Custom Equipment Hy-Brid Lifts HB-830CE 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
Lubrication............................................................................................................................... .................9
Componentsrequiringadjustment.........................................................................................................10
Examination,repair,replacementoflimitedlifecomponents...............................................................10
Safetydevicesandsystemsrequiringchecks.........................................................................................10
Storage............................................................................................................................... .....................10
MajorAlterationsorRepairs...................................................................................................................10
InspectionandRegularMaintenanceChecklists........................................................................................11
MonthlyBatteryCare..............................................................................................................................11
PrestartInspectionChecklist..................................................................................................................12
FrequentInspectionChecklist.................................................................................................................13
PreͲDelivery/AnnualInspectionChecklist...............................................................................................14
TechnicalReferences..................................................................................................................................15
JoystickServiceFlashCodes...................................................................................................................15
ControlModule—GP102HelpMessages................................................................................................16
ControlModuleFlashCodes...................................................................................................................18
HydraulicSchematic................................................................................................................................19
ElectricalSchematic............................................................................................................................... .20
WiringDiagrams............................................................................................................................... ...........22
WiringDiagram.......................................................................................................................................22
MainPower&Safety.............................................................................................................................. 24
DriveCircuit............................................................................................................................... ..............26
Elevate/LowerCircuit.............................................................................................................................. 28
Troubleshooting............................................................................................................................... ...........30
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TroubleshootingFlowchart..................................................................................................................... 30
TroubleshootingFlowchart—Drive&SteerCircuit.................................................................................32
TroubleshootingFlowchart—Elevate&LowerCircuit...........................................................................34
ReplacementParts......................................................................................................................................36
SafetyandControlDecals.......................................................................................................................36
Covers/Other...........................................................................................................................................37
MainPower/SafetyCircuit......................................................................................................................38
DriveCircuitParts...................................................................................................................................39
Elevate/LowerCircuitParts.....................................................................................................................40
Warranty............................................................................................................................... ......................42
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Figure1:StabilityTesting,Equivalent...........................................................................................................6
Figure2:MaintenanceLockPinUse............................................................................................................. 7
Figure3:MaintenanceLockPinStorage.......................................................................................................7
Figure4:BatteryMaintenance.....................................................................................................................8
Figure5:BatteryChargerLEDDisplay..........................................................................................................9
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RevisionTable:
RevisionA(06/29/2010):InitialRelease
RevisionJ(10/24/2012):Revisedlogos
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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
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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 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.

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StabilityTesting
TheHBͲ830CEhasbeenstabilitytestedtostandardsEN280orAS14180.Themostadversestabilitytest
isthetravelingforwardconfiguration.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
HBͲ830CE,thetestweight/pullforceis50.3kg/111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 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
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BatteryMaintenance

Thisunitisequippedwithdeepcycle12Ͳvolt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.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.


xRemovebatterycabinetcover.
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5Ͳtsp.bakingsodaperquartofwarmwater.
xCoatterminalswithacommerciallyavailable
coating.
CAUTION
NEVER ADD ACID TO BATTERY!
ChargingtheBattery
Thisunitisequippedwithdeepcycle12Ͳvolt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.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(Ͳ18°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.
xUnplugcharger.




Figure4:BatteryMaintenance
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
Thechargerwillnotbeginchargingonseverelydischargedbatteries.Thiswillbeevidentbythethree
indicatorsblinkingsimultaneously.

Figure5: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
WheelsTeflonSprayQuarterly

CAUTION
NEVER ADD ACID TO BATTERY!
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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.


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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:
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.

Part #SUPO-613E
REV J
Page 11 of 42

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HBǦ830CE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YNR
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Enable(Mustbeactivatedtodrive)
Joystick(Returntoneutral,drivesforward,reverse,left,right)
LiftEnable(Mustbeactivatedtoelevate)
RockerSwitch(Elevates,Lowers)
Horn
Tilt&OverloadLEDIndicators
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)
Hourmeter(DisplaysDriveHours)
Alarms(Notdamaged,soundsfordescent,overload)
LED(Flasheswhenoverloaded)
Wheels:Frontandrearwheelsrotate,pivot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.




