 -

PARK BRAKE

122 -

PARKING BRAKE(CLOSED WHEN SET)

309

152

123 -

124 -

125 -

126 -

127 -

IGN+12V

- 12V

NOTE: WHEN CIRCUIT IS OPEN TRANSMISSION IS LOCKED IN NEUTRAL

ENGINE & CHASSIS

221

125

2 2

4

6

10

EN

MAIN

CC

CB060A

ENGINE STOP

8

ENGINE STOP

START

STOP

SW2-AUC-1

ON

SW2-B5

UCS10

7

UC

7

7

41SW2-C

SW2

UCS9 41 CC3ENGINE RESTART J10UC9

J11UC10

J1

UCS-1

J2UCS-2 UC2

12 VOLT ENABLE

2

3

3

200

RESTART

200ENGINE STOP

[OPT.]

B

AREVERSE FLOOD[OPT.] 153

CC1-D

E

[OPT.]

224

IGNITION

101CR2

MB

MBMB

R12MB

MB

MB

CR10

(HIGH THROTTLE)

CR1

CB110A CR1

(IGNITION ON)

CR3

CR4MB

R13

25430 87

7 2

86 85

7 2

4

+12V

8

IGN

IGN

IGN

CB1

11

MAIN BOX MAIN BOX

(ENGINE STOPPED)

110

68

R11

D1MB

7

R11

2

MB

CR2112

87a30

(ENGINE STOPPED)

110

41

R11

CR14MB

OFF

STARTIGN

LS1

IP

EN

CC

ECM

SW1

CHASSIS CHASSIS

Red/Blk

Orange

Red

Brown

Red Blue

11

Brown/Black

WhiteBlack

Brown/Red

Red/Blk

Red

Orange

PTO HARNESS

+ -

NOTE: REMOVE STANDARD JUMPER

FROM IGN TO TERM 5

FORD: USE GROUND [STD]ISUZU: MOVE TO +12V FROMLIFT CIRCUIT - SEE LINE 224

IGN; park switch is groundInternational/Ford Hyd Brakes: move R13 toFORD Air Brakes/GMC as shown

0.2A

NEGLIGIBLE A

0.2A ADDED BY TESCO

0.2A

0.4A

0.2A

0.2A

0.4A

6.8A

47.6A 0.2A

REV. C

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Figure 4ELECTRICAL SCHEMATIC, LIGHTING - SHEET 2 OF 9

IP CC7

GC

IGN+12V

150 -

151 -

152 -

153 -

154 -

155 -

156 -

157 -

158 -

159 -

162 -

160 -

161 -

163 -

164 -

165 -

166 -

167 -

168 -

169 -

170 -

171 -

172 -

173 -

174 -

175 -

176 -

IGN+12V

- 12V

- 12V

HEADLIGHT SWITCH

SW3

FLASHER

BEACON

SW7

LIGHTING

13 14

15 16

15A

GC7

15

35 40

15A

LX

P

MB

J13 J7

PLATFORM WORK LIGHTS

SW6

LIGHTS (2)PLATFORM WORK

BP

WORKLIGHTS

LT3

(2)

CB240A

211

MB

8730

(IGN. ON)

CR3

R15

(BODY DOWN)

(BODY DOWN)LIGHTS

116R15

211

8 6

1 4

MAIN BOX

MAIN BOX

CHASSIS

CHASSIS

35 40

LT-5A

LT-5

UCS12 UCS13

UCS11 UCS6

Orange

27.6A

= 2 X 35W6.0A

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Figure 5ELECTRICAL SCHEMATIC, LIFT & STAB. CONTROL - SHEET 3 OF 9

LIFT & STABILIZERS CONTROL

BODY DOWN

STABILIZEREXTENDED

LOWER E-STOP PENDANT E-STOP

(CLOSED WHEN EXT'D)

STABL. EXT'D

BODY UP

ENGINE STOP

R

BODY DOWN

LIFT MODE

LT6

STAB EXT'D

A

261

150

217

152

259

LIFT MODE

G

IP

IP

IPLIFT POWER

[OPT.]

BODY UP

STABSNOT STOWED

200 -

201 -

202 -

203 -

204 -

205 -

206 -

207 -

208 -

209 -

212 -

210 -

211 -

213 -

214 -

215 -

216 -

217 -

218 -

219 -

220 -

221 -

222 -

223 -

224 -

225 -

226 -

227 -

IGN+12V

+12V

UCGC

SW9 SW10-B

221

- 12V

- 12V

GC5 GC6 PC7 PC8

LT7

LT8

SW10-AUC

UPPER E-STOP

UC7 UCS8UCS7 PC8 UC8

219125

STABILIZERSTOWED

STABL. STOWED

PS5ST1 3

2

(CLOSED WHEN STOWED)

SCPS7

(BODY DOWN)

1 3

2

STPS2 STPS2

200

ST

STABILIZERSTOWED

PS2

B ENGINE STOP[OPT.]

