Hy-Brid Lifts SERIES II Maintenance & Troubleshooting Manual
Self-propelled aerial work platform
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Also See for SERIES II:
- Operation & safety manual (28 pages) ,
- Operation & safety manual (32 pages) ,
- Operation & safety manual (32 pages)
Related Manuals for Hy-Brid Lifts SERIES II
Summary of Contents for Hy-Brid Lifts SERIES II
- Page 1 BY CU STO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING MANUAL SUPO-694 REV G SELF-PROPELLED AERIAL WORK PLATFORM HB-1030 HB-1430 SERIES II...
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Page 2: Notes
NOTES If there is a question about application and/or operation, contact: Custom Equipment, LLC 2647 Hwy 175 Richfield, WI 53076 U.S.A. P: +1-262-644-1300 F: +1-262-644-1320 www.hybridlifts.com BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G... -
Page 3: Foreword
Original instructions written in English The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made to service this machine. -
Page 4: Table Of Contents
TABLE OF CONTENTS NOTES ......................................2 FOREWORD ....................................3 TABLE OF CONTENTS ................................4 INDEX OF FIGURES ..................................5 SECTION 1 | SAFETY .................................. 6 1.1 | SAFETY SYMBOLS ..................................6 1.2 | GENERAL RULES AND PRECAUTIONS ........................... 6 1.3 | SAFETY GUIDELINES ..................................7 SECTION 2 | MAINTENANCE .............................. -
Page 5: Index Of Figures
INDEX OF FIGURES FIGURE 1: Maintenance Lock Pin use ..............................7 FIGURE 2: Maintenance Lock Pin storage location ......................... 7 FIGURE 3: Battery Maintenance ................................8 FIGURE 4: Lester Prime Battery Charge Indicator Location ....................... 10 FIGURE 5: Lester SLM Battery charge Indicator Location ......................12 FIGURE 6: Signet Battery Charge Indicator Location ........................ -
Page 6: Section 1 | Safety
SECTION 1 | SAFETY 1.1 | SAFETY SYMBOLS DANGER “DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. FAILURE TO FOLLOW THIS WARNING WILL CAUSE DEATH OR PERSONAL INJURY. WARNING “WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. -
Page 7: Safety Guidelines
SECTION 1 | SAFETY 1.3 | SAFETY GUIDELINES Maintenance Lock The maintenance lock must be placed into position whenever the machine is being serviced in the raised or partially raised position. Serious injury and/or death could result if maintenance lock is not used properly. FIGURE 1: Maintenance Lock Pin use FIGURE 2: Maintenance Lock Pin storage location WARNING... -
Page 8: Section 2 | Maintenance
SECTION 2 | MAINTENANCE 2.1 | BATTERY MAINTENANCE This unit is equipped with deep cycle 12-volt batteries. The care and maintenance of your battery has much to do with how well this unit functions. Battery wiring and water level should be checked monthly. Disconnect battery (either using master power switch or remove battery lead) and make sure the charger is not plugged in before opening caps. - Page 9 SECTION 2 | MAINTENANCE WARNING LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING. To Charge: • Park the machine on a level surface. • Plug charger into AC outlet until charged. •...
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Page 10: Figure 4: Lester Prime Battery Charge Indicator Location
SECTION 2 | MAINTENANCE Battery Charge Indicators: Lester Prime (Charge Status indicated with Amber or Green light; Errors indicated with Red light) FIGURE 4: Lester Prime Battery Charge Indicator Location AMBER (Charge Status) GREEN (Charge Complete) DESCRIPTION (OFF) Bulk/Start charge cycle phase (constant power or constant current) (SLOW) Absorption/Plateau charge cycle phase (constant voltage). - Page 11 SECTION 2 | MAINTENANCE GREEN AMBER DESCRIPTION AC voltage low fault (OFF) (OFF) (SLOW) (Slow blink RED) Over Temperature fault (SLOW) (SLOW) (OFF) (Alternate between slow blink RED and slow blink Charger GREEN) Charger issue (not outputting current, relay didn’t pull in, EEprom error, internal supplies out of range, (SLOW) (OFF)
