Hy-Brid Lifts HB-P3.6 Programming manual

MAINTENANCE & TROUBLESHOOTING MANUAL
PUSH-AROUND AERIAL WORK PLATFORM
SUPO-643E
REV F
HB-P3.6
SERIES I
BY CUSTOM EQUIPMENT LLC

NOTES
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
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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
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 | STABILITY TESTING...................................................................................................................................................................... 7
1.4 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 | MAINTENANCE ................................................................................................................................................... 9
2.1 | BATTERY MAINTENANCE...........................................................................................................................................................9
2.2 | CHARGING THE BATTERY.........................................................................................................................................................9
2.3 | LUBRICATION...............................................................................................................................................................................11
2.4 | COMPONENTS REQUIRING ADJUSTMENT .......................................................................................................................11
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ..............................................................11
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ..................................................................................................11
2.7 | STORAGE ......................................................................................................................................................................................11
2.8 | MAJOR ALTERATIONS OR REPAIRS ......................................................................................................................................11
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 12
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 13
3.2 | FREQUENT INSPECTION CHECKLIST.................................................................................................................................. 14
3.3 | PREDELIVERY/ANNUAL INSPECTION CHECKLIST ......................................................................................................... 15
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 | WIRING DIAGRAM......................................................................................................................................................................22
SECTION 6 | TROUBLESHOOTING 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 AND CONTROL DECALS..........................................................................................................................................30
7.2 | MAIN POWER/SAFETY CIRCUIT ............................................................................................................................................. 31
7.3 | ELEVATE/LOWER CIRCUIT.......................................................................................................................................................32
7.4 | WHEELS/BRAKES.........................................................................................................................................................................34
7.5 | COVERS/OTHER .........................................................................................................................................................................35
SECTION 8 | WARRANTY........................................................................................................................................................36
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INDEX OF FIGURES
FIGURE 1: Equivalent Stability Test........................................................................................................................................................ 7
FIGURE 2: Upper Control Removal...................................................................................................................................................... 7
FIGURE 3: Maintenance Pin Lock Use.................................................................................................................................................8
FIGURE 4: Maintenance Pin Lock Storage .........................................................................................................................................8
FIGURE 5: Battery Charger LED Display............................................................................................................................................ 10
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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
SECTION 1 | SAFETY
1.1 | SAFETY SYMBOLS
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 EN: 280, 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
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SECTION 1 | SAFETY
1.3 | STABILITY TESTING
The HB-P3.6 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 overturning moment created by the test loads and forces is
equivalent to a test on an unloaded machine on a level surface, as shown in the figure below. For the HB-P3.6, the
test weight/pull force is 22.8 kg / 50 lb.
1.4 | SAFETY GUIDELINES
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 maintenance lock in place.
FIGURE 1: Equivalent Stability Test
FIGURE 2: Upper Control Removal
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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.
SECTION 1 | SAFETY
FIGURE 3: Maintenance Pin Lock Use FIGURE 4: Maintenance Pin Lock Storage
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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 27°C will yield run times above the rated capacity and operating batteries below 27°C
will yield run times 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 deep cycle 12-volt AGM maintenance-free 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 27°C drops to 65% at 0°C At -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.
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. DO NOT DISABLE
CHARGER INTERLOCK.
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SECTION 2 | MAINTENANCE
How to read the battery displays
NEVER ADD ACID TO BATTERY!
FIGURE 5: Battery Charger LED 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 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.
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
Red LED
(ON)
Green LED
(OFF)
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
POWER BATTERY 1 STATUS
CHARGING READY
BATTERY 1 STATUS
CHARGING READY
POWER
BATTERY 1 STATUS
CHARGING READY
POWER
Green LED
(OFF)
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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.
SECTION 2 | MAINTENANCE
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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
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.
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SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRE-START 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
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
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:
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.
