Custom Equipment HY-BRID LIFTS PRO PS-1030 Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE &
TROUBLESHOOTING
MANUAL
MOBILE
ELEVATING
WORK
PLATFORMS
ANSI A92.20
CSA B354.6:17
PRO
SERIES
PS-1030
PS-1430
PS-1930
PS5.0-M | REV B
SERIAL NO.
PRO
SERIES
INFORMATION
DE1316
To view machine specific information on your
mobile device, scan the code to the left.
Decals with this code can also be found on the
manual box and base of the machine.

PRO SERIES PS-1030 PS-1430  PS-1930
2
This manual refers to serial number(s):
PS-1030 PS10-50001 -
PS-1430 PS14-50001 -
PS-1930 PS19-50001 -
For older Serial Numbers refer to our website:
www.hybridlifts.com/Manuals.htm
Register your Hy-Brid Lift at:
www.hybridlifts.com/RegisterOnline.htm
to receive product updates and service bulletins.
General Information
2647 Hwy 175
Richfield, WI 53076
U.S.A.
[phone]
[phone]
www.hybridlifts.com
Service Information
[phone]
[email protected]
Parts Information
[phone]
[email protected]
Register your Hy-Brid Lift at:
www.hybridlifts.com/RegisterOnline.htm
Register your Hy-Brid Lift to:
• Recieve product updates and recalls
• Recieve service bulletins, product and part
recalls, and other important notifications
• Comply with ANSI A92.20 Standards
• Provide better records for service
REGISTERING YOUR MEWP WITH THE
MANUFACTURER IS AN ANSI A92.20
REQUIREMENT.

3
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
FORWARD
THE OPERATION AND SAFETY MANUAL MUST BE
READ AND UNDERSTOOD PRIOR TO OPERATING THE
MACHINE.
ANY MODIFICATION ON THIS MACHINE WITHOUT
THE EXPRESS WRITTEN CONSENT OF THE
MANUFACTURER IS PROHIBITED.
Original instructions are 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 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.

PRO SERIES PS-1030 PS-1430  PS-1930
4
TABLE OF CONTENTS
FORWARD ....................................................................................................................................................................................3
TABLE OF CONTENTS............................................................................................................................................................... 4
SECTION 1 SAFETY.....................................................................................................................................................................6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ................................................................................................................................... 6
1.3 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 MAINTENANCE ......................................................................................................................................................8
2.1 | BATTERY MAINTENANCE........................................................................................................................................................... 8
2.2 | CHARGING THE BATTERY......................................................................................................................................................... 8
2.3 | LUBRICATION..............................................................................................................................................................................10
2.4 | COMPONENTS REQUIRING ADJUSTMENT....................................................................................................................... 10
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS.............................................................. 10
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS .................................................................................................. 10
2.7 | STORAGE...................................................................................................................................................................................... 10
2.8 | MAJOR ALTERATIONS OR REPAIRS...................................................................................................................................... 10
SECTION 3 MAINTENANCE CHECKLISTS ............................................................................................................................12
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 12
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 | MACHINE HARNESS WIRING DIAGRAM..............................................................................................................................24
5.3 | LOWER CONTROL WIRING DIAGRAM.................................................................................................................................26
5.4 | UPPER CONTROL WIRING DIAGRAM ..................................................................................................................................28
SECTION 6 TROUBLESHOOTING FLOWCHARTS.............................................................................................................. 30
6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................30
6.2 | DRIVE CIRCUIT...........................................................................................................................................................................32
6.3 | STEER CIRCUIT...........................................................................................................................................................................34
6.4 | ELEVATE CIRCUIT ......................................................................................................................................................................36
6.5 | LOWER CIRCUIT.........................................................................................................................................................................38
SECTION 7 PARTS.................................................................................................................................................................... 40
SECTION 8 WARRANTY.......................................................................................................................................................... 42
8.1 | LIMITED WARRANTY..................................................................................................................................................................42
8.2 | LIMITED WARRANTIES..............................................................................................................................................................42
8.3 | EXCLUSIONS/WHAT IS NOT COVERED ..............................................................................................................................42
8.4 | MAKING A WARRANTY CLAIM................................................................................................................................................42
8.5 | EXCLUSIVE WARRANTY REMEDIES.......................................................................................................................................43
8.6 | DISCLAIMER OF OTHER EXPRESS AND IMPLIED WARRANTIES...................................................................................43
8.7 | LIMITATION OF LIABILITY ........................................................................................................................................................43
SECTION 9 INSPECTION & REPAIR LOG............................................................................................................................. 44

