Hy-Brid Lifts I Series Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
PUSH-AROUND AERIAL WORK PLATFORM
SUPO-722
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HB-P827
HB-P1027
SERIES I

NOTES
If there is a question about application
and/or operation, contact:
Custom Equipment, LLC
2647 Hwy 175
Richfield, WI 53076
U.S.A.
P: [phone]
F: [phone]
www.hybridlifts.com
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FOREWORD
Original instructions written in English.
The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and
maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made
to service this machine.
The operation and safety manual is considered a part of the work platform and contains instructions and operating
procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and
understand all information in the Safety and Operations Manual before operation.
THE OPERATION AND SAFETY MANUAL MUST
BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.
• The user/operator should not accept operating responsibility until the manual has been read and understood as
well as having operated the lift under supervision of an experienced and qualified operator.
• Because the manufacturer has no direct control over machine application and operation, proper safety
practices are the responsibility of the user and all operating personnel.
ANY MODIFICATION ON THIS MACHINE WITH
OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.
DANGER
WARNING
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TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS............................................................................................................................................................... 4
INDEX OF FIGURES.................................................................................................................................................................... 5
SECTION 1 | SAFETY .................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ................................................................................................................................... 6
1.3 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 | MAINTENANCE ................................................................................................................................................... 8
2.1 | BATTERY MAINTENANCE ........................................................................................................................................................... 8
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES................................................................................................................ 8
2.3 | CHARGING THE BATTERY......................................................................................................................................................... 8
2.4 | LUBRICATION.............................................................................................................................................................................. 10
2.5 | COMPONENTS REQUIRING ADJUSTMENT....................................................................................................................... 10
2.6 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS.............................................................. 10
2.7 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS .................................................................................................. 10
2.8 | STORAGE...................................................................................................................................................................................... 10
2.9 | MAJOR ALTERATIONS OR REPAIRS...................................................................................................................................... 10
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 12
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 13
3.2 | PREDELIVERY / FREQUENT / ANNUAL INSPECTION CHECKLIST ............................................................................. 14
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 16
4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 16
4.2 | ELECTRICAL SCHEMATIC........................................................................................................................................................ 18
SECTION 5 | WIRING DIAGRAMS..........................................................................................................................................20
5.1 | WIRING DIAGRAM ......................................................................................................................................................................20
5.2 | UPPER CONTROL WIRING DIAGRAM .................................................................................................................................22
SECTION 6 | TROUBLE SHOOTING FLOWCHARTS...........................................................................................................24
6.1 | TROUBLESHOOTING FLOWCHART: POWER.....................................................................................................................24
6.2 | TROUBLESHOOTING FLOWCHART: ELEVATING ............................................................................................................26
6.3 | TROUBLESHOOTING FLOWCHART: LOWERING .............................................................................................................28
SECTION 7 | PARTS..................................................................................................................................................................30
SECTION 8 | WARRANTY........................................................................................................................................................ 32
SECTION 9 | INSPECTION & REPAIR LOG...........................................................................................................................34
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INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use ........................................................................................................................................................ 7
FIGURE 2: Maintenance Lock Storage................................................................................................................................................. 7
FIGURE 3: Battery Charger LED Display.............................................................................................................................................. 9
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1.1 | SAFETY SYMBOLS
Warnings and instructions that have a direct impact on safety are identified with the following signals:
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.
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 ANSI & OSHA, it is the responsibility of the owner to
instruct operators with the safety requirements made not only by Custom Equipment, LLC, but by the various safety
boards in your area, as well as additional requirements set forth by ANSI and OSHA. 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 SCISSOR LINKS OR PROP
UP PLATFORM UNLESS MAINTENANCE PINS ARE IN
LOCK.
SECTION 1 | SAFETY
DANGER
CAUTION
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 handhold’s
• Before making any adjustments, lubricating or performing any other maintenance, shut o all power controls.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in their proper place.
• Use only approved nonflammable cleaning solvents
• After maintenance, inspect the machine as described for Pre-delivery
FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Storage
WARNING
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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 80°F (27°C) will yield runtime above the rated capacity and operating batteries below
80°F (2rC) will yield runtime below the rated capacity. Cold temperatures can significantly reduce battery capacity.
Although higher temperatures increase the battery capacity they also accelerate corrosion and reduce overall
battery life.
2.2 | BATTERY MAINTENANCE WET CELL BATTERIES
If this unit is equipped with a deep cycle 12-volt Group 27 battery, the care and maintenance of your battery has
much to do with how well this unit functions. Battery wiring and water level should be checked monthly. Do not
overfill. When the cells are too full, fluid will seep out when charging. The solution is at its proper strength when the
battery is manufactured. Use distilled water and keep fluid up to proper level. When required, water should be added
to battery after charging, unless water level is below the plates.