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Page 12: Figure 5: Lester Slm Battery Charge Indicator Location
SECTION 2 | MAINTENANCE Battery Charge Indicators: Lester SLM (Charge Status indicated with Green light; Errors indicated with Red light) FIGURE 5: Lester SLM Battery charge Indicator Location GREEN AMBER DESCRIPTION Charger is o and disconnected from live AC voltage (OFF) (OFF) (OFF) -
Page 13: Figure 6: Signet Battery Charge Indicator Location
SECTION 2 | MAINTENANCE Battery Charge Indicators: Signet FIGURE 6: Signet Battery Charge Indicator Location CHARGING STATE 100% 0-50% Charged Blinking 50-75% Charged Blinking 75-100% Charged Blinking 100% Charged Charge-Flooded Batteries Charge-Sealed Batteries Abnormal Cycle Blinking BY CUSTOM EQUIPMENT LLC MAINTENANCE &... -
Page 14: Figure 7: Pcs/Dual Pro Battery Charge Indicator Location
SECTION 2 | MAINTENANCE Battery Charge Indicators: PCS/Dual Pro The charger will not begin charging on severely discharged batteries. This will be evident by the three indicators blinking simultaneously. FIGURE 7: PCS/Dual Pro Battery Charge Indicator Location Battery 1 Status Battery 2 Status This display indicates that the power is on but there is no... -
Page 15: Lubrication
SECTION 2 | MAINTENANCE 2.3 | LUBRICATION Item Specification Frequency of Lubrication Front Wheels Teflon Spray Quarterly 2.4 | COMPONENTS REQUIRING ADJUSTMENT Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are required. 2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS With proper use, battery maintenance, and regular inspection, there are no limited life components that require routine replacement. -
Page 16: Section 3 | Maintenance Checklists
SECTION 3 | MAINTENANCE CHECKLISTS CAUTION FAILURE TO PERFORM INSPECTIONS AND PREVENTATIVE MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR. Regular inspection and conscientious maintenance is important to efficient economical operation of this machine. It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. - Page 17 THIS PAGE WAS INTENTIONALLY LEFT BLANK BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G...
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Page 18: Pre-Start Inspection Checklist
SECTION 3 | MAINTENANCE CHECKLISTS 3.1 | PRE-START INSPECTION CHECKLIST Pre-start Inspection (Self-Propelled Models) THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR CAUTION AFTER EVERY SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR. -
Page 19: Pre-Delivery/Frequent/Annual Inspection Checklist
SECTION 3 | MAINTENANCE CHECKLISTS 3.2 | PRE-DELIVERY/FREQUENT/ANNUAL INSPECTION CHECKLIST AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED, AND ADJUSTED TO CAUTION MANUFACTURER’S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST, AND ANNUALLY. -
Page 20: Section 4 | Technical References
SECTION 4 | TECHNICAL REFERENCES 4.1 | HYDRAULIC SCHEMATIC 0.5-10.0 GPM THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATIO BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G... - Page 21 SECTION 4 | TECHNICAL REFERENCES DESCRIPTION OF CHANGE ECO # DATE REV BY 3.50 GPM ORIGINALLY DRAWN BY: DJS DATE:05/27/2015 Richfield, WI 53076 Custom Equipment, Inc. Phone: (262)644-1300 HYDR SCH,HBLG SPEC/MATL: Schematic WEIGHT: APPROX. 0.00 LB. DRAWING #: HS-HB SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 2...
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Page 22: Electrical Schematic
SECTION 4 | TECHNICAL REFERENCES 4.2 | ELECTRICAL SCHEMATIC E-STOP E-STOP LWR CTL UPR CTL SWITCH UP/DOWN LWR CTL DRIVE ENABLE ELEV. ENABLE MODE/PH TILT GND ELEV/TILT SENSOR ADDL CHR CONNECTIONS, IF SO EQUIPPED THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION TH BY CUSTOM EQUIPMENT LLC MAINTENANCE &... - Page 23 SECTION 4 | TECHNICAL REFERENCES UP/DOWN UPR CTL MODE INPUT : M1 OPEN (SLOW) M2 CLOSED (FAST) MOTOR CONTROLLER BRAKE SWITCH BRAKE SWITCH (PUMP SIDE) (CTL SIDE) 23 28 4 OHM STR LS-R STR LS-L 87A 87 87A 87 ACTUATOR ( ALL-MOTION ALARM, IF SO EQUIPPED) DATE REV BY...
