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Contents
1. Item Part Description 1 NA B Ground Connection on Pump 2 NA B Power Connection on Pump 3 ELEC 047 Not available as a replacement part Replace with 12V Group 27 Deep Cycle Marine Battery Replacement weight must be minimum 50 Ib 4 1000106550 Drive Control Module Program Specific to this Model Series Only 5 1000106450 Load Control Module GP102 Program Specific to this Model Series Only 6 ELEC 645 Battery Charger 7 ELEC 639 1 Charger Cord NEMA 5 15 P IED 320 C13 8 ELEC 551 Joystick 9 ELEC 071 KIT Emergency Stop Button with Contact Block 10 ELEC 633 1 Master Power Switch Lever 11 ELEC 633 Master Power Switch 12 ELEC 071 KIT Emergency Stop Button with Contact Block 13 ELEC 073E Key Switch 14 ELEC 073E 1 Spare Key 15 ELEC 819 Sleep Timer Relay 16 1002101051 Lower Control Assembly 17 1002101351 Upper Control Assembly Not Pictured SUB A13 Main Cable Not Pictured ELEC 670 2 20 A AGC Fuse Not Pictured 1002100193 Battery Cable Kit Not Pictured 1002101099 Drive Power Cable Kit Part SUPO 613E REV J Page 38 of 42 Drive Circuit Parts Item Part Description 1 1000108202 Caster 2 1000106302 Limit Switch Plate 3 HB PH 13 Guide Block 4 1000102004 Retaining Sleeve 5 HB PH 7 P PH Lock 6 ELEC 123 2 Limit Switch 7 NA Brake Connecti2. SOLEBOD OPERATED samon CONTROL SIDE DRIVE PART ELEC 062 YW Reset TDR2 2 HR Sleep Timer 02 24 11 09 14 10 07 22 10 06 23 10 t MOVE SHARK IS RED WIRE TO OUTPUTOFUCE STOP Moved 24VDC Output from Pump to Shark ADDED TIME DELAY RELAY TDR1 ADDED DIODES AT TILT OL ALARM Custom Equipment Inc Richfield WI 53095 Phone 262 644 1300 WIRING SCHEMATIC HB 830CE SHARK JOYSTICK CABLE 06 15 10 Part No WD 1002100194 WS 1002100194 Part SUPO 613E Page 21 of 42 REV J JOYSTICK SHARK MULTI AXIS POWER IN 2 BUS HIGH SBUS LOW BATTERY NEG ania 10 CONDUCTOR CONNECTOR TO LOWER CONTROL 3 ORANGE ESTOPIN 4 5 RED WHITE PUMP SOLENOD PUMP UP UP SWITCH 7 YELLOW JS BUS HIGH PURPLE JS BUSLOW 9 BROWN PLATFORM MODE 10 BLACK BATTERY NEG 11 GREEN PUMP DOWN DOWN SW DOWN ALARM GRAY veg 1081 10 10 TO LOWER CONTROLS 10 CONDUCTOR SOCKET FEMALE 22222111 CONDUCTOR E E TOE STOP PANEL MOUNT PLUG MOVE TILT LED RED WIRE FROM CONN PLUG TERM 12 TO TERM 4 07 19 2010 l MOVE SHARK RED WIRE FROM E STOP TO LIFT ENABLE 06 23 2010 INITIAL RELEASE 05 03 2010 DESCRIPTION Cus
3. MOVIE OIN MOOTH3INI 1111 al 102 22 X90 TH31NI GSAOWSY QNO 119170 Std NOILVA3T3 01 24 8 SNOLLO3NNOO 1 WIRING DIAGRAM ELEVATE LOWER CIRCUIT Q31ON SYSHM 1d39X3 8 S38IM TIV 600 F 910 060 010 080 090 X BuIpiam 5131 379 LON OG HOLIMS LOANNOOSIG JO OL H 19 40 MS HOLIMS A33 29 0142 9 010 349 180534 NMOGidn NMOQ XOVI8 8 508 st sna sr 137905 YOLONGNOD 0 0109105 935 Ar 3079 39NVHO 490183 10311409 YAddN OL YOLOANNOD HOLONGNOD 0b HLON31 ON HOLIMS MOO TH31NI Hd OL aseg 1 7 860101200 59 0388 1844 5 NOLLOM 30 1832530 Part SUPO 613E REV J Does the machine have function Drive Steer Elevate Lower Yes but some function s are not working properly Does Platform Control Display a Fault Code Check Component or Condition Referenced by Fault Code Are the batteries connected Check per wiring diagra
