Custom Equipment Hy-Brid Lifts HB 1030CE Programming manual

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
TableofContents
Safety............................................................................................................................................................5
SafetySymbols............................................................................................................................... ...........5
GeneralRulesandPrecautions.................................................................................................................5
SafetyGuidelines............................................................................................................................... .......6
MaintenanceLock.....................................................................................................................................6
Maintenance............................................................................................................................... ..................6
BatteryMaintenance................................................................................................................................7
Lubrication............................................................................................................................... .................8
Componentsrequiringadjustment...........................................................................................................9
Examination,repair,replacementoflimitedlifecomponents.................................................................9
Safetydevicesandsystemsrequiringchecks...........................................................................................9
Storage............................................................................................................................... .......................9
MajorAlterationsorRepairs.....................................................................................................................9
OtherProcedures............................................................................................................................... .......9
SettingtheTiltSensor...........................................................................................................................9
VoltageTestPoints............................................................................................................................... 9
StabilityTesting............................................................................................................................... ..............9
InspectionandRegularMaintenanceChecklists........................................................................................10
MonthlyBatteryCare..............................................................................................................................10
PrestartInspectionChecklist..................................................................................................................11
FrequentInspectionChecklist.................................................................................................................12
PreͲDelivery/AnnualInspectionChecklist...............................................................................................13
TechnicalReferences..................................................................................................................................14
PlatformControlErrorDisplay................................................................................................................14
HydraulicSchematic................................................................................................................................15
ElectricalSchematic............................................................................................................................... .17
WiringDiagrams............................................................................................................................... ...........19
WiringDiagram.......................................................................................................................................19
MainPower&Safety.............................................................................................................................. 21
SUPO-611E
REV F
Page 1 of 40
DriveCircuit.............................................................................................................................................23
Elevate/LowerCircuit..............................................................................................................................25
Troubleshooting..........................................................................................................................................27
TroubleshootingFlowchart.....................................................................................................................27
TroubleshootingFlowchart—Drive&SteerCircuit.................................................................................29
TroubleshootingFlowchart—Elevate&LowerCircuit...........................................................................31
ReplacementParts............................................................................................................................... .......33
SafetyandControlDecals.......................................................................................................................33
MainPower/SafetyCircuit......................................................................................................................34
DriveCircuitParts...................................................................................................................................35
SteerCircuitParts............................................................................................................................... ....36
Elevate/LowerCircuitParts.....................................................................................................................37
Covers/Other...........................................................................................................................................39
Warranty............................................................................................................................... ......................40

RevisionTable:
RevisionA(01/14/2010):InitialRelease
RevisionF(10/24/2012):Revisedlogos



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SUPO-611E
REV F
Page 2 of 40

DriveCircuit.............................................................................................................................................23
Elevate/LowerCircuit..............................................................................................................................25
Troubleshooting..........................................................................................................................................27
TroubleshootingFlowchart.....................................................................................................................27
TroubleshootingFlowchart—Drive&SteerCircuit.................................................................................29
TroubleshootingFlowchart—Elevate&LowerCircuit...........................................................................31
ReplacementParts............................................................................................................................... .......33
SafetyandControlDecals.......................................................................................................................33
MainPower/SafetyCircuit......................................................................................................................34
DriveCircuitParts...................................................................................................................................35
SteerCircuitParts............................................................................................................................... ....36
Elevate/LowerCircuitParts.....................................................................................................................37
Covers/Other...........................................................................................................................................39
Warranty............................................................................................................................... ......................40

RevisionTable:
RevisionA(01/14/2010):InitialRelease
RevisionB(04/08/2010):RevisedCover,p.33Ͳ38PartNumbersforreplacementparts
RevisionC(06/15/2010):Revisedpages2,3,9Ͳ11,addedp.12,revisedp.34:Addedstabilitytesting
information,revisedinspectionchecklists
RevisionD(07/21/2010):Revisedpages3,15,37Ͳ38
RevisionE(11/15/2010):Revisedpages3,9
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
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SUPO-611E
REV F
Page 3 of 40
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
SUPO-611E
REV F
Page 4 of 40

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 or 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HyͲBridLiftselfͲpropelled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.

