Hy-Brid Lifts III Series Programming manual

BY CUSTOM EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-729
REV B
HB-1230
SERIES III

NOTES
If there is a question about application
and/or operation, contact:
Custom Equipment, LLC
2647 Hwy 175
Richfield, WI 53076
U.S.A.
P: [phone]
F: [phone]
www.hybridlifts.com
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FOREWORD
Original instructions written in English
The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and
maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made
to service this machine.
The operation and safety manual is considered a part of the work platform and contains instructions and operating
procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and
understand all information in the Safety and Operations Manual before operation.
THE OPERATION AND SAFETY MANUAL MUST
BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.
• The user/operator should not accept operating responsibility until the manual has been read and understood as
well as having operated the lift under supervision of an experienced and qualified operator.
• Because the manufacturer has no direct control over machine application and operation, proper safety
practices are the responsibility of the user and all operating personnel.
ANY MODIFICATION ON THIS MACHINE WITH
OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.
DANGER
WARNING
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TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS............................................................................................................................................................... 4
INDEX OF FIGURES.................................................................................................................................................................... 5
SECTION 1 | SAFETY .................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS .................................................................................................................................. 6
1.3 | SAFETY GUIDELINES.................................................................................................................................................................... 7
SECTION 2 | MAINTENANCE ................................................................................................................................................... 8
2.1 | BATTERY MAINTENANCE ........................................................................................................................................................... 8
2.2 | CHARGING THE BATTERY......................................................................................................................................................... 8
2.3 | LUBRICATION.............................................................................................................................................................................. 12
2.4 | COMPONENTS REQUIRING ADJUSTMENT ...................................................................................................................... 12
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ............................................................. 12
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ................................................................................................. 12
2.7 | STORAGE ..................................................................................................................................................................................... 12
2.8 | MAJOR ALTERATIONS OR REPAIRS...................................................................................................................................... 12
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 15
3.1 | PRESTART INSPECTION CHECKLIST................................................................................................................................... 16
3.2 | PREDELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST...................................................................................17
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 18
4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 18
4.2 | ELECTRICAL SCHEMATIC .......................................................................................................................................................20
4.3 | CONTROL BOARD DIAGNOSTIC..........................................................................................................................................22
SECTION 5 | WIRING DIAGRAMS..........................................................................................................................................24
5.1 | WIRING DIAGRAM .....................................................................................................................................................................24
5.2 | LWR CTL WIRING DIAGRAM ...................................................................................................................................................26
5.3 | UPPER CONTROLS WIRING DIAGRAM................................................................................................................................28
SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................30
6.1 | MAIN POWER/SAFETY CIRCUIT.............................................................................................................................................30
6.2 | DRIVE CIRCUIT...........................................................................................................................................................................32
6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................34
6.4 | LOWER CIRCUIT.........................................................................................................................................................................36
SECTION 7 | PARTS..................................................................................................................................................................38
SECTION 8 | WARRANTY........................................................................................................................................................40
SECTION 9 | INSPECTION AND REPAIR LOG .....................................................................................................................42
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INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use ........................................................................................................................................................ 7
FIGURE 2: Maintenance Lock Storage................................................................................................................................................. 7
FIGURE 3: Battery Charger LED Display.............................................................................................................................................. 9
REVISION:
REV B: Reference 3206,3215........................................................................................................................................JANUARY 2018
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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
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 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 SCISSORS LINKS OR PROP UP PLATFORM
UNLESS MAINTENANCE PINS ARE IN PLACE
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.
C
C
FIGURE 1: Maintenance Lock Use FIGURE 2: Maintenance Lock Storage
FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY RESULT IN MACHINE DAMAGE,
PERSONNEL INJURY, OR DEATH.
Other Guidelines
• Never work under an elevated platform until maintenance locks have been engaged.
• Remove all rings, watches, and jewelry when performing any maintenance.
• Do not wear long hair unrestrained or loose fitting clothing and neckties which may become caught on or
entangled in equipment.
• Observe and obey all warnings and cautions on machine and in manual.
• Keep oil, grease, water, etc. wiped from standing surfaces and handholds.
• Before making any adjustments, lubricating or performing any other maintenance, shut o all power controls.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in their proper place.
• Use only approved nonflammable cleaning solvents.
• After maintenance, inspect the machine as described for Pre-delivery.
WARNING
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SECTION 2 | MAINTENANCE
2.1 | BATTERY MAINTENANCE
This unit is equipped with 12-volt AGM maintenance-free batteries.