OVERRIDE [OPT]

STABL. EXT'D STABL. EXT'D STABL. EXT'D

[OPT. MULTIPLE STABILIZER SWITCHES]

STABL. STOWED

LS6-A LS6-B LS6-C

113

IP

STSTST

SW11

E

CC1-D[OPT.]

105

OPT. +12V LIFT SIGNALFOR HIGH THROTTLEFOR CHASSIS OTHERTHAN FORD

STABL. STOWED

PS5-AST1 3

2

PS5-B PS5-CST ST1 3

2

1 3

2

PS5-B PS5-CST ST1 3

2

1 3

2

30

CR4

87A

30

R13

87 8 6

CR4 CR6

(BRAKE SET)

8586

CR7

R15

R16

R16

41

(NEUTRAL)

(NEUTRAL)

STABL. EXT'D

(BODY DOWN)

CB320A

LIFT CONTROL

LIFT MODE

86 85

R14

(STABS STOWED)

118

120118

213

207

MB

MB

MB

MB

(LIFT MODE)

30 87

CR6203MB

MB

MB

MB

D2

D3

D4R12 114

(ENGINE RUNNING)

IGN LIFTMODE

7 2

7 2

1 4

8 6

IGN

IGN

IGN

IGN

17

18 J161817A17

37

21

37

2222

23

24

LIFT

25

26

27

27

27

BODY DOWN

BODY DOWN

IGN

IGN

+12V

MAIN BOX

LIFT

21

23

24

25

26

27

19 J8J15 J9

R14

STABL. STOWED

MB

7 220

20IGN

86

STABL. STOWED

85

CR13

[ENG. STOP OPT.]

MB

30

CR13

87A

(STAB STOWED)

205 3617B17B 17C

30

CR14

87A

(STAB STOWED)

109 7

CHASSIS

Black Red

Orange/Blk Orange/Red

Blue/Blk Blue/Red

Black Black/Red

Brown (4)

Blue (4)

Brown

Rh/Wht Gr/Ylw

Rd/Blk

BlackBlack

0.2A

0.2A

0.4A

0.4A

1.5A

1.5A

1.5A13.2A 13.2A4.5A

1.5A

1.5A

0.4A

0.2A

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Figure 6ELECTRICAL SCHEMATIC, LIFT & STAB. CONTROL - SHEET 4 OF 9

LIFT UP [LOWER]

LIFT UP LIFT UP

SOL5

[UPPER]

[LOWER]

MAX HEIGHT(OPEN @ HEIGHT)

LOWERING ALARM

LIFT UP

LOWER ALARM

MOTION ALARM

STABILIZERS

STABILIZERS

ENABLE

STABL. RETRACT

STABL. EXTEND

SOL4

SOL3

PTO

SOL2

STABILIZERS

PTO

STABILIZERS

EXTEND

RETRACT

[UPPER]

[LOWER]ENABLE

EXTEND

RETRACT

LIFT DOWN

LIFT DOWN

[UPPER]

UC

GCEN

AG

MVAG

MV

MV

CC

ALL

[OPT.]

250 -

251 -

252 -

253 -

254 -

255 -

256 -

257 -

258 -

259 -

262 -

260 -

261 -

263 -

264 -

265 -

266 -

267 -

268 -

269 -

270 -

271 -

272 -

273 -

274 -

275 -

276 -

+12V

IGN+12V

SW12

SW13

SW14

SW15

SW14-B

SW14-A

SW15-A

SW15-B

SW15-C

SW16

SW17

SW18

SW19

-12V

PC-3 PC-4

GC-1 GC-2

AG-1

AG-2

AG-4

AG-3

HIGH THROTTLE

105

PC-3

GC-1

PC-3

GC-1

PC-6

GC-4

GC-3

PC-5UC

GC

UC

GC

UP INHIBIT261

LIFT DOWN

SOL6

LIFT DOWN

SC

-12V

(PLAT. RETRACTED)

LT-3BP

UC-6

UCS3

UC4

UC5

THROTTLE INHIBIT254

MODELIFT

UC3

LS14

BP

1 3

2

PLAT RETRACTED

LS15

BP

1 3

2PLAT RETRACTED

265

PLAT RETRACTED302

273G

273 G

[OPT.] LIFT W/O STABL'S

(OPEN @ HEIGHT)

LS15 BP

9

S1 S2

315F

321G

320F

319E

(STABL'S EXTENDED)

CR7

ALL MOTIONALARM [OPT.]

(BODY DOWN)

C

68

R16

COMPRESSOR [OPT.]

