Custom Equipment HY-BRID LIFTS I HB-P4.5 Programming manual

MAINTENANCE & TROUBLESHOOTING MANUAL
PUSH-AROUND AERIAL WORK PLATFORM
SUPO-648
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HB-P4.5
HB-P5.0
SERIES I
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: [phone]
F: [phone]
www.hybridlifts.com
NOTES
If there is a question about application
and/or operation, contact:
Custom Equipment, LLC
2647 Hwy 175
Richfield, WI 53076
U.S.A.
P: [phone]
F: [phone]
www.hybridlifts.com
MAINTENANCE & TROUBLESHOOTING
HBP4.5/HBP5.0
SUPO648
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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
FOREWORD
MAINTENANCE & TROUBLESHOOTING
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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 | STABILITY TESTING...................................................................................................................................................................... 7
1.4 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 | MAINTENANCE .................................................................................................................................................10
2.1 | BATTERY MAINTENANCE AGM BATTERIES......................................................................................................................... 10
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES ............................................................................................................. 10
2.3 | CHARGING THE BATTERY........................................................................................................................................................11
2.4 | LUBRICATION.............................................................................................................................................................................. 13
2.5 | COMPONENTS REQUIRING ADJUSTMENT....................................................................................................................... 13
2.6 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS .............................................................13
2.7 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ................................................................................................. 13
2.8 | STORAGE .................................................................................................................................................................................... 13
2.9 | MAJOR ALTERATIONS OR REPAIRS ..................................................................................................................................... 13
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 14
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 15
3.2 | FREQUENT INSPECTION CHECKLIST.................................................................................................................................. 16
3.3 | PREDELIVERY/ANNUAL CHECKLIST ....................................................................................................................................17
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 18
4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 18
4.2 | ELECTRICAL SCHEMATIC........................................................................................................................................................20
SECTION 5 | WIRING DIAGRAMS.......................................................................................................................................... 22
5.1 | WIRING DIAGRAM ......................................................................................................................................................................22
5.2 | UPPER CONTROL WIRING DIAGRAM..................................................................................................................................24
SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................26
6.1 | TROUBLESHOOTING FLOWCHART: POWER.....................................................................................................................26
6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING .............................................................................................................28
6.3 | TROUBLESHOOTING FLOWCHART: LOWERING.............................................................................................................30
SECTION 7 | PARTS DIAGRAMS............................................................................................................................................. 32
7.1 | SAFETY AND CONTROL DECALS...........................................................................................................................................32
7.2 | MAIN POWER/SAFETY CIRCUIT ............................................................................................................................................33
7.3 | ELEVATE/LOWER CIRCUT PARTS...........................................................................................................................................34
7.4 | WHEELS/BREAKS.........................................................................................................................................................................36
7.5 | COVERS/OTHER ......................................................................................................................................................................... 37
SECTION 8 | WARRANTY........................................................................................................................................................38
SECTION 9 | INSPECTION AND REPAIR LOG .....................................................................................................................40
NOTES........................................................................................................................................................................................42
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INDEX OF FIGURES
FIGURE 1: Equivalent Stability Test........................................................................................................................................................ 7
FIGURE 2: Maintenance PIN Lock Use................................................................................................................................................ 7
FIGURE 3: Maintenance PIN Lock Storage......................................................................................................................................... 7
FIGURE 4: Battery Maintenance Access............................................................................................................................................ 10
FIGURE 5: Battery Charger LED Display............................................................................................................................................ 12
Revision Log:
REV A: Initial Release...................................................................................................................................................................FEB 2014
REV B:.............................................................................................................................................................................................MAY 2014
REV F: Reference 2804..............................................................................................................................................................DEC 2015
REV G:..........................................................................................................................................................................................JUNE 2016
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1.2 | GENERAL RULES AND PRECAUTIONS
MAINTENANCE INFORMATION IS FOR USE
BY TRAINED PERSONNEL ONLY.
NEVER REACH BETWEEN SCISSORS
LINKS OR PROP UP PLATFORM UNLESS
MAINTENANCE PINS ARE IN PLACE.
SECTION 1 | SAFETY
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
CAUTION
DANGER
WARNING
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, 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.
1.1 | SAFETY SYMBOLS
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SECTION 1 | SAFETY
1.3 | STABILITY TESTING
The HB-P4.5 and HB-P5.0 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 HB-
P4.5 and the HB-P5.0, the test weight/pull force is 22.8 kg / 50 lb.