NOTE: The surrounding temperature greatly aects the power reserve within a battery.
EXAMPLE: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C). At 0°F (-18°C), this battery will
drop to 40% eciency.
NEVER ADD ACID TO BATTERY!
2.2 | CHARGING THE BATTERY
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME
AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
The charger may include an interlock circuit. If so equipped, the unit will not operate while charging.
Operating while charging will shorten battery life.
To charge:
• Park the machine on a level surface.
• Plug charger into AC outlet until charged.
• For best battery life, leave the charger plugged in until machine will be used again. The charger will maintain the
battery charge.
CAUTION
WARNING
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Lester Prime Charge Status Lights:
SECTION 2 | MAINTENANCE
DO NOT OPERATE UNIT WHILE
CHARGING. DO NOT DISABLE
CHARGER INTERLOCK.
FIGURE 3: Battery Charger LED Display
WARNING
Bulk/Start charge cycle phase (constant power or constant current)
Absorption/Plateau charge cycle phase (constant voltage).
Greater than 80% charged
Finish charge cycle phase (constant current). Not all charge profiles
include a Finish phase. Applies to wet cell batteries only.
Balance/Equalize phase. An extended charge cycle is occurring
because a trigger condition has been met (cycle count, etc). Not all
charge profiles include a Balance/Equalize phase. Applies to wet cell
batteries. This happens usually every 30 cycles or when the voltage at
shut o is less than 2.5 volts/cell. Or 30vdc
Charge cycle complete
Charge cycle complete. Post Charge phase (constant voltage flat, etc.)
Not all charge profiles include a Post Charge phase. Applies to AGM or
gel cell batteries only.
AMBER (Charge Status) DESCRIPTION
GREEN (Charge Complete)
(SLOW)
(FAST)
(SOLID ON)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(FAST)
(SOLID ON)
(SLOW)
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AC voltage low fault
(Slow blink RED)
Over Temperature fault
(Alternate between slow blink RED and slow blink
GREEN)
Charger issue (not outputting current, relay didn’t
pull in, EEprom error, internal supplies out of range,
etc.)
(Alternate between slow blink RED and slow blink
AMBER)
Battery not present in On-board mode only (Ob=1).
(Fast blink RED)
Under voltage fault
(Alternate between fast blink RED and fast blink
GREEN)
Over voltage fault
(Alternate between fast blink RED and slow blink
GREEN)
Overall charge maximum time
(Alternate between fast blink RED and fast blink
AMBER)
Phase maximum time
(Alternate between fast blink RED and slow blink
AMBER)
Temperature probe or lockout
(Solid on RED)
Charger
Battery
Vehicle
RED DESCRIPTION
GREEN AMBER
(SLOW)
(SLOW)
(SLOW)
(FAST)
(FAST)
(FAST)
(FAST)
(FAST)
(SOLID ON)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(SLOW)
(SLOW)
(FAST)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(SLOW)
(FAST)
(SLOW)
Lester PrimeCharger fault indicators are listed below.
SECTION 2 | MAINTENANCE
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Charger is o and disconnected from live AC voltage
LED Check during charge initialization which occurs for the first
few seconds
Start/Bulk charge cycle phase (constant power/constant current)
or Plateau/Absorption charge cycle phase (constant voltage)
Finish charge cycle phase (constant current). (Not all charge
profiles include a Finish phase.)
OR
Equalize/Balance charge cycle phase (constant current), which
occurs when a trigger condition has been met. (Not all charge
profiles include a Finish phase.)
OR
Post Charge phase (constant-voltage float). (Not all charge profiles
include a Post Charge phase.)
Charge Cycle Complete
Charger-related fault that causes the unit to stop charging.
Charger-related fault that does not cause the unit to stop charging.
Charging will continue but performance will be reduced.
Battery-related fault.
MIN VOLTAGE-Minimum voltage was not met after a specified
time from the start of the charge cycle
MAX VOLTAGE - Maximum voltage was met.
PHASE-Maximum time for a particular charge cycle phase
(start/bult, plateau/absorption, finish) was met.
MAX TIME- Maximum time for the overall charge cycle was met.
Active Charge Profile DIP switch positions are invalid.
