Custom Equipment Hy-Brid Lifts 2 Series Programming manual

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Table of Contents
Safety ............................................................................................................................................................ 5
Safety Symbols .......................................................................................................................................... 5
General Rules and Precautions ................................................................................................................. 5
Stability Testing......................................................................................................................................... 6
Safety Guidelines ...................................................................................................................................... 7
Maintenance Lock..................................................................................................................................... 7
Maintenance ................................................................................................................................................. 7
Battery Maintenance ................................................................................................................................ 8
Charging the Battery ................................................................................................................................. 8
Lubrication ................................................................................................................................................ 9
Components requiring adjustment........................................................................................................... 9
Examination, repair, replacement of limited life components................................................................. 9
Safety devices and systems requiring checks ......................................................................................... 10
Storage .................................................................................................................................................... 10
Major Alterations or Repairs................................................................................................................... 10
Inspection and Regular Maintenance Checklists ........................................................................................ 10
Monthly Battery Care.............................................................................................................................. 10
Prestart Inspection Checklist .................................................................................................................. 11
Frequent Inspection Checklist.................................................................................................................12
Pre-Delivery/Annual Inspection Checklist............................................................................................... 13
Technical References .................................................................................................................................. 15
Hydraulic Schematic................................................................................................................................ 15
Electrical Schematic ................................................................................................................................ 16
Wiring Diagrams.......................................................................................................................................... 18
Lower Control Wiring Diagram ............................................................................................................... 18
Upper Control Wiring Diagram ............................................................................................................... 20
Troubleshooting.......................................................................................................................................... 22
Troubleshooting Flowchart..................................................................................................................... 22
Troubleshooting Flowchart-Elevate Circuit ............................................................................................ 24
Troubleshooting Flowchart-Lower Circuit .............................................................................................. 26
Replacement Parts ...................................................................................................................................... 28
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SafetyandControlDecals.......................................................................................................................28
MainPower/SafetyCircuit......................................................................................................................29
Elevate/LowerCircuitParts.....................................................................................................................30
Wheels/Brakes........................................................................................................................................31
Other.......................................................................................................................................................32
Warranty.................................................................................................................................................33

RevisionTable:
RevisionA(12/17/2012):InitialRelease
RevisionB(3/11/13):Revisedp.3,29,30
RevisionC(6/6/13):Revisedp.3,31


