ML50-20 rev 7 - Amazon S3...BLUE (14-16) 12.0A = 4 X 35W 27.6A Jan. 14 Property of American Airlines...

MAINTENANCE LIFT

Electrical Schematics

Manufactured by

Tl8t:D TE co EQUIPf\.fENT LLCCoral Springs, Florida

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SYSTEM SCHEMATICS 2-5Page 1

ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC

Section 5: System Schematics

1. ELECTRICAL SCHEMATIC

A. How to Read This Schematic

B. ELECTRICAL SCHEMATIC - SHEET 1 OF 7

C. ELECTRICAL SCHEMATIC - SHEET 2 OF 7

D. ELECTRICAL SCHEMATIC - SHEET 3 OF 7

E. ELECTRICAL SCHEMATIC - SHEET 4 OF 7

F. ELECTRICAL SCHEMATIC - SHEET 5 OF 7

G. ELECTRICAL SCHEMATIC - SHEET 6 OF 7

H. ELECTRICAL SCHEMATIC - SHEET 7 OF 7

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MAINTENANCE2-5Page 2

TESCO EQUIPMENT LLC ML50-20 MAINTENANCE LIFT

Figure 1HYDRAULIC SCHEMATIC - ML2 WITH RETURN FILTER

PS

2

CO

DE

61

T-1

6A

CA

VIT

Y

T-1

3A

CA

VIT

YO

R X

GC

A-X

XN

PLU

GD

LD

A-D

HN

VA

LV

E

FLO

WS

AV

AIL

AB

LE

:Z

ER

O (

DIS

EN

GA

GE

D)

11 G

PM

@ L

O T

HR

OT

TLE

WIT

H O

N-D

EM

AN

DE

NG

AG

EM

EN

T

T-2

2A

CA

VIT

Y

T-5

A C

AV

ITY

NF

DD

-LG

N

FD

EA

-LA

N

RV

ED

LA

N

(OP

TIO

NA

L)

CO

DE

61

W/O

-RIN

G

-16

W/O

-RIN

G

-32

PR

FB

-LA

N-B

BB

& R

ES

ER

VO

IRM

AIN

MA

NIF

OLD

-16

FLO

W C

ON

TR

OL

LO

WE

RIN

G

STA

BIL

IZE

R

DO

5 T

YP

E

STA

BIL

IZE

RLE

FT

SID

EF

RO

NT

STA

BIL

IZE

RLE

FT

SID

ER

EA

R

STA

BIL

IZE

RR

IGH

T S

IDE

V2

V1

C2

C1

RE

AR

V2

V1

C2

C1

VA

LV

E

V2

V1

C2

C1

STA

BIL

IZE

R

V2

V1

C2

C1

RIG

HT

SID

EF

RO

NT

ALR

AU

X P -6-1

2B

1

-12

A1

-10

12 V

DC

EM

ER

GE

NC

Y P

UM

P

1/8

NP

T-8

-16

SO

L4

PT

SO

L3

EN

GIN

E D

RIV

EN

PU

MP

MS

OL2

VA

LV

EC

HE

CK

1800 P

SI N

OM

.

SY

ST

EM

RE

LIE

F

P

100/4

00)

(PR

FB

LE

NR

ED

UC

ER

PR

ES

SU

RE

T

(NE

ED

LE

VA

LV

E)

FLO

W C

ON

TR

OL

AU

X P

G1

P1

31

24

SO

L1

PB

U V

ALV

EO

PT

ION

AL

-6-6

ST

RA

INE

RS

ISO

LA

TIO

NV

ALV

E

TA

NK

M

12V

DC

PU

MP

RE

SE

RV

OIR

50 G

AL

HA

ND

P2

PU

MP

SS

UC

TIO

N

D

G2

-04

LO

WE

RIN

G V

ALV

ES

GR

AV

ITY

DO

WN

SO

L6

B2

SO

L6A

PO

WE

R U

P

LIF

T C

YLIN

DE

RS

AU

X T

-12

RE

TU

RN

UP

TO

50 G

PM

PR

ES

S. F

ILT

ER

S)

FIL

TE

R

RE

TU

RN

(ALT

ER

NA

TIV

E T

O

T

BR

EA

TH

ER

SO

L9

A

FLO

W C

ON

TR

OL

(NE

ED

LE

VA

LV

E)

HY

DR

AU

LIC

DR

IVE

N/C

OO

LE

DA

IR C

OM

PR

ES

SO

R

FR

OM

MA

IN

AU

X P

PO

RT

MA

NIF

OLD

P

VA

LV

EA

IR C

OM

PR

ES

SO

RT

O A

UX

SA

ND

WIC

H

RE

LIE

F

D05 T

YP

ELIF

T V

ALV

E

1200 P

SI N

OM

.