5
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
TABLE OF CONTENTS
FIGURE 1: Maintenance Lock Use .........................................................................................................................................................7
FIGURE 2: Maintenance Lock Storage.................................................................................................................................................. 7
FIGURE 3: Battery Location .....................................................................................................................................................................8
FIGURE 4: Charger Cord Location ........................................................................................................................................................8
FIGURE 5: Battery Charger LED Display...............................................................................................................................................9
FIGURE 6: LED Light Diagnostic Location........................................................................................................................................ 20
FIGURE 7: EZ Cal Handheld Controller............................................................................................................................................. 20
REVISION LOG:
REV A..............................................................................................................................................................................................May 2020
REV B................................................................................................................................................................................. November 2020
INDEX OF FIGURES

PRO SERIES PS-1030 PS-1430  PS-1930
6
SECTION 1 SAFETY
1.1 | SAFETY SYMBOLS
MAINTENANCE INFORMATION IS FOR USE BY
TRAINED PERSONNEL ONLY.
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.
1.2 | GENERAL RULES AND PRECAUTIONS
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 ANSI, OSHA and CSA, 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 ANSI, OSHA or CSA. If
you come across a situation that you think might be unsafe, stop the platform and request further information
from qualified sources before proceeding.
NEVER REACH BETWEEN SCISSORS LINKS OR PROP
UP PLATFORM UNLESS MAINTENANCE PINS ARE IN
PLACE.

7
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 1 SAFETY
1.3 | SAFETY GUIDELINES
Maintenance Lock
The maintenance lock must be placed into position whenever the machine is being serviced in the raised or
partially raised position. Serious injury and/or death could result if maintenance lock is not used properly.
FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Storage
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.

PRO SERIES PS-1030 PS-1430  PS-1930
8
SECTION 2 MAINTENANCE
NEVER ADD ACID TO BATTERY!
2.1 | BATTERY MAINTENANCE
This unit is equipped with deep cycle 12-volt
batteries. The care and maintenance of your
batteries 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.
• Remove side cover 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.
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.
2.2 | CHARGING THE BATTERY
The charger may include an interlock circuit. If so
equipped, the unit will not operate while charging.
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.
FIGURE 3: Battery Location
FIGURE 4: Charger Cord Location
Hydraulic Pump Side
Lower Controls Side

9
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 2 MAINTENANCE
BATTERIES GENERATE EXPLOSIVE GASES. KEEP
SPARKS AND FLAME AWAY FROM BATTERIES. DO NOT
SMOKE WHILE CHARGING.
FIGURE 5: Battery Charger LED Display
DO NOT OPERATE UNIT WHILE CHARGING. DO NOT
DISABLE CHARGER INTERLOCK.
Battery Charge Display: Pro Charging Systems IS2412
MEANING
(OFF) (SOLID)
Standby Mode
(Or battery/ connection error)
(FLASHING) (SOLID)
Normal Charging
Bulk Charging
(SOLID) (SOLID)
Normal Charging
Absorption Stage
(SOLID) (SOLID)
Charge Complete
Flat/Maintenance Mode
(FLASHING) (FLASHING)
Charger Error

PRO SERIES PS-1030 PS-1430  PS-1930
10
SECTION 2 MAINTENANCE
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. Contact the manufacturer if adjustments are
required.
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 the
Maintenance 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.

