Hy-Brid Lifts 1 Series Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
PUSH-AROUND AERIAL WORK PLATFORM
SUPO-643
REV A
HB-P527
SERIES I

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P527
SUPO643
REV A
2
FOREWORD
Original instructions written in English
The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and
maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made
to service this machine.
The operation and safety manual is considered a part of the work platform and contains instructions and operating
procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and
understand all information in the Safety and Operations Manual before operation.
THE OPERATION AND SAFETY MANUAL MUST
BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.
• The user/operator should not accept operating responsibility until the manual has been read and understood as
well as having operated the lift under supervision of an experienced and qualified operator.
• Because the manufacturer has no direct control over machine application and operation, proper safety
practices are the responsibility of the user and all operating personnel.
ANY MODIFICATION ON THIS MACHINE WITH
OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.
DANGER
WARNING
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
3

TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS............................................................................................................................................................... 4
INDEX OF FIGURES.................................................................................................................................................................... 5
SECTION 1 | SAFETY.................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ................................................................................................................................... 6
1.3 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 | MAINTENANCE ................................................................................................................................................... 8
2.1 | BATTERY MAINTENANCE........................................................................................................................................................... 8
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES................................................................................................................8
2.3 | CHARGING THE BATTERY.........................................................................................................................................................8
2.4 | REMOVING PLATFORM CONTROL....................................................................................................................................... 10
2.5 | LUBRICATION..............................................................................................................................................................................10
2.6 | COMPONENTS REQUIRING ADJUSTMENT....................................................................................................................... 10
2.7 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ..............................................................10
2.8 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS.................................................................................................. 10
2.9 | STORAGE...................................................................................................................................................................................... 10
2.10 | MAJOR ALTERATIONS OR REPAIRS.................................................................................................................................... 10
SECTION 3 | MAINTENANCE CHECKLISTS ..........................................................................................................................11
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 12
3.2 | FREQUENT INSPECTION CHECKLIST.................................................................................................................................. 13
3.3 | FREQUENT INSPECTION CHECKLIST.................................................................................................................................. 14
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 16
4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 16
4.2 | ELECTRICAL SCHEMATIC........................................................................................................................................................ 18
SECTION 5 | WIRING DIAGRAMS..........................................................................................................................................20
5.1 | WIRING DIAGRAM ......................................................................................................................................................................20
5.2 | UPPER CONTROL WIRING DIAGRAM .................................................................................................................................22
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS...........................................................................................................24
6.1 | TROUBLESHOOTING FLOWCHART: POWER.....................................................................................................................24
6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING ............................................................................................................26
6.3 | TROUBLESHOOTING FLOWCHART: LOWERING.............................................................................................................28
SECTION 7 | PARTS DIAGRAMS.............................................................................................................................................30
7.1 | SAFETY CONTROL DECALS .....................................................................................................................................................30
7.2 | MAIN POWER/SAFETY CIRCUIT ............................................................................................................................................. 31
7.3 | ELEVATE/LOWER CIRCUIT PARTS .........................................................................................................................................32
7.4 | WHEELS/BREAKS.........................................................................................................................................................................34
7.5 | COVERS/OTHER .........................................................................................................................................................................35
SECTION 8 | WARRANTY........................................................................................................................................................36
NOTES........................................................................................................................................................................................38
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
4
INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use ........................................................................................................................................................ 7
FIGURE 2: Maintenance Lock Storage................................................................................................................................................. 7
FIGURE 3: Battery Charger LED Display.............................................................................................................................................. 9
FIGURE 4: Platform Control Removal................................................................................................................................................ 10
Revisions:
Revision A: Initial Release.............................................................................................................................................September 2015
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
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
1.1 | SAFETY SYMBOLS
1.2 | GENERAL RULES AND PRECAUTIONS
Custom Equipment, LLC designed the Hy-Brid Lift push-around 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, LLC conforms to specified ANSI and CSA
requirements, it is the responsibility of the owner to instruct operators with the safety requirements made not only
by Custom Equipment, LLC, but by the various safety boards in your area, as well as additional requirements set
forth by ANSI abd 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.
SECTION 1 | SAFETY
MAINTENANCE INFORMATION IS FOR USE BY
TRAINED PERSONNEL ONLY.
NEVER REACH BETWEEN SCISSOR LINKS OR
PROP UP PLATFORM UNLESS MAINTENANCE PINS
ARE IN LOCK.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
6
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.
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 handhold’s
• 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
FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY
RESULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
7