T1

ML2 5

020 H

ydra

ulic

Syste

m w

ith F

PP

Manifold

s F

edE

X

REV. F

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ITEM QTY TESCO NO PART NUMBER/DESCRIPTION NOTE

1 1 HYPU10030 • PUMP, 19 GPM

2 1 TR32N12NEHNN • HYDRAULIC POWER MODULE W/RETURNFILTER, 32 Gallon

1 HYMS20047 •• CARTRIDGE, Stabilizer Flow Control Valve

1 HYMS20049 •• CARTRIDGE, Handpump Valve

1 HYVA10246 •• CARTRIDGE, Pressure Reducing, 100-400psi

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

1 HYMS20041 •• VALVE, D05 3 Pos./4 Way Stabilizer

1 HYMS20040 •• VALVE, D05 2 Pos./4 Way Lift

1 HYMS20048 •• CARTRIDGE, Lift Flow Control Valve

1 HYMS20045 •• GAUGE, 0-2000 PSI

1 HYMS20046 •• CARTRIDGE, System Relief Valve

1 HYMS20052 •• VALVE, Check, Inlet

1 HYFI10017 •• FILTER ELEMENT, Return

3 2 HYVA10210 • VALVE, LOWERING 2-WAY N/C

4 4 HYCY10046 • CYLINDER, Double Acting Stabilizer

5 2 HYCY10001 • CYLINDER, Single Acting Lift

6 1 HYPS10003-1 • SWITCH, Pressure Stabilizer

7 1 HYVA10273 • VALVE, Sandwich Lift Pressure

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THIS PAGE INTENTIONALLY LEFT BLANK


MAINTENANCE2-5Page 4Mar. 08

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Figure 2HOW TO READ THIS SCHEMATIC

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Figure 3ELECTRICAL SCHEMATIC - SHEET 1 OF 7

6

BATTERY

BACKUPALARM

112

102

203

CC1-A

CC1-B

CC2 CC

EN

110

ENGINERUNNING

IGN ON

CC1-D PIN C ON PTO HARNESS 8 PIN CON

NUETRAL200

203

IGNITION

12VDC

IGNITION SW.

100 -

101 -

102 -

103 -

104 -

105 -

106 -

107 -

108 -

109 -

112 -

110 -

111 -

ENGINECONTROLMODULE

HI THROTTLE

STARTER

BACKUP ALARM

STARTER

REVERSE SWITCH(CLOSED IN REVERSE)

ENGINE STOP

113 -

114 -

115 -

116 -

117 -

TRANSMISSIONOIL PRESS.

(ENGINE RUNNING)

PS1

118 -

119 -

120 -

121 -

PARK BRAKE

122 -

309

152

123 -

124 -

125 -

126 -

127 -

IGN+12V

- 12VENGINE & CHASSIS

224

125

2 2

3

3

4

6

11

12

EN

MAIN

CC

CB060A

ENGINE STOP

8

5SW2-B UCS10

UCS-2

ENGINE STOP

START

STOP

UC-1 SW2-A

ON

7

7

UC

41SW2

SW2-C UC9 CC341ENGINE RESTARTJ10

UCS9

J11UC10

UC2J2

UCS-1

J1

IGNITION SWITCH

IGNITION SWITCH

PC-2PC-1

GC-9

NEUTRAL/PARKLOCK / INDICATOR

-+ HOUR

HOUR METERMETER

IP

7B

7B

7B

7B

(GROUNDED IN NEUTRAL)

TCM

EN CC4NEUTRAL/PARK INDICATION

[TRANSMISION]

(ENGINE STOPPED)

(PARK BRAKE SET)

R14

(STABS STOWED)

IGNITION

101

110

200

120 207

MB

MB

R12MB

MB

MB

R11

CR10

(HIGH THROTTLE)

CR1

B

CB110A CR1

(IGNITION ON)