1.4 | 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: Equivalent Stability Test
FIGURE 2: Maintenance PIN Lock Use FIGURE 3: Maintenance PIN Lock Storage
MAINTENANCE & TROUBLESHOOTING
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SECTION 1 | SAFETY
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
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THIS PAGE WAS INTENTIONALLY LEFT BLANK
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SECTION 2 | MAINTENANCE
2.1 | BATTERY MAINTENANCE AGM BATTERIES
Battery cycle life will vary significantly depending on the depth of discharge. The deeper the depth of discharge the
fewer cycles a battery will deliver. Conversely, the shallower the depth of discharge the more cycles a battery will
deliver. To optimize the health of your battery, limit discharge to 80%.
The performance and life of a battery will vary with application, usage, temperature and depth of discharge. AGM
batteries tend to deliver higher than their rated capacity (up to 10-15% higher) for -30 cycles until they are “broken in”
and settle at their rated capacity.
Operating batteries above 80°F (27°C) will yield runtimes above the rated capacity and operating batteries below
80°F (2rC) will yield runtimes below the rated capacity. Cold temperatures can significantly reduce battery capacity.
Although higher temperatures increase the battery capacity they also accelerate corrosion and reduce overall
battery life.
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES
If this unit is equipped with a deep cycle 12-volt Group 27 battery, the care and maintenance of your battery has
much to do with how well this unit functions. Battery wiring and water level should be checked monthly. Do not
overfill. When the cells are too full, fluid will seep out when charging. The solution is at its proper strength when
the battery is manufactured. Use distilled water and keep fluid up to proper level. When required, water should be
added to battery after charging, unless water level is below the plates.
• Slide cabinet open to access battery.
• Remove battery caps and check fluid level.
• Fill each cell (if needed) to split ring with distilled water.
• Reinstall caps.
• Wash all dirt, debris, acid, etc., o battery whenever corrosion is detected. Use a solution of 5ml baking soda
per 0.95 liters of warm water.
• Coat terminals with a commercially available coating.
• Close cabinet and latch in place.
FIGURE 4: Battery Maintenance Access
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2.3 | CHARGING THE BATTERY
This unit is equipped with either a deep cycle 12-volt AGM maintenance-free battery or a deep cycle Group 27
battery.
Batteries should be fully charged after each use. Opportunity charging can be done but the batteries should be fully
charged at least every other day if they are used daily. Charge in a ventilated area as gases may be released through
the pressure relief valve if the batteries are excessively over-charged.
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.
Do not operate unit while charging. Shortened battery life will result.
• Park the machine on a level surface.
• Plug charger into AC outlet until charged.
• For best battery life, leave charger plugged in until machine will be used again. The charger will maintain the
battery charge
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME
AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
DO NOT OPERATE UNIT WHILE CHARGING NEVER ADD ACID TO BATTERY!
SECTION 2 | MAINTENANCE
MAINTENANCE & TROUBLESHOOTING
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SECTION 2 | MAINTENANCE
How to read battery display
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 bother outputs are
finished charging and are in a float maintenance mode.
FIGURE 5: Battery Charger LED Display
POWER BATTERY 1 STATUS
CHARGING READY
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
Green LED
(ON)
Red LED
(ON)
Green LED
(OFF)
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
POWER BATTERY 1 STATUS
CHARGING READY
POWER BATTERY 1 STATUS
CHARGING READY
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SECTION 2 | MAINTENANCE
2.4 | LUBRICATION
Item Specification Frequency of Lubrication
Wheels Teflon Spray Quarterly
2.5 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are
required.
2.6 | 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.
2.7 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS
Check safety functions as part of daily inspection. Check that the brakes are holding.
2.8 | 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 the
Maintenance Manual.
2.9 | 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.
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SECTION 3 | MAINTENANCE CHECKLISTS
FAILURE TO PERFORM INSPECTIONS AND PREVENTATIVE
MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN THE
UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT
IN INJURY OR DEATH OF THE OPERATOR.
Regular inspection and conscientious maintenance is important to 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 required and included in this manual:
• Pre-Start (Required before operation at each work shift)
• Frequent (Required at intervals not more than three months)
• Pre-Delivery/Annual (Required at intervals not more than twelve months)
The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week,
5 load cycles per hour).
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SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRE-START INSPECTION CHECKLIST
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: SERIAL NUMBER:
• Keep inspection records up-to-date.
• Record and report all discrepancies to your supervisor.
• 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. ڧڧڧ
There are no loose or missing parts. ڧڧڧ
Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly
marked.