SUPO-611E
REV F
Page 5 of 40
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
Maintenance

WARNING
FAILURE TO COMPLY WITH 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.

MaintenancePin
LocationWheninUse
PinStorageLocation
SUPO-611E
REV F
Page 6 of 40

F
T
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
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I
t
F
L

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
F
igure4:Batter
y

DO NOT
O
DO NOT
D
T
hesolutioni
p
roperlevel.
p
lates.

L
ubricatio
n
tem
F
rontWheels
L
owerSlider
B

y
ChargerLEDD
i
W
A
O
PERATE U
D
ISABLE C
H
satitsprop
e
Whenrequi
r
n

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A
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IT WHILE
H
ARGER IN
rstrengthw
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ed,watersh
o
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T
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TERLOCK.
h
enthebatt
e
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uldbeadde
S
pecification
T
eflonSpray
T
eflonSpray

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.
e
ryismanufa
c
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a
F
Q
A
Thisdis
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Thecha
r
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Thisdi
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r
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Thisdi
andth
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n
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tured.Use
d
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F
requencyof
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uarterly
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sneededto
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germustse
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e
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ingd/ccurr
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e
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n
gandarein

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istilledwat
e
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,unlesswat
e
Lubrication
preventchat
t
CA
E
R ADD ACI
D
s
thatpoweri
e
ctiontoaba
e
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e
d
eliverd/cc
u
e
sthatpowe
u
tputsare
e
nttothe
e
sthatpowe
utsarefinish
afloatmain
t

e
randkeepfl
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rlevelisbel
t
erwhenfull
y
UTIO
N
D
TO BATT
i
son
ttery.
e
ly5
u
rrent.
ris
rison
ed
t
enance
uidupto
owthe
y
loaded
N
ERY!
SUPO-611E
REV F
Page 7 of 40

Figure4:BatteryChargerLEDDisplay

50% 75% 100% GEL
Charger LED Display
Charging State
0 to 50% charged Blinking Off Off NA
50% to 75% charged On Blinking Off NA
75% to 100% charged On On Blinking NA
100% charged On On On NA
Charge for flooded type batteries NA NA NA Off
Charge for Sealed type batteries NA NA NA On
Abnormal Cycle Off Off Blinking NA


WARNING
DO NOT OPERATE UNIT WHILE CHARGING.
DO NOT DISABLE CHARGER INTERLOCK.
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
FrontWheelsTeflonSprayQuarterly
LowerSliderBlockChannelTeflonSprayAsneededtopreventchatterwhenfullyloaded




CAUTION
NEVER ADD ACID TO BATTERY!
SUPO-611E
REV F
Page 8 of 40

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.
Safetydevicesandsystemsrequiringchecks
Checksafetyfunctionsaspartofdailyinspection.Checkthattheelectromagneticbrakesareholding.
Storage
Afterperiodsofstorage,exposuretoextremesofambientconditionsͲheat,cold,moisture,dustetc.inspectthe
machine.RefertothePreͲDelivery/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.
OtherProcedures
SettingtheTiltSensor
1. Verifythatunitispowered(redorgreenLEDilluminated/blinking).
2. Zerounit(teachunithome/levelposition).
a. Operatetiltplatformuntilithasreachedthedesiredhomeposition(level).
b. Pressandholdthebuttonontopofthemodulefor5seconds(bothLEDswillbeOFF).
c. RedandGreenLEDswillnowFLASH.Usernowhas5secondsto“program”
d. Pressandreleasebutton3timeswithin5secondperiod.
e. RedandGreenLEDswillturnonsolidfor2seconds,indicatingpositionisbeinglearned.
VoltageTestPoints
Contacttechnicalassistanceformoredetail.
StabilityTesting
TheHB1430CE&HB1030CEhave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HB1030CE,thetestweight/pullforceis52kg/115lb.FortheHB1430CE,thetestweightis55.3
kg/122lb.