SECTION 2 | MAINTENANCE
2.1 | BATTERY MAINTENANCE
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 runtime above the rated capacity and operating batteries below
80°F (2rC) will yield runtime 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.
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.
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME
AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
8
SECTION 2 | MAINTENANCE
Do not operate unit 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 charger plugged in until machine will be used again, the charger will maintain the
battery charge.
DO NOT OPERATE UNIT
WHILE CHARGING
NEVER ADD ACID TO BATTERY.
FIGURE 3: Battery Charger LED Display
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 do 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.
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
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
9

SECTION 2 | MAINTENANCE
2.4 | REMOVING PLATFORM CONTROL
For maintenance, the upper control panel will need to be unscrewed and removed in order to operate from ground
level. Elevate the platform to set the mainenance lock in place.
2.5 | LUBRICATION
Item Specification Frequency
Wheels Teflon Spray Quarterly
2.6 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are
required.
2.7 | 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.
2.8 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS
Check safety functions as part of daily inspection. Check that the brakes are holding.
2.9 | 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.
2.10 | 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.
FIGURE 4: Platform Control Removal
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
10
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).
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
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
11

SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRESTART INSPECTION CHECKLIST
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.
• 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
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:
Emergency Stop (stops all movement)
Up/Down Controls (Elevates, Lowers, Enable button must be pressed)
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
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)
Alarm (Not damaged, sounds for descent)
Up/Down Rocker Switch (Elevates, Lowers)

ڧ
ڧ
ڧ
ڧ

ڧ
ڧ
ڧ
ڧ

ڧ
ڧ
ڧ
ڧ
Wheels: Front and rear wheels rotate freely. ڧڧڧ
Brakes engage and hold when platform is elevated. ڧڧڧ
Date: Inspected By:
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.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
12
SECTION 3 | MAINTENANCE CHECKLISTS
3.2 | FREQUENT INSPECTION CHECKLIST
Model Number: Serial Number:
• 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. ڧڧڧ
Inspect the condition of hydraulic fluid in reservoir. Oil should have a clear amber color. ڧڧڧ
Inspect the entire machine for signs of damage, broken welds, loose bolts, or improper repairs.
(Check for corrosion, cracking, abrasion, etc.) ڧڧڧ
Check that all snap rings are secure in grooves on pivot pins ڧڧڧ
Check if tires are leaning in or out. ڧڧڧ
Verify that bubble level is in place. ڧڧڧ
Verify that maintenance and inspection records are up t o date. ڧڧڧ
Check the tires for damage. ڧڧڧ
Check the hydraulic fluid level with the platform fully lowered. ڧڧڧ
Functional Tests
Perform all check on Pre-Start inspection checklist. ڧڧڧ
Functions operate smoothly ڧڧڧ
Functions operate over full range of motion ڧڧڧ
Emergency lowering — Manual override functions properly ڧڧڧ
Check that the platform does not drift down with a full load ڧڧڧ
Wheels lubricated if needed ڧڧڧ
Comments:
Date: Inspected By:
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.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
13

SECTION 3 | MAINTENANCE CHECKLISTS
3.3 | FREQUENT INSPECTION CHECKLIST
Model Number: Serial Number:
• 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:
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.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
14
THIS PAGE WAS INTENTIONALLY LEFT BLANK
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
15

SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No HS-HB-P3.6/527
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
16
SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
17

4.2 | ELECTRICAL SCHEMATIC
Part No WS-143-20-001-50


1&
12
1&





$03
$UPJXDUG6LJQDO
7,0(
'(/$<
5(/$<
0RWLRQ$ODUPLIVR(TXLSSHG
%HDFRQ/LJKWLIVR(TXLSSHG
$03
$
%
&
'








7+,6'5$:,1*,6&21),'(17,$/$1'35235,(7$5<72&86720(48,30(17$1',6/2$1(',1(;3(&7$7,217
+
SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
18
12
0
2))


3803
62/(12,'
62/(12,'
23(5$7('
839$/9(
62/(12,'
23(5$7('
'2:19$/9(
'RZQ6LJQDO
&
%
$








%6,=(
25,*,1$//<'5$:1%<
&XVWRP(TXLSPHQW,QF
5LFKILHOG:,
3KRQH
'$7(
:6+%3
6&$/(
'21276&$/('5$:,1*
+
$7,7:,//%(.(37&21),'(17,$/$1'86('21/<)257+(385326()25:+,&+,7,6/2$1('
63(&0$7/:LULQJ'LDJUDP
'5$:,1*:6
5(9
'(6&5,37,212)&+$1*(
'$7( 5(9%<
$ ,1,7,$/5(/($6(

