Tesco ML50-20 Maintenance Manual
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Tesco ML50-20 Maintenance Manual

Tesco ML50-20 Maintenance Manual

Maintenance lift
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MAINTENANCE LIFT
Maintenance
Manufactured by
Tl8t:D
co
TE
EQUIPf\.fENT LLC
Coral Springs, Florida

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Summary of Contents for Tesco ML50-20

  • Page 1 MAINTENANCE LIFT Maintenance Manufactured by Tl8t:D EQUIPf\.fENT LLC Coral Springs, Florida...

  • Page 2: Table Of Contents

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TABLE OF CONTENTS CHAPTER 2: MAINTENANCE Page PERIODIC MAINTENANCE ............1 HYDRAULIC OIL RECOMMENDATIONS .
  • Page 3 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC ELECTRICAL SCHEMATIC - SHEET 6 OF 7 - - - - - - - - - - - - - - - - - - - - - - - - -Figure 8 ..1 ELECTRICAL SCHEMATIC - SHEET 7 OF 7 - - - - - - - - - - - - - - - - - - - - - - - - -Figure 9 .
  • Page 4 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC LIST OF FIGURES CHAPTER 2: MAINTENANCE 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 CYLINDER UPPER ROLLER......... Page 6 2-1 Figure 4 GREASE POINTS - ROLERS AND PINS ............
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  • Page 6: Chapter 2: Maintenance

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC CHAPTER 2: MAINTENANCE Section 1: Servicing 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 Maintenance Chart below.

  • Page 7: Hydraulic Oil Recommendations

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC PERIODIC MAINTENANCE CHART PERIOD (HOURS) PROCEDURE OTHER Check platform understructure for cracked welds or corrosion. Check condition of placards and safety warning decals. Replace return filter 6 mos. Check that all wiring terminals are secure.

  • Page 8: Checking Hydraulic Oil Level

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC CHECKING HYDRAULIC OIL LEVEL Maintaining proper hydraulic oil level is important. DO NOT overfill the hydraulic oil reservoir. Hydraulic oil expands when heated. 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.

  • Page 9: Lubrication

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC LUBRICATION 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 to remove dirt and foreign material.

  • Page 10: Figure 4

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC Ref. Figure 4 Ref. Figure 4 Ref. Figure 3 Ref. Figure 4 Ref. Figure 4 Ref. Figure 4 Ref. Figure 4 GREASE ALL TRACKS Figure 2 GREASE POINTS DIAGRAM SERVICING Page 5 May 08...

  • Page 11: Grease Points - Lift Cylinder Upper Roller

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC GREASE POINT Do not NOTE: grease bleed valve shown below BLEED VALVE GREASE POINT BUTT END OF CYLINDER Figure 3 GREASE POINTS - LIFT CYLINDER UPPER ROLLER MAINTENANCE Page 6 May 08...

  • Page 12: Grease Points - Rolers And Pins

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC REAR GREASE POINT GREASE POINT SCISSOR UPPER & LOWER PIVOT PINS - BOTH SIDES SCISSOR UPPER & LOWER ROLLERS - BOTH SIDES SCISSOR CENTER PINS - BOTH SIDES UPPER AND LOWER SCISSOR ARM END PINS -...
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  • Page 14: Hydraulic System

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC 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.

  • Page 15: Procedure For Bleeding Air From Hydraulic System

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC CAUTION WHEN MAKING HYDRAULIC SYSTEM ADJUSTMENTS, THE HYDRAULIC OIL MUST BE AT NORMAL OPERATING TEMPERATURE. PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC SYSTEM Bleeding Stabilizer Cylinders. Stabilizer installations for unit, are equipped with double acting rod type hydraulic cylinders.

  • Page 16: Hi-Lift Cylinder Bleed Valve Adjustments

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC (12) With the scissor in its fully lowered position, check the hydraulic oil level. Refill reservoir if needed. BLEED VALVES DETAIL VIEW BLEED VALVE Figure 1 LIFT CYLINDER BLEED VALVE HYDRAULIC SYSTEM ADJUSTMENTS Page 3...

  • Page 17: Hydraulic Adjustments - Hydraulic Power Module

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC HYDRAULIC ADJUSTMENTS - HYDRAULIC POWER MODULE ITEM FUNCTION SETTING PROCEDURE A Pressure Gauge Used for reading system pressures. Lift Down Speed 60 sec -- Raise lift fully. Activate lift down function and record the time...
  • Page 18 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC STABILIZER Figure 2 HYDRAULIC SYSTEM HYDRAULIC SYSTEM ADJUSTMENTS Page 5 Jan. 14...
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  • Page 20: General Information

    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 in troubleshooting operational malfunctions in the ML50-20 Lift hydraulic and electrical systems. Before starting troubleshooting procedures, verify that the correct operating procedures were used.

  • Page 21: Introduction

    UP switches function as the ENABLE switch. ELECTRICAL SYSTEM The Model ML50-20 has a 12-volt DC electrical system that controls all functions of the Hi-lift. The components of the electrical system are located in the lower control station, the upper control station, and main electrical box.