GREEN DESCRIPTIONRED AMBER
(OFF)
(OFF)
(SLOW)
(FAST)
(OFF)
(OFF)
(OFF)
(SOLID ON)
(OFF)
(OFF)
(OFF)
(OFF)
(SOLID ON)
(OFF)
(SLOW)
(FAST)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(OFF)
(ALTERNATING) (ALTERNATING)
(SOLID ON)
Lester SLM Charge indicators are listed below.
SECTION 2 | MAINTENANCE
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SECTION 2 | MAINTENANCE
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.
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THIS PAGE WAS INTENTIONALLY LEFT BLANK
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SECTION 3 | MAINTENANCE CHECKLISTS
Regular inspection and conscientious maintenance is important to ecient economical operation of this machine.
It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at
the stated intervals or more frequently if required by local operating conditions. The following inspection checklists
are included in this manual:
• Pre-Start (required before operation at each work shift)
• Pre-Delivery/Frequent/Annual (Required every 3 months, after periods of storage, and after any alterations or
repairs)
The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week,
5 load cycles per hour).
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.
CAUTION
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SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRE-START INSPECTION CHECKLIST
Y-Yes/Acceptable N-No/Unacceptable R-Repaired N/A - Not equipped with this feature Y N R N/A
VISUAL INSPECTIONS
There are no loose or missing parts. □ □ □ □
Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly marked. □ □ □ □
Check the platform rails and safety gate for damage. □ □ □ □
Platform and base controls are not missing, damaged, or disconnected. □ □ □ □
Electrical cables and wires are not torn, frayed, or disconnected. □ □ □ □
Hydraulic hoses are not torn or loose, and there are no leaks. Hoses and the cables have no worn areas or
chafing. □ □ □ □
Check the tires for damage. Check that wheel axle retaining rings and any set screw(s) in rear wheel are tight. □ □ □ □
Check that all snap rings are secure in grooves on pivot pins. □ □ □ □
FUNCTIONAL TESTS
Gate closes automatically and latches. □ □ □ □
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) □ □ □ □
For Actuator-Steered models: Enable Switch (Does not elevate unless enable is pressed) □ □ □ □
For Counter-Rotate Steering models: Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode) □ □ □ □
Joystick (Return to neutral, drives forward & reverse,)
Enable Trigger (Must be activated for joystick-operated movement)
For Actuator-Steered models: Thumb rocker steers right & left
For Counter-Rotate Steering models: Elevates & lowers
□
□
□
□
□
□
□
□
□
□
□
□
□
□
□
□
If so equipped, horn sounds when button is pressed. □ □ □ □
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement) □ □ □ □
For Actuator-Steered models: Key Switch (On or O)
For Counter-Rotate Steering models: Key Switch (Selects Platform Control, Ground Control, or O) □ □ □ □
Up/Down Rocker Switch (Elevates, Lowers) □ □ □ □
Descent Alarm (Not damaged, sounds for descent; may also sound for drive & elevate, if so equipped) □ □ □ □
Tilt Alarm (Not damaged, sounds when tilted and machine elevated above designated height)
If so equipped, elevating beyond this height may also be prevented. □ □ □ □
Master Power Switch disconnects battery □ □ □ □
Wheels: Front and rear wheels rotate freely.
For Counter-Rotate Steering models: Front wheels pivot freely. □ □ □ □
Drives in slow speed when elevated. □ □ □ □
Brakes: Machine stops when joystick released. □ □ □ □
Pothole guards deploy and lock when platform is elevated. □ □ □ □
Lift does not elevate when pothole guards are blocked. □ □ □ □
Date: Inspected by:
Model: Serial Number:
• Keep inspection records up-to-date.
• Record and report all discrepancies to your supervisor.
• A dirty machine cannot be properly inspected.
THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR
AFTER EVERY SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD
AFFECT THE SAFETY OF THE OPERATOR.
CAUTION
Pre-start Inspection (Self-Propelled Models)
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Model: Serial Number:
• Check each item listed below.
• Use proper operating, service, and maintenance manual for specific information and settings
• If an item is found to be unacceptable make the necessary repairs and check the “repaired” box.
• When all items are “acceptable”, the unit is ready for service.
• If an item is found to be unacceptable, make the necessary repairs and check the “repaired” box. When all
items are “acceptable,” the unit is ready for service.
Y — Yes/Acceptable N — No/Unacceptable R — Repaired N/A — Not equipped with this feature
AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED, AND ADJUSTED TO
MANUFACTURER’S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO
EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS,
WHICHEVER COMES FIRST, AND ANNUALLY.