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3.2 | FREQUENT 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
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
FUNCTIONAL TESTS
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:
SECTION 3 | MAINTENANCE CHECKLISTS
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
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3.3 | PRE-DELIVERY/ANNUAL 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
BASE: Y N R PLATFORM: Y N R
Inspect Slide Tracks For Damage ڧڧڧ All Rails In Place/Secure ڧڧڧ
All Frame Bolts Tight ڧڧڧ No Bent Rails ڧڧڧ
Pump Secure ڧڧڧ No Broken Welds ڧڧڧ
DC Motor Secure ڧڧڧ Platform Power Outlet* Safe/Working ڧڧڧ
Battery Hold Down Secure ڧڧڧ Entrance Gate Closes Freely ڧڧڧ
Batteries Fully Charge ڧڧڧ Cables In Place/Secure ڧڧڧ
Counterweights Secured ڧڧڧ FUNCTIONS:
Wheels: Grease Casters ڧڧڧ Elevate/Lower Operational ڧڧڧ
Wheels: Bolts/Nuts Tight ڧڧڧ Master Power Switch Breaks Circuits ڧڧڧ
Maintenance Locks ڧڧڧ Emergency Stop Breaks Circuits ڧڧڧ
All Shields/Guards In Place ڧڧڧ Emergency Down Operational ڧڧڧ
Hydraulic Oil Level ڧڧڧ Motion Alarms Functional ڧڧڧ
Check All Hydraulic Hoses For Leaks ڧڧڧ Brakes: Operational ڧڧڧ
Check All Hydraulic Fittings For Leaks ڧڧڧ Bubble Level In Place ڧڧڧ
SCISSORS: Overload Light And Alarm Activate ڧڧڧ
No Broken Welds ڧڧڧ If Overloaded Platform Stops Elevating ڧڧڧ
Ret. Rings Secure Pivots ڧڧڧ Battery Voltage: <12.5V, Charge ڧڧڧ
No Bent Beam Members ڧڧڧ WIRING/OTHER:
All Rollers Turn Freely ڧڧڧ Switches Secure ڧڧڧ
DECALS: Contact(S) Secure ڧڧڧ
Legibility ڧڧڧ Terminals Secure (No Loose Wiring) ڧڧڧ
Correct Capacity Noted ڧڧڧ Manuals Included ڧڧڧ
Proper Placement/Quantity ڧڧڧ Battery Charger Secure/Operational ڧڧڧ
Comments:
Date: Inspected By:
SECTION 3 | MAINTENANCE CHECKLISTS
*If Installed
THIS CHECKLIST MUST BE USED MONTHLY OR AFTER EVERY 100 HOURS OF
USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.
MAINTENANCE & TROUBLESHOOTING
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
MAINTENANCE & TROUBLESHOOTING
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SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
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SECTION 4 | TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC
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SUPO643E
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SECTION 4 | TECHNICAL REFERENCES
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SUPO643E
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SECTION 5 | WIRING DIAGRAMS
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SECTION 5 | WIRING DIAGRAMS
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MAINTENANCE & TROUBLESHOOTING
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SECTION 5 | WIRING DIAGRAMS
5.2 | WIRING DIAGRAM
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MAINTENANCE & TROUBLESHOOTING
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SECTION 5 | WIRING DIAGRAMS
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MAINTENANCE & TROUBLESHOOTING
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS
6.1 | TROUBLESHOOTING FLOWCHART: POWER
Troubleshooting Step 1: Main Power
Rev. B
Does the machine
function:
(Elevate/Lower)
Is the battery connected? Is the battery filled with
water and fully charged?
Is short protection
fuse blown?
Contact Hy-Brid Lifts with questions
about a different problem
Yes
Is the battery charger
plugged in?
No
Yes Yes
No No
Yes
Yes
Connect
battery.
Is the master
power switch off?
No No
Turn master
power switch on.
No
Replace with 20 Amp
AGC Fuse.
WARNING
Any modification on this machine without
the express consent of the manufacturer
is prohibited.
See Wiring
Diagram
WD-143-20-001-
51 See SD-Battery-01
See also Main Power & Safety Circuit
Wiring Diagram: WD-143-20-001-51
Or
Schematic: WS-143-20-001-51
Unplug the charger.
Machine should not be
operated while battery is
charging.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
24
SECTION 6 | TROUBLESHOOTING FLOWCHARTS
Is E-Stop Button
depressed/activated:
Yes
Are all power
supply connections and
switches functioning
properly?
Visually inspect wire
harness from lower
controls to upper.
Is there damage?
See
Elevating
Problems
Flowchart
See
Lowering
Problems
Flowchart
No
Yes
Repair or
Replace
identified
problem.
No
Is machine in the
elevated or lowered
position?
Yes
Machine is Down
Machine is Up
WARNING
Failure to comply with safety precautions
may result in damage, injury, or death.
Refer to Maintenance Manual for
complete warnings
No
Replace
wire harness
or repair
wire
Check wiring connections
to identify a power supply
problem.