213

209

D 272

317

250 D

ALARM [OPT.] ALL MOTION

IGNLIFT

MODE

30 87

(DOWN CONTROLACTIVE)

CR9269

30 87A

28

28

28

- 12V

S11S10

S3 S4

S5 S6- 12V

THROTTLE

CR10MB

86 85

29 30 31

LIFT

LIFT

LIFT

33

33

34

UP INHIBIT

CR9MB

86 85

S7 S8

- 12V

MAIN BOX

MAIN BOX

31

32

UPPER

J3

J20 J19

J18

J17

DXMB

28

86 8533

THROTTLE INHIBIT

CR5MB

267

(THROTTLE INHIBIT)

87A

CR5

30

LOWER

J14

F126

COMPRESSOR INHIBIT

COMPRESSOR INHIBIT

COMPRESSOR INHIBIT

33AD5MB

D6MB

OIL OVERHEAT

87a30

CR17323

CR11273

30 87

PLATFROM

CR11MB

86 85

RETRACTED

PLATFROM

CR12MB

86 85

RETRACTED

CHASSIS

CHASSIS

Black

White

Rd/Wy Bd/Yl

Brown Black

Blue

THESE CONNECTIONS MADE AT UPPER CONTROLSWAS FOR PBU OPTION

REMOVE FOR ALL MOTION ALARM

RELOCATED FROM LINE 205

PTO REQUEST 0.2A

3.0A

4.0A

4.0A

4.0A

7.2A

7.2A

7.2A

4.0A4.0A

7.2A

4.0A

3.0A

0.2A

1.0A (?)

6.0A

6.0A

0.2A

0.2A

0.2A

0.2A

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Figure 7ELECTRICAL SCHEMATIC, OPTIONS - SHEET 5 OF 9

PLATFORM

HYDRAULIC

PLATFORMRETRACT

PLATFORM

HYDRAULICPUMP

COMPRESSORINHIBIT

EXTEND

ENABLE

PUMP

300 -

301 -

302 -

303 -

304 -

305 -

306 -

307 -

308 -

309 -

312 -

310 -

311 -

313 -

314 -

315 -

316 -

317 -

318 -

319 -

320 -

321 -

322 -

323 -

324 -

325 -

327 -

311

+12V

IGN+12V

-12V

-12V

DOWN

326 -

UC

COMPRESSOR

UCS-3 UCS-4

SWC

CH

PS2

CompressorLow Air Pressure

COMPRESSOR

CHCompressor Fan

CH

Compressor Solenoid

SCISSOR HEIGHTSC

LS16-2

BP

(PLAT. RETRACTED)

315

LS16 BP(PLAT. EXTENDED)

UC

GC

STABL. RETRACT

CLOSED WHEN HOT (140 F)

HYD OIL TEMP

TS1 MV

252

OIL OVERHEAT

R

LT9IP

HYD OIL OVERHEAT

BP

1 3

2 BP

1 3

2PLATF EXT

SOL9

PLATF RETR

SOL10

ELECTRIC

CON1

ELECT

CON1

-+

HYDRAULIC

HYDRAULICPUMP

PUMP

MB

MB

CC

CC

MV

EXTEND

RETRACT

PLATFORM

PC-1

PC-2

EXTEND

0RETRACT

310

SW21

SW21-A

SW21-B

SW23

M1

PC-3

PC-3

HYDR.PUMP

AUX PUMP

CC

CB4150A

MV-1 MV-2 MV-3

F251

256 PTOC

322H

RETRACT

GC-8

RETRACT

GC-1

SWXX-B

GC-7

EXTEND

GC-1

SWXX-A

PLATFORM 0

EXTEND

LT-10

LT-9

LT-1

F262

G266

H307

1

R12

4

(ENGINE RUNNING)

114

IGNLIFT MODE

+12V

44 44

45

46

MAIN BOX

MAIN BOX

LT2

BLACK

RED

BLACK

J24

16

319

87A

COMPRESSOR INHIBIT

CR8

30

CR8MB

J4 LT7

J21

J23

43

42

14

LIFT UP

E258

LIFT DOWN

PLATFORM EXTEND / RETRACT

COMPRESSOR INHIBIT

39

LIFT86 85

OIL OVERHEAT

MB36CR17

OIL OVERHEAT

YEL/GRN

CR12 275

30 87a

CHASSIS

CHASSIS

Black Green

WHT BLK

Rd/Wh Rd/Yl

Rd/Bl

Rd/Yl

N/A WITH ENGINE STOP; see line 202

3.0A

3.0A

0.5A

130A APPROX.

0.2A

1.5A

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ENGINERUNNING

ENGINERUNNING

[OPT.]

112 -

113 -

114 -

115 -

116 -

TRANSMISSIONOIL PRESS.