Part# SUPO-633E
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Original instructions are written in English
Foreword
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.
The operation and safety manual is considered a part of the work platform and contains
instructions and operating procedures essential to properly and safely operate the Custom
Equipment Hy-Brid Lift. Users must read and understand all information in the Safety and
Operations Manual before operation.
DANGER
THE OPERATION AND SAFETY MANUAL
MUST BE READ AND UNDERSTOOD
PRIOR TO OPERATING THE MACHINE.
THE USER/OPERATOR SHOULD NOT ACCEPT OPERATING RESPONSIBILITY UNTIL THE
MANUAL HAS BEEN READ AND UNDERSTOOD AS WELL AS HAVING OPERATED THE
LIFT UNDER SUPERVISION OF AN EXPERIENCED AND QUALIFIED OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE
APPLICATION AND OPERATION, PROPER SAFETY PRACTICES ARE THE
RESPONSIBILITY OF THE USER AND ALL OPERATING PERSONNEL.
WARNING
ANY MODIFICATION ON THIS MACHINE WITHOUT THE
EXPRESS WRITTEN CONSENT OF THE
MANUFACTURER IS PROHIBITED.
If there is a question on application and/or operation, contact:
Custom Equipment, Inc.
2647 Hwy 175
Richfield, WI 53076
USA
Phone: [phone]
Fax: [phone]
www.hybridlifts.com
For additional reference and troubleshooting information, please see www.hybridlifts.com.
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Safety
Safety Symbols
DANGER
FAILURE TO FOLLOW THIS WARNING
WILL CAUSE DEATH OR PERSONAL INJURY.
"DANGER" indicates an imminently hazardous
situation, which, if not avoided,
will
result in
death o
r serious injury.
WARNING
FAILURE TO FOLLOW THIS WARNING MAY
CAUSE DEATH OR PERSONAL INJURY.
"WARNING" indicates a potentially hazardous
situation, which, if not avoided,
could
result in
death or serious injury
CAUTION
FAILURE TO FOLLOW THIS WARNING
MAY CAUSE INJURY OR DAMAGE EQUIPMENT
"CAUTION" indicates a potentially hazardous
situation which, if not avoided,
could
result in
minor or moderate injury or damage to
equipment
General Rules and Precautions
Custom Equipment, Inc. designed the Hy-Brid Lift push-around scissor lift to be safe and reliable. It is
intended for elevating personnel, along with their necessary tools and materials to overhead work
locations.
Vibration does not create significant hazards on this machine.
An operator of any type of work platform is subject to certain hazards that cannot be protected by
mechanical means. It is therefore essential that operators be competent, careful, physically and
mentally fit and thoroughly trained in safe operation of this machine.
Although Custom Equipment, Inc. conforms to specified EN: 280 requirements, it is the responsibility
of the owner to instruct operators with the safety requirements made not only by Custom Equipment,
Inc., but by the various safety boards in your area, as well as additional requirements set forth by EN:
280 If you come across a situation that you think might be unsafe, stop the platform and request
further information from qualified sources before proceeding.
WARNING
MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY
WARNING
NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS
MAINTENANCE PINS ARE IN PLACE.
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Stability Testing
The HB-P830CE has been stability tested to standards EN280 or AS 14180. The most adverse stability
test is the stationary, lateral slope configuration for both units. The overturning moment created by the
test loads and forces is equivalent to a test on an unloaded machine on a level surface, as shown in the
figure below. For the HB-P830, the test weight/pull force is 22.8 kg /50 lb.
Figure 1: Stability Testing, Equivalent
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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 2: Maintenance Lock Pin Use
Figure 3: Maintenance Lock Pin Storage
Maintenance
WARNING
FAILURE TO COMPLY WIT
H THE LISTED SAFETY PRECAUTIONS MAY
RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH.
xNever work under an elevated platform until maintenance locks have been engaged.
xRemove all rings, watches, and jewelry when performing any maintenance.
xDo not wear long hair unrestrained or loose fitting clothing and neckties which may
become caught on or entangled in equipment.
xObserve and obey all warnings and cautions on machine and in manual.
xKeep oil, grease, water, etc. wiped from standing surfaces and handholds.
xBefore making any adjustments, lubricating or performing any other maintenance, shut
off all power controls.
xBattery should always be disconnected during replacement of electrical components.
xKeep all support equipment and attachments stowed in their proper place.
xUse only approved nonflammable cleaning solvents.
xAfter maintenance, inspect the machine as described for Pre-delivery.
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Battery Maintenance
This unit is equipped with a deep cycle 12-volt Group 27 battery. 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. Do
not overfill. When the cells are too full, fluid will seep out when charging. The solution is at its proper strength
when the battery is manufactured. Use distilled water and keep fluid up to proper level. When required, water
should be added to battery after charging, unless water level is below the plates.
Figure 4: Battery Maintenance
xSlide cabinet open to access battery.
xRemove battery caps and check fluid level.
xFill each cell (if needed) to split ring with
distilled water.
xReinstall caps.
xWash all dirt, debris, acid, etc., off battery
whenever corrosion is detected. Use a
solution of 5-tsp. baking soda per quart of
warm water.
xCoat terminals with a commercially
available coating.
xClose cabinet and latch in place.
CAUTION
NEVER ADD ACID TO BATTERY!
Charging the Battery
This unit is equipped with a deep cycle 12-volt battery. 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. Do not overfill.
When the cells are too full, fluid will seep out when charging.
Note: The surrounding temperature greatly affects the power reserve within a battery.
Example: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C) At 0°F (-18°C), this battery
will drop to 40% efficiency.
WARNING
LEAD-
ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND
FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
xPark the machine on a level surface.
xPlug charger into AC outlet until charged. (Indicated by solid lights)
xFor best battery life, leave charger plugged in until machine will be used again. The charger will maintain the
battery charge.
The charger will not begin charging on severely discharged batteries.
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Figure 5: Battery Charger LED Display
WARNING
DO NOT OPERATE UNIT WHILE CHARGING.
The solution is at its proper strength when the battery is manufactured. Use distilled water and keep fluid up to
proper level. When required, water should be added to battery after charging, unless water level is below the
plates.
Lubrication
Item
Specification
Frequency of Lubrication
Wheels
Teflon Spray
Quarterly
Components requiring adjustment
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are required.
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.
CAUTION
NEVER ADD ACID TO BATTERY!
This display indicates that power is on but there is no
connection to a battery. The charger must see
approximately 5 volts on a battery in order to deliver
d/c current.
This display indicates that power is on and that the
output is delivering d/c current to the batteries.
This display indicates that power is on and
that the output is finished charging and is in a
float maintenance mode.
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Storage
After periods of storage, exposure to extremes of ambient conditions-heat, cold, moisture, dust etc. inspect the machine.
Refer to the Pre-Delivery/ Frequent Inspection Checklist in the Maintenance Manual.
Major Alterations or Repairs
Any alterations must be approved by the manufacturer. Major repairs, which affect the stability, strength, or performance
of the machine must also be approved by the manufacturer, recorded, and include machine inspection and testing. Never
attach pipe racks, material lifting devices, or make any other alteration that is not part of the intended design of the