See
Electrical Schematic
WS-143-20-001-51
Or Pictorial Schematic
WSP-143-20-001-51
And Instruction
Circuit Check-HB-P3.6-
Power
Reset E-Stop
button. Pull out at
both upper control
and lower control
locations.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
25

SECTION 6 | TROUBLESHOOTING FLOWCHARTS
6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING
Troubleshooting Step 2A: Elevating
Rev. B
Does machine elevate? Does the
pump run?
NotAtAll
Ascent speed
slow or erratic?
Is the
emergency down
valve open?
Yes
No
Is battery fully
charged?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is there a restriction in
hydraulic hose?
Yes, but
not properly
Starts ascending,
then stops?
Is platform
overloaded?
Yes
Can you see
anything obstructing
the components?
Are power connections
to elevate circuit and
switches functioning
properly?
Remove
obstruction
Yes
No
Goes up, but
comes down
Replace or
repair identified
problem. See
Parts List.
No
Close
emergency
down valve
Yes
Yes
Remove overload. Lower to
stowed position before
continuing use.
Yes
No
No
Yes
Yes
See also
Wiring Diagram WD-143-20-001-51 or
Schematic: WS-143-20-001-51
And
Hydraulic Schematic HS-HB-P3.6 Or
Pictorial Hydraulic Circuit HSP-HB-P3.6
No
Check wiring
connections in elevate
components.
See Electrical
Schematic
WS-143-20-001-51
Or
Pictorial Schematic
WSP-143-20-001-51
And instruction
Circuit Check-HB-P3.6-
Elevate
Yes
WARNING: Set up for maintenance safety:
Remove load from platform.
Check for overhead obstructions.
Platform movement may occur.
Never Reach between scissors links or prop up
platform unless maintenance pins are in place.
No
No
Is armguard
limit switch
damaged?
See Lowering
Problems
Flowchart
No
Yes
No
Replace
limit
switch.
Replace
hydraulic
hose.
Charge battery.
See SD-Battery-01
Yes
MAINTENANCE & TROUBLESHOOTING
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SUPO643E
REV F
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS
Is hydraulic
fluid low?
Yes
Contact
Hy-Brid Lifts
Is up/down
switch
damaged?
Is Overload
Enable
Limit Switch
damaged?
No
Yes
Replace
OL Enable
LS
Yes
Time and parts
available?
Yes Replace Pump
Assembly
Does pump operate?
Try replacing
up valve
No
Is there a different problem
(something is leaking, unusually
noisy, etc.)
Troubleshooting Flowcharts--General Notes:
Inspect parts for visible damage as they are encountered.
After each step, check if problem has been indentified and/or resolved.
If so, make the recommended fix or see a referenced document.
If not, continue troubleshooting.
If a part has been identified as needing replacement, see the Parts View
To identify part number to order.
If any wiring or components have been altered from the original
manufacture, problems may not be identifiable.
WARNING
Any modification on this machine without
the express consent of the manufacturer
is prohibited.
WARNING
Failure to comply with safety precautions
may result in damage, injury, or death.
Refer to Maintenance Manual for
complete warnings
Check wiring connections
in elevate components.
See Electrical Schematic
WS-143-20-001-51
Or
Pictorial Schematic
WSP-143-20-001-51
And instruction
Circuit Check-HB-P3.6-
Elevate
Yes No
No
Level of skill
with hydraulic
maintenance?
Are power
connections to
elevate circuit and
switches functioning
properly?
Replace or
repair
identified
problem.
See Parts
List.
Check Hydraulic Circuit.
(Additional tools and higher
level of skill required) See
Hydraulic Schematic
HS-HB-P3.6
No
No
Experienced
with hydraulic
systems
Not experienced
with hydraulics
No
Yes
Yes
Reference Revision B
Replace damaged
switch at upper
control.
With platform
lowered, fill pump
reservoir with at
least 1.25 liters of
oil.
Flush down valve by
simultaneously pressing
up switvh and pulling e-
down cable control for 30
sec.
There may be foreign
matter lodged.
Replace pump
assembly.
May be worn
or defective.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS
6.3 | TROUBLESHOOTING FLOWCHART: LOWERING
Troubleshooting Step 2B: Lowering
Rev. B
Does machine
lower?
Not
at all
Descent speed slow or
erratic?
Are any structural
members bent?
Contact manufacturer to
arrange replacement.
Is there a
restriction in
hydraulic hose?
Yes
Yes Yes
Creeps down? Or
Goes up and Comes
Back Down?
Has master power
switch been turned
off?
Is E-Stop
activated?