• Slide cabinet open to access battery.
• Remove battery caps and check fluid level.
• Fill each cell (if needed) to split ring with distilled water.
• Reinstall caps.
• Wash all dirt, debris, acid, etc., o battery whenever corrosion is detected. Use a solution of 5ml baking soda per
0.95 liters of warm water.
• Coat terminals with a commercially available coating.
• Close cabinet and latch in place.
2.3 | CHARGING THE BATTERY
This unit is equipped with either a deep cycle 12-volt AGM maintenance-free battery or a deep cycle Group 27
battery. Batteries should be fully charged after each use. Opportunity charging can be done but the batteries should
be fully charged at least every other day if they are used daily. Charge in a ventilated area as gases may be released
through the pressure relief valve if the batteries are excessively over-charged.
NOTE: The surrounding temperature greatly aects the power reserve within a battery.
EXAMPLE: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C) At 0°F (-18°C), this battery
will drop to 40% eciency.
WARNING
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND
FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE
CHARGING.
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Do not operate unit while charging. Shortened battery life will result.
• Park the machine on a level surface
• Plug charger into AC outlet until charged.
• For best battery life, leave charger plugged in until machine will be used again, the charger will maintain the
battery charge.
DO NOT OPERATE UNIT WHILE CHARGING NEVER ADD ACID TO BATTERY.
FIGURE 3: Battery Charger LED Display
How to read battery display
This display indicates that the power is on but there is no connection to a battery.
The charger must see approximately five (5) volts on a battery do deliver D/C
current.
This display indicates that power is on and that both outputs are delivering D/C
current to the batteries.
This display indicates that power is on and that both outputs are finished charging
and are in a float maintenance mode.
SECTION 2 | MAINTENANCE
CAUTION
WARNING
POWER BATTERY 1 STATUS
CHARGING READY
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
Green LED
(ON)
Red LED
(ON)
Green LED
(OFF)
Green LED
(ON)
Red LED
(OFF)
Green LED
(ON)
POWER BATTERY 1 STATUS
CHARGING READY
POWER BATTERY 1 STATUS
CHARGING READY
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SECTION 2 | MAINTENANCE
2.4 | LUBRICATION
Item Specification Frequency
Wheels Teflon Spray Quarterly
2.5 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are
required.
2.6 | 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.
2.7 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS
Check safety functions as part of daily inspection. Check that the brakes are holding.
2.8 | 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.
2.9 | 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.
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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
Regular inspection and conscientious maintenance is important to ecient economical operation of this machine.
It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at
the stated intervals or more frequently if required by local operating conditions. The following inspection checklists
are required and included in this manual:
• Pre-Start (Required before operation at each work shift)
• Frequent (Required at intervals not more than three months)
• Pre-Delivery/Annual (Required at intervals not more than twelve months)
The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week,
5 load cycles per hour).
SECTION 3 | MAINTENANCE CHECKLISTS
CAUTION
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3.1 | PRESTART INSPECTION CHECKLIST
SECTION 3 | MAINTENANCE CHECKLISTS
Y-Yes/Acceptable N-No/Unacceptable R-Repaired Y N R
VISUAL INSPECTIONS
Check that there are no damaged, dented, or bent structural members □ □ □
There are no loose or missing parts. □ □ □
Check that warning and instructional labels are legible and secure. Ensure the load capacity is clearly
marked.
□ □ □
Check the platform rails and safety gate for damage. □ □ □
Platform and base controls are not missing, damaged, frayed, or disconnected. □ □ □
Hydraulic hoses are not torn or loose, and there are no leaks. Check that hoses and cables have no
worn areas or chafing. □ □ □
Check the tires for damage. □ □ □
Check that all snap rings are secure in grooves on pivot pins. □ □ □
FUNCTIONAL TESTS
Gate closes automatically and latches (alignment can be adjusted with screw-on toe board or railing). □ □ □
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) □ □ □
Up/Down Controls (Elevates, Lowers, Enable button must be pressed). □ □ □
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) □ □ □
Key Switch (Selects Platform Control, Ground Control, or O). □ □ □
Alarm (Not damaged, sounds for descent). □ □ □
Up/Down Rocker Switch (Elevates/Lowers). □ □ □
Wheels: Front and rear wheels rotate freely. □ □ □
Brakes engage and hold when platform is elevated. □ □ □
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.
Pre-start Inspection (Push-Around Models)
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3.2 | PREDELIVERY / FREQUENT / ANNUAL 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
Date: Inspected by:
AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED, AND ADJUSTED TO
MANUFACTURER’S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO
EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS,
WHICHEVER COMES FIRST, AND ANNUALLY.