machine.
Inspection and Regular Maintenance Checklists
CAUTION
FAILURE TO PERFORM INSPECTIONS AND PREVENTITIVE 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. Make checks at the stated
intervals or more frequently if required by local operating conditions. The following inspection checklists are required and
included in this manual:
Pre-Start (Required before operation at each work shift)
Monthly Battery Maintenance
Frequent (Required at intervals not more than three months)
Pre-Delivery/Annual (Required at intervals not more than twelve months)
The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20h per week, 5 load cycles
per h).
Monthly Battery Care
WARNING
THIS CHECKLIST MUST BE USED AT MONTHLY OR AFTER EVERY 100 HOURS OF USE. FAILURE TO
DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.
MODEL NUMBER _____________ SERIAL NUMBER ______________
1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.
Y-Yes/Acceptable N-No/Unacceptable R-Repaired
Description
Y
N
R
1. Remove battery cabinet cover.
2. Remove battery caps and check fluid level.
3. Fill each cell (if needed) to split ring with distilled water.
4. Reinstall caps.
5. Wash all dirt, debris, acid, etc., off battery whenever corrosion is detected. Use a solution
of
5-tsp. baking soda per quart of warm water.
6. Coat terminals with a commercially available coating.
DATE _______________ INSPECTED BY ____________________________
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Prestart Inspection Checklist
WARNING
THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR AFTER EVERY SIX TO EIGHT HOURS OF USE.
FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.
MODEL HB-P830CE SERIAL NUMBER ______________
1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
3. A dirty machine cannot be properly inspected.
Y-Yes/Acceptable N-No/Unacceptable R-Repaired
Description
Y
N
R
Visual Inspections
Check that there are no damaged, dented, or bent structural members.
There are no loose or missing parts.
Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly
marked.
Check the platform rails and safety gate for damage.
Platform and base controls are not missing, damaged, or disconnected.
Electrical cables and wires are not torn, frayed, or disconnected.
Hydraulic hoses are not torn or loose, and there are no leaks. Check that hoses and the cables have no
worn areas or chafing.
Check the hydraulic fluid level with the platform fully lowered.
Check the tires for damage.
Check that all snap rings are secure in grooves on pivot pins.
Functional Tests
Gate closes automatically and latches.
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement)
Up/Down Controls (Elevates, Lowers, Enable button must be pressed)
Base Controls: Check all switches and push buttons for proper operation.
Emergency
Stop (Stops all movement)
Key Switch (Selects Platform Control, Ground Control, or Off)
Up/Down Rocker Switch (Elevates, Lowers)
Alarm (Not damaged, sounds for descent, overload)
LED (Flashes when overloaded)
Wheels: Front and rear wheels rotate freely.
Brakes engage and hold when platform elevated.
Platform does not elevate when overloaded.
When overloaded, platform stops elevating when at a height between 81cm and 94 cm from the
ground.
DATE _______________ INSPECTED BY ____________________________
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Frequent Inspection Checklist
WARNING
AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED AND ADJUSTED TO MANUFACTURER'S
REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY
3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST.
MODEL NUMBER HB-P830CE SERIAL NUMBER ______________
xCheck each item listed below.
xUse proper operating, service, and maintenance manual for specific information and settings
xIf an item is found to be unacceptable make the necessary repairs and check the “repaired” box.
xWhen all items are “acceptable”, the unit is ready for service.
Description
Y
N
R
Visual Inspections
Perform all checks on the Pre-Start Inspection Checklist.
Inspect the condition of hydraulic fluid in reservoir. Oil should have a clear amber color.
Inspect the entire machine for signs of damage, broken welds, loose bolts, or improper repairs. (Check
for corrosion, cracking, abrasion, etc.)
Check that all snap rings are secure in grooves on pivot pins.
Check if tires are leaning in or out.
Verify that bubble level is in place.
Verify that maintenance and inspection records are up to date.
Functional Tests
Perform all checks on the Pre-Start Inspection Checklist.
Functions operate smoothly.
Functions operate over full range of motion.
Emergency Lowering—Manual override functions properly.
Ground Controls override platform controls.
Check that the platform does not drift down with a full load.
Wheels lubricated if needed.
Comments:
DATE _______________ INSPECTED BY _______________________________
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Pre-Delivery/Annual Inspection Checklist
WARNING
AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED AND ADJUSTED TO MANUFACTURER'S REQUIREMENTS BY A QUALIFIED
MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 12 MONTHS.
MODEL NUMBER: HB-P830CE SERIAL NUMBER ______________
xCheck each item listed below.
xUse proper operating, service, and maintenance manual for specific information and settings
xIf an item is found to be unacceptable make the necessary repairs and check the “repaired” box.
xWhen all items are “acceptable”, the unit is ready for service.
Check
Y
N
R
Check
Y
N
R
Base:
Inspect slide tracks for damage
Decals:
All frame bolts tight
Legibility
Pump Secure
Correct capacity noted
DC motor secure
Proper placement quantity
Battery Hold Downs Secure
Wiring:
Batteries Fully Charged
Switches secure
Counterweights secured
Contactor(s) secure
Wheels: Grease Casters
Tight on terminals (No loose wiring)
Wheels: Bolts/Nuts Tight
Functions:
Maintenance Locks: Pins in storage location
Elevate/Lower Operational
All Shields/Guards in place
Emergency Stop Breaks Circuits
Hydraulic Oil Level 1” from top
Emergency Down Operational
Check all hydraulic hoses for leaks
Motion Alarms Functional
Check all hydraulic fittings for leaks
Brakes: Operational
Scissors:
Bubble Level in Place
Broken Welds
When overloaded, platform stops elevating
when at a height 81
- 94 cm from ground
Bent Beam Members
All rollers Turn Freely
Ret. Rings Secure On Pivots
Battery Charger Secure/Operational
Broken welds
Platform:
All rails in place/secure
No bent rails
No broken welds
Platform power outlet safe/working (if installed)
Entrance gate Closes Freely
Operator/Service Manual Included
Cables in place/secure
Comments:
DATE _______________ INSPECTED BY _______________________________
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Does the machine
function:
(Elevate/Lower)
Is the battery connected? Is the battery filled with
water and fully charged?
Is short protection
fuse at pump blown?
Contact Hy-Brid Lifts with questions
about a different problem
Yes
Is the battery charger
plugged in?
No
Yes Yes
No No
Yes
Yes
Connect
battery.
Is the master
power switch off?
No No
Turn master
power switch on.
No
Replace with 20 Amp
AGC Fuse.
WARNING
Any modification on this machine without
the express consent of the manufacturer
is prohibited.
See Wiring
Diagram
WD-HB-P830CE See SD-Battery-01
See also Main Power & Safety Circuit
Wiring Diagram: WD-HB-P830CE Power
Or
Schematic: WS-HB-P830CE-Power
Unplug the charger.
Machine should not be
operated while battery is
charging.
Reference Revision B
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Is key switch
turned on in the desired
selection?
(may select upper controls or
lower controls)
No
Is either E-Stop Button
depressed/activated:
Yes
Yes
Reference Revision B
Are all power
supply connections and
switches functioning
properly?
Visually inspect wire
harness from lower
controls to upper.
Is there damage?
Turn key switch on
Reset E-Stop
buttons. Pull out
at both upper
control and lower
control locations.
See
Elevating
Problems
Flowchart
See
Lowering
Problems
Flowchart
No
Yes
Repair or
Replace
identified
problem.
No
Is machine in the
elevated or lowered
position?
Yes
Machine is Down
Machine is Up
Troubleshooting Flowcharts--General Notes:
Inspect parts for visible damage as they are encountered.