ڧڧڧ
Check the platform rails and safety gate for damage. ڧڧڧ
Platform and base controls are not missing, damaged, or disconnected. ڧڧڧ
Electrical cables and wires are not torn, frayed, or disconnected. ڧڧڧ
Hydraulic hoses are not torn or loose, and there are no leaks. Check that hoses and cables have no
worn areas or chafing. ڧڧڧ
Check the tires for damage. ڧڧڧ
Check that all snap rings are secure in grooves on pivot pins. ڧڧڧ
FUNCTIONAL TESTS
Gate closes automatically and latches (alignment can be adjusted with screw-on toe board or
railing). ڧڧڧ
Platform Controls — Check all switches and push buttons for proper operation:
Up/Down Controls (Elevates, Lowers, Enable button must be pressed) ڧڧڧ
Emergency Stop (stops all movement) ڧڧڧ
Base Controls — Check all switches and push buttons for proper operation
Emergency Stop (stops all movement) ڧڧڧ
Key Switch (Selects Platform Control, Ground Control, or O) ڧڧڧ
Alarm (Not damaged, sounds for descent) ڧڧڧ
Up/Down Rocker Switch (Elevates, Lowers) ڧڧڧ
Wheels: Front and rear wheels rotate freely. ڧڧڧ
Brakes engage and hold when platform is elevated. ڧڧڧ
DATE: INSPECTED BY:
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• 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
Description YNR
VISUAL INSPECTIONS
Perform all the checks on the Pre-Start Inspection Checklist. □□ □
Inspect the condition of hydraulic fluid in reservoir. Oil should have a clear amber color. □□ □
Inspect the entire machine for signs of damage, broken welds, loose bolts, or improper repairs.
(Check for corrosion, cracking, abrasion, etc.)
□□ □
Check that all snap rings are secure in grooves on pivot pins □□ □
Check if tires are leaning in or out. □□ □
Verify that bubble level is in place. □□ □
Verify that maintenance and inspection records are up t o date. □□ □
Check the hydraulic fluid level with the platform fully lowered. □□ □
Functional Tests
Perform all check on Pre-Start inspection checklist. □□ □
Functions operate smoothly □□ □
Functions operate over full range of motion □□ □
Emergency lowering — Manual override functions properly □□ □
Check that the platform does not drift down with a full load □□ □
Wheels lubricated if needed □□ □
Comments:
DATE: INSPECTED BY:
SECTION 3 | MAINTENANCE CHECKLISTS
3.2 | FREQUENT INSPECTION CHECKLIST
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: SERIAL NUMBER:
MAINTENANCE & TROUBLESHOOTING
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SECTION 3 | MAINTENANCE CHECKLISTS
3.3 | PRE-DELIVERY/ANNUAL CHECKLIST
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: 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
BASE: Y N R PLATFORM: Y N R
Inspect slide tracks for damage □□□ All rails in place/secure □□□
All frame bolts tight □□□ No bent rails □□□
Pump Secure □□□ No broken welds □□□
DC motor secure □□□ Platform power outlet safe/working (if installed) □□□
Battery Hold Downs Secure □□□ Entrance gate closes freely □□□
Batteries Fully Charged □□□ Cables in place/secure □□□
Counterweights secured □□□ FUNCTIONS:
Wheels: Grease casters □□□ Elevate/Lower Operational □□□
Wheels: Bolts/Nuts Tight □□□ Master Power Switch Breaks Circuits □□□
Maintenance Locks: Pins storage
location □□□
Emergency Stop Breaks Circuits □□□
All Shields/Guards in place □□□ Emergency Down Operational □□□
Hydraulic Oil Level □□□ Motion Alarms Functional □□□
Check all hydraulic hoses for leaks □□□ Brakes: Operational □□□
Check all hydraulic fittings for leaks □□□ Bubble Level in Place □□□
SCISSORS
When beginning to elevate, overload light and
alarm activate. Then, if not overloaded, allows
elevation to continue, and light and alarm stop.
□□□
No Broken Welds □□□ When overloaded, platform stops elevating. □□□
Ret. Rings Secure on Pivots □□□ Check battery Voltage: <12.5V, charge. □□□
No Bent Beam Members □□□ WIRING/OTHER:
All rollers turn freely □□□ Switches secure □□□
DECALS: Contactor(s) secure □□ □
Legibility □□□ Tight on terminals (no loose wiring) □□□
Correct capacity noted □□□ Operator / Service Manual Included □□□
Proper placement quantity □□□ Battery Charger Secure / Operational □□□
COMMENTS:
Date: Inspected By:
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No. HS-HB-P4.5/5.0
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SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
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