CAUTION
Y N R N/A Y N R N/A
Base: Rails/Extending platform:
Inspect slide tracks for damage □ □ □ □ Extends freely □ □ □ □
All frame bolts tight □ □ □ □ Cables in place/secure □ □ □ □
Pump Secure □ □ □ □ Locks in Stowed Position □ □ □ □
DC motors secure □ □ □ □ Locks in Extended Position □ □ □ □
Batteries Fully Charged □ □ □ □ Functions:
For actuator-steered models:
Tie rods secure □ □ □ □ All Functions (Srive,Elevate,Steer) Operational
(see Pre-Start Inspection for details) □ □ □ □
Wheels: Pothole guards deploy when platform elevated □ □ □ □
Snap Rings Secure □ □ □ □ Emergency Stop Breaks Circuits □ □ □ □
Bolts/Nuts Tight □ □ □ □ Slow Speed limit switch Set properly □ □ □ □
All Shields/Guards in place □ □ □ □ Pothole interlock functions correctly □ □ □ □
Scissors: Brakes: Operational □ □ □ □
No Broken Welds □ □ □ □ Emergency Down Operational □ □ □ □
No Bent Beam Members □ □ □ □ Wiring:
All rollers Turn Freely □ □ □ □ Switches secure □ □ □ □
Ret. Rings Secure On Pivots □ □ □ □ Contactor(s) secure □ □ □ □
Maintenance Locks:
Stored in designated location □ □ □ □ Tight on terminals (No loose wiring) □ □ □ □
Platform: Oil: Level 1” from top (when platform stowed) □ □ □ □
No Bent rails □ □ □ □ Check all hose for leaks □ □ □ □
No Broken welds □ □ □ □ Check all fittings for leaks □ □ □ □
All rails in place/secure □ □ □ □ Battery Charger Secure/Operational □ □ □ □
110V outlet safe/working (if applicable) □ □ □ □ Tilt sensor □ □ □ □
Entrance gate Closes Freely □ □ □ □ Warning Horn (if applicable) □ □ □ □
Decals: Hour meter operational □ □ □ □
Legibile □ □ □ □ Battery indication operational □ □ □ □
Correct capacity noted □ □ □ □ Operator’s Manual is on the unit □ □ □ □
Proper placement & quantity □ □ □ □ If equipped with load sensing:
Overload light & alarm sounds when overloaded □ □ □ □
Date: Inspected by:
SECTION 3 | MAINTENANCE CHECKLISTS
3.2 | PRE-DELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
Part No. HS-129-20-201-50
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SECTION 4 | TECHNICAL REFERENCES
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SECTION 4 | TECHNICAL REFERENCES
+
-
+
-
-
+
M
M
M
NO
NC
NC
E-STOP
NC
E-STOP
OFF
OFF
UP/DOWN ROCKER
LOWER CONTROL
NO
ELEV. ENABLE
JOYSTICK
BRAKE SWITCH
(CTL SIDE)
BRAKE SWITCH
(PUMP SIDE)
TS-100
B+
B- M1+ M1- M2+ M2-
P15-7 P15-10 P15-12
P15-9
P15-14P15-13
P15-8
P15-6 P15-5
P15-15
P15-3
P15-11
P15-4
P15-2 P15-1
P9-9
P9-8
P9-6
P9-7 P9-5 P9-3 P9-4
P9-2 P9-1
P12-12 P12-11P12-10 P12-9
P12-8
P12-7
P12-6
P12-5 P12-4
P12-3P12-2 P12-1
NC
DRIVE ENABLE
NO NO
NO
NC
ANG. SENS. 1
V
1
2
43
2
3
4
+
-
BRAKE
(PUMP
SIDE)
BRAKE
(CTL
SIDE)
PH LS-L
1
56
KEYSWITCH
PH LS-R
(OPTIONAL FLASHING BEACON)
1K
1W
CHR INTLK,IF SO EQUIPPED
ADDL CHR
CONNECTIONS,
IF SO EQUIPPED
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:
ELEC SCH,HB-1230 S3
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 #: WS-129-20-316-50
REV
DESCRIPTION OF CHANGE
DATE REV BY
C Revise Charger Wiring (Lester Chrger)
07/10/2017
GLH
ECO #
2017-3156
SHEET 1 OF 1
WEIGHT: APPROX. 0.00 LB.
C
4.2 | ELECTRICAL SCHEMATIC
Part No. WS-129-20-316-50
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