After each step, check if problem has been indentified and/or resolved.
If so, make the recommended fix or see a referenced document.
If not, continue troubleshooting.
If a part has been identified as needing replacement, see the Parts View
to identify part number to order.
If any wiring or components have been altered from the original
manufacture, problems may not be identifiable.
WARNING
Failure to comply with safety precautions
may result in damage, injury, or death.
Refer to Maintenance Manual for
complete warnings
No
Replace
wire harness
or repair
wire
Check wiring connections
to identify a power supply
problem.
See
Electrical Schematic
WS-HB-P830CE
Or Pictorial Schematic
WSP-P830CE
And Instruction
Circuit Check-HB-
P830CE-Power
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Does machine elevate? Does the
pump run?
Not At All
Ascent speed
slow or erratic?
Is the
emergency down
valve open?
Yes
No
Is battery fully
charged?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is there a restriction in
hydraulic hose?
Yes, but
not properly
Starts ascending,
then stops?
Is platform
overloaded?
Yes
Can you see
anything obstructing
the components?
Are power connections
to elevate circuit and
switches functioning
properly?
Remove
obstruction
Yes
No
Goes up, but
comes down
Replace or
repair identified
problem. See
Parts List.
No
Y
e
Close
emergency
down valve
Yes
Yes
Remove overload. Lower to
stowed position before
continuing use.
Yes
No
No
Yes
Yes
See also
Wiring Diagram WD-HB-P830CE Elevating
or Schematic: WS-HB-P830CE-Elevating
And
Hydraulic Schematic HS-HB-P830CE Or
Pictorial Hydraulic Circuit HSP-HB-P830CE
No
Check wiring
connections in elevate
components.
See Electrical
Schematic
WS-HB-P830CE
Or
Pictorial Schematic
WSP-HB-P830CE
And instruction
Circuit Check-HB-
P830CE-Elevate
Yes
WARNING: Set up for maintenance safety:
Remove load from platform.
Check for overhead obstructions.
Platform movement may occur.
Never Reach between scissors links or prop up
platform unless maintenance pins are in place.
No
No
Is armguard
limit switch
damaged?
See Lowering
Problems
Flowchart
No
Yes
No
Replace
limit
switch.
Replace
hydraulic
hose.
Charge battery.
See SD-Battery-01
Yes
Reference Revision C
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Is hydraulic
fluid low?
Yes
Contact
Hy-Brid Lifts
Is up/down
switch
damaged?
Is Overload
Enable
Limit Switch
damaged?
No
Yes
Replace damaged
rocker switch at
upper or lower
control.
Replace
OL Enable
LS
Yes
Time and parts
available?
Yes Replace Pump
Assembly
Does pump operate?
Try replacing
up valve
No
Is there a different problem
(something is leaking, unusually
noisy, etc.)
Replace pump
assembly.
May be worn
or defective.
Troubleshooting Flowcharts--General Notes:
Inspect parts for visible damage as they are encountered.
After each step, check if problem has been indentified and/or resolved.
If so, make the recommended fix or see a referenced document.
If not, continue troubleshooting.
If a part has been identified as needing replacement, see the Parts View
To identify part number to order.
If any wiring or components have been altered from the original
manufacture, problems may not be identifiable.
WARNING
Any modification on this machine without
the express consent of the manufacturer
is prohibited.
WARNING
Failure to comply with safety precautions
may result in damage, injury, or death.
Refer to Maintenance Manual for
complete warnings
Check wiring connections
in elevate components.
See Electrical Schematic
WS-HB-P830CE
Or
Pictorial Schematic
WSP-HB-P830CE
And instruction
Circuit Check-HB-P830CE-
Elevate
Yes No
No
Level of skill
with hydraulic
maintenance?
Are power
connections to
elevate circuit and
switches functioning
properly?
Replace or
repair
identified
problem.
See Parts
List.
Check Hydraulic Circuit.
(Additional tools and higher
level of skill required) See
Hydraulic Schematic
HS-HB-P830CE
No
No
Flush down valve by
simultaneously pressing
up switch at base and
pulling e-down cable
control for 30 sec.
There may be foreign
matter lodged.
Experienced
with hydraulic
systems
Not experienced
with hydraulics
No
Yes
Yes
With platform
lowered, fill pump
reservoir with at
least 1.8 liters of oil.
Reference Revision C
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Does machine
lower?
Not
at all
Descent speed slow or
erratic?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is there a
restriction in
hydraulic hose?
Yes
Yes Yes
Creeps down? Or
Goes up and Comes
Back Down?
Has key switch
been turned off?
Is an E-Stop
activated?
Is emergency
down valve
open?
Yes
Foreign matter
lodged in up or
down valve?
Down Valve Coil
mounting nut too tight?
Nut should only be lightly
snug: 30 in.-lb.
No
Yes
Starts descending,
then stops?
Are maintenance lock
pins installed?
Yes No
Will Manual
Override lower
the platform?
Turn key to
upper or lower
ON position.
Pull out
emergency
stop button at
upper and
lower controls.
No
No No
Check manual override cable, lever, and fastening points
Yes
See also
Wiring Diagram WD-HB-P830CE Elevating
or Schematic: WS-HB-P830CE-Elevating
And
Hydraulic Schematic HS-HB-P830CE Or
Pictorial Hydraulic Circuit HSP-HB-P830CE
WARNING: Set up for maintenance safety:
Remove load from platform.
Check for overhead obstructions.
Platform movement may occur.
Never Reach between scissors links or prop up
platform unless maintenance pins are in place.
Yes, but
not properly
No
No
WARNING: Double check that
maintenance pins are in place
Yes Yes No
Yes
Does the
armguard Limit
switch appear
damaged?
No
Remove
ML Pins
Yes
Replace
limit switch
at base
Yes
No
Close
emergency
down valve.
Check cable
connections.
Flush down valve by
simultaneously pressing up
switch at base and down
switch on platform control
for 30 sec.
Replace
hydraulic hose
Disassemble and clean.
Look for residue in screen
and on O-ring or damage
to O-ring.
Replace coil
and lightly
tighten nut.
No
Reference Revision A
Part# SUPO-633E
REV C
Page 26 of 34
Does the up/
down switch
appear
damaged?
Is battery
charged?
Faulty down
valve?
Electrical problem?
Disconnect coil.
Check if unit stops drifting.
Check voltage at coil—should be
0 V when not energized.
Damaged cylinder or
damaged seal in cylinder?
Run unit up and then check for
oil flow out of return line. Bad
cylinder seal if oil is flowing
from return line.
Yes
Faulty check valve
in pump?
Listen carefully near motor
when not energized—may be
running backwards
Does the overload
Limit switch
appear damaged?
Level of skill with
hydraulic maintenance?
Not experienced
with hydraulics
Yes
Replace rocker
switch at upper
or lower control.
Replace
limit switch
at base
Yes
Troubleshooting Flowcharts--General Notes:
Inspect parts for visible damage as they are encountered.
After each step, check if problem has been indentified and/or resolved.
If so, make the recommended fix or see a referenced document.
If not, continue troubleshooting.
If a part has been identified as needing replacement, see the Parts View
To identify part number to order.
If any wiring or components have been altered from the original
manufacture, problems may not be identifiable.
WARNING
Any modification on this machine without
the express consent of the manufacturer
is prohibited.
WARNING
Failure to comply with safety precautions
may result in damage, injury, or death.
Refer to Maintenance Manual for
complete warnings
Check wiring connections in lowering
components.
See Electrical SchematicWS-HB-
P830CE Or
Pictorial SchematicWSP-HB-P830CE
And instruction
Circuit Check-HB-P830CE-Elevate
Charge battery.
See SD-Battery-01
Yes
No
No
OK
No
Yes
Level of skill
with hydraulic
maintenance?
Check Hydraulic
Circuit. (Additional
tools required,
higher level of skill
required)
Refer to Hydraulic
Schematic HS-HB-
P830CE
Are power
connections to
lowering circuit and
switches functioning
properly?
Replace or repair
identified problem.
See Parts List.
Contact
Hy-Brid
Lifts
No
Yes
No
No
Experienced with
Hydraulic systems
Experienced
With hydraulic
systems
Not experienced
With hydraulics
Yes or Don’t know
Replace
down valve. Might be able to repair with seal
kit;, probably need to replace
cylinder. If walls inside cylinder
are scratched or pitted, cylinder
needs replacement.
Yes
Replace
pump.
Replac
e down
valve
No No
Reference Revision A
Part# SUPO-633E
REV C
Page 27 of 34