Figure5:StabilityTest,Equivalent
SUPO-611E
REV F
Page 9 of 40
InspectionandRegularMaintenanceChecklists
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:
PreͲStart(Requiredbeforeoperationateachworkshift)
MonthlyBatteryMaintenance
Frequent(Requiredatintervalsnotmorethanthreemonths)
PreͲDelivery/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upͲtoͲdate.
2. Recordandreportalldiscrepanciestoyoursupervisor.
3. Adirtymachinecannotbeproperlyinspected.
YͲYes/AcceptableNͲNo/UnacceptableRͲRepaired
Description Y N R
MonthlyBatteryCare:
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5Ͳtsp.bakingsodaperquartofwarmwater.
6. Coatterminalswithacommerciallyavailablecoating.


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.
SUPO-611E
REV F
Page 10 of 40

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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
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wheelaxleretainingringsandsetscrewinrearwheelaretight.
Checkthatallsnapringsaresecureingroovesonpivotpins.
FunctionalTests
Gateclosesautomaticallyandlatches(alignmentcanbeadjustedwithscrewontoeboardorrailingif
necessary).
PlatformControls:Checkallswitchesandpushbuttonsforproperoperation.
EmergencyStop(Stopsallmovement)
Drive/Steer&Up/DownModeButton(Selectsdrive/steerorelevatemode)
Joystick&ThumbRockerSwitch
(Returntoneutral,drivesforward&reverse,elevates&lowers)
DriveEnableTrigger(Mustbeactivatedtodrive)
Horn
DiagnosticDisplay(Displaystilt,overload)
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.
Drivesinslowspeedwhenelevated.
Brakes:Machinestopswhenjoystickreleased.
Potholeguardsdeployandlockwhenplatformisraised.
Liftdoesnotelevatewhenpotholeguardsareblocked.


SUPO-611E
REV F
Page 11 of 40
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___________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PreͲStart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.
Checkelectricalmotorbrushes(every150hours) 
Verifythatmaintenanceandinspectionrecordsareuptodate. 
FunctionalTests
PerformallchecksonthePreͲStartInspectionChecklist. 
Functionsoperatesmoothly.
Functionsoperateoverfullrangeofmotion.
ElevatedandLowereddrivespeedsdonotexceedspecificationslistedinOperatorsmanual. 
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_______________________________ 

SUPO-611E
REV F
Page 12 of 40


PreǦDelivery/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:HB1030CEorHB1430CE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YNR
Base:
Inspect slide tracks for damage
Decals:
Steering
actuator pinned
Legibility
All frame bolts tight
Correct capacity noted
Pump Secure
Proper placement quantity
Tie Rod secure
Wiring:
DC motor secure
Switches secure
Battery Hold Downs Secure
Contactor(s) secure
Batte
ries Fully Charged
Tight on terminals
(No loose wiring)
Counterweights secured
Functions:
Wheels: Snap Rings Secure
Drive, Lift, Steer Functioins
Operational
Wheels: Bolts/Nuts Tight
Emergency Stop Breaks Circuits
Maintenance Locks
:Pinsincabinet
Slow Speed limit switch Set properly
All Shields/Guards in place
Emergency Down Operational
Hydraulic Oil
Level 1
”
from top
Pothole guards deploy when platform
Check all
hydraulic
hose
s
for leaks
Pothole i
nterlock functions correctly
Check all
hydraulic
fittings for leaks
Brakes: Operational
Scissors:
Tilt sensor
Functional
Broken Welds
Warning Horn
Alarms
Bent Beam Members
Motion Alarms Functional
All rollers Turn Freely
Ho
ur meter operational
Ret. Rings Secure On Pivots
Battery indication operational
Broken welds
Verify
Overload Calibration
Platform:
Battery Charger Secure/Operational
All rails in place/secure
No bent rails
No broken w
elds
110V outlet safe/working
(if installed)
Entrance gate Closes Freely
Operator/Service Manual Included
Cables in place/secure
Extending platform e
xtends freely
Extending platform
Locks in Stowed Position
ExtendingplatformLocksinExtendedPosition
Comments:


SUPO-611E
REV F
Page 13 of 40
TechnicalReferences
PlatformControlErrorDisplay
DisplayDescription
01Systeminitializationerror
02Systemcommunicationerror
03Invalidoptionsetting
11Freewheelswitchonmotorisopen
12ChassisUporDownONatpowerͲup
18Potholeguarderror
31PressureSensorFault
32AngleSensorFault
42PlatformLeftTurnSwitchONatpowerͲup
43PlatformRightTurnSwitchONatpowerͲup
46PlatformJoystickEnableSwitchONatpowerͲup
47PlatformJoysticknotinneutralatpowerͲup
54LiftUpCoilFault
55LiftDownCoilFault
58BrakeFault
60MotorFault
61MotorControllerFault
62TemperatureFault
63ChargerFault
64MotorControllerFault
68LowVoltageFault
80Over80%Load
90Over90%Load
99Over100%Load
OLOverloadedPlatform
LLMachineTiltedbeyondsafelimits
PlatformControlBatteryMonitor
DisplayBatteryPercentDescription
ͲͲ
ͲͲ
ͲͲ
90PercentofBatteryCharge
Ͳ
ͲͲ
ͲͲ
70PercentofBatteryCharge
Ͳ
Ͳ
ͲͲ
50PercentofBatteryCharge
Ͳ
Ͳ
Ͳ
30PercentofBatteryCharge

Ͳ
Ͳ
20ChargeBattery


Ͳ
10VeryLowCharge
SUPO-611E
REV F
Page 14 of 40

SUPO-611E
REV F
Page 15 of 40
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










Thispageintentionallyleftblank.

SUPO-611E
REV F
Page 16 of 40

SUPO-611E
REV F
Page 17 of 40 SUPO-611E
REV F
Page 18 of 40

SUPO-611E
REV F
Page 19 of 40 SUPO-611E
REV F
Page 20 of 40

SUPO-611E
REV F
Page 21 of 40 SUPO-611E
REV F
Page 22 of 40

SUPO-611E
REV F
Page 23 of 40 SUPO-611E
REV F
Page 24 of 40

SUPO-611E
REV F
Page 25 of 40 SUPO-611E
REV F
Page 26 of 40

Does the machine have any
function:
(Drive, Steer Elevate/Lower)
Are the batteries
connected?
Check per wiring diagram.
Connect batteries.
See wiring diagram & battery
connection sequence.
No
Are the batteries fully
charged?
(Check voltmeter at lower control or check
voltage across battery terminals using
voltmeter/multi-meter)
Charge batteries.
Replace batt
e
Or
Replace cha
r
(Load test batteries, individually, di
s
If batteries do
not take charge
No
Is short protection fuse at
pump blown?
Replace Fuse
Yes
Is key switch turned o
n
Turn key switch on
No
Is there a different
problem? Contact CEI for further troubleshooting
See Drive & Steer Problems Flowchart
See Elevating & Lowering Problems Flowcharts
Yes, but some
function(s) are
not working properly
Is master disconnect
switch open?
Close Switch.
No
Yes
Yes
Yes
Does Platform
Control Display a
Fault Code?
Check Component
or Condition
Referenced by
Fault Code
SUPO-611E
REV F
Page 27 of 40
e
ries
r
ger
s
connected from machine)
n
?Are both E-Stop buttons
off?
Reset E-Stop buttons. Pull
out at both upper control and
lower control locations.
No
Check for loose wiring connections. Check for ground connection at pump.
See wiring diagrams. Check for continuity in connections use Voltmeter/
Multi-meter at 400V setting.
Contact CEI for further troubleshooting
Consider Signet charger failure (interlock contacts)
Still no
functions?
Is unit overloaded?
Remove load. Safety function
activated.
Yes
No
Is charger plugged in?
Unplug charger. Unit will not
operate while charging.
Yes
Is Upper Control
plugged in?
Connect Upper Control box.
No
Yes Yes Yes
Yes
No
SUPO-611E Hy-Brid Troubleshooting Flowchart
Revision A: Initial Release 01/14/2010
SUPO-611E
REV F
Page 28 of 40

