Hy-Brid Lifts HB-1230 User manual

MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-646
REV A
HB-1230
SERIES I
BY CUSTOM EQUIPMENT LLC

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
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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
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TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS............................................................................................................................................................... 4
INDEX OF FIGURES.................................................................................................................................................................... 5
SECTION 1 | SAFETY.................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ................................................................................................................................... 6
1.3 | 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
2.9 | OTHER PROCEDURES.............................................................................................................................................................. 10
SECTION 3 | MAINTENANCE CHECKLISTS ..........................................................................................................................11
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 12
3.2 | MONTHLY INSPECTION CHECKLIST ................................................................................................................................... 13
3.1 | 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 DIAGNOSTICS........................................................................................................................................20
SECTION 5 | WIRING DIAGRAMS.......................................................................................................................................... 22
5.1 | WIRING DIAGRAM .....................................................................................................................................................................23
5.2 | LOWER CONTROLS WIRING DIAGRAM ..............................................................................................................................24
5.3 | UPPER CONTROLS WIRING DIAGRAM................................................................................................................................26
5.4 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................28
5.5 | DRIVE CIRCUIT ...........................................................................................................................................................................30
5.6 | ELEVATE/LOWER CIRCUIT ......................................................................................................................................................32
SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................34
6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................34
6.2 | DRIVE CIRCUIT...........................................................................................................................................................................36
6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................38
6.4 | LOWER CIRCUIT........................................................................................................................................................................ 40
SECTION 7 | PARTS DIAGRAMS.............................................................................................................................................42
7.1 | SAFETY AND CONTROL DECALS...........................................................................................................................................42
7.2 | MAIN POWER/SAFETY CIRCUIT .............................................................................................................................................43
7.3 | DRIVE CIRCUIT............................................................................................................................................................................44
7.4 | ELEVATE / LOWER CIRCUIT ....................................................................................................................................................46
7.5 | COVERS.........................................................................................................................................................................................48
7.6 | RAILINGS.......................................................................................................................................................................................49
SECTION 8 | WARRANTY........................................................................................................................................................50
SECTION 9 | ADDITIONAL RESOURCES .............................................................................................................................. 52
NOTES........................................................................................................................................................................................54
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Revision Log
Revision A..........................................................................................................................................................................December 2013
INDEX OF FIGURES
FIGURE 1: Battery Charger LED Display .............................................................................................................................................. 9
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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 self-propelled scissors 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 American National Standards Institute ANSI/SIA A92.6
Standard, 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 A92.6. 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
SECTION 1 | SAFETY
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SECTION 1 | SAFETY
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 Operation and Safety Manual.
• Keep oil, grease, water, etc. wiped from standing surfaces and handholds.
• Before making any adjustments, lubricating or performing any other maintenance, shut o all power controls.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in their proper place.
• Use only approved nonflammable cleaning solvents.
• After maintenance, inspect the machine as described for Pre-delivery.
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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 runtimes above the rated capacity and operating batteries below
80°F (27°C) will yield runtimes below the rated capacity. Cold temperatures can significantly reduce battery capacity.
Although higher temperatures increase the battery capacity they also accelerate corrosion and reduce overall
battery life.
2.2 | CHARGING THE BATTERY
This unit is equipped with a two deep cycle 12-volt AGM maintenance-free batteries.
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.
NEVER ADD ACID TO BATTERY!
To Charge:
• Park the machine on a level surface.
• Plug charger into AC outlet until charged.
• Unplug charger.
LEADACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. DO
NOT SMOKE WHILE CHARGING.
The charger will not begin charging on severely discharged batteries. This will be evident by the three indicators
blinking simultaneously.
SECTION 2 | MAINTENANCE
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DO NOT OPERATE UNIT WHILE CHARGING.
DO NOT DISABLE CHARGER INTERLOCK.
How to read the battery displays
SECTION 2 | MAINTENANCE
FIGURE 1: Battery Charger LED Display
Power
Power
Power
Green LED (ON)
Green LED (ON)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Green LED (OFF)
Green LED (OFF)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Green LED (OFF)
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.
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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SECTION 2 | MAINTENANCE
2.3 | LUBRICATION
There are no components that routinely need lubrication.
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, battery maintenance, 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 electromagnetic brakes are holding.
2.7 | STORAGE
After periods of storage, exposure to extremes of ambient conditions-heat, cold, moisture, dust etc., inspect the
machine. 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.
