Custom equipment Hy-brid lifts hb 1030ce Programming manual

MAINTENANCE & TROUBLESHOOTING MANUAL

SELF-PROPELLED AERIAL WORK PLATFORM

SUPO-714

REV C

HB-1030CE

HB-1430CE

SERIES III

BY CUSTOM EQUIPMENT LLC

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

NOTES

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

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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.

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.

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.

ANY MODIFICATION ON THIS MACHINE WITH

OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.

DANGER

WARNING

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

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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

1.4 | STABILITY TESTING ...................................................................................................................................................................... 8

SECTION 2 | MAINTENANCE ................................................................................................................................................... 9

2.1 | BATTERY MAINTENANCE........................................................................................................................................................... 9

2.2 | CHARGING THE BATTERY......................................................................................................................................................... 9

2.3 | LUBRICATION...............................................................................................................................................................................11

2.4 | COMPONENTS REQUIRING ADJUSTMENT .......................................................................................................................11

2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ..............................................................11

2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ..................................................................................................11

2.7 | STORAGE ......................................................................................................................................................................................11

2.8 | MAJOR ALTERATIONS OR REPAIRS ......................................................................................................................................11

SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 12

3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 13

3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST.................................................................................. 14

SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 16

4.1 | HYDRAULIC SCHEMATIC HSHBCE...................................................................................................................................... 16

4.2 | ELECTRICAL SCHEMATIC WS1122030151.................................................................................................................... 18

4.3 | CONTROL BOARD DIAGNOSTIC..........................................................................................................................................20

SECTION 5 | WIRING DIAGRAMS.......................................................................................................................................... 22

5.1 | WIRING DIAGRAM PART NO. WD1122030151 ............................................................................................................22

5.2 | LOWER CONTROLS WIRING DIAGRAM WD1122130751........................................................................................24

5.3 | UPPER CONTROLS WIRING DIAGRAM PART NO. WD1122130851.......................................................................26

SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................28

6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................28

6.2 | DRIVE CIRCUIT...........................................................................................................................................................................30

6.3 | STEER CIRCUIT...........................................................................................................................................................................32

6.4 | ELEVATE CIRCUIT ......................................................................................................................................................................34

6.5 | LOWER CIRCUIT.........................................................................................................................................................................36

SECTION 7 | PARTS.................................................................................................................................................................38

SECTION 8 | WARRANTY........................................................................................................................................................40

NOTES........................................................................................................................................................................................42

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

REV C

INDEX OF FIGURES

REVISION DATES:

REV A....................................................................................................................................................................................... June 2016

REV B (REF 2966).................................................................................................................................................................. July 2016

REV C...................................................................................................................................................................................October 2017

FIGURE 1: Maintenance Lock Use ....................................................................................................................................................... 7

FIGURE 2: Maintenance Lock Pin Storage.......................................................................................................................................... 7

FIGURE 3: Battery Charger LED Display............................................................................................................................................ 10

MAINTENANCE & TROUBLESHOOTING

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SECTION 1 | SAFETY

1.1 | SAFETY SYMBOLS

1.2 | GENERAL RULES AND PRECAUTIONS

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.

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

FAILURE TO FOLLOW THIS WARNING MAY CAUSE

INJURY OR DAMAGE TO EQUIPMENT.

“CAUTION” indicates a potentially hazardous situation

which, if not avoided, could result in minor or

moderate injury or damage to equipment

Custom Equipment, LLC designed the Hy-Brid Lift self-propelled scissor lift to be safe and reliable. It is intended for

elevating personnel, along with their necessary tools and materials to overhead work locations.

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, LLC 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, LLC, 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.

MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY

NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM

UNLESS MAINTENANCE PINS ARE IN PLACE

MAINTENANCE & TROUBLESHOOTING

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SUPO714

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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.

FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS

MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH.

Other Guidelines

• Never work under an elevated platform until maintenance locks have been engaged.

• Remove all rings, watches, and jewelry when performing any maintenance.

• Do not wear long hair unrestrained or loose ﬁtting clothing and neckties which may become caught on or

entangled in equipment.

