Custom equipment Hy-brid lifts ii series Programming manual

MAINTENANCE & TROUBLESHOOTING MANUAL

SELF-PROPELLED AERIAL WORK PLATFORM

SUPO-653

REV C

HB-830CE

HB-1230CE

SERIES II

BY CUSTOM EQUIPMENT LLC

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

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 FOREWORD

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MAINTENANCE & TROUBLESHOOTING

HB-830CE/HB-1230CE

SUPO-653

REV C

MAINTENANCE & TROUBLESHOOTING

HB-830CE/HB-1230CE

SUPO-653

REV C

B Y C U S TO M EQUIPMENT LLC

2 3

TABLE OF CONTENTS INDEX OF FIGURES

REVISION DATES:

REV A........................................................................................................................................................................................................Date

REV B.......................................................................................................................................................................................October 2014

REV C...........................................................................................................................................................................................March 2015

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 ......................................................................................................................................................... 16

4.2 | ELECTRICAL SCHEMATIC........................................................................................................................................................ 18

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

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

5.1 | WIRING DIAGRAM .....................................................................................................................................................................22

5.2 | LOWER CONTROLS WIRING DIAGRAM ..............................................................................................................................24

5.3 | UPPER CONTROLS WIRING DIAGRAM................................................................................................................................26

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

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

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

6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................32

6.4 | LOWER CIRCUIT.........................................................................................................................................................................34

SECTION 7 | PARTS DIAGRAMS............................................................................................................................................36

7.1 | SAFETY AND CONTROL DECALS..........................................................................................................................................36

7.2 | MAIN POWER/SAFETY CIRCUIT ............................................................................................................................................. 37

7.3 | DRIVE CIRCUIT........................................................................................................................................................................... 40

7.4 | ELEVATELOWER CIRCUIT.......................................................................................................................................................44

7.5 | COVERS.........................................................................................................................................................................................48

7.6 | RAILINGS.......................................................................................................................................................................................49

SECTION 8 | WARRANTY........................................................................................................................................................50

NOTES........................................................................................................................................................................................54

FIGURE 1: Maintenance lock use ......................................................................................................................................................... 7

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

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

B Y C U S TO M EQUIPMENT LLC

MAINTENANCE & TROUBLESHOOTING

HB-830CE/HB-1230CE

SUPO-653

REV C

MAINTENANCE & TROUBLESHOOTING

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SUPO-653

REV C

B Y C U S TO M EQUIPMENT LLC

4 5

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

SECTION 1 | SAFETY SECTION 1 | SAFETY

1.1 | SAFETY SYMBOLS

1.2| GENERAL RULES AND PRECAUTIONS

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, 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.

MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY

NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM

UNLESS MAINTENANCE PINS ARE IN PLACE

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 Storage

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1.4 | STABILITY TESTING

This machine has been stability tested to standards EN: 280 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 EN280:2013, chapter 6.1.4.2.1, or AS14180 chapter 6.5.2, on an

inclination of 2.5º, with 299.5 kg (660 lb.) 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-1230CE S2 the test weight/pull force is 24.6 kg (54.3 lb.)

For the HB-830CE S2 the test weight/pull force is 24.8 kg (54.6 lb.)

SECTION 2 | MAINTENANCE

2.1 | BATTERY MAINTENANCE

This unit is equipped with 12-volt AGM maintenance-free 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!

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.

SECTION 1 | SAFETY

B Y C U S TO M EQUIPMENT LLC

MAINTENANCE & TROUBLESHOOTING

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B Y C U S TO M EQUIPMENT LLC

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SECTION 2 | MAINTENANCE

How to read the battery displays

2.3 | LUBRICATION

Item Speciﬁcation Frequency of Lubrication

Wheels Teﬂon Spray Quarterly

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

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

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10 11

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)

THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR

AFTER EVER SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD

AFFECT THE SAFETY OF THE OPERATOR.

MODEL NUMBER: 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 Y N R

VISUAL INSPECTIONS

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. Hoses and the cables have no worn

areas or chaﬁng. □ □ □

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. □ □ □

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

Emergency Stop (Stops all movement) □ □ □

Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode) □ □ □

Joystick (Return to neutral, drives forward & reverse, elevates & lowers) □ □ □

Drive Enable Trigger (Must be activated to drive) □ □ □

Horn Alarm sounds when button is pushed. □ □ □

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

Emergency Stop (Stops all movement) □ □ □

Key Switch (Selects Platform Control, Ground Control, or O) □ □ □

Up/Down Rocker Switch (Elevates, Lowers) □ □ □

Alarm (Not damaged, sounds for descent, overload) □ □ □

Wheels: Front and rear wheels rotate freely. Front wheels pivot freely. □ □ □

Drives in slow speed when elevated. □ □ □

Brakes: Machine stops when joystick released. □ □ □

Pothole guards deploy and lock when platform is elevated. □ □ □

Lift does not elevate when pothole guards are blocked. □ □ □

DATE: INSPECTED BY:

SECTION 3 | MAINTENANCE CHECKLISTS

3.1 | PRESTART INSPECTION CHECKLIST

B Y C U S TO M EQUIPMENT LLC

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3.2 | PREDELIVERY/ANNUAL/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 NUMBER: 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.

