Hy-Brid Lifts HB-1230CE Programming manual

MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-717
REV A
SERIES III
HB-1230CE
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
MAINTENANCE & TROUBLESHOOTING
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SUPO717
REV A
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Original instructions written in English
The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and
maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made
to service this machine.
The operation and safety manual is considered a part of the work platform and contains instructions and operating
procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and
understand all information in the Safety and Operations Manual before operation.
THE OPERATION AND SAFETY MANUAL MUST
BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.
• The user/operator should not accept operating responsibility until the manual has been read and understood as
well as having operated the lift under supervision of an experienced and qualified operator.
• Because the manufacturer has no direct control over machine application and operation, proper safety
practices are the responsibility of the user and all operating personnel.
ANY MODIFICATION ON THIS MACHINE WITH
OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.
DANGER
WARNING
FOREWORD
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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
1.4 | STABILITY TESTING ......................................................................................................................................................................8
SECTION 2 | MAINTENANCE .................................................................................................................................................10
2.1 | BATTERY MAINTENANCE......................................................................................................................................................... 10
2.2 | CHARGING THE BATTERY....................................................................................................................................................... 10
2.3 | LUBRICATION...............................................................................................................................................................................11
2.4 | COMPONENTS REQUIRING ADJUSTMENT .......................................................................................................................11
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ..............................................................11
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ..................................................................................................11
2.7 | STORAGE ..................................................................................................................................................................................... 12
2.8 | MAJOR ALTERATIONS OR REPAIRS ..................................................................................................................................... 12
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 14
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 15
3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST.................................................................................. 16
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 18
4.1 | HYDRAULIC SCHEMATIC ........................................................................................................................................................ 18
4.2 | ELECTRICAL SCHEMATIC .......................................................................................................................................................20
4.3 | CONTROL BOARD DIAGNOSTIC..........................................................................................................................................22
SECTION 5 | WIRING DIAGRAMS..........................................................................................................................................24
5.1 | WIRING DIAGRAM .....................................................................................................................................................................24
5.2 | LOWER CONTROLS WIRING DIAGRAM .............................................................................................................................26
5.3 | UPPER CONTROLS WIRING DIAGRAM ...............................................................................................................................28
SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................30
6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................30
6.2 | DRIVE CIRCUIT...........................................................................................................................................................................32
6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................34
6.4 | LOWER CIRCUIT.........................................................................................................................................................................36
SECTION 7 | PARTS.................................................................................................................................................................38
SECTION 8 | WARRANTY........................................................................................................................................................40
SECTION 9 | INSPECTION AND REPAIR LOG .....................................................................................................................42
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INDEX OF FIGURES
REVISION DATES:
REV A ..........................................................................................................................................................................................April 2016
FIGURE 1: Maintenance Lock Use ....................................................................................................................................................... 7
FIGURE 2: Maintenance Lock Pin Storage.......................................................................................................................................... 7
FIGURE 3: Battery Charger LED Display.............................................................................................................................................. 9
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SECTION 1 | SAFETY
1.1 | SAFETY SYMBOLS
1.2 | GENERAL RULES AND PRECAUTIONS
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
Custom Equipment, LLC designed the Hy-Brid Lift self-propelled scissor lift to be safe and reliable. It is intended for
elevating personnel, along with their necessary tools and materials to overhead work locations.
An operator of any type of work platform is subject to certain hazards that cannot be protected by mechanical
means. It is therefore essential that operators be competent, careful, physically and mentally fit and thoroughly
trained in safe operation of this machine.
Although Custom Equipment, LLC conforms to specified EN: 280 requirements, it is the responsibility of the owner
to instruct operators with the safety requirements made not only by Custom Equipment, LLC, but by the various
safety boards in your area, as well as additional requirements set forth by EN: 280 If you come across a situation
that you think might be unsafe, stop the platform and request further information from qualified sources before
proceeding.
MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY
NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM
UNLESS MAINTENANCE PINS ARE IN PLACE
CAUTION
DANGER
WARNING
WARNING
WARNING
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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.
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.
WARNING
FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Pin Storage
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1.4 | STABILITY TESTING
This machine has been stability tested to standards EN280 or AS 14180. The most adverse stability test is the
stationary, lateral slope configuration for both units.
The stability test is to be done in compliance with EN280:2013, chapter 6.1.4.2.1, or AS14180 chapter 6.5.2, on an
inclination of 2.5º, with 299.5 kg (660 lb.) on the platform, located as described in the standards.
This test can be simulated on a level surface with no load on the platform, using a side pull that causes the same
overtirning moment as the loads and inclination described above.
This equivalent test can be done as shown in the figure below.
For the HB-1230CE S3.1 the test weight/pull force is 24.6 kg (54.3 lb.)
SECTION 1 | SAFETY
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SECTION 2 | MAINTENANCE
2.1 | BATTERY MAINTENANCE
This unit is equipped with 12-volt AGM maintenance-free batteries.