• Observe and obey all warnings and cautions on machine and in manual.

• Keep oil, grease, water, etc. wiped from standing surfaces and handholds.

• Before making any adjustments, lubricating or performing any other maintenance, shut o all power controls.

• Battery should always be disconnected during replacement of electrical components.

• Keep all support equipment and attachments stowed in their proper place.

• Use only approved nonﬂammable cleaning solvents.

• After maintenance, inspect the machine as described for Pre-delivery.

FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Pin Storage

MAINTENANCE & TROUBLESHOOTING

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1.4 | STABILITY TESTING

This machine 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 stability test is to be done in compliance with EN280:2015, chapter 6.1.4.2.1, or AS14180 chapter 6.5.2, on an

inclination of 2º, with 408 kg (900 lb.) for model HB-1030CE and 365 kg (804 lb.) for HB-1430CE on the platform,

located as described in the standards.

This test can be simulated on a level surface with no load on the platform, using a side pull that causes the same

overtirning moment as the loads and inclination described above. This equivalent test can be done as shown in the

ﬁgure below.

For the HB-1030CE S3 the test weight/pull force is 52 kg (115 lb.)

For the HB-1430CE S3 the test weight/pull force is 55.3 kg (122 lb.)

SECTION 1 | SAFETY

MAINTENANCE & TROUBLESHOOTING

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SECTION 2 | MAINTENANCE

2.1 | BATTERY MAINTENANCE

This unit may be equipped with 12-volt AGM maintenance-free batteries or with deep cycle 12-volt batteries.

NOTE: The surrounding temperature greatly aects 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% eciency.

NEVER ADD ACID TO BATTERY!

Battery Maintenance - WET CELL 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.

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.

2.2 | CHARGING THE BATTERY

BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND

FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.

The charger is equipped with an interlock circuit. The unit will not operate while charging. Shortened battery life

will result.

To Charge:

• Park the machine on a level surface.

• Plug charger into AC outlet until charged.

• For best battery life, leave the charger plugged in until machine will be used again. The charger will maintain

the battery charge.

MAINTENANCE & TROUBLESHOOTING

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SECTION 2 | MAINTENANCE

How to read the battery displays

FIGURE 3: Battery Charger LED Display

DO NOT OPERATE UNIT WHILE CHARGING. DO NOT DISABLE CHARGER INTERLOCK.

Power

Green LED (ON)

Red LED (OFF)

Red LED (ON)

Red LED (OFF)

Red LED

(FLASHING)

Green LED (OFF)

Green LED (ON)

Red LED (OFF)

Red LED (ON)

Red LED (OFF)

Red LED

(FLASHING)

Green LED (OFF)

Green LED (ON)

This display indicates that the

power is on but there is no

connection to a battery. The

charger must see

approximately ﬁve (5) volts on a

battery to deliver D/C current.

This display indicates that

power is on and that both

outputs are delivering D/C

current to the batteries.

This display indicates that

power is on and that both

outputs are ﬁnished charging

and are in a ﬂoat maintenance

mode.

A ﬂashing red light indicates

there is a problem with a

battery, such as low voltage or

a bad cell.

Battery 1 Status

Charging Ready

Battery 2 Status

Charging Ready

Battery 1 Status

Charging Ready

Battery 2 Status

Charging Ready

Battery 1 Status

Charging Ready

Battery 2 Status

Charging Ready

Battery 1 Status

Charging Ready

Battery 2 Status

Charging Ready

MAINTENANCE & TROUBLESHOOTING

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2.3 | LUBRICATION

Item Speciﬁcation Frequency of Lubrication

Wheels Teﬂon Spray Quarterly (Optional)

2.4 | COMPONENTS REQUIRING ADJUSTMENT

Under normal use, no components should require adjustment.

• If a pump is replaced contact your dealer for pump relief setting.

• If the load sensing calibration is not functioning correctly, contact your dealer for calibration.

2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS

With proper use, regular battery charging, and regular inspection, there are no limited life components that require

routine replacement.

2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS

Check safety functions as part of daily inspection. Check that the brakes are holding.