Part #SUPO-613E
REV J
Page 12 of 42
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_______________________________ 
Part #SUPO-613E
REV J
Page 13 of 42



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:HBǦ830CE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 roller tracks for damage
Decals:
All frame bolts tight
Legibility
Pump Secure
Correct capacity noted
DC motor
s
secure
Proper placement quantity
Battery Hold Downs Secure
Wi
ring:
Batteries Fully Charged
Switches secure
Wheels: Snap Rings Secure
Contactor(s) secure
Wheels: Bolts/Nuts Tight
Tight on terminals
(No loose wiring)
Maintenance Locks: Pins in cabinet
Functions:
All Shields/Guards in place
Drive, Lift, Steer Functions
Operational
Hydraulic Oil
Level 1
”
from top
Emergency Stop Breaks Circuits
Check all
hydraulic
hose
s
for leaks
Slow Speed limit switch Set properly
Check all
hydraulic
fittings for leaks
Emergency Down Ope
rational
Scissors:
Pothole guards deploy when platform
Broken Welds
Pothole interlock functions correctly
Bent Beam Members
Brakes: Operational
All rollers Turn Freely
Tilt sensor
Functional
Ret. Rings Secure On Pivots
Warning Horn
Alarms
Broken welds
Motion Alarms Functional
Platform:
Hour meter operational
All rails in place/secure
Battery indication operational
No bent rails
Verify
Overload Calibration
No broken welds
Battery Char
ger Secure/Operational
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 Sto
wed Position
ExtendingplatformLocksinExtendedPosition
Comments:


Part #SUPO-613E
REV J
Page 14 of 42
TechnicalReferences
JoystickServiceFlashCodes


TheamberServiceIndicatorLEDdisplays
diagnosticcodes.

Asequenceofflashes,separatedbyapause,followedbyarepetitionofthesequence.Thenumberof
flashesindicatesacondition.

FlashCodeDescriptionNotes
1UserFaultPossiblestalltimeoutorusererror.Releasethejoystickto
neutralandtryagain.
2BatteryFaultTrychargingbatteries.Batteriesmayrequirereplacing.Check
batteriesandcables.
3LeftMotorFaultCheckleftmotor,connections,andcabling
4RightMotorFaultCheckrightmotor,connections,andcabling.
5LeftParkBrakeFaultCheckleftparkbrake,connections,andcabling.
6RightParkBrakeFaultChecktherightparkbrake,connectionsandcabling
7RemoteFaultChecktheCommunicationsBusconnectorsandwiring.
ReplacetheRemote(Joystick).
8PowerModuleFaultChecktheCommunicationsBusconnectorsandwiring.
ReplacethePowerModule.
9CommunicationsFaultOnecauseofthiserroriswhentheunitispowereddown
withoutturningoffthejoystick(i.e.usingtheemergencystop).
Toclear,withthemachineon(usingthekeyswitch),turnthe
joystickoffandbackon(joystickon/offbutton).

Checkthatbatteryvoltageisgreaterthan17V.ChecktheBus
Cable.ReplacethePowerModule.ReplacetheRemote
(Joystick).
10UnknownFaultCheckallconnectionsandwiring.Contactmanufacturer.
11IncompatibleRemoteTheRemoteisincompatiblewiththePowerModule.Ensure
thatthecorrectpartnumberisused.

Seealso“UpperControlBatteryGaugeIndicator”codeslistedintheOperator’sManual.