BASE: Y N R PLATFORM: Y N R
Inspect slide tracks for damage □ □ □ All rails in place/secure □ □ □
All frame bolts tight □ □ □ No bent rails □ □ □
Pump Secure □ □ □ No broken welds □ □ □
DC motor secure □ □ □ Platform power outlet safe/working (if installed) □ □ □
Battery Hold Downs Secure □ □ □ Entrance gate closes freely □ □ □
Batteries Fully Charged □ □ □ Cables in place/secure □ □ □
Counterweights secured □ □ □ Functions:
Wheels: Grease casters □ □ □ Elevate/Lower Operational □ □ □
Wheels: Bolts/Nuts Tight □ □ □ Master Power Switch Breaks Circuits □ □ □
Maintenance Locks: Pins storage location □ □ □ Emergency Stop Breaks Circuits □ □ □
All Shields/Guards in place □ □ □ Emergency Down Operational □ □ □
Hydraulic Oil Level □ □ □ Motion Alarms Functional □ □ □
Check all hydraulic hoses for leaks □ □ □ Brakes: Operational □ □ □
Check all hydraulic fittings for leaks □ □ □ Bubble Level in Place □ □ □
SCISSORS
When beginning to elevate, overload light and alarm
activate. Then, if not overloaded, allows elevation to
continue, and light and alarm stop.
□ □ □
No Broken Welds □ □ □ When overloaded, platform stops elevating. □ □ □
Ret. Rings Secure on Pivots □ □ □ Check battery Voltage: <12.5V, charge. □ □ □
No Bent Beam Members □ □ □ WIRING / OTHER:
All rollers turn freely □ □ □ Switches secure □ □ □
DECALS: Contactor(s) secure □ □ □
Legibility □ □ □ Tight on terminals (no loose wiring) □ □ □
Correct capacity noted □ □ □ Operator / Service Manual Included □ □ □
Proper placement quantity □ □ □ Battery Charger Secure / Operational □ □ □
COMMENTS:
CAUTION
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No HS-HB-P830CE
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No HS-HB-P830CE
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SECTION 4 | TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC
Part No WS-144-20-002-50
+
-
NC
NO
NC
-
+
M
V
1
2
3 4
OFF
NO
20 AMP
PUMP
SOLENOID
SOLENOID
OPERATED
UP VALVE
SOLENOID
OPERATED
DOWN VALVE
(OPTIONAL LIGHT)
20 AMP
(OPTIONAL ALL-MOTION ALARM)
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY: DJS
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:06/20/2017
ELEC SCH,HB-P
SCALE:1:1
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL:
DRAWING #: WS-144-20-002-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
A INITIAL RELEASE
12/23/2015
DJS
ECO #
2017-3153A
SHEET 1 OF 1
WEIGHT: APPROX. 0.00 LB.
A
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4.2 | ELECTRICAL SCHEMATIC
Part No WS-144-20-002-50
+
-
NC
NO
NC
-
+
M
V
1
2
3 4
OFF
NO
20 AMP
PUMP
SOLENOID
SOLENOID
OPERATED
UP VALVE
SOLENOID
OPERATED
DOWN VALVE
(OPTIONAL LIGHT)
20 AMP
(OPTIONAL ALL-MOTION ALARM)
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY: DJS
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:06/20/2017
ELEC SCH,HB-P
SCALE:1:1
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL:
DRAWING #: WS-144-20-002-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
A INITIAL RELEASE
12/23/2015
DJS
ECO #
2017-3153A
SHEET 1 OF 1
WEIGHT: APPROX. 0.00 LB.
A
SECTION 4 | TECHNICAL REFERENCES
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SECTION 5 | WIRING DIAGRAMS
5.1 | WIRING DIAGRAM
Part No WD-144-20-002-50
UP
-
+
PUMP
RESERVOIR
+
-
HYD PUMP
M
BATTERY
BATTERY
CHARGER
UPPER
CONTROL
POWER
SWITCH
NO NC
ARMGUARD /
OVERLOAD
LIMIT SWITCH
+
-
CYLINDER
ELEC-641E
143-01-025-50
ELEC-641E
OPTIONAL
FLASHING
BEACON
LIGHT
C
B
A
A
B
C
D
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
B-SIZE
ORIGINALLY DRAWN BY:
Custom Equipment, Inc.
Richfield, WI 53076
Phone: [phone]
DATE:
WD,HB-P827/1027
SCALE:1:1
DO NOT SCALE DRAWING
THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED.
SPEC/MATL: Schematic
DRAWING #: WD-144-20-002-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
A
INITIAL RELEASE
06/23/2016
GLH
ECO #
2017-3153A
SHEET 1 OF 3
WEIGHT: APPROX. 0.00 LB.
A
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