Replacement Parts
CAUTION
USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF NON
-OEM PAR
TS WILL
VOID WARRANTY.
DANGER
REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY
,
OR SAFETY FUNCTION OF THE UNIT:
BATTERY, HYDRAULIC CYLINDER , AND A
LL STRUCTURAL
COMPONENTS.
Listed below are replacement parts that may be available and listed for reference. These represent current
revisions. Refer to our website, www.hybridlifts.com for more complete part listings and earlier revisions.
Several parts are model, serial number, or manufacture date specific. Contact your dealer for replacement part
availability and pricing.
Safety and Control Decals
Refer to Operator’s Manual for decal part numbers and locations
Part# SUPO-633E
REV C
Page 28 of 34
Main Power/Safety Circuit
Item #
Part #
Description
1
(ELEC-047)
Not available as a replacement part. Replace battery with 12V,
Group 27 Deep Cycle Marine Battery. Replacement weight
must be minimum 50 lb.
2
1002103551-KIT
Upper Control Assembly
3
ELEC-071-KIT
Emergency Stop Button with Contact Block
4
ELEC-633-1
Battery Disconnect Lever
4
ELEC-633-KIT
Master Power Switch
5
NA
B+ Power Connection Location on Pump
6
ELEC-639-5
Charger Cord (Bare Wire/IEC-320 C-13)
7
ELEC-071-KIT
Emergency Stop Button with Contact Block
8
ELEC-746
Battery Charger
9
ELEC-073E
Key Switch
9
ELEC-073E-KEY
Spare Key
10
NA
B-“Ground” Connection Location on Pump
(Not Pictured)
1002103850
1002103851
Battery Cables
(Not Pictured)
ELEC-670-2
20A AGC Fuse
Part# SUPO-633E
REV C
Page 29 of 34