Part #SUPO-613E
REV J
Page 15 of 42

ControlModule—GP102HelpMessages
WhentheEZcalhandͲhelddeviceisconnectedtotheGP102controlmodule,thefirstmenuavailableis“HELP”–
justpresstheENTERbuttontoseeamessagedescribingthecurrentstatusoftheGP102;thiscanbeveryhelpful
indiagnosingproblemswiththesystem.WhenanEZcalisunavailable,anLEDontheGP102flashestoprovide
limiteddiagnostics(seeAppendixFour).
Thefollowingmessagesmightbedisplayed:
EVERYTHINGOK
TheGP102isinplatformmodeanddetectsnoproblems.Ifproblemsarebeingexperiencedwiththesystem,use
theDIAGNOSTICSmenustocheckforfaultysensorsand/orswitches.LEDonsteady.
INGROUNDMODE!
TheGP102isingroundmodeanddetectsnoproblems.IMPORTANT:Normallytheoverloadcutoutsystemis
inhibitedingroundmode.Thevehicleshouldnotbeusedtoraiseheavyloadsingroundmode,incasethe
platformisoverloaded.LEDonsteady.
ARMGUARDACTIVE!
TheGP102hasstoppeddescentattheArmguardheight,andisdelayingto“givetheoperatortheopportunityto
seewhetherpersons…couldbeinjured”(perEN2805.4.4).Vehiclemovementwillcontinuetobestoppedafter
thedelayuntilallfunctionsarereleased.LEDflashcode4.
B+SUPPLYTOOLOW
TheGP102isdesignedforuseon12Vand24Vbatterypoweredvehicles;itcannotoperatewithasupplybelow
about9V.The“BATTERY”voltagecanbecheckedinthe“SENSORS”menu(availableinthe“DIAGNOSTICS”menu).
LEDflashcode7.
DRIVE/LIFTSELECTINPUTSFAULTY!
Neitherthedriveselect(P2Ͳ7)northeliftselect(P2Ͳ8)inputisactive,orbothareactive–theGP102cannot
determinethevehicleuse.Allvehicleoperationwillbepreventeduntiltheproblemiscorrected.LEDflashcode2.
ELEVATIONSWITCHSHIFTED?
TheGP102usestheelevationswitchincombinationwiththeheightsensortoensurecorrectfunctionalityofboth;
anyofthefollowingfaultsmaybedetected:
xTheelevationswitchshouldchangestatenearthepointatwhichitdidduringloadcalibrationAllvehicle
operationwillbepreventeduntiltheproblemiscorrected.LEDflashcode4.
ELEVATIONSWITCHSTUCK?
TheGP102usestheelevationswitchincombinationwiththeheightsensortoensurecorrectfunctionalityofboth;
anyofthefollowingfaultsmaybedetected:
xWhentheplatformiselevated,themeasuredheightshouldbeabovethatstoredduringload
calibration.
xWhentheplatformisnotelevated,themeasuredheightshouldbebelowthatstoredduringload
calibration.Allvehicleoperationwillbepreventeduntiltheproblemiscorrected.LEDflashcode4.
EMSINPUTSFAULTY!
TheEMSplatform(P2Ͳ1)andEMSground(P2Ͳ2)inputsareeitherbothactiveorbothinactive–theGP102cannot
determinewhethertobeinplatformorgroundmode.Allvehicleoperationwillbepreventeduntiltheproblemis
corrected.LEDflashcode2.
FACTORYOVERRIDE
Toallowvehiclemovementduringmanufacture,theGP102isdeliveredina“FACTORYOVERRIDE”statewhich
disablesallfunctionality.Thefirstloadcalibration(evenifnotcompleted)willterminatethisstate.LEDflashcode
15.
FAULT:BADTILTSENSOR
TheGP102hasdetectedthatitsintegraltiltsensorisfaulty–themodulemayneedtobereplaced.IMPORTANT:If
theGP102isinstalledincorrectly,thisfaultmayoccurerroneously.LEDflashcode8.
HEIGHTNOTCALIBRATED
Duringthefirstphaseofloadcalibration(“DYNAMIC”),theGP102calibratestheminimumandmaximumoutputof
theheightsensorsothatplatformheightcanbedetermined.Thiscalibrationmustbesuccessfullycompleted!LED
flashcode1.
IDLETIMEOUTACTIVE!
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Ifconfigured,theGP102willturnoffallitsoutputsafterasettimewithnovehiclefunctionsoperated;thissaves
batterypowerandsilencesanyalarmstillsoundingwhenthevehiclewasleft.Anyvehiclefunctionwillendthe
idletimeoutandrestorenormaloperationoftheGP102outputs.LEDstaysoff.
INVALIDHEIGHT–CHECKSENSORS