11
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
THIS PAGE WAS INTENTIONALLY LEFT BLANK

PRO SERIES PS-1030 PS-1430  PS-1930
12
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 minimal 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 EVERY SIX TO EIGHT
HOURS OF USE. FAILURE TO DO SO COULD AFFECT
THE SAFETY OF THE OPERATOR.
• Keep inspection records up-to-date.
• Record and report all discrepancies to your
supervisor.
• A dirty machine cannot be properly inspected.
3.1 | PRESTART INSPECTION CHECKLIST

13
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 3 MAINTENANCE CHECKLISTS
PRO SERIES PRE-START INSPECTION CHECKLIST
(Print this page for additional inspections)
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A-Not Equipped Y N R N/A
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.
If machine is equipped with LeakGuard check tray for hydraulic fluid
Check the tires for damage.
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 Mode Button (Selects drive/steer mode)
Up/Down Button (Selects elevate mode)
Joystick: (Return to neutral, drives forward & reverse,)
Enable Trigger (Must be activated for joystick-operated movement)
Rocker Switch (Moves front wheels left and right)
Elevates & lowers
Horn sounds when button is pressed.
Information button cycles through battery life (percent), load capacity (percent),
and hour meter (hours) when pressed.
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement/Disconnects battery)
Key Switch/Master Power Switch (Selects Platform Control, Ground Control, or O )
Up/Down Rocker Switch (Elevates, Lowers)
Descent/Tilt Alarm
(Not damaged, sounds for descent; may also sound for drive & elevate, if so equipped)
Wheels: Front wheels rotate freely. They are not bent, and lug nuts are tight.
Drives in slow speed when elevated.
Brakes: Machine stops when joystick released. Brakes hold the unit when on an allowable grade.
Alarm sounds and machine moves feely when brakes are released.
Brakes engage when power is cycled.
Pothole guards deploy and lock when platform is elevated.
Lift does not elevate when pothole guards are blocked.
DATE: INSPECTED BY:
Model: Serial No.

PRO SERIES PS-1030 PS-1430  PS-1930
14
SECTION 3 MAINTENANCE CHECKLISTS
Model:
Serial No.
• 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.
3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST
WORK PLATFORMS SHALL BE INSPECTED,
SERVICED, AND ADJUSTED TO MANUFACTURER’S
REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR
TO EACH SALE, LEASE, OR RENTAL, AND EVERY 3
MONTHS OR 150 HOURS, WHICHEVER COMES FIRST,
AND ANNUALLY.
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A-Not Equipped Y N R N/A
BASE:
Inspect slide tracks for damage
All frame bolts tight
Pump secure
DC drive motors secure
Batteries fully charged
Tie rods secure
WHEELS:
Snap rings secure
Bolts/nuts tight
SCISSORS:
No broken welds
No bent beam members
All rollers turn freely
Retaining rings secure on pivots
Maintenance locks: Stored and securely connected
Scissor beam tube bolts tight
PLATFORM:
No bent rails
No broken welds
All rails in place/secure
110V outlet safe/working
Entrance gate closes freely

15
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 3 MAINTENANCE CHECKLISTS
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A-Not Equipped Y N R N/A
DECALS:
Legibile
Correct capacity noted
Proper placement & quantity.
RAILS/EXTENDING PLATFORM:
Extends freely
Cables in place/secure
Locks in stowed position
Locks in extended position
FUNCTIONS:
All functions (Drive,Elevate,Steer) operational (see Pre-Start Inspection for details)
Pothole guards deploy when platform elevated
Emergency stop breaks circuits
Slow speed mode activates just after units pothole bars are deployed
Pothole interlock functions correctly
BRKAES:
Operational
EMERGENCY DOWN:
Operational
WIRING:
Switches secure
Contactor(s) secure
Tight on terminals (No loose wiring)
OIL:
Level 1” from top (when platform stowed)
OTHER:
Check all hoses for leaks
Check all fittings for leaks
Battery charger secure/operational
When tilted past the allowable degree, unit will not elevate
Warning horn
Hour meter operational
Battery indication operational
Operator’s Manual is on the unit
Overload light & alarm sounds when overloaded
DATE: INSPECTED BY:

PRO SERIES PS-1030 PS-1430  PS-1930
16
SECTION 4 TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No. HS-112-20-501-50
M
2 GPM
AIR
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
HYDR SCH,PS1930 S5
HS-112-20-501
1:1 N/A 1 OF 1
T.VUE 04/29/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
04/29/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
04/16/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY

17
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 4 TECHNICAL REFERENCES
M
2 GPM
AIR
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
HYDR SCH,PS1930 S5
HS-112-20-501
1:1 N/A 1 OF 1
T.VUE 04/29/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
04/29/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
04/16/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY
BY CUSTOM EQUIPMENT LLC
2647 HWY 175, RICHFIELD, WI, 53076