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Page 24: Led Drive Board Diagnostics-Blue Controller
SECTION 4 | TECHNICAL REFERENCES 4.3 | LED DRIVE BOARD DIAGNOSTICS-BLUE CONTROLLER NOTE: If LED Diagnostics light flashes rapidly for 10 seconds when joystick enable switch is squeezed, before reading error code, use this table. Programmer Display LED Code Explanation Possible Cause Temperature >92º... -
Page 25: Led Drive Board Diagnostics-Black Controller
SECTION 4 | TECHNICAL REFERENCES 4.4 | LED DRIVE BOARD DIAGNOSTICS-BLACK CONTROLLER NOTE: If no rapid flash is displayed and codes are immediately displayed, use this table. Programmer Display LED Code Explanation Possible Cause Temperature >92º C or <-25ºC. Over-/under-temp. Excessive load on vehicle. -
Page 26: Section 5 | Wiring Diagrams
SECTION 5 | WIRING DIAGRAMS 5.1 | WIRING DIAGRAM Part No. WD-112-20-216-50 1002101798 ELEC-641A PUMP DOWN UPR CTL WD-112-21-204-50 RESERVOIR HYD PUMP M ACTUATOR LWR CTL SEE WD-112-21-205-50 RIGHT TURN LEFT TURN LIMIT SWITCH LIMIT SWITCH TILT SENSOR ADDITIONAL CHARGER CONNECTIONS, IF SO EQUIP BATTERY 18 19... - Page 27 SECTION 5 | WIRING DIAGRAMS TB#29-PSS (BLK) TB#27-PSB (YEL) BOARD M1-PSM (VIOLET) DRIVE BOARD M2-PSM (BLUE) ELEC-641C TB#28-PSB (YEL) GND ELEV/TILT BRAKE TB#30-PSS (BLK) LIMIT SWITCH MICROSWITCH MICROSWITCH TB#26-CSS (BLK) BRAKE TB#23-CSB (YEL) MODE/PH LIMIT SWITCH BOARD M1-CSM (GREY) BOARD M2-CSM (YEL) DRIVE TB#24-CSB (YEL) ELEC-641A...
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Page 28: Lower Controls Wiring Diagram
SECTION 5 | WIRING DIAGRAMS 5.2 | LOWER CONTROLS WIRING DIAGRAM Part No. 112-21-205-50 A: MOTOR CTL CONNECTOR E-STOP DESCENT/MOTION SUB A8-102 TILT GND ELEV/TILT LIMIT SWITCH (Located Under Scissors) SUB A8-106 SUB A8-107 2120 1918 1615141312 MODE/PH (ALL-MOTION ALARM, IF SO EQUIPPED) LIMIT SWITCH (ALL-MOTION ALARM, IF SO EQUIPPED) (Located In Base) - Page 29 SECTION 5 | WIRING DIAGRAMS C: TILT SENSOR CONNECTOR SUB A8-108 (BEACON LIGHT, IF SO EQUIPPED) LIGHT KEY SWITCH Down Coil Coil 112-21-225-50 Pump Sol. Coil TO ACTUATOR SUB A8-104 RIGHT STEER LIMIT SWITCH 2 1110 LEFT STEER LIMIT SWITCH DATE REV BY DESCRIPTION OF CHANGE...
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Page 30: Upper Controls Wiring Diagram
SECTION 5 | WIRING DIAGRAMS 5.3 | UPPER CONTROLS WIRING DIAGRAM Part No. WD-112-21-204-50 RIGHT LEFT F: JOY ENABLE THROTTLE THROTTLE DOWN D: MAIN CONNECTION THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND IS LOANED IN EXPEC BY CUSTOM EQUIPMENT LLC MAINTENANCE &... - Page 31 SECTION 5 | WIRING DIAGRAMS YSTICK CONNECTION LIFT ENABLE DRIVE ENABLE DATE REV BY DESCRIPTION OF CHANGE ECO # INITIAL RELEASE 2015-2583 11/09/2015 ORIGINALLY DRAWN BY: DATE: Richfield, WI 53076 Custom Equipment, Inc. Phone: (262)644-1300 9 8 7 WD,UPR CTL HBLG SPEC/MATL: Wiring Diagram WEIGHT: APPROX.
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Page 32: Section 6 | Trouble Shooting Flowcharts
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS 6.1 | MAIN POWER/SAFETY CIRCUIT BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G... - Page 33 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G...
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Page 34: Drive Circuit
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS 6.2 | DRIVE CIRCUIT Does the machine Is either of two brake drive? Is there a trouble Is either or two brakes switches damaged or Is drive unit dam (Elevate, Lower, and code displayed? manually released? disconnected? Steer OK) - Page 35 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS Are all connections to Is there moisture or maged? drive control board corrosion in any Replace drive control board secure? connections? Still no drive? Allow to dry for 24 hours and try again. Reconnect unit Board probably will need replacement.
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Page 36: Steer Circuit
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS 6.3 | STEER CIRCUIT Check for power connection. Does machine steer ? No; Drive, elevate and See Hy-Brid Troubleshooting. (drive, elevate, lower OK) lower not operating (Power connections at pump, fuse, etc.) No; Steering Not operating properly Verify joystick... - Page 37 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS Contact CEI for further troubleshooting Replace limit switch and/or readjust. R1 Failure. Replace Relay. R2, R3, or R4 failure. Listen for clicks, try switching relays around. Replace relay(s). Replace actuator Hy-Brid Troubleshooting Flowchart Steer Problems Revision A: Initial Release 01/14/2010 BY CUSTOM EQUIPMENT LLC...