*/+
(&2

6+((72)
:(,*+7$3352;/%
$
SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
19

SECTION 5 | WIRING DIAGRAMS
5.1 | WIRING DIAGRAM
Part No WD-143-20-001-50


'2:1
83


3803
5(6(592,5


+<'3803
0
%$77(5<
%$77(5<
&+$5*(5
32:(5
6:,7&+



(/(&
$
%
&
'








7+,6'5$:,1*,6&21),'(17,$/$1'35235,(7$5<72&86720(48,30(17$1',6/2$1(',1(;3(&7$
7
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
20
833(5
&21752/
12 1&
$50*8$5'
29(5/2$'
/,0,76:,7&+


&
%
$








%6,=(
25,*,1$//<'5$:1%<'-6
&XVWRP(TXLSPHQW,QF
5LFKILHOG:,
3KRQH
'$7(
:'+%3
6&$/(
'21276&$/('5$:,1*
7
,217+$7,7:,//%(.(37&21),'(17,$/$1'86('21/<)257+(385326()25:+,&+,7,6/2$1('
63(&0$7/:LULQJ'LDJUDP
'5$:,1*:'
5(9
'(6&5,37,212)&+$1*(
'$7( 5(9%<
$ ,1,7,$/5(/($6(

'-6
(&2

6+((72)
:(,*+7$3352;/%
$
SECTION 5 | WIRING DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
21

5.2 | UPPER CONTROL WIRING DIAGRAM
Part No WD-143-21-004-50



12
(1$%/(

1&
(6723

12
(/(9

12
/:5
7'5





$50*8$5'7,0(5
$/$50
/('
/
/
/
/
/
/
/
$
%
&
'








7+,6'5$:,1*,6&21),'(17,$/$1'35235,(7$5<72&86720(48,30(17$1',6/2$1(',1(;3(
&
SECTION 5 | WIRING DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
22
12 1&
/,0,7
6:,7&+
839$/9(',2'(
'2:19$/9(',2'(
/
/
/
/
/
/
/
/
/
/
/
&
%
$








%6,=(
25,*,1$//<'5$:1%<
&XVWRP(TXLSPHQW,QF
5LFKILHOG:,
3KRQH
'$7(
:'+%3835&7/
6&$/(
'21276&$/('5$:,1*
&
7$7,217+$7,7:,//%(.(37&21),'(17,$/$1'86('21/<)257+(385326()25:+,&+,7,6/2$1('
63(&0$7/:LULQJ'LDJUDP
'5$:,1*:'
5(9
'(6&5,37,212)&+$1*(
'$7( 5(9%<
$ ,1,7,$/5(/($6(

*/+
(&2

6+((72)
:(,*+7$3352;/%
$
SECTION 5 | WIRING DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
23

SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
6.1 | TROUBLESHOOTING FLOWCHART: POWER
Troubleshooting Step 1: Main Power
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
24
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
25

6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING
Troubleshooting Step 2A: Elevating
pg
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
26
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
27

6.3 | TROUBLESHOOTING FLOWCHART: LOWERING
Troubleshooting Step 2B: Lowering
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
28
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
29

SECTION 7 | PARTS DIAGRAMS
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
mode, serial number, or manufacture date specific. Contact your dealer for replacement part availability and pricing.
7.1 | SAFETY CONTROL DECALS
Part Number Description
143-21-006-50-K DECAL KIT, HB-P527
DE600E-14 DECAL,MAINT LOCK
DE601 DECAL,LOGO HY-BRID
DE603-14 MODEL# DECAL-HB-P527
DE666 DECAL, LWR
DE669 DECAL, CONTROL UPR
DE673 DECAL,HYDR FLUID
DE674 DECAL,HYDR FLUID
DE675 DECAL,NO FORK
DE706 DECAL,UPR HB
DE726 DECAL,CAPACITY,500#,1P,I,WO/SO
DE727 DECAL,KEEP
DE728 DECAL,CLEAR
DE730 DECAL,OL ALARM
DE746 DECAL,LANYARD ATTACHMENT
DE751 DECAL,E-DOWN CABLE
DE760 DECAL,E-STOP HANDLE
USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF
NONOEM PARTS WILL VOID WARRANTY.
REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE
STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY,
HYDRAULIC CYLINDER, AND ALL STRUCTURAL COMPONENTS.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
30
7.2 | MAIN POWER/SAFETY CIRCUIT
Item # Part Number Description
1 N/A B- "GROUND" CONNECTION AT PUMP
2 N/A B+ CONNECTION AT PUMPB1
3 ELEC-047-6 BATTERY,12V,GR24 AGM
4 HARD-684 BATTERY STRAP,VELCRO
5 ELEC-634C TERMINAL COVER (RED)
6 ELEC-633-2 SWITCH,BATT DISCONNECT
6 ELEC-633-3 SPARE KEY
8 ELEC-634D TERMINAL BOOT (BLACK)
9 ELEC-641-002 CABLE,6GA,BLACK,12,B/B
10 143-01-025-50 CABLE,6GA,RED,26,R/R,.38 EYES
11 143-01-025-51 CABLE,6GA,BLK,22,B/B,.38 EYES
12 ELEC-746 CHARGER,12V
13 ELEC-639-1 CORD,NEMA 515/IEC C13,12.0
14 ELEC-071-KIT EMERGENCY STOP BUTTON
15 143-21-004-D-50 CTL,UPR ASSEMBLY
16 ELEC-670-2 20A AGC FUSE
SECTION 7 | PARTS DIAGRAMS












MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
31

7.3 | ELEVATE/LOWER CIRCUIT PARTS
SECTION 7 | PARTS DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
32
Item # Part Number Description
1 HYDR-002 Hydraulic Pump
2
HYDR-019
HYDR-022-3
HYDR-681
Hydraulic Fitting
Low Pressure Hydraulic Line
Hydraulic Grommet
3 HYDR-032 Hydraulic Fluid: Not available as a replacement part. Replace with Flomite
#150, Dexron II, Mobil-DTE 2, or equivalent.
4 HYDR-035 Hydraulic Fitting
5 HYDR-600-9 Hydraulic Line
6 HYDR-604 Hydraulic Fitting
7 143-07-005-02 Spacer
8 HYDR-050-8 Hydraulic Pump
9HYDR-673
HYDR-665
Up Valve Coil
Up Valve
10 HYDR-674 Start Solenoid (12V)
11 HYDR-673
HYDR-007-2E-5
Down Valve Coil (12V)
Down Valve
12 WHEE-605-P Shaft Spacer
13 LAS-M115 Emergency Down Lever
14 HARD-650 1/16 Shaft Collar
15 ELEC-123-5 Armguard / Overload Switch
16 ELEC-602-KIT Enable Button
17 ELEC-636 Overload Indicator Light (Not applicable on this model)
18 ELEC-635 Descent Alarm
19 ELEC-002A-KIT Up / Down Rotary Switch
20 143-01-023-02 Maintenance Lock Chock
21 HARD-644-03 Emergency Down Cable
(Not Pictured) ELEC-632 Time Delay Relay (Not active on this model)
(Not Pictured) HARD-021 Retaining Ring,1.25 in.
SECTION 7 | PARTS DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
33

7.4 | WHEELS/BREAKS
Item # Part Number Description
1 143-21-008-50-K Rigid Caster Assembly
2 143-21-009-50-K Swivel Caster Assembly
3
WHEE-706-KIT
WHEE-002-1
WHEE-002-2
Wheel 20.32 cm (8”)
Bearing Kit
Axle Kit
4 HARD-690 Spring
5 143-01-023-02 Brake Actuator
6 143-01-026-02 Brake Cam
SECTION 7 | PARTS DIAGRAMS
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
34
7.5 | COVERS/OTHER








SECTION 7 | PARTS DIAGRAMS
Item # Part Number Description
1 1000307601 RAIL,GATE LATCH
2 HARD-086 LEVEL,BUBBLE
3 143-05-003-01 COVER,PUMP
4 143-05-001-01 COVER, SIDE (BATT.)
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
35