NOTE: The surrounding temperature greatly aects the power reserve within a battery.
EXAMPLE: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C). At 0°F (-18°C), this battery will
drop to 40% eciency.
NEVER ADD ACID TO BATTERY!
2.2 | CHARGING THE BATTERY
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME
AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
The charger is equipped with an interlock circuit. The unit will not operate while charging. Shortened battery life
will result.
To charge:
• Park the machine on a level surface.
• Plug charger into AC outlet until charged.
• For best battery life, leave the charger plugged in until machine will be used again. The charger will maintain
the battery charge.
FIGURE 3: Battery Charger LED Display
CAUTION
WARNING
WARNING
DO NOT OPERATE UNIT WHILE
CHARGING. DO NOT DISABLE
CHARGER INTERLOCK.
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SECTION 2 | MAINTENANCE
How to read the battery displays
2.3 | LUBRICATION
Item Specification Frequency of Lubrication
Wheels Teflon Spray Quarterly
2.4 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment.
• If a pump is replaced contact your dealer for pump relief setting.
• If the load sensing calibration is not functioning correctly, contact your dealer for calibration.
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS
With proper use, regular battery charging, and regular inspection, there are no limited life components that require
routine replacement.
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS
Check safety functions as part of daily inspection. Check that the brakes are holding.
Power
Power
Power
Power
Green LED (ON)
Green LED (ON)
Green LED (ON)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Red LED
(FLASHING)
Green LED (OFF)
Green LED (OFF)
Green LED (ON)
Green LED (ON)
Red LED (OFF)
Red LED (ON)
Red LED (OFF)
Red LED
(FLASHING)
Green LED (OFF)
Green LED (OFF)
Green LED (ON)
Green LED (ON)
This display indicates that the
power is on but there is no
connection to a battery. The
charger must see
approximately five (5) volts on a
battery to deliver D/C current.
This display indicates that
power is on and that both
outputs are delivering D/C
current to the batteries.
This display indicates that
power is on and that both
outputs are finished charging
and are in a float maintenance
mode.
A flashing red light indicates
there is a problem with a
battery, such as low voltage or
a bad cell.
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
Battery 1 Status
Charging Ready
Battery 2 Status
Charging Ready
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2.7 | STORAGE
After periods of storage, exposure to extremes of ambient conditions-heat, cold, moisture, dust etc. inspect the
machine. Batteries will need to be charged. Refer to the Pre-Delivery/ Frequent Inspection Checklist in this manual.
2.8 | MAJOR ALTERATIONS OR REPAIRS
Any alterations must be approved by the manufacturer. Major repairs, which aect the stability, strength, or
performance of the machine must also be approved by the manufacturer, recorded, and include machine
inspection and testing. Never attach pipe racks, material lifting devices, or make any other alteration that is not part
of the intended design of the machine.
SECTION 2 | MAINTENANCE
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SECTION 3 | MAINTENANCE CHECKLISTS
Regular inspection and conscientious maintenance is important to ecient economical operation of this machine.
It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at
the stated intervals or more frequently if required by local operating conditions. The following inspection checklists
are included in this manual:
• Pre-Start (required before operation at each work shift)
• Pre-Delivery/Frequent/Annual (Required every 3 months, after periods of storage, and after any alterations or
repairs)
The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week,
5 load cycles per hour)
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SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRESTART INSPECTION CHECKLIST
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A - Not equipped with this feature Y N R N/A
VISUAL INSPECTIONS
There are no loose or missing parts. ڧڧڧ ڧ
Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly marked. ڧڧڧ ڧ
Check the platform rails and safety gate for damage. ڧڧڧ ڧ
Platform and base controls are not missing, damaged, or disconnected. ڧڧڧ ڧ
Electrical cables and wires are not torn, frayed, or disconnected. ڧڧڧ ڧ
Hydraulic hoses are not torn or loose, and there are no leaks. Hoses and the cables have no worn areas or
chafing. ڧڧڧ ڧ
Check the tires for damage. Check that wheel axle retaining rings and any set screw(s) in rear wheel are tight. ڧڧڧ ڧ
Check that all snap rings are secure in grooves on pivot pins. ڧڧڧ ڧ
FUNCTIONAL TESTS
Gate closes automatically and latches. ڧڧڧ ڧ
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) ڧڧڧ ڧ
For Actuator-Steered models: Enable Switch (Does not elevate unless enable is pressed) ڧڧڧ ڧ
For Counter-Rotate Steering models: Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode) ڧڧڧ ڧ
Joystick (Return to neutral, drives forward & reverse,)
Enable Trigger (Must be activated for joystick-operated movement)
For Actuator-Steered models: Thumb rocker steers right & left
For Counter-Rotate Steering models: Elevates & lowers
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
ڧ
If so equipped, horn sounds when button is pressed. ڧڧڧ ڧ
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) ڧڧڧ ڧ
For Actuator-Steered models: Key Switch (On or O)
For Counter-Rotate Steering models: Key Switch (Selects Platform Control, Ground Control, or O) ڧڧڧ ڧ
Up/Down Rocker Switch (Elevates, Lowers) ڧڧڧ ڧ
Descent Alarm (Not damaged, sounds for descent; may also sound for drive & elevate, if so equipped) ڧڧڧ ڧ
Tilt Alarm (Not damaged, sounds when tilted and machine elevated above designated height)
If so equipped, elevating beyond this height may also be prevented. ڧڧڧ ڧ
Master Power Switch disconnects battery ڧڧڧ ڧ
Wheels: Front and rear wheels rotate freely.