Thereisaproblemwhichpreventsthevehicleheightbeingdetermined;theremaybeafaultwiththeheight
sensor,orthevehiclemayhavebeenmodifiedordamagedsincethelastcalibrationoccurred.Allvehicle
operationwillbepreventeduntiltheproblemiscorrected.LEDflashcode9.
INVALIDLOAD–CHECKSENSORS
Thereisaproblemwhichpreventstheestimatedloadbeingdetermined;theremaybeafaultwiththeheight
sensorortheloadsensor,orthevehiclemayhavebeenmodifiedordamagedsincethelastcalibrationoccurred.
Allvehicleoperationwillbepreventeduntiltheproblemiscorrected.LEDflashcode6.
LOADNOTCALIBRATED
Duringthesecondandthirdphasesofloadcalibration(“LOADED”and“EMPTY”),theGP102calibratesthelift
cylinderpressureatvariousheightscorrespondingtoafullyloadedandunloadedplatform.Thiscalibrationmust
besuccessfullycompleted!LEDflashcode1.
NOLASTCALDATE!
Attheendofloadcalibration,theGP102promptsforentryofthecurrentdatetoaidinvehiclemaintenance.A
nonͲzerodatemustbeentered!Whenload(re)calibrationisbegun,thelastCALDATEiserasedandcannotbereͲ
entereduntilcalibrationiscompleted;thisensuresthatapartlycalibratedvehiclecannotbeoperated.LEDflash
code1.
P3Ͳ4SHORTTO0V?
TheGP102startuptestsdetectedthatsomethingisoverloadingtheoutputonP3Ͳ4.Allvehicleoperationwillbe
preventeduntiltheproblemiscorrected.LEDflashcode5.
P3Ͳ4SHORTTOSUPPLY?
TheGP102startuptests(orthecontinuousmonitoringduringanypreventionofvehiclemovement)detectedthat
somethingisprovidingapermanentsupplyonP3Ͳ4(defeatingtheinternalcutout).Allvehicleoperationwillbe
preventeduntiltheproblemiscorrected.LEDflashcode3.
P3Ͳ6SHORTTO0V?
TheGP102startuptestsdetectedthatsomethingisoverloadingtheoutputonP3Ͳ6.Allvehicleoperationwillbe
preventeduntiltheproblemiscorrected.LEDflashcode5.
P3Ͳ6SHORTTOSUPPLY?
TheGP102startuptestsdetectedthatsomethingisprovidingapermanentsupplyonP3Ͳ6(defeatingtheinternal
cutout).Allvehicleoperationwillbepreventeduntiltheproblemiscorrected.LEDflashcode3.
P4Ͳ1ORP5Ͳ1SHORTTO0V?
TheGP102startuptestsdetectedthatsomethingisoverloadingthe5VsupplyprovidedonP4Ͳ1orP5Ͳ1.Allvehicle
operationwillbepreventeduntiltheproblemiscorrected.LEDflashcode7.
TESTINGHWFS
WhentheGP102ispoweredup,itcarriesoutvariousteststoensurethatitisfunctioningsafely.
TOOHIGH–DRIVEPREVENTED
Adrivefunctionhasbeenselectedbuttheplatformisraisedabovethe“MAXDRIVE”setting.Thedrivefunction
willbepreventeduntiltheplatformislowered.LEDflashcode8.
TOOHIGH–LIFTUPPREVENTED
Thelift/upfunctionhasbeenselectedbuttheplatformisraisedabovethe“MAXLIFT”setting.Thelift/upfunction
willbepreventeduntiltheplatformislowered.LEDflashcode8.
UP/DOWNSELECTINPUTSACTIVETOGETHER!
Theupselect(P2Ͳ3and/orP2Ͳ5)andthedownselect(P2Ͳ4and/orP2Ͳ6)areactivetogether–theGP102cannot
determinethevehicleuse.Allvehicleoperationwillbepreventeduntiltheproblemiscorrected.LEDflashcode2.
VEHICLEOVERLOADED
Theestimatedloadintheplatformexceedsthe“OVERLOADAT”settinginthe“ADJUSTMENTS”“LOAD”menu.The
GP102willactivatethecutouttopreventvehicleoperationuntiltheplatformloadisreduced.LEDflashcode8.
VEHICLETILTED
Eitherthe“X”or“Y”tilt(measuredbytheGP102integraltiltsensor)exceedsthe“XTRIP”or“YTRIP”settinginthe
“ADJUSTMENTS”“TILT”menu.LEDflashcode8.
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WAITINGFORB+ONP2Ͳ12
ThesupplyonP2Ͳ12providespowerfortheoutputsP3Ͳ1/2/3/4.TheGP102cannotfunctionifthesupplyisnot
present.SincethesupplyonP2Ͳ12isswitchedtoP3Ͳ4,vehicleoperationwillbeprevented.LEDflashcode7.
WAITINGFORNEUTRAL
WhentheGP102ispoweredup,allcontrolsmustbeinneutraltoallowsafetestingofthefailsafeoutput;no
functionsarealloweduntiltestingiscomplete.LEDflashcode2.