Is emergency
down valve
open?
Yes
Foreign matter
lodged in up or
down valve?
Down Valve Coil
mounting nut too tight?
Nut should only be lightly
snug: 30 in.-lb.
No
Yes
Starts descending,
then stops?
Are maintenance lock
pins in place?
Yes No
Will Manual
Override lower
the platform?
Turn key
to
ON position.
No
No No
Check manual override cable, lever, and fastening points
Yes
See also
Wiring Diagram WD-143-20-001-51 or
Schematic: WS-143-20-001-51
And
Hydraulic Schematic HS-HB-P3.6 Or
Pictorial Hydraulic Circuit HSP-HB-P3.6
WARNING: Set up for maintenance safety:
Remove load from platform.
Check for overhead obstructions.
Platform movement may occur.
Never Reach between scissors links or prop up
platform unless maintenance pins are in place.
Yes, but
not properly
No
No
WARNING: Double check that
maintenance pins are in place
Yes Yes No
Yes
Does the
armguard Limit
switch appear
damaged?
No
Yes Yes
No
Close
emergency
down valve.
Check cable
connections.
Replace
hydraulic hose
Disassemble and clean.
Look for residue in screen
and on O-ring or damage
to O-ring.
Replace coil
and lightly
tighten nut.
No
Pull out
emergency
stop button at
upper controls.
Replace
limit switch
Stow
ML Pins
Flush down valve by
simultaneously pressing up
switch and pulling e-down
cable control for 30 sec.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS
Does the up/
down switch
appear
damaged?
Is battery
charged?
Faulty down
valve?
Electrical problem?
Disconnect coil.
Check if unit stops drifting.
Check voltage at coil—should be
0 V when not energized.
Damaged cylinder or
damaged seal in cylinder?
Run unit up and then check for
oil flow out of return line. Bad
cylinder seal if oil is flowing
from return line.
Yes
Faulty check valve
in pump?
Listen carefully near motor
when not energized—may be
running backwards
Does the overload
Limit switch
appear damaged?
Level of skill with
hydraulic maintenance?
Not experienced
with hydraulics
Yes Yes
t
Check wiring connections in lowering
components.
See Electrical Schematic
WS-143-20-001-51 Or
Pictorial Schematic
WSP-143-20-001-51
And instruction
Circuit Check-HB-P3.6-Elevate
Charge battery.
See SD-Battery-01
Yes
No
No
OK
No
Yes
Level of skill
with hydraulic
maintenance?
Check Hydraulic
Circuit. (Additional
tools required,
higher level of skill
required)
Refer to Hydraulic
Schematic HS-HB-
P3.6
Are power
connections to
lowering circuit and
switches functioning
properly?
Replace or repair
identified problem.
See Parts List.
Contact
Hy-Brid
Lifts
No
Yes
No
No
Experienced with
Hydraulic systems
Experienced
With hydraulic
systems
Not experienced
With hydraulics
Y es or Don’t know
Replace
down valve. Might be able to repair with seal
kit;, probably need to replace
cylinder. If walls inside cylinder
are scratched or pitted, cylinder
needs replacement.
Yes
Replace
pump.
Replace
down
valve
No No
Reference Revision B
Replace switch
at upper
control.
Replace
limit switch
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
29

SECTION 7 | PARTS DIAGRAMS
Listed in the following section are diagrams for parts that may be available for replacement and for reference. These
represent current model revisions. Refer to our website, www.hybridlifts.com for more complete part listings and
earlier revisions. Several parts are model-, serial number-, or manufacture date-specific. Contact your dealer for
replacement part availability and pricing.
7.1 | SAFETY AND CONTROL DECALS
Refer to the Hy-Brid Lifts Operation and Safety Manual for decal part numbers and locations.
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, CONTROL BOARD, AND ALL
STRUCTURAL COMPONENTS.