PRO SERIES PS-1030 PS-1430  PS-1930
18
SECTION 4 TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC
Part No. WS-112-20-501-50
OFFOFF
1K
1W
+
-
-
+
-
+
M
NO NC
P-12
1
B1
F1 F3 F4F2 E2E1
C5C3C1C2 C4 B10 B7B4 B6B8 B12 A10 B5 A1A7A4 C8
B- M1+
P-3
1
M2-
P-4
2
P-4
1
P-3
2
M1- M2+ B+
P-4
4
P-4
3
P-9
8
P-9
3
P-9
5
P-9
4
P-9
2
P-12
12
P-12
4
P-15
7
P-9
1
P-15
1
P-12
5
P-12
7
P-12
10
P-15
10
P-15
4
P-12
8
P-12
6
TS-100
ANG SENS 1
ANG SENS 2
PRES SENS 1
M
BEACON
J1
J2 J3
J9
J14
J4
J5 J6J7 J8
J10
J11
J12
J13
J15
STEERING
CONTACTOR
T1 GRD
T2
REV
+BAT
FWD
NC NO NO
NC
M
TB1
30 AMP
20 AMP
TB1
TB1
NONO
K5 K2
M
H1H2
TB
1
2
TB
3
4
L2
L1
23
9
8
7
456
1
10 11 12
13 14 15
23
9
8
7
456
1
10 11 12
23
9
8
7
456
1
23
6
5
4
1
123
41 2 3
12
5
4 3
2 1
KEY SWITCH / PF CTRL
KEY SWITCH / GRND CTRL
DOWN VALVE
UP VALVE
ANGLE SENSOR #1 ANGLE SENSOR #2
PRESSURE SENSOR SIGNAL
SENSOR POWER
LOW SIDE ALARM OUTPUT
DOWN SIGNAL
UP SIGNAL
LOW SIDE LED OUTPUT
BRAKE COIL SIGNAL
MAIN POWER CONTACTOR SIGNAL
POTHOLE L/S SIGNAL
PUMP CONTACTOR SIGNAL
EZCAL 232 COM PORT CANBUS HIGH CANBUS LOW EZCAL 232 COM PORT EZCAL 232 COM PORT EZCAL 232 COM PORT
LEFT STEER SIGNAL
RIGHT STEER SIGNAL
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
ELEC SCH,PRO SERIES,S5
WS-112-20-501
1:1 N/A 1 OF 1
T.VUE 04/13/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
04/29/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
2019-3296
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
Revise Hydraulic Pump Ground Connection
04/21/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY
A,J B C
D
F,G
E
K
H,L,