CR3

R13

R13

68

254

1 4

30 87

7 2

7 2

1 4

4

+12V

8

IGN

IGN

CB1

MAIN BOX MAIN BOX

E

227

R11 MB110

(ENGINE STOPPED)

68 7 2

R11

MB

IGN

IGN

DP

M

J

204

204

K

204

L

204

204 N

WHITE/PURPLE

MB

86 85

MBCR4

11IGNDP

OFF

STARTIGN

LS3

LS1

IP

EN

CC

CC

ECM

SW1

PARKING BRAKE (isuzu)(CLOSED WHEN SET)

CHASSIS CHASSIS

BLACK/WHITE

WHITE/ORANGE

CC9

BROWN

BROWN/RED

RED

BRN/BLK

RED/BLK

BLUE (14-4)RED (14-4)

YELLOW/GREEN

Orange

BLUE/GREY

+ -

110Q

Q 102

0.2A

0.2A ADDED BY TESCO

0.2A

0.4A

0.4A

6.8A

47.6A

NEGLIGIBLE A

0.2A

Rev. D

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IP CC7

J7BP

GC-8BP

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

PLATFOR WORKLIGHT

BEACONLIGHT

ICC LIGHTS

REAR FLOODLIGHT

LT3

LT4

HEADLIGHT SWITCH

SW3

PLATFORM WORK LIGHTS

FLASHER

BEACON

SW6

SW7

LIGHTING

13 14

15 16

15A

GC7

15

35 40

15A

LX

P

MB

J13

CB240A

211

MB

8730

(IGN. ON)

CR3

R15

(BODY DOWN)

(BODY DOWN)LIGHTS

116R15

211

8 6

1 4

MAIN BOX

MAIN BOX

H204

CHASSIS

CHASSIS

LT-5

LT-5A

35 40

UCS11

UCS12

UCS6

UCS13

GRN/RED

ORANGE

BLUE (14-16)

12.0A= 4 X 35W

27.6A

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LIFT & STABILIZERS CONTROL

BODY DOWN

BODY DOWN

STABILIZEREXTENDED

LOWER E-STOP UPPER E-STOP

STABL. STOWED

(BODY DOWN)

BODY UP

ENGINE STOP

R

BODY DOWN

LIFT MODE

LT6

STAB EXT'D

A

LS5

(CLOSED WHEN STOWED)

LS7

[OPT. ENGINE STOP]

200

219

261

125

150

217

202

152

259

ST

SC

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

GC

STABILIZERSTOWED

SW9SW10-A

224

- 12V

- 12V

GC5 GC6 UC7 UCS8

STABILIZERSTOWED

LT7

LT8

UPPER E-STOP

SW10-B

PC-7 PC8UCUCS7 PC8 UC8

34

CR20

(GROUND POWER CONNECTED)

33 R

LT9

GROUND POWERCONNECTED

123 IP GROUNDPOWERWARNINGLIGHT

(CLOSED WHEN EXT'D)

STABL. EXT'D

PS2 ST

OVERRIDE [OPT]STABL. STOWED

IP

SW11

30

CR4

87A 30

CR5

87A

87A30

30

R13

87 8 6

CR4

B ENGINE STOP[OPT.]

CR6

(BRAKE SET)

R14

8586

CR7

R15

R16

R16

41

(NEUTRAL)

CR8

(NEUTRAL)

STABL. STOWED

STABL. EXT'D

(BODY DOWN)

(STAB STOWED)

(BODY DOWN)

CB320A

LIFT CONTROL

LIFT MODE

86 85

R14

(STABS STOWED)

86 85

CR8

86

STABL. STOWED

85

CR5

118

120118

205

215

213

207

113

MB

[ENG. STOP OPT.]

MB

MB

MB

MB

MB

MB

(LIFT MODE)

30 87

CR6203MB

MB

MB

MB

R12 114

(ENGINE RUNNING)

IGN LIFTMODE

7 2

7 2

7 2

1 4

8 6

IGN

IGN

IGN

IGN

17

18 19

36

1817A17

20

37

21

38

20

37

22

38

22

23

24

LIFT

25

26

27

27

27

BODY DOWN

BODY DOWN

BODY DOWN

IGN

IGN

+12V

MAIN BOX

E

LIFT

CC1-D

105+12V LIFT SIGNALFOR HIGH THROTTLE

21

12

14

13

15

2

J16J8 J15 J9

112N

112M

112K

112L

156H

112J

GC-9 PC-1 PC-2

IGN 43IT

IGN

CHASSIS

Orange/Blk Orange/Red

Blue/Blk Blue/Red

Black Black/Red

ORG (14-4)