Elevate/Lower Circuit Parts
Item #
Part #
Description
1
ELEC-635
Descent Alarm
2
HYDR-050-7
Hydraulic Pump
3
ELEC-635-1
Overload Alarm
4
ELEC-636
Overload Indicator Light
5
ELEC-632
Time Delay Relay
6
ELEC-133B
Rocker Switch
7
HARD-644-03
Emergency Down Cable
8
ELEC-002A-KIT
Up/Down Rotary Switch
9
ELEC-636
Overload Indicator Light
10
ELEC-602-KIT
Enable Button
11
1002103651-KIT
Hydraulic Cylinder
12
HYDR-671
Pressure Switch
13
1002103691
Manifold Block Assembly
(Not Pictured)
HYDR-044-FL3
Hirschmann Connector with Diode
14
HYDR-007-2F
Down Valve & Coil
14
HYDR-007-2E-5
Down Valve
14
HYDR-007-2E-6
Down Valve Coil (12V)
15
HARD-650
1/16 Shaft Collar
16
LAS-M115
Emergency Down Lever
(Not Labeled)
HYDR-600-5
Hydraulic Hose
17
HYDR-674
Start Solenoid (12 V)
18
HYDR-677
Hydraulic Fitting
19
HYDR-022-3
Low Pressure Hydraulic Line
20
(HYDR-032)
Hydraulic Fluid: Not available as a replacement part. Replace with Flomite
#150, Dexron II, Mobil-DTE 2, or equivalent.
21
HYDR-665
Up Valve
21
HYDR-673
Up Valve Coil
22
ELEC-123-5
Armguard Switch
23
ELEC-123-5
Overload Switch
(Not Pictured)
HARD-022
Retaining Ring, 1.25”
Part# SUPO-633E
REV C
Page 30 of 34
Wheels
/
Item#
P
1
1
W
1
W
2
2
W
2
W
3
4
5
6