4. Is up down switch Contact CEI for further damaged Is down valve stuck open sid low troubleshooting wered fill Flush valve by simultaneously Replace rocker switch at o 1 below pressing up switch at base and down upper or lower control rvoir Switch on platform control for 30 sec setting With black lad on stripe side and red on other side should get a resistance reading Switch leads no reading Replace bad diode Flush down valve by IeXhera avestiiofiendn simultaneously pressing up Switch Check integrity of electrical 5 at base and down switch gt connections There may be a Replace pump May hydraulic hose platform control for 30 sec loose connection or momentary be worn or defective There may be foreign matter short lodged Replace hydraulic hose Check for loose electrical connections 94 Replace down coil Damaged cylinder damaged seal in cylinder aulty check valve in pump it stops Nut should only be lightly snug should 30 in Ib Replace coil and lightly ed tighten nut Listen carefully near motor when not energized may be running backwards Replace pump and then check for oil flow out of return line Bad cylinder seal if oil is flowing from return line to repair
5. 1439530 NMOGidn NMOd dnd 019080 HOLIMS LO3NNOOSIG 40 3016 AYALLY8 OL 618 OIN AYLLY MOVIE OIN 3CON WHOS m 018088 MOOTH3INI 1111 MOTISA sng Sn 148905 2 0 X90 TH31NI 1111 GSAOWSY 2109705 935 Ar 3079 90153 YAddN OL YOLOANNOD YOLINONOI 0 Page 25 of 42 HLON31 55010120075 201 99 s H 1 SNOLLO3NNOO MS HOLIMS A33 N WIRING DIAGRAM MAIN POWER SAFETY CIRCUIT Part SUPO 613E Q31ON SYSHM 1432 3 8 S38IM TIV WIRING DIAGRAM Gs DRIVE CIRCUIT JOYSTICK SHARK MULT AXIS PONERIN 2 HIGH BATTERY NEG 10 CONDUCTOR CONNECTOR TO LOWER CONTROL 3 ORANGE ESTOPIN 4 5 RED 24V PONEROUT WHITE PUMP SOLENOD PUMP UP UP SWITCH 7 YELLOW 6 BUS HIGH PURPLE 58800 9 BROWN PLATFORM MODE 0 BLACK BATTERY NEG 11 GREEN PUMP DOWN DOWN SW DOWN ALARM 1 GRAY 310814 10 10 0384 TO LOWER CONTROLS 10 CONDUCTOR SOCKET FEMALE CONDUCTOR E E TOE STOP PANEL MOUNT PLUG MOVE TILT LED RED WIRE FROM CONN PLUG TERM 12 TO TERM 4 07 19 2010 l MOVE SHARK RED WIRE FROM E STOP TO L
6. ds In D e Hvdraulic Oil Level 1 from top heck all hvd hoses for leak heck all h ittings for leak i Broken Weld Bent Beam olle n Ret Rings Se e On Pivo Broken weld Platform A in place secure No bent rai NO broken weld OV outlet safe workine if installed ntrance gate Close ee Operato ervice Manual In ded ables in place secure xtending platform extends free xtending platform Locks in Stowed Position Extending platform Locks in Extended Position Comments Part SUPO 613E REV J INSPECTED BY Page 14 of 42 Technical References Joystick Service Flash Codes The amber Service Indicator LED displays diagnostic codes A sequence of flashes separated by a pause followed by a repetition of the sequence The number of flashes indicates a condition Flash Code Description Notes 1 User Fault Possible stall timeout or user error Release the joystick to neutral and try again 2 Battery Fault Try charging batteries Batteries may require replacing Check batteries and cables 3 Left Motor Fault Check left motor connections and cabling 4 Right Motor Fault Check right motor connections and cabling 5 Left Park Brake Fault Check left park brake connections and cabling 6 Right Park Brake Fault Check the right park brake connections and cabling 7 Remote Fault Check the Communications Bus connectors and wiring Replace th