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Page 38: Elevate Circuit
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS 6.4 | ELEVATE CIRCUIT Does machine raise/ Is emergency down Does pump operate? Is hydraulic fluid low lower? valve open? With platform lowered Check for power connection. See Hy-Brid Close emergency down pump reservoir to 1" be Troubleshooting valve top of reservoir... - Page 39 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS Is down valve stuck Is enable button Is up/down switch Contact CEI for further open? working? damaged? troubleshooting. d, fill Flush valve by simultaneously Replace enable button/ Replace rocker switch at elow pressing up switch at base and down contact block at upper upper or lower control.
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Page 40: Lower Circuit
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS 6.5 | LOWER CIRCUIT Check for Is enable Does machine raise/ obstructions Check for power connection. button lower? between any See Hy-Brid troubleshooting. working? scissors beams. Yes, but not Replace enable button/ properly contact block at upper control. - Page 41 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS Check power solenoid. See Contact CEI for further Elevating Problems. troubleshooting. n obstruction in Is there an obstruction in down aulic hose? valve? hydraulic hose. Flush valve by simultaneously pressing up switch at base and down switch on platform control for 30 sec.
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Page 42: Section 7 | Parts
CONTROL BOARD (ELEC-903), AND ALL STRUCTURAL COMPONENTS. Refer to the Hy-Brid Lifts Operation and Safety Manual for decal part numbers and locations. In addition to the decals listed in the Operation and Safety Manual, a partial list of replacement parts . These represent current model revisions. - Page 43 SECTION 7 | PARTS Description Part Number Notes DECALS,HB-1030,KIT 112-21-218-50-K DECALS,HB-1430,KIT 112-21-218-55-K DRIVE MOTOR BRAKE L,HB,DUM ELEC-627-5L DRIVE MOTOR BRAKE R,HB,DUM ELEC-627-5R DRIVE MOTOR,24V ELE,HB,DUM ELEC-626-4L-KIT YELLOW & GREY LEADS DRIVE MOTOR,24V ELE,HB,DUM ELEC-626-4R-KIT BLUE & VIOLET LEADS EMERGENCY STOP BUTTON ELEC-071-KIT Not available as a replacement part.
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Page 44: Section 8 | Warranty
SECTION 8 | WARRANTY LIMITED WARRANTY Warranty Statement—North America Only LIMITED WARRANTIES Subject to the terms, conditions and limitations set forth herein, Custom Equipment, LLC (the “Company”) warrants to the first end-user (“Buyer”) that: Limited Product Warranty For a period of 12 months from the date that a new product manufactured by the Company (“Product”) is delivered to the Buyer, the Product will (i) conform to the specifications published by the Company for such Product as of the date of delivery;... - Page 45 SECTION 8 | WARRANTY EXCLUSIVE WARRANTY REMEDIES Exclusive Repair or Replace Remedy The Company’s sole obligation and Buyer’s exclusive remedy with respect to any defect in the Product occurring during the warranty periods set forth in Section 1 of this Limited Warranty shall be for the Company, at its option, to repair or replace (or have one of its designated authorized dealers repair or replace) the Product or part, component or assembly thereof that contains a defect in materials or workmanship.
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Page 46: Section 9 | Inspection And Repair Log
SECTION 9 | INSPECTION AND REPAIR LOG Date Comments BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G... - Page 47 SECTION 9 | INSPECTION AND REPAIR LOG Date Comments BY CUSTOM EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-694 HB-1030/HB-1430 REV G...
- Page 48 © 2018 Custom Equipment, LLC 2647 Highway 175 Richfield, WI 53076 U.S.A. Tel. +1-262-644-1300 Fax. +1-262-644-1320 www.hybridlifts.com service@customequipmentlifts.com “Hy-Brid Lifts” is a trademark of Custom Equipment, LLC. These machines comply with ANSI/SIA A92.6 Revision Date: January 2018 Printed in the U.S.A.
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Questions and answers
Trying find out why my lift goes up by itself
The Hy-Brid Lifts SERIES II lift should not go up by itself under normal operation. To raise the platform, the Lift/Lower Enable Button must be pressed while also holding the Up Button. If the lift is elevating unintentionally, it may be due to a malfunction in the control system, such as a stuck button or electrical issue. Inspect the controls and ensure no buttons are engaged unintentionally.
This answer is automatically generated
Seems system is lockked