For Counter-Rotate Steering models: Front wheels pivot freely. ڧڧڧ ڧ
Drives in slow speed when elevated. ڧڧڧ ڧ
Brakes: Machine stops when joystick released. ڧڧڧ ڧ
Pothole guards deploy and lock when platform is elevated. ڧڧڧ ڧ
Lift does not elevate when pothole guards are blocked. ڧڧڧ ڧ
Date: Inspected by:
Model: Serial Number:
• Keep inspection records up-to-date.
• Record and report all discrepancies to your supervisor.
• A dirty machine cannot be properly inspected.
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.
CAUTION
MAINTENANCE & TROUBLESHOOTING
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3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST
SECTION 3 | MAINTENANCE CHECKLISTS
Model: Serial Number:
• Check each item listed below.
• Use proper operating, service, and maintenance manual for specific information and settings
• If an item is found to be unacceptable make the necessary repairs and check the “repaired” box.
• When all items are “acceptable”, the unit is ready for service.
• If an item is found to be unacceptable, make the necessary repairs and check the “repaired” box. When all
items are “acceptable,” the unit is ready for service.
Y
— Yes/Acceptable N — No/Unacceptable R — Repaired N/A — Not equipped with this feature
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, AND ANNUALLY.
CAUTION
Y N R N/A Y N R N/A
Base: Rails/Extending platform:
Inspect slide tracks for damage ڧڧڧ ڧ Extends freely ڧڧڧ ڧ
All frame bolts tight ڧڧڧ ڧ Cables in place/secure ڧڧڧ ڧ
Pump Secure ڧڧڧ ڧ Locks in Stowed Position ڧڧڧ ڧ
DC motors secure ڧڧڧ ڧ Locks in Extended Position ڧڧڧ ڧ
Batteries Fully Charged ڧڧڧ ڧ Functions:
For actuator-steered models:
Tie rods secure ڧڧڧ ڧ All Functions (Srive,Elevate,Steer) Operational
(see Pre-Start Inspection for details) ڧڧڧ ڧ
Wheels: Pothole guards deploy when platform elevated ڧڧڧ ڧ
Snap Rings Secure ڧڧڧ ڧ Emergency Stop Breaks Circuits ڧڧڧ ڧ
Bolts/Nuts Tight ڧڧڧ ڧ Slow Speed limit switch Set properly ڧڧڧ ڧ
All Shields/Guards in place ڧڧڧ ڧ Pothole interlock functions correctly ڧڧڧ ڧ
Scissors: Brakes: Operational ڧڧڧ ڧ
No Broken Welds ڧڧڧ ڧ Emergency Down Operational ڧڧڧ ڧ
No Bent Beam Members ڧڧڧ ڧ Wiring:
All rollers Turn Freely ڧڧڧ ڧ Switches secure ڧڧڧ ڧ
Ret. Rings Secure On Pivots ڧڧڧ ڧ Contactor(s) secure ڧڧڧ ڧ
Maintenance Locks:
Stored in designated location ڧڧڧ ڧ Tight on terminals (No loose wiring) ڧڧڧ ڧ
Platform: Oil: Level 1” from top (when platform stowed) ڧڧڧ ڧ
No Bent rails ڧڧڧ ڧ Check all hose for leaks ڧڧڧ ڧ
No Broken welds ڧڧڧ ڧ Check all fittings for leaks ڧڧڧ ڧ
All rails in place/secure ڧڧڧ ڧ Battery Charger Secure/Operational ڧڧڧ ڧ
110V outlet safe/working (if applicable) ڧڧڧ ڧ Tilt sensor ڧڧڧ ڧ
Entrance gate Closes Freely ڧڧڧ ڧ Warning Horn (if applicable) ڧڧڧ ڧ
Decals: Hour meter operational ڧڧڧ ڧ
Legibile ڧڧڧ ڧ Battery indication operational ڧڧڧ ڧ
Correct capacity noted ڧڧڧ ڧ Operator’s Manual is on the unit ڧڧڧ ڧ
Proper placement & quantity ڧڧڧ ڧ If equipped with load sensing:
Overload light & alarm sounds when overloaded ڧڧڧ ڧ
Date: Inspected by:
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No. HS-129-20-201-51
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SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
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