Does the machine drive?
(Elevate, Lower OK)
Is either or two brakes
manually released?
Is either of two brake
switches damaged or
disconnected?
Is drive unit damaged?
Flip brake handle(s) at rear of
machine to engage brakes.
Yes
No
Replace brake switch. Note that
brake limit switch tabs are
delicate. Use caution not to
break off.
Yes
No
Replace drive unit
Yes
Driving slowly? Are batteries fully charged? Charge Batteries
Drives slow when
lowered?
Drives fast when elevated?
Does not drive when
elevated?
Is mode limit switch
damaged or blocked with
debris?
Do pothole guards and
lock deploy properly?
Clean any debris from pothole arm
mechanism
Yes
Is mode limit switch
damaged or blocked with
debris?
Che
No
Drives intermittently? Check wiring connection
integrity.
Is there moisture or
corrosion in any
connections?
Check connections
at both pump and
board. See wiring
diagrams.
Yes, but not properly
Is machine tilted?
(Tilt sensor will be beeping, but
functions should not be disabled)
Is machine overloaded?
(Safety feature stops all
function if overloaded)
Yes
Does not Steer? Consider relay failure, relay
block wiring.
Check wire connections at actuator.
Pull test connections—if failure,
crimp on new connector(s)
SUPO-611E
REV F
Page 29 of 40
Are all connections to
drive control board
secure?
Reconnect
No
Is there moisture or
corrosion in any
connections?
No
Yes
Allow to dry for 24 hours and try again.
Board probably will need replacement.
Apply dielectric grease to connectors at
main wire harness.
Yes
Replace drive control boardNo
Contact CEI for further troubleshooting.
Consider brake damage, broken joystick
handle (drive enable), bad hour meter, loose
connections in lower and upper control
Still no drive?
Clean any debris from limit switch area.
Check for proper connection inside limit switch. (See wiring
diagram).
Replace mode limit switch.
Yes Contact CEI for further troubleshooting.
Consider board failure or loose wiring.
Contact CEI for further troubleshooting.
Consider board failure, pothole interlock limit switch
failure, control module failure failure, disconnected,
damaged, or failed height transducer.
Clean any debris from limit switch area.
ck for proper connection inside limit switch. (See wiring diagram).
Replace mode limit switch.
Contact CEI for further troubleshooting.
Consider board failure or incorrect wiring.
Air dry all connections and try again. Board
probably will need replacement. Apply
dielectric grease to connectors at cable.
Contact CEI for further troubleshooting.
Consider board failure
Remove load.
SUPO-611E Hy-Brid Troubleshooting Flowchart
Drive & Steer Problems
Revision A: Initial Release 01/14/2010
Check steer actuator for
failure. Apply 24V to
actuator leads.
Check joystick
thumb switch
SUPO-611E
REV F
Page 30 of 40

Does machine raise/
lower? Does pump operate?
Check for power connection. See Hy-Brid Troubleshooting
Replace pump assembly
No
Ascent speed slow or
erratic?
Is emergency down
valve open?
Close emergency down
valve or cable connections
Is hydraulic fluid
With platform low
e
pump reservoir to
1
top of reserv
o
Yes
No
Is battery fully charged? Is emergency down
valve open?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
I
R
Charge battery. Close emergency down
valve.
Yes, but
not properly
Is power solenoid
damaged?
Replace
solenoid.
Are diodes functioning
properly?
Measure resistance across diode—Ohm meter/multi-meter at 40 kȍ
Will not descend?
Creeps down?
Has key switch been
turned off? Is an E-Stop activated? Is battery charged?
Turn key to on position. Pull out emergency stop button
at upper and lower controls. Charge batteries.
Is emergency down
valve open?
Close emergency down valve.
Check cable connections.
Disassemble and clean. Look for residue in
screen and on O-ring or damage to O-ring.
Replace down valve.
Faulty down
valve?
Electrical
problem?
Foreign matter
lodged in up or
down valve?
Disconnect coil. Check if unit
s
drifting. Check voltage at coil—
s
be 0 V when not energized
Run unit up a
n
Might be able to
walls inside cyli
n
Starts elevating,
then stops?
Are pothole guards
blocked?
Is pothole limit switch
functionning?
Remove
obstruction.
Replace limit
switch or repair
connections.
SUPO-611E
REV F
Page 31 of 40
Is down valve stuck
open?
low?
e
red, fill
1
" below
o
ir
Flush valve by simultaneously
pressing up switch at base and down
switch on platform control for 30 sec.
Contact CEI for further
troubleshooting.
Check integrity of electrical
connections, There may be a
loose connection or momentary
short.
Flush down valve by
simultaneously pressing up switch
at base and down switch on
platform control for 30 sec.
There may be foreign matter
lodged.
I
s there a restriction in
hydraulic hose? Replace pump. May
be worn or defective.
R
eplace hydraulic hose.
Is up/down switch
damaged?
Replace rocker switch at
upper or lower control.
setting. With black lad on stripe side and red on other side, should get a resistance reading. Switch leads, no reading.
Replace bad diode.
SUPO-611e Hy-Brid Troubleshooting Flowchart
Elevate & Lower Problems
Revision A: Initial Release 01/14/2010
Replace down solenoid. Check for loose electrical
connections.
s
tops
s
hould
.
Damaged cylinder or
damaged seal in
cylinder?
Coil mounting nut too
tight?
n
d then check for oil flow out of return line. Bad cylinder
seal if oil is flowing from return line.
repair with seal kit;, probably need to replace cylinder. If
n
der are scratched or pitted, cylinder needs replacement.
Nut should only be lightly snug:
30 in.-lb. Replace coil and lightly
tighten nut.
Faulty check valve in
pump?
Listen carefully near motor when
not energized—may be running
backwards. Replace pump
SUPO-611E
REV F
Page 32 of 40