ControlModuleFlashCodes
TheGP102hasabuiltͲinLEDtoprovidesimplediagnosticswhennoEZcalisavailable.Pleasenotethattheuseof
anEZcalprovidessignificantlybetterdiagnosticsthroughtheHELPmessages(seeAppendixThree).AnEZcalisalso
necessarytocalibrateaGP102.
LEDonsteady
ThisindicatesnofaultwiththeGP102
LEDoffalways
ThisindicatesnopowertotheGP102,oridletimeout–activatealiftordrivefunctiontocanceltheidle
timeout.
LEDflashcode1
ThisindicatestheGP102hasnotbeenproperlycalibrated.
LEDflashcode2
ThisindicatesafaultwiththeswitchinputstotheGP102.CheckwiringtoconnectorP2.
LEDflashcode3
ThisindicatesafaultwiththeshutdownoutputsoftheGP102–ashorttothesupplyhasbeendetected.
CheckwiringfrompinsP3Ͳ4andP3Ͳ6.
LEDflashcode4
Thisindicatesthatarmguardisactive,orthatthereisafaultwiththeelevationswitch–theGP102
verifiescorrectopeningandclosingoftheelevationswitchagainsttheheightsensor.Checkingthe
elevationswitchonP2Ͳ10.Iftheheightsensorhasbeenadjustedorreplaced,repeattheCALIBRATE
HEIGHTprocedure.
LEDflashcode5
ThisindicatesafaultwiththeshutdownoutputsoftheGP102–ashortto0V(ground)hasbeendetected.
CheckwiringfrompinsP3Ͳ4andP3Ͳ6.
LEDflashcode6
Thisindicatesafaultwiththeloadmeasurement–checkthepressuretransducerandwiringfromitto
connectorP4.
LEDflashcode7
ThisindicatesafaultwiththesupplytotheGP102–checkbatterysupplyatleast8VonpinP2Ͳ12;also
checkthatthereisnotashortto0V(ground)onpinP4Ͳ1.Ifloadcellsorstraingaugesareconnectedto
P5A/P5B/P6A/P6B,disconnectthem–ifthefaultchangesthenoneormoreisshortingthesupplyoneach
pin1.
LEDflashcode8
Thisisnotafault–itindicatestheGP102haspreventedafunction;functionscanbepreventedifthe
platformisoverloaded,ifthemachineistiltedtoofar,oriftheplatformistoohigh.
LEDflashcode9
Thisindicatesafaultwiththeheightmeasurement–checktheheighttransducer(EZfit)andwiringfromit
toconnectorP4.
LEDflashcode10 
ThisindicatestheGP102iscarryingoutstartuptests. 
LEDflashcode15 
ThisindicatestheGP102isin“FACTORYOVERRIDE”(seeAppendixNine)andoverloadfunctionsare
disabled–thisaidsmanufacturebyallowingvehiclemovementbeforethemachineisbuiltsufficientlyto
becalibrated.
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WIRING DIAGRAM
MAIN POWER/SAFETY CIRCUIT
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WIRING DIAGRAM
MAIN POWER/SAFETY CIRCUIT
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WIRING DIAGRAM
DRIVE CIRCUIT
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WIRING DIAGRAM
DRIVE CIRCUIT
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WIRING DIAGRAM
ELEVATE/LOWER CIRCUIT
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WIRING DIAGRAM
ELEVATE/LOWER CIRCUIT
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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 batteri
e
Or
Replace charg
e
(Load test batteries, individually, disc
o
If batteries do
not take charge
No
Is short protection fuse at
pump blown?
Replace Fuse
Yes
Is key switch turned on?
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
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a
tteries
h
arger
disconnected from machine)
on?
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 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-613E HB-830CE Troubleshooting Flowchart
Revision A: Initial Release 06/01/2010
Revision B: Added Sleep Timer 06/29/2010
Is unit in Sleep Mode?
Turn the power off and back
on using the key switch at the
base controls.
No
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Does the machine
drive?
(Elevate, Lower, and
Steer OK)
Is either or two brakes
manually released?
Is either of two brake
switches damaged or
disconnected?
Is drive unit d
a
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 dri
v
Yes
Driving slowly? Are batteries fully charged?
If resistor is installed, check using Ohmmeter/Mul