WHT (16-2)

BLUE (14-4)

BLK (16-2)

BLUE (3) RED (1) GREEN

Black (2)

0.2A

0.2A

0.4A

0.2A

0.4A

0.4A

0.2A

1.5A

1.5A

1.5A13.2A 13.2A4.5A

1.5A

1.5A

1.5A

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LIFT & STABILIZERS CONTROL

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

PRESSURE

EXTEND

RETRACT

[UPPER]

[LOWER]ENABLE

Compressor

EXTEND

RETRACT

LS14

LIFT DOWN

LIFT DOWN

[UPPER]

UC

GC

BUILD UP

EN

307

AG

MVAG

BP

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+12VLIFT

MODE

SW12

SW13

SW14

SW15

SW14-B

SW14-A

SW15-A

SW15-B

SW15-C

SW16

SW17

SW18

SW19

-12V

PC3 PC4

GC-1 GC-2

AG-1

AG-2

AG-4

AG-3

HIGH THROTTLE

105

PC3

GC-1

PC3

GC-1

PC6

GC-4

GC-3

PC5UC

GC

UC

GC

UP INHIBIT261

LIFT DOWN

SOL6

LIFT DOWN

SOL6A

LIFT DOWN

SC

SC

-12V

UC-6

UC-5

UC4UC3

UCS3

[OPT.] LIFT W/O STABL'S

(OPEN @ HEIGHT)

ALL MOTIONALARM [OPT.]

PBU[OPT.]

SOL1

C

LS15

MV

D 272

256 D

BP

ALARM [OPT.] ALL MOTION

9

S1 S2

308F

R 311

S 312

T 313

(STABL'S EXTENDED)

CR7

(BODY DOWN)

68

R16213

209

MB

MB

IGNLIFT

MODE

30 87

(DOWN CONTROLACTIVE)

CR9269

30 87A

28

28

28

- 12V

S11S10

S3 S4

S5 S6- 12V

THROTTLE

CR10MB

86 85

J18

32

30 31

LIFT

LIFT

LIFT

33

33

34

33A

UP INHIBIT

CR9MB

86 85

S7 S8

- 12VJUMPER

MAIN BOX

MAIN BOX

31

J3 J20

J17

29

J19

28

COMPRESSOR INHIBIT

COMPRESSOR INHIBIT

COMPRESSOR INHIBIT

OIL OVERHEAT

87a30

CR21300

CHASSIS

CHASSIS

WHT (16-2) BLK (16-2)

BLKBLUE/BLK

0.2A

3.0A

3.0A

4.0A

4.0A

4.0A

7.2A

7.2A

7.2A

4.0A4.0A

7.2A

4.0A

3.0A

3.0A

0.2A

1.0A (?)

6.0A

6.0A

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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 -

326 -

+12V

IGN+12VLIFT

MODE

-12V

-12V

SWC

COMPRESSOR

UCS-3UC

UCS-4

COMPRESSOR

PS2

Low Air PressureCompressor

CH

Compressor Solenoid

CH

Compressor FanCH

STABL. RETRACTINHIBIT

308

COMPRESSOR

SOL 9

CLOSED WHEN HOT (140 F)

HYD OIL TEMP

TS1 MV

252

OIL OVERHEAT

R

LT10IP

HYD OIL OVERHEAT

AIR COMPRESSOR

C 255

251 F

268 T

262 S

1

R12

4

(ENGINE RUNNING)

114

IGNLIFT

MODE

LIFT

44 44

45

46

MAIN BOX

MAIN BOX

LT8J4

REDORANGE

BLACK

LIFT DOWN

LIFT UP

258 R

MBCR2

COMPRESSOR INHIBIT

30

CR2

87A

311

10

86 85

OIL OVERHEAT

MB42CR21

OIL OVERHEAT

CHASSIS

CHASSIS

WHT BLK

0.2A

1.5A

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TABLES OF VEHICLE CONNECTIONS

ISUZU NPR

IGNITION

HIGH THROTTLE

STARTER

LINE NO. LOCATION I/O TYPE

MARKER LIGHTS

HEADLIGHTS

REVERSE

109

OUTPUT +12VDC WHEN IGNITION ON

INPUT 12V FOR HIGH THROTTLE TO N.O.CONTACTS (TERMINAL 30) OF RELAY CR10. THIS ISWIRED TO GROUND IN STANDARD MAIN BOX.