2.7 | STORAGE

After periods of storage, exposure to extremes of ambient conditions-heat, cold, moisture, dust etc. inspect the

machine. Batteries will need to be charged. Refer to the Pre-Delivery/ Frequent Inspection Checklist in this manual.

2.8 | MAJOR ALTERATIONS OR REPAIRS

Any alterations must be approved by the manufacturer. Major repairs, which aect 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.

SECTION 2 | MAINTENANCE

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

REV C

SECTION 3 | MAINTENANCE CHECKLISTS

Regular inspection and conscientious maintenance is important to ecient 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 included in this manual:

• Pre-Start (required before operation at each work shift)

• Pre-Delivery/Frequent/Annual (Required every 3 months, after periods of storage, and after any alterations or

repairs)

The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week,

5 load cycles per hour)

MAINTENANCE & TROUBLESHOOTING

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SECTION 3 | MAINTENANCE CHECKLISTS

3.1 | PRESTART INSPECTION CHECKLIST

Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A - Not equipped with this feature Y N R N/A

VISUAL INSPECTIONS

There are no loose or missing parts. ڧڧڧ ڧ

Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly marked. ڧڧڧ ڧ

Check the platform rails and safety gate for damage. ڧڧڧ ڧ

Platform and base controls are not missing, damaged, or disconnected. ڧڧڧ ڧ

Electrical cables and wires are not torn, frayed, or disconnected. ڧڧڧ ڧ

Hydraulic hoses are not torn or loose, and there are no leaks. Hoses and the cables have no worn areas or

chaﬁng. ڧڧڧ ڧ

Check the tires for damage. Check that wheel axle retaining rings and any set screw(s) in rear wheel are tight. ڧڧڧ ڧ

Check that all snap rings are secure in grooves on pivot pins. ڧڧڧ ڧ

FUNCTIONAL TESTS

Gate closes automatically and latches. ڧڧڧ ڧ

Platform Controls: Check all switches and push buttons for proper operation.

Emergency Stop (Stops all movement) ڧڧڧ ڧ

For Actuator-Steered models: Enable Switch (Does not elevate unless enable is pressed) ڧڧڧ ڧ

For Counter-Rotate Steering models: Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode) ڧڧڧ ڧ

Joystick (Return to neutral, drives forward & reverse,)

Enable Trigger (Must be activated for joystick-operated movement)

For Actuator-Steered models: Thumb rocker steers right & left

For Counter-Rotate Steering models: Elevates & lowers

If so equipped, horn sounds when button is pressed. ڧڧڧ ڧ

Base Controls: Check all switches and push buttons for proper operation.

Emergency Stop (Stops all movement) ڧڧڧ ڧ

For Actuator-Steered models: Key Switch (On or O)

For Counter-Rotate Steering models: Key Switch (Selects Platform Control, Ground Control, or O) ڧڧڧ ڧ

Up/Down Rocker Switch (Elevates, Lowers) ڧڧڧ ڧ

Descent Alarm (Not damaged, sounds for descent; may also sound for drive & elevate, if so equipped) ڧڧڧ ڧ

Tilt Alarm (Not damaged, sounds when tilted and machine elevated above designated height)

If so equipped, elevating beyond this height may also be prevented. ڧڧڧ ڧ

Master Power Switch disconnects battery ڧڧڧ ڧ

Wheels: Front and rear wheels rotate freely.

For Counter-Rotate Steering models: Front wheels pivot freely. ڧڧڧ ڧ

Drives in slow speed when elevated. ڧڧڧ ڧ

Brakes: Machine stops when joystick released. ڧڧڧ ڧ

Pothole guards deploy and lock when platform is elevated. ڧڧڧ ڧ

Lift does not elevate when pothole guards are blocked. ڧڧڧ ڧ

Date: Inspected by:

Model: Serial Number:

• Keep inspection records up-to-date.

• Record and report all discrepancies to your supervisor.

• A dirty machine cannot be properly inspected.

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.

CAUTION

MAINTENANCE & TROUBLESHOOTING

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3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST

SECTION 3 | MAINTENANCE CHECKLISTS

Model: Serial Number:

• Check each item listed below.