t
setting). Resistance across resistor should be
a
Drives slow when
lowered?
Drives fast when elevated?
Does not drive when
elevated?
Is mode limit switch
damaged or blocked wit
h
debris?
Do pothole guards and
lock deploy properly?
Clean any debris from pothole arm
mechanism
Yes
Contact
C
Consider board
Is mode limit switch
damaged or blocked with
debris?
Yes
Are brakes hot?
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?
Is there a trouble
code displayed?
Refer to trouble
code table
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u
nit damaged?
c
e drive unit
Yes
Are all connections to
drive joystick and 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 board
and/or joystick.
No
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?
r
/Multi-meter (400 ȍ
d
be approx. 4 ȍ)
t
ch
d
with
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.
t
act CEI for further troubleshooting.
b
oard failure, pothole interlock limit switch
failure
Clean any debris from limit switch area.
Check for proper connection inside limit switch. (See wiring diagram).
Replace mode limit switch.
Contact CEI for further troubleshooting.
Consider board failure or incorrect wiring.
o
r Allow to dry for 24 hours and try again.
Board probably will need replacement.
Apply dielectric grease to connectors at
main wire harness.
Contact CEI for further troubleshooting.
Consider board failure
SUPO-613E HB-S830CE Troubleshooting
Flowchart
Drive Problems
Revision A: Initial Release 06/01/2010
Is a drive motor
damaged?
Replace drive
motor.
Part #SUPO-613E
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Does machine raise/
lower? Does pump operate?
Check for power connection. See Main 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 lo
w
With platform lowere
pump reservoir to 1"
b
top of reservoir
Yes
No
Is battery fully charged? Is emergency down
valve open?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is
t
Re
p
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 kȍs
e
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 sto
p
drifting. Check voltage at coil—sh
o
be 0 V when not energized.
Run unit up and
t
Might be able to re
walls inside cylind
e
Starts elevating,
then stops?
Are pothole guards
blocked?
Is pothole limit switch
functionning?
Remove
obstruction.
Replace limit
switch or repair
connections.
Check GP102 for
flash codes and
diagnose if
possible.
Part #SUPO-613E
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Is down valve stuck
open?
u
id low?
o
wered, fill
t
o 1" below
e
rvoir
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.
Is there a restriction in
hydraulic hose? Replace pump. May
be worn or defective.
Replace hydraulic hose.
Is up/down switch
damaged?
Replace rocker switch at
upper or lower control.
k
ȍsetting. With black lad on stripe side and red on other side, should get a resistance reading. Switch leads, no reading.
Replace bad diode.
SUPO-613E HB-S830CE Troubleshooting Flowchart
Elevate & Lower Problems
Revision A: Initial Release 06/01/2010
Replace down coil. Check for loose electrical
connections.
it stops
—
should
e
d.
Damaged cylinder or
damaged seal in
cylinder?
Coil mounting nut too
tight?
and then check for oil flow out of return line. Bad cylinder
seal if oil is flowing from return line.
to repair with seal kit;, probably need to replace cylinder. If
y
linder 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
Part #SUPO-613E
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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,HYDRAULICCYLINDER,JOYSTICKAND
CONTROLMODULES,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.
Part #SUPO-613E
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Covers/Other