19
MAINTENANCE & TROUBLESHOOTING MANUAL PS5.0-M REV B
SECTION 4 TECHNICAL REFERENCES
OFFOFF
1K
1W
+
-
-
+
-
+
M
NO NC
P-12
1
B1
F1 F3 F4F2 E2E1
C5C3C1C2 C4 B10 B7B4 B6B8 B12 A10 B5 A1A7A4 C8
B- M1+
P-3
1
M2-
P-4
2
P-4
1
P-3
2
M1- M2+ B+
P-4
4
P-4
3
P-9
8
P-9
3
P-9
5
P-9
4
P-9
2
P-12
12
P-12
4
P-15
7
P-9
1
P-15
1
P-12
5
P-12
7
P-12
10
P-15
10
P-15
4
P-12
8
P-12
6
TS-100
ANG SENS 1
ANG SENS 2
PRES SENS 1
M
BEACON
J1
J2 J3
J9
J14
J4
J5 J6J7 J8
J10
J11
J12
J13
J15
STEERING
CONTACTOR
T1 GRD
T2
REV
+BAT
FWD
NC NO NO
NC
M
TB1
30 AMP
20 AMP
TB1
TB1
NONO
K5 K2
M
H1H2
TB
1
2
TB
3
4
L2
L1
23
9
8
7
456
1
10 11 12
13 14 15
23
9
8
7
456
1
10 11 12
23
9
8
7
456
1
23
6
5
4
1
123
41 2 3
12
5
4 3
2 1
KEY SWITCH / PF CTRL
KEY SWITCH / GRND CTRL
DOWN VALVE
UP VALVE
ANGLE SENSOR #1 ANGLE SENSOR #2
PRESSURE SENSOR SIGNAL
SENSOR POWER
LOW SIDE ALARM OUTPUT
DOWN SIGNAL
UP SIGNAL
LOW SIDE LED OUTPUT
BRAKE COIL SIGNAL
MAIN POWER CONTACTOR SIGNAL
POTHOLE L/S SIGNAL
PUMP CONTACTOR SIGNAL
EZCAL 232 COM PORT CANBUS HIGH CANBUS LOW EZCAL 232 COM PORT EZCAL 232 COM PORT EZCAL 232 COM PORT
LEFT STEER SIGNAL
RIGHT STEER SIGNAL
DESCRIPTION
SCALE WEIGHT (LBS.)
SHEET
THIRD ANGLE PROJECTION
DRAWN
NAME DATE
P: 1-262-644-1300
F: 1-262-247-0073
ELEC SCH,PRO SERIES,S5
WS-112-20-501
1:1 N/A 1 OF 1
T.VUE 04/13/2020
SIZE
B
DWG NO.
A
REV
DO NOT SCALE DRAWING
04/29/2020 T.VUE APPROVED
DATE REV BY DESCRIPTION OF CHANGE
REVISION HISTORY
ECO #
2019-3296
THE INFORMATION CONTAINED IN THIS DRAWING IS
THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND
IS LOANED IN EXPECTATION THAT IT WILL BE KEPT
CONFIDENTIAL. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF
CUSTOM EQUIPMENT IS PROHIBITED.
Revise Hydraulic Pump Ground Connection
04/21/2020 T.VUE
REV
A
CONFIGURATIONS
-50: GENERAL ASSEMBLY
A,J B C
D
F,G
E
K
H,L,
BY CUSTOM EQUIPMENT LLC
2647 HWY 175, RICHFIELD, WI, 53076

PRO SERIES PS-1030 PS-1430  PS-1930
20
SECTION 4 TECHNICAL REFERENCES
4.3 | CONTROL BOARD DIAGNOSTIC
When using the LED for diagnosis, note that a
DUAL FLASH code is indicated. The LED will flash
on/o a certain number of times, pause o for
a short delay, then flash on/o a second certain
number of times, followed by a much longer
pause o. The sequence will then repeat.
EXAMPLE: The LED flash code 3-2 will look like:
on/o/on/o/on/o-short-delay/on/o/on/o-
long-delay/repeat
FIGURE 6: LED Light Diagnostic Location
LED Code Possible Cause
Fast Flash Control Module is not calibrated, Do not operate unit.
Steady
Unit has just been powered on. You may need to wait for initialization, then re-select function.
Ready to operate, things should be working normally.
A function is selected but the enable trigger is not squeezed.
1-1 The control module is not calibrated. Do not use this unit.
2-1
The key switch selector switch indicate the mode in which the TS100 must operate. If neither
input is active, or if both are active together, the TS100 does not know how to function.
Check key switch and wiring to P15-1 and P12-1.
2-2
A safety feature is locking functions or a switch has failed.
Check that platform is not overloaded, operating on a level surface, and pothole guards deploy.
Check that joystick is neutral when powered on.
Check that joystick trigger is not closed for too long without selecting a function.
Check for failed joystick, selector switches, and up/down switches.
3-x
There is a problem with the drive contactor or valve wiring, or with the motor power wiring;
disconnect connector P9 to see if the problem is caused by drive contactor or valve wiring (if
the fault clears, check for an illegal B+ supply in to P9)
Check motor power wiring; with the drive contactor open the B+ power terminals should be at
10V-15V (significantly lower than B+) If the LED is steady at power-on, and the fault (3-5) occurs
after a delay when attempting to drive or lift, the motor may be stalled and causing an overload
of the TS100 or there is a power wiring error like connecting the B+ cable to a motor stud
FIGURE 7: EZ Cal Handheld Controller
If a handheld controller (Part no: ELEC-646-5)
is available, it will display error codes and their
description