/
Brakes
P
art#
1
002103160
W
HEEͲ706ͲK
I
W
HEEͲ002Ͳ1
1
002103161
W
HEEͲ706
W
HEEͲ002Ͳ1
H
ARDͲ687
1
000116002
1
000132402
1
43Ͳ01Ͳ028Ͳ
0
I
T
0
2

Description
RigidCaster
Wheel(8”)
BearingKit
SwivelCast
e
Wheel(8”)
BearingKit
Spring
BrakeActua
t
BrakeWeld
m
BrakeCam
Assembly
e
rAssembly
t
or
m
ent

Part# SUPO-633E
REV C
Page 31 of 34

Other
Item #
Part #
Description
1
HARD-086
Level
2
MISC-031
Anti-Slip Tape
3
HARD-603
Manual Box
4
1000307601
Gate Latch
5
1000132101
Cabinet Latch
Part# SUPO-633E
REV C
Page 32 of 34
Warranty

LIMITEDPRODUCTWARRANTY

1.LimitedWarranties.Subjecttotheterms,conditionsandlimitationssetforthherein,Custom
Equipment,Inc.(the“Company”)warrantstothefirstendͲuser(“Buyer”)that:
(a)LimitedProductWarranty.Foraperiodof24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;and(ii)befreeofanydefectinmaterialand/orworkmanshipundernormal
useandmaintenance;and
(b) ExtendedStructuralandChassisWarranty.Foraperiodof60monthsfromthedatethat
theProductisdeliveredtotheBuyer,thechassisandotherstructuralcomponentsof
suchProductwillbefreefromdefectsinmaterialand/orworkmanshipundernormal
useandmaintenance.

2.Exclusions/WhatIsNotCovered.ThefollowingitemsareNOTcoveredunderthisLimited
Warranty:
(a) Defectsin,anddamageorlossrelatingto,anybatteriesincorporatedbytheCompany
intoormadeapartoftheProduct.Anysuchdefects,damageorlossshallbeexclusively
coveredbythebatterymanufacturer’swarranty,ifany.Formoreinformationregarding
thebatterywarranty,theBuyershouldcontactthebatterymanufacturerusingthe
contactinformationshownonthebattery;
(b)Damageorlossresultingfromorcausedbycarrierhandling;
(c)Damageorlossresultingfromorcausedbynormalwearandtear,weathering,lackof
useorusewithincompatibleequipmentorsoftware;
(d)Damageresultingfromorcausedbyimpropermaintenance,improperhandlingor
storage,improperuse,abuse,neglect,operationbeyondratedcapacity,oroperation
afterdiscoveryofdefectiveorwornparts;
(e)Anypart,componentorassemblyalteredormodifiedinanywaynotapprovedin
writingbytheCompany;
(f)DamagetoanyequipmentorpartsnotmanufacturedbytheCompany;and
(g)ActsofGod,accidentsoranyothercausesbeyondtheCompany’sreasonablecontrol.