2.9 | OTHER PROCEDURES
Voltage Test Points
Contact technical assistance for more details.
Wire Connections
When disconnecting or reconnecting any wires, make sure the master power switch in in the OFF position.
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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)
• Frequent
• 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
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3.1 | PRESTART INSPECTION CHECKLIST
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 YNR
VISUAL INSPECTIONS
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; there are no leaks; hoses and the cables have no worn areas or
chafing. ڧڧڧ
Check the tires for damage. Check that wheel axle retaining rings and set screw in rear wheel are
tight. 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 if
necessary). ڧڧڧ
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) ڧڧڧ
Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode) ڧڧڧ
Joystick (Return to neutral, drives forward & reverse, elevates & lowers) ڧڧڧ
Drive Enable Trigger (Must be activated to drive) ڧڧڧ
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) ڧڧڧ
Key Switch (Selects Platform Control, Ground Control, or O) ڧڧڧ
Up/Down Rocker Switch (Elevates, Lowers) ڧڧڧ
Alarm (Not damaged, sounds for descent, tile) ڧڧڧ
Wheels: Front and rear wheels rotate freely. ڧڧڧ
Drives in slow speed when elevated. ڧڧڧ
Brakes: Machine stops when joystick released. ڧڧڧ
Pothole guards deploy and lock when platform is elevated. ڧڧڧ
Lift does not elevate when pothole guards are blocked. ڧڧڧ
DATE INSPECTED BY
SECTION 3 | MAINTENANCE CHECKLISTS
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3.2 | MONTHLY INSPECTION CHECKLIST
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 YNR
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
Check electrical motor brushes (every 150 hours) ڧڧڧ
DATE INSPECTED BY
THIS CHECKLIST MUST BE USED MONTHLY OR AFTER EVERY 100 HOURS OF
USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.
SECTION 3 | MAINTENANCE CHECKLISTS
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3.1 | 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 ڧڧڧ Extends freely ڧڧڧ
All frame bolts tight ڧڧڧ Cables in place/secure ڧڧڧ
Pump Secure ڧڧڧ Locks in Stowed Position ڧڧڧ
DC motors secure ڧڧڧ Locks in Extended Position ڧڧڧ
Covers screwed on ڧڧڧ Functions: Y N R
Batteries Fully Charged ڧڧڧ All Functions Operational ڧڧڧ
Wheels: Y N R Emergency Stop Breaks Circuits ڧڧڧ
Snap Rings Secure ڧڧڧ Slow Speed limit switch Set properly ڧڧڧ
Bolts/Nuts Tight ڧڧڧ Wiring: Y N R
Scissors: Y N R Switches secure ڧڧڧ
Broken Welds ڧڧڧ Contactor(s) secure ڧڧڧ
Bent Beam Members ڧڧڧ Tight on terminals (No loose wiring) ڧڧڧ
All rollers Turn Freely ڧڧڧ Pothole guards deploy when platform elevated ڧڧڧ
Ret. Rings Secure On Pivots ڧڧڧ Pothole interlock functions correctly ڧڧڧ
Emergency Down Operational ڧڧڧ Oil: Level 1” from top ڧڧڧ
Maintenance Locks: ڧڧڧ Brakes: Operational ڧڧڧ
Pins in cabinet ڧڧڧ Check all hose for leaks ڧڧڧ
Platform: Y N R Check all fittings for leaks ڧڧڧ
Bent rails ڧڧڧ Battery charger: Y N R
Broken welds ڧڧڧ Secure/Operational ڧڧڧ
All rails in place/secure ڧڧڧ Tilt sensor ڧڧڧ
110V outlet safe/working (if applicable) ڧڧڧ Warning Horn (if applicable) ڧڧڧ
Entrance gate Closes Freely ڧڧڧ Hour meter operational ڧڧڧ
Decals: Y N R Battery indication operational ڧڧڧ
Legibility ڧڧڧ All Shields/Guards in place ڧڧڧ
Correct capacity noted ڧڧڧ Operator/Service Manual ڧڧڧ
Proper placement quantity ڧڧڧ
DATE INSPECTED BY
SECTION 3 | MAINTENANCE CHECKLISTS
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
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SECTION 4 | TECHNICAL REFERENCES
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SECTION 4 | TECHNICAL REFERENCES
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SECTION 4 | TECHNICAL REFERENCES
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