• Use proper operating, service, and maintenance manual for speciﬁc information and settings

• If an item is found to be unacceptable make the necessary repairs and check the “repaired” box.

• When all items are “acceptable”, the unit is ready for service.

• If an item is found to be unacceptable, make the necessary repairs and check the “repaired” box. When all

items are “acceptable,” the unit is ready for service.

Y — Yes/Acceptable N — No/Unacceptable R — Repaired N/A — Not equipped with this feature

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, AND ANNUALLY.

CAUTION

Y N R N/A Y N R N/A

Base: Rails/Extending platform:

Inspect slide tracks for damage ڧڧڧ ڧ Extends freely ڧڧڧ ڧ

All frame bolts tight ڧڧڧ ڧ Cables in place/secure ڧڧڧ ڧ

Pump Secure ڧڧڧ ڧ Locks in Stowed Position ڧڧڧ ڧ

DC motors secure ڧڧڧ ڧ Locks in Extended Position ڧڧڧ ڧ

Batteries Fully Charged ڧڧڧ ڧ Functions:

For actuator-steered models:

Tie rods secure ڧڧڧ ڧ All Functions (Srive,Elevate,Steer) Operational

(see Pre-Start Inspection for details) ڧڧڧ ڧ

Wheels: Pothole guards deploy when platform elevated ڧڧڧ ڧ

Snap Rings Secure ڧڧڧ ڧ Emergency Stop Breaks Circuits ڧڧڧ ڧ

Bolts/Nuts Tight ڧڧڧ ڧ Slow Speed limit switch Set properly ڧڧڧ ڧ

All Shields/Guards in place ڧڧڧ ڧ Pothole interlock functions correctly ڧڧڧ ڧ

Scissors: Brakes: Operational ڧڧڧ ڧ

No Broken Welds ڧڧڧ ڧ Emergency Down Operational ڧڧڧ ڧ

No Bent Beam Members ڧڧڧ ڧ Wiring:

All rollers Turn Freely ڧڧڧ ڧ Switches secure ڧڧڧ ڧ

Ret. Rings Secure On Pivots ڧڧڧ ڧ Contactor(s) secure ڧڧڧ ڧ

Maintenance Locks:

Stored in designated location ڧڧڧ ڧ Tight on terminals (No loose wiring) ڧڧڧ ڧ

Platform: Oil: Level 1” from top (when platform stowed) ڧڧڧ ڧ

No Bent rails ڧڧڧ ڧ Check all hose for leaks ڧڧڧ ڧ

No Broken welds ڧڧڧ ڧ Check all ﬁttings for leaks ڧڧڧ ڧ

All rails in place/secure ڧڧڧ ڧ Battery Charger Secure/Operational ڧڧڧ ڧ

110V outlet safe/working (if applicable) ڧڧڧ ڧ Tilt sensor ڧڧڧ ڧ

Entrance gate Closes Freely ڧڧڧ ڧ Warning Horn (if applicable) ڧڧڧ ڧ

Decals: Hour meter operational ڧڧڧ ڧ

Legibile ڧڧڧ ڧ Battery indication operational ڧڧڧ ڧ

Correct capacity noted ڧڧڧ ڧ Operator’s Manual is on the unit ڧڧڧ ڧ

Proper placement & quantity ڧڧڧ ڧ If equipped with load sensing:

Overload light & alarm sounds when overloaded ڧڧڧ ڧ

Date: Inspected by:

MAINTENANCE & TROUBLESHOOTING

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THIS PAGE WAS INTENTIONALLY LEFT BLANK

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

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SECTION 4 | TECHNICAL REFERENCES

4.1 | HYDRAULIC SCHEMATIC HSHBCE

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

REV C

SECTION 4 | TECHNICAL REFERENCES

MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

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SECTION 4 | TECHNICAL REFERENCES

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HB1030CE/HB1430CE

SUPO714

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SECTION 4 | TECHNICAL REFERENCES

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MAINTENANCE & TROUBLESHOOTING

HB1030CE/HB1430CE

SUPO714

REV C

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