Custom Equipment HY-BRID LIFTS I HB-P4.5, Maintenance & Troubleshooting Manual

Page 1: ...MAINTENANCE TROUBLESHOOTING MANUAL PUSH AROUND AERIAL WORK PLATFORM SUPO 648 REV G HB P4 5 HB P5 0 SERIES I BY CUSTOM EQUIPMENT LLC ...

Page 2: ...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 no...

Page 3: ...HEMATIC 18 4 2 ELECTRICAL SCHEMATIC 20 SECTION 5 WIRING DIAGRAMS 22 5 1 WIRING DIAGRAM 22 5 2 UPPER CONTROL WIRING DIAGRAM 24 SECTION 6 TROUBLESHOOTING FLOWCHARTS 26 6 1 TROUBLESHOOTING FLOWCHART POWER 26 6 2 TROUBLESHOOTING FLOWCHART ELEVATING 28 6 3 TROUBLESHOOTING FLOWCHART LOWERING 30 SECTION 7 PARTS DIAGRAMS 32 7 1 SAFETY AND CONTROL DECALS 32 7 2 MAIN POWER SAFETY CIRCUIT 33 7 3 ELEVATE LOWE...

Page 4: ... 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 1 1 SAFETY SYMBOLS MAINTE...

Page 5: ...gs 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 off 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 ...

Page 6: ...nless 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 off 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 l...

Page 7: ...al 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...

Page 8: ...rty machine cannot be properly inspected Y Yes Acceptable N No Unacceptable R Repaired Description Y N R VISUAL INSPECTIONS Check that there are no damaged dented or bent structural members ڧ ڧ ڧ There are no loose or missing parts ڧ ڧ ڧ Check that warning and instructional labels are legible and secure Ensure that load capacity is clearly marked ڧ ڧ ڧ Check the platform rails and safety gate for ...

Page 9: ...TED 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 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...

Page 10: ...ICAL REFERENCES 4 1 HYDRAULIC SCHEMATIC Part No HS HB P4 5 5 0 MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 18 SECTION 4 TECHNICAL REFERENCES MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 19 ...

Page 11: ... 72 5 1 6 SECTION 4 TECHNICAL REFERENCES MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 20 0 0 2 3803 62 12 62 12 23 5 7 83 9 9 62 12 23 5 7 2 1 9 9 12 5 9 6 5 37 21 7 1 7 5 6 6 5 9 63 2 211 7 216 72 7 0 5 21 027 21 50 237 6 XVWRP TXLSPHQW QF 5LFKILHOG 3KRQH 7 3 57 12 6 75 6 0 7 3 6 1 7 7 7 37 21 17 1 86 21 25 7 385326 25 7 6 2 1 SECTION 4 TECHNICAL REFERENCES MAINTENANCE TROUBLESHOOTI...

Page 12: ...BLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 22 833 5 21752 12 1 50 8 5 29 5 2 0 7 6 7 237 21 6 1 21 7 6 25 1 5 1 XVWRP TXLSPHQW QF 5LFKILHOG 3KRQH 7 5 1 5 0 3 6 2 127 6 5 1 1 7 7 7 37 21 17 1 86 21 25 7 385326 25 7 6 2 1 63 0 7 6FKHPDWLF 5 1 5 9 6 5 37 21 2 1 7 5 9 0RYH HDFRQ LUH WR 2SS 6LGH RI LVF 6Z 2 6 7 2 7 3352 SECTION 5 WIRING DIAGRAMS MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV ...

Page 13: ... 17 1 35235 7 5 72 86720 48 30 17 1 6 2 1 1 MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 24 SECTION 5 WIRING DIAGRAMS 12 5 12 1 0 7 6 7 77 77 3803 62 83 2 6 25 1 5 1 XVWRP TXLSPHQW QF 5LFKILHOG 3KRQH 7 3 835 7 6 2 127 6 5 1 3 7 7 21 7 7 7 37 21 17 1 86 21 25 7 385326 25 7 6 2 1 63 0 7 LULQJ LDJUDP 5 1 5 9 6 5 37 21 2 1 7 5 9 77 0 7 5 5 1 6 2 6 7 2 7 3352 MAINTENANCE TROUBLESHOOTING H...

Page 14: ...RTS 6 1 TROUBLESHOOTING FLOWCHART POWER Troubleshooting Step 1 Main Power MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 26 SECTION 6 TROUBLE SHOOTING FLOWCHARTS MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 27 ...

Page 15: ...S 6 2 TROUBLESHOOTING FLOWCHART ELEVATING Troubleshooting Step 2A Elevating MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 28 SECTION 6 TROUBLE SHOOTING FLOWCHARTS MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 29 ...

Page 16: ...TS 6 3 TROUBLESHOOTING FLOWCHART LOWERING Troubleshooting Step 2B Lowering MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 30 SECTION 6 TROUBLE SHOOTING FLOWCHARTS MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 31 ...

Page 17: ...BSITE DE679 DECAL HYDR FLUID DE706 DECAL UPR DE718 DECAL CE MARK DE723 DECAL WHEEL LOAD HB P4 5 DE727 DECAL KEEP DE728 DECAL CLEAR DE729 DECAL WHEEL LOAD HB P5 0 DE730 DECAL OL ALARM DE731 DECAL QR CODES DE739 DECAL LWR DE740 DECAL LWR PWR DE742 DECAL CAPACITY 550 1P I WO SO MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 32 7 2 MAIN POWER SAFETY CIRCUIT SECTION 7 PARTS DIAGRAMS Item Pa...

Page 18: ...Lever 10 HARD 650 7 16 Shaft Collar 11 HYDR 044 FL3 Hirschmann Connector with Diode 12 144 21 012 51 K Hydraulic Cylinder 13 HARD 644 06 Emergency Down Cable 13 HARD 644 07 Emergency Down Cable Handle only 14 HYDR 674 Start Solenoid 12 V 15 HYDR 665 Up Valve 15 HYDR 673 Up Valve Coil 16 HYDR 050 7 Hydraulic Pump 17 HYDR 032 Hydraulic Fluid Not available as a replacement part Replace with Flomite 1...

Page 19: ... 0 SUPO 648 REV G 36 SECTION 7 PARTS DIAGRAMS 7 5 COVERS OTHER Item Part Number Description 1 HARD 086 Level 2 1000132101 Cabinet Latch 3 1000307601 Gate Latch HARD 649 SCREW 1100 Gate Latch Mounting Hardware 1 4 X 1 25 Barrel Screw 10 24 10 24 X 1 2 Screw 4 HARD 606 2 Gate Sprinng HARD 649 SCREW 1100 Gate Spring Mounting Hardware 1 4 X 1 25 Barrel Screw 10 24 10 24 X 1 2 Screw 5 HARD 603 Manual B...

Page 20: ...oducts 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 th...

Page 21: ...NSPECTION AND REPAIR LOG Date Comments MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 40 SECTION 9 INSPECTION AND REPAIR LOG Date Comments MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 41 ...

Page 22: ...NOTES MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 42 NOTES MAINTENANCE TROUBLESHOOTING HB P4 5 HB P5 0 SUPO 648 REV G 43 ...

Page 23: ... 2647 Highway 175 Richfield WI 53076 U S A Tel 1 262 644 1300 Fax 1 262 644 1320 www hybridlifts com Service Customequipmentlifts com Hy Brid Lifts is a trademark of Custom Equipment LLC These machines comply with specified EN 280 requirements Revision Date June 2016 Printed In The USA BY CUSTOM EQUIPMENT LLC ...