N/A

CC3

CC4

CONNECTION

CC2

CC6-A,B

CC7

CC1-D

CC5-A,B

LOCK NEUTRAL 125,126 N/A N/A

101,104

105

CC1-A,BIGNITION INTERRUPT &

OUTPUT +12VDC WHEN IN REVERSE[NOT REQUIRED IF CHASSIS EQUIPPED WITH ALARM]

INPUT +12VDC TO OPERATE STARTER [OPTIONAL]

PARK SIGNAL J-122 PIN 5 WHT/RED118 GROUNDED WHEN IN PARK

123125

150

CHASSISWIRE NO.

INPUT TO VEHICLE OROUTPUT FROM VEHICLE

107

OUTPUT +12VDC WHEN PARKING LIGHTS ON

ISUZU NPR 2008/2013 WITH AUTO TRANSMISSION ( NON ALLISON)

N/ACC1-C

PTO LEFT REMOTE CONNECTOR

AT IGNITION SWITCH

WHITE / RED

PIN C ON 8 PIN CONNECTORPink

AT IGNITION SWITCH

BLACK / WHITE

DRIVER DASH GREEN/RED

N/A

N/A

OUTPUT TO GROUND WHEN PARKING BRAKE ONCC9 PARKING BRAKE WHITE/BLK120

PA30

OA25

PA29

DIESEL

GASUNDER DASH OBD-II DIAGNOSTIC

AT TAILLIGHT - BLUE

32

1

8

7 6

4

5

DPDT RELAYWIRING

WITH OCTAL BASEIN MAIN BOX

SPDT RELAY[AUTOMOTIVE TYPE]

WIRINGON CIRCUIT BOARD

IN MAIN BOX

86

85

87A

87

30

COM (1)

COM (2)

NO (2)

COIL

COIL

NC (2)

85

NC (1)

COIL

COIL

COM

NC

NO

85

87

30

87A

86

86

TOP

NO (1)

6 5

4321

8 7

TOP

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GRD

ETM-68A

PTO

RPM1

12V

InPower Throttle

CANL

IP

CANH

30

TIME DELAY

VCM-03.10SA

87A

86

85

MB

10 +120VACGROUND POWER

A1

GROUND POWER

CONNECTED

A2

CR20GP

120VAC WHEN GROUND

GROUNDPOWER

221200

106 -

105 -

103 -

104 -

4 DLC Cable

CC1-D

IGNITION SWITCHCC1-B

HI THROTTLE

CONTROLMODULE

ENGINE

253 -

252 -GC-1

ENABLE[LOWER]

SW13GC GC-2

SOL2

PTO

EN

PTO

-12V

200 -

201 -

121 -

122 -

123 -

- 12V

-12VIGN

+12V

87

(HIGH THROTTLE)

254CR10

227

30E4

LIFT 28

106

P

S10 - 12V

S11

LIFT

MODELIFT

MAIN BOX

OIL OVERHEAT

87a30

CR21300

30

CR4

87A 30

CR5

87A B ENGINE STOP[OPT.]

(NEUTRAL)

CR8

(STAB STOWED)

(BODY DOWN)

118 205

215

11336

123

(GROUND POWER)

14

CR20

13

87A30

CR8

(BODY DOWN)

215

MAIN BOXMAIN BOX

ECM

253 P

EN

CHASSIS

CHASSISCHASSIS

BLACKRED

GRN

YEL RED

OPTION FOR GAS ENGINE THROTTLE RAMP UP W/ TIME DELAY

OPTIONS

OPTION FOR GROUND / SHORE POWER

7.2A 3.0A

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TABLE OF CONTENTS

CHAPTER 3: OVERHAUL

Section 1: Overhaul ProcedureGENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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ML50-20 rev 7 - Amazon S3...BLUE (14-16) 12.0A = 4 X 35W 27.6A Jan. 14 Property of American Airlines...

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Transcript of ML50-20 rev 7 - Amazon S3...BLUE (14-16) 12.0A = 4 X 35W 27.6A Jan. 14 Property of American Airlines...