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
REV F
2
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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
3

TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS............................................................................................................................................................... 4
INDEX OF FIGURES.................................................................................................................................................................... 5
SECTION 1 | SAFETY.................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS..................................................................................................................................6
1.3 | 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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
4
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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
5

FAILURE TO FOLLOW THIS WARNING WILL CAUSE
DEATH OR PERSONAL INJURY.
“DANGER” indicates an imminently hazardous situation,
which, if not avoided, will result in death or serious
injury.
FAILURE TO FOLLOW THIS WARNING MAY CAUSE
DEATH OR PERSONAL INJURY.
“WARNING” indicates a potentially hazardous situation,
which, if not avoided, could result in death or serious
injury
FAILURE TO FOLLOW THIS WARNING MAY CAUSE
INJURY OR DAMAGE TO EQUIPMENT.
“CAUTION” indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury or damage to equipment
CAUTION
DANGER
WARNING
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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
6
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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
7

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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
8
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.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
9

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)
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
10
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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
11

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.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
12
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.
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
13

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
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
14
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
HBP3.6
SUPO643E
REV F
15

SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
16
SECTION 4 | TECHNICAL REFERENCES
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
17

SECTION 4 | TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC


1&
12
1&




$03
$UPJXDUG6LJQDO
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
18
SECTION 4 | TECHNICAL REFERENCES
12
0
2))



3803
62/(12,'
62/(12,'
23(5$7('
839$/9(
62/(12,'
23(5$7('
'2:19$/9(
'RZQ6LJQDO
7,0(
'(/$<
5(/$<
5(9,6,216
5(9 '(6&5,37,21 '$7( %<
$ ,1,7,$/5(/($6(  '-6
MAINTENANCE & TROUBLESHOOTING
HBP3.6
SUPO643E
REV F
19