ReplacementParts

CAUTION
USEONLYMANUFACTURERAPPROVEDREPLACEMENTPARTS.USEOFNONͲOEMPARTSWILL
VOIDWARRANTY.


DANGER
REPLACEMENTOFTHEFOLLOWINGCOMPONENTSWILLAFFECTTHESTRENGTH,STABILITY,
ORSAFETYFUNCTIONOFTHEUNIT:BATTERY(ELECͲ047),HYDRAULICCYLINDER(HYDRͲ007Ͳ1
ORHYDRͲ041Ͳ2),DRIVECONTROLBOARD(ELECͲ903),ANDALL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.

SUPO-611E
REV F
Page 33 of 40
MainP
o
Item#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
(NotPictur
e
(NotPictur
e
o
wer/Safet
y
Des
c
B+
P
Fus
e
BͲ“
G
Batt
e
Batt
e
Batt
e
Mas
t
Tilt
S
Batt
e
Con
t
Eme
Tilt
A
Key
S
Spa
r
Mai
n
Eme
Joys
t
Con
t
Upp
e
Low
e
e
d)
Batt
e
e
d)
Batt
e
y
Circui
t

c
ription
P
owerConne
c
e

G
round”Con
n
e
ry
e
ryTray
e
ryStrap
t
erPowerSwi
t
S
ensor
e
ryCharger
t
rolModule
rgencyStopS
w
A
larm
S
witch
r
eKey
n
WireHarnes
s
rgencyStopS
w
t
ick
t
rolModule,U
e
rControlAss
e
e
rControlAss
e
e
ryChargerC
o
e
ryCables
c
tionLocatio
n
n
ectionLoca
t
t
ch
w
itch
s

w
itch
pper
e
mbly
e
mbly
o
rd
n
onPump
t
iononPump
Part
#
NA
ELEC
Ͳ
NA
(ELE
C
HBͲ0
0
HAR
D
ELEC
Ͳ
ELEC
Ͳ
ELEC
Ͳ
ELEC
Ͳ
SUB
A
ELEC
Ͳ
ELEC
Ͳ
ELEC
Ͳ
ELEC
Ͳ
SUB
A
ELEC
Ͳ
ELEC
Ͳ
SUB
A
SUB
A
SUB
A
ELEC
Ͳ
ELEC
Ͳ