Base: Y N R Extending platform: Y N R

Inspect slide tracks for damage □ □ □ Extends freely □ □ □

All frame bolts tight □ □ □ Cables in place/secure □ □ □

Pump Secure □ □ □ Locks in Stowed Position □ □ □

DC motors secure □ □ □ Locks in Extended Position □ □ □

Covers screwed on □ □ □ Functions: □ □ □

Batteries Fully Charged □ □ □ All Functions Operational □ □ □

Wheels: □ □ □ Emergency Stop Breaks Circuits □ □ □

Snap Rings Secure □ □ □ Slow Speed limit switch Set properly □ □ □

Bolts/Nuts Tight □ □ □ Wiring: □ □ □

Scissors: □ □ □ Switches secure □ □ □

Broken Welds □ □ □ Contactor(s) secure □ □ □

Bent Beam Members □ □ □ Tight on terminals (No loose wiring) □ □ □

All rollers Turn Freely □ □ □ Pothole guards deploy when platform elevated □ □ □

Ret. Rings Secure On Pivots □ □ □ Pothole interlock functions correctly □ □ □

Emergency Down Operational □ □ □ Oil: Level 1” from top □ □ □

Maintenance Locks: □ □ □ Brakes: Operational □ □ □

Pins in cabinet □ □ □ Check all hose for leaks □ □ □

Platform: □ □ □ Check all ﬁttings for leaks □ □ □

Bent rails □ □ □ Battery Charger □ □ □

Broken welds □ □ □ Secure/Operational □ □ □

All rails in place/secure □ □ □ Tilt sensor □ □ □

110V outlet safe/working (if applicable) □ □ □ Warning Horn (if applicable) □ □ □

Entrance gate Closes Freely □ □ □ Hour meter operational □ □ □

Decals: □ □ □ Battery indication operational □ □ □

Legibility □ □ □ All Shields/Guards in place □ □ □

Correct capacity noted □ □ □ Operator/Service Manual □ □ □

Proper placement quantity □ □ □ Overload light & alarm sound when

overloaded. □ □ □

Date: Inspected By:

SECTION 3 | MAINTENANCE CHECKLISTS

THIS PAGE WAS INTENTIONALLY LEFT BLANK

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SECTION 4 | TECHNICAL REFERENCES

1300 psi

8960 kPa

3.78 L/min

TEST PORT

SAEORM #4

HEX SOCKET 3/16

TEST PORT

SAEORM #4

HEX SOCKET 3/16

B-SIZE

ORIGINALLY DRAWN BY: DJS

Custom Equipment, Inc.

Richfield, WI 53076

Phone: (262)644-1300

DATE:10/03/2014

HYDR SCH,HB-830/1230CE S2

SCALE:1:1

DO NOT SCALE DRAWING

THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.

SPEC/MATL: Schematic

DRAWING #: HS-129-20-201-51

REV

DESCRIPTION OF CHANGE

DATE

REV BY

ECO #

SHEET 1 OF 2

WEIGHT: APPROX. 0.00 LB.

4.1 | HYDRAULIC SCHEMATIC

SECTION 4 | TECHNICAL REFERENCES

B Y C U S TO M EQUIPMENT LLC

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SECTION 4 | TECHNICAL REFERENCES SECTION 4 | TECHNICAL REFERENCES

E-STOP

OFF

UP/DOWN ROCKER

LOWER CONTROL

ELEV. ENABLE

JOYSTICK

BRAKE SWITCH

(CTL SIDE)

BRAKE SWITCH

(PUMP SIDE)

TS-100

B+

B-

M1+

M1-

M2+

M2-

P15-7

P15-10 P15-12

P15-9

P15-14P15-13

P15-8

P15-6 P15-5

P15-15

P15-3

P15-11

P15-4

P15-2 P15-1

P9-9

P9-8

P9-6

P9-7 P9-5

P9-3 P9-4P9-2 P9-1

P12-12 P12-11P12-10

P12-9

P12-8

P12-7

P12-6

P12-5 P12-4

P12-3P12-2 P12-1

DRIVE ENABLE

ANG. SENS. 1

ANG. SENS. 2

PRESS. SENS. 2

BRAKE

(PUMP

SIDE)

BRAKE

(CTL

SIDE)

PH LS-L

5 6

KEYSWITCH

PH LS-R

HORN

PRESS. SENS. 1

B-SIZE

ORIGINALLY DRAWN BY:

Custom Equipment, Inc.

Richfield, WI 53076

Phone: (262)644-1300

DATE:

ELEC SCH,HB-1230CE S2

SCALE:1:1

DO NOT SCALE DRAWING

THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.

SPEC/MATL: Schematic

DRAWING #: WS-129-20-201-51

REV

DESCRIPTION OF CHANGE

DATE

REV BY

REVISE LED CONNECTIONS

09/24/2021

ECO #

2015-2439

SHEET 1 OF 1

WEIGHT: APPROX. 0.00 LB.