  • Page 22: Troubleshooting Chart - General

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC When a component is repaired or replaced, always check the hydraulic circuit for the correct indicated pressure, correct actuator speeds, and correct hydraulic fluid level. Troubleshooting Chart - General TROUBLESHOOTING TROUBLE PROBABLE CAUSE Ground level controls will not operate with the Vehicle not in lift mode (Parking brake off) vehicle’s engine running.
  • Page 23 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TROUBLESHOOTING TROUBLE PROBABLE CAUSE Stabilizers will not extend. Vehicle not in lift mode (Parking brake off) Emergency stop activated Circuit breaker tripped or blown fuse Defective solenoid coil or relay Damaged wiring or bad ground...
  • Page 24 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TROUBLESHOOTING TROUBLE PROBABLE CAUSE Platform mounted work light not operating. Burned fuse Dead or low battery Defective light bulb in work light Corrosion build up on light bulb terminals Damaged or defective control switch...
  • Page 25 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TROUBLESHOOTING TROUBLE PROBABLE CAUSE There is no hydraulic fluid flow or pressure from Shut off valve closed hydraulic oil pump when the engine is running. Clogged filter Blockage on pump's suction port or collapsed...

  • Page 26: Introduction

    Scissor frame, platform Repair cracks or damage by welding or splicing as required except where the structural integrity of the unit is affected. Consult with Tesco for approved methods or guidelines for conducting repairs on damaged area. Handrails Replace sections of damaged handrail with a new piece of metal.
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  • Page 28: Hydraulic Schematic

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC Section 5: System Schematics HYDRAULIC SCHEMATIC 4 Stabilizers and Return Filter Figure 1 ELECTRICAL SCHEMATIC How to Read This Schematic Figure 2 ELECTRICAL SCHEMATIC - SHEET 1 OF 7 Figure 3 ELECTRICAL SCHEMATIC - SHEET 2 OF 7...

  • Page 29: Hydraulic Schematic - Ml2 With Return Filter

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC REV. F Figure 1 HYDRAULIC SCHEMATIC - ML2 WITH RETURN FILTER MAINTENANCE Page 2 Nov. 13...
  • Page 30 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC ITEM TESCO NO PART NUMBER/DESCRIPTION NOTE HYPU10030 • PUMP, 19 GPM TR32N12NEHNN • HYDRAULIC POWER MODULE W/RETURN FILTER, 32 Gallon HYMS20047 •• CARTRIDGE, Stabilizer Flow Control Valve HYMS20049 •• CARTRIDGE, Handpump Valve HYVA10246 •• CARTRIDGE, Pressure Reducing, 100-400 HYMS20042 ••...
  • Page 31 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC THIS PAGE INTENTIONALLY LEFT BLANK MAINTENANCE Page 4 Mar. 08...

  • Page 32: How To Read This Schematic

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC Figure 2 HOW TO READ THIS SCHEMATIC SYSTEM SCHEMATICS Page 5 Mar. 08...

  • Page 33: Electrical Schematic - Sheet 1 Of 7

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC 12VDC 100 - BATTERY CC1-A WHITE/ORANGE IGNITION RED/BLK 101 - IGNITION SWITCH 0.2A 102 - ENGINE STOP START (ENGINE STOPPED) IGNITION SW. 0.2A ADDED BY TESCO 103 - IGNITION SWITCH CC1-B ENGINE 104 -...

  • Page 34: Section 5: System Schematics

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC +12V - 12V ORANGE 150 - (BODY DOWN) HEADLIGHT SWITCH 151 - 152 - (IGN. ON) LIGHTS (BODY DOWN) 27.6A 153 - 154 - 155 - GC-8 GRN/RED BEACON 156 - LIGHT BLUE (14-16)

  • Page 35: Figure 5

    ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC +12V - 12V B ENGINE STOP ENGINE STOP 200 - [OPT.] [OPT.] (NEUTRAL) (STAB STOWED) 201 - (BODY DOWN) 202 - SW10-A SW10-B PC-7 UCS7 UCS8 LIFT MODE 203 - LOWER E-STOP UPPER E-STOP...
  • Page 36 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC LIFT +12V MODE -12V SW12 SOL1 J3 J20 LIFT 250 - PRESSURE BUILD UP ENABLE 7.2A [UPPER] 3.0A [OPT.] UCS3 251 - SOL2 CR21 SW13 LIFT GC-1 GC-2 252 - ENABLE - 12V 7.2A 3.0A...
  • Page 37 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC LIFT +12V MODE -12V CR21 LIFT OIL OVERHEAT 300 - OIL OVERHEAT HYD OIL TEMP 0.2A CLOSED WHEN HOT (140 F) 301 - LT10 HYD OIL OVERHEAT 302 - 1.5A OIL OVERHEAT 303 -...
  • Page 38 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TABLES OF VEHICLE CONNECTIONS ISUZU NPR 2008/2013 WITH AUTO TRANSMISSION ( NON ALLISON) CHASSIS INPUT TO VEHICLE OR CONNECTION ISUZU NPR LINE NO. LOCATION I/O TYPE OUTPUT FROM VEHICLE WIRE NO. AT IGNITION SWITCH IGNITION INTERRUPT &...
  • Page 39 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC OPTIONS OPTION FOR GAS ENGINE THROTTLE RAMP UP W/ TIME DELAY 103 - InPower Throttle IGNITION SWITCH CC1-B ENGINE CANH 104 - CONTROL MODULE ETM-68A CR10 DLC Cable CANL 105 - HI THROTTLE RPM1...
  • Page 40 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC TABLE OF CONTENTS CHAPTER 3: OVERHAUL Page Section 1: Overhaul Procedure GENERAL INFORMATION ............1...
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  • Page 42 ML50-20 MAINTENANCE LIFT TESCO EQUIPMENT LLC CHAPTER 3: OVERHAUL Section 1: Overhaul Procedure GENERAL INFORMATION If an overhaul of a component is needed (or required), refer to Chapter 5, Manufacturer’s Data for pertinent information. The section that covers the component should be read in full and understood completely before attempting an overhaul.
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