#
Ͳ
670Ͳ2
C
Ͳ047)
0
01ͲP
D
Ͳ054
Ͳ
633ͲKIT
Ͳ
633Ͳ1
Ͳ
829
Ͳ
747
A
8350E
Ͳ
071ͲKIT
Ͳ
635Ͳ2
Ͳ
073E
Ͳ
073EKEY
A
13006E
Ͳ
071ͲKIT
Ͳ
601Ͳ100
A
9350E
A
9003E
A
8003E
Ͳ
639Ͳ11
Ͳ
641Ͳ100&1
0
0
02101650
SUPO-611E
REV F
Page 34 of 40

DriveCircuitParts

Item#Part#Description
1ELECͲ626Ͳ3RElectricDriveMotor(Right/ControlSide)
2ELECͲ627Ͳ4BrakeMicroswitch
3ELECͲ627Ͳ3RBrake(Left)
4ELECͲ627Ͳ3LBrake(Right)
5SUBA9003EPlatformControlAssembly
6ELECͲ626Ͳ3LElectricDriveMotor(Left/ControlSide)
7WHEEͲ600Ͳ110”x4”Wheel
8SUBA8350EBaseControlModule
9SUB904DriveControlBoard(specifictothismodel/seriesonly)
10ELECͲ610Ͳ1HourMeter

SUPO-611E
REV F
Page 35 of 40
SteerCircuitParts


Item#Part#Description
1HBͲSTͲ2ͲAͲPTieRodͲLong
2PBͲ0018ͲPCenterSteerPin
3HBͲSTͲ4ͲBͲPCCenterSteerWeldment
4PBͲ0021ͲPCaster
5HBͲSTͲ3ͲAͲPTieRodͲShort
6SUBA9003EPlatformControlsAssembly
7SUBA8350ELowerControlModule
8SUBA29ͲKITSteerActuatorAssembly
9ELECͲ631Relay
10ELECͲ624LimitSwitch
11WHEEͲ60410”X2”WHEEL
(NotPictured)(NoPart#)7AACGFuse

SUPO-611E
REV F
Page 36 of 40

Elevate/LowerCircuitParts


SUPO-611E
REV F
Page 37 of 40

Item#Part#Description
1HBͲPHͲ21ͲRͲPCHB2ͲPotholeBarͲR(For10”FrontWheelModels)
2HYDRͲ050Ͳ1EHydraulicPump
(NotPictured)(HYDRͲ032)HydraulicFluid
Notavailableasareplacementpart.ReplacewithFlomite#150,
DexronII,MobilͲDTE2,orequivalent.
3HBͲMLͲPMaintenanceLockPin
4(VariesbyModel)
1022100450
1022100550

HydraulicCylinder(For10’Models)
HydraulicCylinder(For14’Models)
5ELECͲ647AngleTransducer
6HARDͲ644
HARDͲ644Ͳ01
EͲDownCable(1430)
EͲDownCable(1030)
7ELECͲ829TiltSensor
8SUBA8305ELowerControlModule
(NotPictured)ELECͲ635Ͳ2Beeper
9HBͲPHͲ21ͲLͲPCHB2ͲPotholeBarͲL(For10”FrontWheelModels)
10ELECͲ071ͲKITEͲStop
11ELECͲ133BRockerSwitch
12HYDRͲ665UpValve
13HYDRͲ66418VCoil
141020100201PumpMountPlate
15HYDRͲ66624VSolenoid
16HYDRͲ044ͲFL3HirschmannConnectorw/suppressionDiode
17LASͲM115EͲDownValveActuator
18WHEEͲ605Spacer
19HARDͲ6501/16ShaftCollar
20HYDRͲ007Ͳ2EDownValve&Coil
21(VariesbyModel)
HYDRͲ600or
HYDRͲ600Ͳ6
HydraulicHose
22HYDRͲ626FlowControl
23SUBA003EUpperControlAssembly
24HBͲPHͲ7ͲPPHLockWeldment
25LASͲM220ͲPPotholeArm
26ELECͲ623Ͳ2LimitSwitch
27LASͲM222ͲPLimitSwitchPlate
28ELECͲ623Ͳ2LimitSwitch
291000105902PHPickͲUpArm
30HBͲPHͲ13GuideBlock
31HBͲPHͲ20PotholeGuardActuator
32HARDͲ072Spring
33ELECͲ648PressureTransducer
SUPO-611E
REV F
Page 38 of 40