Item # Part Number Description Qty. Um
1 143-21-006-51 DECALS,HB-P3.6 1 EA
1.1 DE727 DECAL,KEEP 2 EA
1.2 DE728 DECAL,CLEAR 2 EA
1.3 DE600E-14 DECAL,MAINT LOCK(SYMBOLS) 1 EA
1.4 DE600E-24F DECAL,WHEEL LOAD HB-P3.6 4 EA
1.5 DE751 DECAL,E-DOWN CABLE 1 EA
1.6 DE601 DECAL,LOGO HY-BRID 1 EA
1.7 DE603-5 MODEL# DECAL-HB-P3.6 2 EA
1.8 DE746 DECAL,LANYARD ATTACHMENT 1 EA
1.9 DE666 DECAL, LWR 1 EA
1.1 DE675 DECAL,NO FORK 1 EA
1.11 DE718 DECAL,CE 1 EA
1.12 DE706 DECAL,UPR HB,ZTR,MID 1 EA
1.13 DE726 DECAL,CAPACITY,500#,1P,I,WO/SO 1 EA
1.14 DE730 DECAL,OL ALARM 1 EA
2 DE669 DECAL,CTL UPR 1 EA
3 N/A SERIAL NUMBER LOCATION 1 EA
4 N/A SERIAL NUMBER REFERENCE 1 EA
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
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SECTION 7 | PARTS DIAGRAMS
7.2 | MAIN POWER/SAFETY CIRCUIT
Item # Part Number Description
1 ELEC-047-6 Not available as a replacement part. Replace battery with 12V, Group 24
AGM Battery. Replacement weight must be minimum 22.7 kg (50 lb).
2 HARD-684 Battery Strap
3 ELEC-633-2
ELEC-663-3
Master Power Switch with Key
Spare Key
4 ELEC-746 Battery Charger
5 ELEC-639-6 Charger Cord (bare wire/IEC-320 C-13)
6 ELEC-071-KIT Emergency Stop Button with Contact Block
7 143-21-004-51 Upper Control Assembly
8 N/A B+ Power Connection Location on Pump
9 N/A B- “Ground” Connection Location on Pump
NOT PICTURED 143-01-025-50
143-01-025-51
ELEC-641-002
Battery Cables
NOT PICTURED ELEC-670-2 20A AGC Fuse
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
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SECTION 7 | PARTS DIAGRAMS
7.3 | ELEVATE/LOWER CIRCUIT
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
32
SECTION 7 | PARTS DIAGRAMS
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
18 ELEC-635 Descent / Overload Alarm
19 ELEC-002A-KIT Up / Down Rotary Switch
20 143-01-023-02 Maintenance Lock Check
21 HARD-644-03 Emergency Down Cable
(Not Pictured) ELEC-632 Time Delay Relay
(Not Pictured) HARD-021 Retaining Ring, 2.54 cm
MAINTENANCE & TROUBLESHOOTING
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SUPO643E
REV F
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SECTION 7 | PARTS DIAGRAMS
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
7.4 | WHEELS/BRAKES
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
34
SECTION 7 | PARTS DIAGRAMS
Item # Part Number Description
1 MISC-031-05-KIT ANTI-SLIP TAPE,4.00,37.50 LENG
2 MISC-031-06-KIT ANTI-SLIP TAPE,4.00,16.00 LENG
3 143-05-001-01 COVER,SIDE (BATT.)
4 HARD-086 LEVEL,BUBBLE
5 1000307601 RAIL,GATE LATCH
6 143-05-003-01 COVER,PUMP
7.5 | COVERS/OTHER
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
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LIMITED PRODUCT WARRANTY
Warranty Statement — International
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:
1. Limited Product Warranty
for a period of 24 months from the date that a new product manufactured by the Company (“Product”) is
delivered to 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
2. Extended Structural and Chassis Warranty
For 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 damages 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; 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.
Buyer shall retain all defective Products or parts, components or assemblies thereof for a minimum period of six (6)
months. 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 REPAIR OR REPLACE WARRANTY 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, remanufactured or refurbished replacement parts. 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 necessary to remedy such defect. Buyer shall be responsible for payment of any
SECTION 8 | WARRANTY
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
36
costs or fees due to the authorized dealer to perform any warranty service.
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 merchantability, non-infringement of proprietary or third-party rights or fitness of
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 or
contract or tort (including negligence and strict liability) or otherwise, even if the company has been specifically
advised of the possibilities of such damages.
SECTION 8 | WARRANTY
MAINTENANCE & TROUBLESHOOTING
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SUPO643E
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Push-Around Aerial Work Platform
Maintenance & Troubleshooting Manual
HB-P3.6
© 2014 Custom Equipment, LLC
2647 Highway 175
Richfield, WI 53076
U.S.A.
Tel.: [phone]
Fax: [phone]
www.hybridlifts.com
[email protected]
“Hy-Brid Lifts” is a trademark of Custom Equipment, LLC.
These machines comply with specified EN: 280 requirements
Revision Date: November 2014
Printed In The USA
BY C U STO M EQUIPMENT L LC