3.MakingaWarrantyClaim.AsaprerequisitetomakinganyclaimunderthisLimitedWarranty,
BuyermustgivetheCompanywrittennoticeofanysuspecteddefectpromptlyafterdiscovery.
Suchnoticeshallspecificallyidentifythesuspecteddefect,theoriginaldeliverydateand
completeBuyeridentificationandlocationinformation.TheCompanywillnotacceptany
ProductforwarrantyservicewithoutreceivingBuyer’swrittennoticeandissuingareturngoods
authorization.BuyershallretainalldefectiveProductsorparts,componentsorassemblies
thereofforaminimumperiodofsix(6)months.IfrequestedbytheCompany,Buyershallreturn
thedefectiveProduct,orparts,componentsorassembliesthereof,totheCompany,F.O.B,
Company’sdesignatedlocation.AllreturnedProductsorparts,componentsorassemblies
thereofthatarereplacedunderthisLimitedWarrantyshallbecomethepropertyofthe
Part# SUPO-633E
REV C
Page 33 of 34

Company.TheCompanyreservestherighttoreviewBuyer’smaintenanceandoperation
recordsandprocedurestodetermineiftheallegeddefect(s)wereduetoanyoftheitemslisted
inSections2ofthisLimitedWarranty.TheCompanyshallnotbeliableforanyclaimunderthis
LimitedWarrantyifBuyerfailstosatisfytheconditionssetforthinthisSection.

4. ExclusiveRepairorReplaceWarranty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.The
Companyreservestheright,atitsdiscretion,tousenew,remanufacturedorrefurbished
replacementparts.NotwithstandinganythinginthisLimitedWarrantytothecontrary,the
CompanyshallnotbeobligatedtoreplacetheentireProductifacovereddefectcanbe
remediedbytherepairorreplacementofadefectivepart,componentorassembly.The
Companyshallberesponsibleforthecostofallpartsnecessarytoremedysuchdefect.Buyer
shallberesponsibleforpaymentofanycostsorfeesduetotheauthorizeddealertoperform
anywarrantyservice.

5.DisclaimerofOtherExpressandImpliedWarranties.EXCEPTFORTHELIMITEDWARRANTIES
SETFORTHINSECTION1ABOVE,THECOMPANYMAKESNOOTHERREPRESENTATIONSOR
WARRANTIESANDHEREBYDISCLAIMSALLEXPRESSORIMPLIEDREPRESENTATIONSOR
WARRANTIESREGARDINGTHEPRODUCT,INCLUDING,WITHOUTLIMITATION,ANYIMPLIED
WARRANTYOFMERCHANTABILITY,NON‐INFRINGEMENTOFPROPRIETARYORTHIRD‐PARTY
RIGHTSORFITNESSFORAPARTICULARPURPOSE.THEREARENOWARRANTIESWHICHEXTEND
BEYONDTHEDESCRIPTIONONTHEFACEHEREOF.Noemployeeorrepresentativeofthe
Companyoranyofitsauthorizeddealersisauthorizedtomodifyanyterm,conditionor
limitationinthisLimitedWarrantyunlesssuchmodificationismadeinwritingandsignedbyan
officeroftheCompany.

6.LimitationofLiability.NOTWITHSTANDINGANYTHINGINTHISWARRANTYTOTHECONTRARY,
INNOEVENTSHALLTHECOMPANYORANYOFITSAFFILIATESORSUBSIDIARIESBELIABLETO
BUYERFORANYINDIRECT,SPECIAL,EXEMPLARY,PUNITIVEORCONSEQUENTIALDAMAGES
(INCLUDINGLOSTPROFITS,LOSTREVENUE,DOWNTIME,LOSSOFBUSINESSOPPORTUNITYOR
OTHERECONOMICLOSSES),WHETHERINANACTIONINCONTRACTORTORT(INCLUDING
NEGLIGENCEANDSTRICTLIABILITY)OROTHERWISE,EVENIFTHECOMPANYHASBEEN
SPECIFICALLYADVISEDOFTHEPOSSIBILITIESOFSUCHDAMAGES.