Item#Part#Description
11000500201Cover,Side
2HARDͲ633CCabinetLatchCam
3HARDͲ633BCabinetLatchHandle
41000103001Step
51000500701Cover,PumpTop
61000500201Cover,Side
71000500601Cover,PumpEnd

Part #SUPO-613E
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MainPower/SafetyCircuit

Item#Part#Description
1NABͲ“Ground”ConnectiononPump
2NAB+PowerConnectiononPump
3(ELECͲ047)Notavailableasareplacementpart.Replacewith12V,Group27DeepCycle
MarineBattery.Replacementweightmustbeminimum50lb.
41000106550DriveControlModule,ProgramSpecifictothisModel/SeriesOnly
51000106450LoadControlModule(GP102),ProgramSpecifictothisModel/SeriesOnly
6ELECͲ645BatteryCharger
7ELECͲ639Ͳ1ChargerCord(NEMA5Ͳ15ͲP/IEDͲ320C13)
8ELECͲ551Joystick
9ELECͲ071ͲKITEmergencyStopButtonwithContactBlock
10ELECͲ633Ͳ1MasterPowerSwitchLever
11ELECͲ633MasterPowerSwitch
12ELECͲ071ͲKITEmergencyStopButtonwithContactBlock
13ELECͲ073EKeySwitch
14ELECͲ073EͲ1SpareKey
15ELECͲ819SleepTimerRelay
161002101051LowerControlAssembly
171002101351UpperControlAssembly
NotPicturedSUBA13MainCable
NotPicturedELECͲ670Ͳ220AAGCFuse
NotPictured1002100193BatteryCableKit
NotPictured1002101099DrivePowerCableKit
Part #SUPO-613E
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DriveCircuitParts

Item#Part#Description
11000108202Caster
21000106302LimitSwitchPlate
3HBͲPHͲ13GuideBlock
41000102004RetainingSleeve
5HBͲPHͲ7ͲPPHLock
6ELECͲ123Ͳ2LimitSwitch
7NABrakeConnectionTerminals
81000106450DriveControlBoard(specifictothismodel/seriesonly)
9ELECͲ627Ͳ3RBrake(Left)
10ELECͲ627Ͳ4BrakeMicroswitch
11ELECͲ627Ͳ3LBrake(Right)
12ELECͲ826Ͳ3RElectricDriveMotor(RightSide)
13ELECͲ604&ELECͲ871HornButton&ContactBlock/Base
14ELECͲ551Joystick
15ELECͲ602&ELECͲ072 DriveEnableButton&ContactBlocks
16ELECͲ826Ͳ3LElectricDriveMotor(LeftSide)
17WHEEͲ707Wheel,10”
18ELECͲ610Ͳ2HourMeter
19ELECͲ631Relay
20WHEEͲ706&HARDͲ001Ͳ2Wheel,8”&Bearing
(NotPictured)ELECͲ809120OhmResistor
Part #SUPO-613E
REV J
Page 39 of 42