SECTION 8 | WARRANTY
Limited warranty
WARRANTY STATEMENTNORTH AMERICA ONLY
LIMITED WARRANTIES
Subject to the terms, conditions and limitations set forth herein, Custom Equipment, LLC (The “company” warrants
to the first end-user (“buyer”) that:
Limited product warranty
For a period of 12 months from the date that a new product manufactured by the company (“product”) is
delivered to the buyer, the product will (i) conform to the specifications published by the company for such
product as of the date of delivery; and (ii) be free of any defect in material and/or workmanship under normal
use and maintenance; and
Extended structural and chassis warranty
For a period of 60 months from the date that the product is delivered to the buyer, the chassis and other
structural components of such product will be free from defects in material and/or workmanship under
normal use and maintenance.
EXCLUSIONS / WHAT IS NOT COVERED
The following items are not covered under this limited warranty:
• Defects in, and damage or loss relating to, any batteries incorporated by the company into or made a part of the
product. Any such defects, damage or loss shall be exclusively covered by the battery manufacturer’s warranty,
if any. For more information regarding the battery warranty, the buyer should contact the battery manufacturer
using the contact information shown on the battery;
• Damage or loss resulting from or caused by carrier handling;
• Damage or loss resulting from or caused by normal wear and tear, weathering, lack of use or use with
incompatible equipment or software;
• Damage resulting from or caused by improper maintenance, improper handling or storage, improper use,
abuse, neglect, operation beyond rated capacity, or operation after discovery of defective or worn parts;
• Any part, component or assembly altered or modified in any way not approved in writing by the company;
• Damage to any equipment or parts not manufactured by the company; and
• Acts of god, accidents or any other causes beyond the company’s reasonable control.
MAKING A WARRANTY CLAIM
As a prerequisite to making any claim under this limited warranty, buyer must give the company written notice
of any suspected defect promptly after discovery. Such notice shall specifically identify the suspected defect, the
original delivery date and complete buyer identification and location information. The company will not accept any
product for warranty service without receiving buyer’s written notice and issuing a return goods authorization. If
requested by the company, buyer shall return the defective product, or parts, components or assemblies thereof,
to the company, f.O.B, company’s designated location. All returned products or parts, components or assemblies
thereof that are replaced under this limited warranty shall become the property of the company. The company
reserves the right to review buyer’s maintenance and operation records and procedures to determine if the alleged
defect(s) were due to any of the items listed in sections 2 of this limited warranty. The company shall not be liable
for any claim under this limited warranty if buyer fails to satisfy the conditions set forth in this section.
EXCLUSIVE WARRANTY REMEDIES
Exclusive repair or replace remedy
The company’s sole obligation and buyer’s exclusive remedy with respect to any defect in the product
occurring during the warranty periods set forth in section 1 of this limited warranty shall be for the company,
at its option, to repair or replace (or have one of its designated authorized dealers repair or replace) the
product or part, component or assembly thereof that contains a defect in materials or workmanship. The
company reserves the right, at its discretion, to use new, re-manufactured or refurbished replacement parts.
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
36
Notwithstanding anything in this limited warranty to the contrary, the company shall not be obligated to
replace the entire product if a covered defect can be remedied by the repair or replacement of a defective part,
component or assembly. The company shall be responsible for the cost of all parts and labor charges, up to
the maximum labor amount determined in accordance with section 4(b) of this limited warranty, necessary to
remedy such defect.
Labor charges
If field repairs or parts replacement are necessary on any product covered by this limited warranty, the
company will reimburse its designated authorized dealer for those direct labor costs incurred to perform such
field repairs or parts replacement up to the maximum amount specified in the company’s current field service
rate (hereinafter, the “fsr”) or in any ‘flat rate guides’ or similar agreement established with the authorized dealer
(such maximum amount shall be referred to in this limited warranty as the “maximum labor amount”). Current
versions of the company’s fsr and flat rate guides are incorporated by reference into this limited warranty. For a
current copy of the company’s fsr and flat rate guides, buyer should contact the company at 1-866-334-0756.
Buyer shall be responsible for any costs or fees due to the authorized dealer in excess of the maximum labor
amount.
DISCLAIMER OF OTHER EXPRESS AND IMPLIED WARRANTIES
Except for the limited warranties set forth in section 1 above, the company makes no other representations
or warranties and hereby disclaims all express or implied representations or warranties regarding the product,
including, without limitation, any implied warranty of merchantability, non-infringement of proprietary or third-party
rights or fitness for a particular purpose. There are no warranties which extend beyond the description on the face
hereof. No employee or representative of the company or any of its authorized dealers is authorized to modify any
term, condition or limitation in this limited warranty unless such modification is made in writing and signed by an
ocer of the company.
LIMITATION OF LIABILITY
Notwithstanding anything in this warranty to the contrary, in no event shall the company or any of its aliates or
subsidiaries be liable to buyer for any indirect, special, exemplary, punitive or consequential damages (including
lost profits, lost revenue, down time, loss of business opportunity or other economic losses), whether in an action
in contract or tort (including negligence and strict liability) or otherwise, even if the company has been specifically
advised of the possibilities of such damages.
Version of 2.1.13
SECTION 8 | WARRANTY
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
37

NOTES
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
38
NOTES
MAINTENANCE & TROUBLESHOOTING
HBP527
SUPO643
REV A
39