7. 010 0 nennen nnne 34 Replacemient Parts dm oet axle edu reete 36 Safety and Control Decals o aeo EO 36 Cover OEM 37 Main Power Safety enne nnne trennt entran enr sitne ttes siiis esten senten ns 38 Drive Circuit eme 39 Elevate Lower Circuit Parts cesses seiten eres sse ense tens se essen 40 dais 42 Figure 1 Stability Testing Equivalent esses eene 6 Figure 2 Maintenance Lock Pin 5 7 Figure 3 Maintenance Lock Pin 7 Figure 4 Battery Maintenance ci e i gear dee a a cu aat anecdote 8 Figure 5 Battery Charger LED Display nennen ennemi 9 Revision Table Revision A 06 29 2010 Initial Release Revision J 10 24 2012 Revised logos Part SUPO 613E Page 3 of 42 REV J Original instructions written English Foreword The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing an
8. RR ER 12 Frequent Inspection Checklist seriea rrt ennt det ott vri cere bc ear aeter vue ee veste ve Tea Et iets 13 Pre Delivery Annual Inspection Checklist esistente 14 Technical 5 tr sac rere pera edere RE te 15 Joystick Service Flash Cod s s Du 15 Control Module GP102 Help Messages esses enne enne tnn nnns ener nina nasse sns ranas 16 Control Module Flash 18 Hydraulic Schematic e eur nn 19 Electrical Schematic ot Lr iere Ton tene oU nh LE ae ive E Ru ennai LR ED EXER E ud 20 ETE ET 22 WAKING 22 Main POWE 24 26 Elevate Lower 22 2 000 nete sese ense tenere site ense tres ses ense nn 28 iid ite hd em OiR 30 Part SUPO 613E Page 2 of 42 REV J Troubleshooting reet IG 30 Troubleshooting Flowchart Drive amp Steer 2 eene nnne 32 Troubleshooting Flowchart Elevate amp Lower Circuit
9. TO LOWER CONTROLS 10 CONDUCTOR SOCKET FEMALE CONDUCTOR sans eb STOP rect ea E PANEL MOUNT PLUG MOVE TILT LED RED WIRE FROM CONN PLUG TERM 12 TO TERM 4 07 19 2010 l MOVE SHARK RED WIRE FROM E STOP TO LIFT ENABLE 06 23 2010 INITIAL RELEASE 05 03 2010 DESCRIPTION Custom Equipment Inc UPPER CONTROL WIRING 8FT LL 1002101597 1002101099A BATTERY 1002101599 PUMP RESERVOR me 1002101098 LOWER CONTROLS r som EATERY CHARGER BATTERY Custom Equipment Inc Rows Part SUPO 613E AOL a Sm CONTROL WIRING CE LIII l Welding Tolerances X 060 030 XXX 010 ss 1S0101Z001 7610012001 GM Wed S00 060 F 5 zsa _ ee 3 d 010 2 060 F 090 seoueJojo 5131 379 LON Od 39 1 1 ININ 1 8 001 999 292 Qu uawdinb3 Uojsn 96065 IM EJ Wavv 10 111 LY 530010 aaaav 0026180 INIL 03004 JO OL 31646 oj duing 9 AVES 01 2 90 9801 8311 3315 93009
10. AVES 01 2 90 TYL YINI 3315 a3aav Wavy 1439530 NMOd dnd 04 0 80 HOLIMS LO93NNOOSIQ 30 3018 AH3 LLV8 OL 61 yovia 81 MOVIE DSN H3JONVHO GSA0W NMON8 IQON WHOALW 1d sna st 390 TH31NI al 015 ATWWad MOTISA sna sr 133908 YOLONGNOD 0 039 AvC 3178 40153 IOS1NOO Y3ddN 01 01000 02 0 Page 23 of 42 0 34V QNO 119170 54 HLON3T 20151533 3016 ON HOIMS 30001 OL aseg pajeoo1 ON HOLIMS LIATTMOO TH3INI Hd OL aseg 1 NOUWASTS 0 09 8 11111111 LIT 21 SNOLLO3NNOO MS HOLIMS A33 1 44 PT ANANI IOG 589 03188 Luvd 0 9 2313 Lud 30 130830 YILIN LIONYNOH Part SUPO 613E REV J 0310 SYSHM 1d39X3 8 S38IM TIV WIRING DIAGRAM MAIN POWER SAFETY CIRCUIT JOYSTICK SHARK MULTI AXIS POWER IN 2 JSBUS LOW BATTERY NEG 10 CONDUCTOR CONNECTOR LOWER CONTROL 3 ORANGE ESTOPIN 4 BUE 5 RED 24V PONEROUT WHITE PUMP SOLENOID PUMP UP UP SWITCH 7 YELLOW JS BUS HIGH 8 PURPLE JS BUSLOW 9 BROWN PLATFORM MODE 10 BLACK BATTERY NEG 11 GREEN PUMP DOWN DOWN SW DOWN ALARM 7 GRAY