(ENGINE RUNNING)

PS1

309

159

221

IGNITION

101

EN

UC9 CC3

STOP

ON

START

UC10

MB

ENGINE STOP

108 -

109 -

112 -

110 -

111 -

STARTER

STARTERSW2

SW2-C

SW2-B

ENGINE RESTART

CB1 CR1

(IGNITION ON)

SW2-A UC

5

7

41

SW4

PLATFORM FLOODS

BP BP

BP

BP

BP

GC BP

PLATFORM FLOODLIGHTS

BODY INTERIORLIGHTS

REAR FLOODLIGHT

BEACONLIGHT

BEACONLIGHT

PLATFORM FLOODLIGHTS

BODY INTERIORLIGHTS

REAR FLOODLIGHT

LT2

LT3

LT4

LT5

TIMER SWITCH

INTERIOR LIGHTS[TIMER SWITCH IS STD.]

BEACON

SW5

SW7

REVERSE FLOOD

A107

SW5-A SW5-B

15 1615

35 40

152 -

153 -

154 -

155 -

156 -

157 -

158 -

159 -

1515A

41

FLASHER

LX

P

MB35 40

7

UC-1 UC-2

HOUR METER STOP

ENGINE STOP

104

110

1027

3-WAY SWITCHES[OPT.]

IGNITION

101MB

R12MB

MB

CB1 CR1

(IGNITION ON)

CR3

7 2

CR2

MB

110 MB

MB

D1

(ENGINE STOPPED)

R11 R11

7 28 6

+12V IGN

IGN+12V

8

IGN

IGN

RELOCATE THIS WIRE FROM

IGN TO 8

CB240A MB

(BODY DOWN)LIGHTS

R15211

1 4

8730

(IGN. ON)

CR3116

8

LT-5

LT-5A

OPTIONS

OPTION FOR BEACON ON WHEN ENGINE RUNNING (CONTINENTAL)NOTE: For this option, the body interior lights and platform floods must bothbe on timer switches. The rear flood must be either on a timer or be a reverse light(Continental wires the rear flood as a reverse light).

OPTION FOR ENGINE RESTART FROM UPPER CONTROLS

NOTE: REMOVE STANDARD JUMPER

FROM IGN TO TERM 5

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[THIS SWITCH REPLACES STD.JUMPER WIRE FROM IGN TO 17]

6

203

IPLS3

(CLOSED WHEN MICO BRAKE SET)

MICO [OPT]

120 - PARK BRAKE

125

6

THIS WIRE INTERNALTO MICO CONTROL UNIT

-12V

LOWER E-STOP UPPER E-STOPLIFT MODE[LIFT/DRIVE]

SW8

LIFT MODEGC

203 -

204 -

UCGCSW9 SW10

221

GC5 GC6 UC1 UC2

-12V

NEUTRAL INDICATION

TCM[ALLISON TRANSMISION]

(GROUNDED IN NEUTRAL)

CC4EN

CC6-B

CC6-A

124 -

125 -

126 -

NEUTRALLOCK

NOTE: WHEN CIRCUIT IS OPEN TRANSMISSION IS LOCKED IN NEUTRAL

11

12

11

12

IGN+12V

- 12V

42

(GROUND POWER CONNECTED)

CR20

GROUNDPOWERCONNECTED

GROUND POWERCONNECTED

R

LTX

CR20

125

GP

IP GROUNDPOWERWARNINGLIGHT

217 -

GROUND POWER

315 -

316 -

120VAC WHENGROUND POWER

CONNECTED

CR20

(GROUND POWER CONNECTED)

316

217

316

+120VAC GROUND

41 42

3433

A1 A2

42

+12V

306 -

BPPS17 PLATFORM

EXTEND

-12V

BPPS17-A

SW21

SW21-A EXTEND

AU-1 AU-4

PLATF INHIBIT

SOL9

PLATF EXT

BP1 3

2

1 3

2

PLATF INHIBIT

LT-1

MBR13

7 2

IGN

+12V

30

R13

87 8 6

CR4 CR6

(BRAKE SET)(NEUTRAL) LIFT MODE

86 85120118

MBIGN

17

18 191817A17

IGN

+12V

(PARK BRAKE SET)

R14

(STABS STOWED)

120 207R13

681 4

IGN

MODELIFT

IGN

J22

J6

14J23

J25

OPTION FOR MICO BRAKE

OPTION FOR LIFT/DRIVE SWITCH

OPTION FOR NO VEHICLE MOVEMENT (NEUTRAL LOCK) WHEN GROUND POWER CONNECTED

OPTIONS

OPTION FOR PLATFORM EXTEND INHIBIT

1.5A

3.0A

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Figure 10ELECTRICAL SCHEMATIC, TABLES OF VEH. CONNECTIONS - SHEET 8 OF 9

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Figure 11ELECTRICAL SCHEMATIC, TABLES OF VEH. CONNECTIONS

DPDT & SPDT RELAY WIRING - SHEET 9 OF 9

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Date post:	18-Mar-2020
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