11. Ascent speed slow or erratic tarts elevating then stops Will not descend Creeps down Part SUPO 613E REV J members bent Are any structural Measure resistance across diode Ohm meter multi meter at 40 se Contact manufacturer to arrange replacement Is battery fully charged Is emergency down valve open Charge battery Are pothole guard blocked Remove obstruction turned off 1as key switch bee Close emergency down Rep valve 5 pothole limit switc functionning Is an E Stop activated Turn key to on position s emergency down valve open Pull out emergency stop button at upper and lower controls Oreign matte lodged in up or down valve valve Disassemble and clean Look for residue in Screen and on O ring or damage to O ring Close emergency down valve Check cable connections Faulty down Replace limit Switch or repair connections Is battery charged Charge batteries Electrical problem Disconnect coil Check if unit sto drifting Check voltage at coil shc be 0 V when not energized Replace down valve Run unit up and Might be able to re walls inside cylinde Page 34 of 42
12. 5 Oututu2oy 0 0 x XX 090 x X q 01 60 60 ZN SIL Jar 1405534 INT 1138 39155384 mu 1904 1531 JAWA df 013 WIAD 3509 34155 349 3195 39 0 39055384 a JAWA NAD 809415 34155 394 SUPO 613E ss 13069 4 3 4498 LOWER CONTROL E STOP AFUSE P2 1 Platorm 2 2 Ground P2 12 8 me P3 4 Failsafe Output P4 6 B Supply 4 2 4 Output P4 7 Neg BATTERY CHARGER PART ELEC 640 i P26 GND Down HOV ACPO P4 9 B Supply P4 3 5 Output P4 8 Neg P2 3 UP FWD NV BATTERY 2 4 DWNIREV PART ELEC ONT P3 5 B Ve paa P2 8 Lift Mode P3 1 TitLamp P27 Drive Mode P3 2 Overload Alarm 240 Elevation P3 3 Overload Lamp BATTERY DISCONNECT PART HELE SCISSORS UP SHARK JOYSTICK PART LEC PART ELEC SH5 Part SUPO 613E REV J Page 20 of 42 HOURMETER PART ELEC SHARK MOTOR CONTROLLER PART ELEC XXX SHARK 12PINPORT CONNECTOR R1 nicum Os None a E 0 SWITCH ACTIVATED WHEN PART HELECXXX x 97 ACTUATOR NES DESCENT ALARM LONER COUR PART LEC NS wi uud SHARK BUS CONECTOR
13. Part SUPO 613E Page 42 of 42 REV J
14. it carries out various tests to ensure that it is functioning safely TOO HIGH DRIVE PREVENTED A drive function has been selected but the platform is raised above the MAX DRIVE setting The drive function will be prevented until the platform is lowered LED flash code 8 TOO HIGH LIFT UP PREVENTED The lift up function has been selected but the platform is raised above the MAX LIFT setting The lift up function will be prevented until the platform is lowered LED flash code 8 UP DOWN SELECT INPUTS ACTIVE TOGETHER The up select P2 3 and or P2 5 and the down select P2 4 and or P2 6 are active together the GP102 cannot determine the vehicle use All vehicle operation will be prevented until the problem is corrected LED flash code 2 VEHICLE OVERLOADED The estimated load in the platform exceeds the OVERLOAD AT setting in the ADJUSTMENTS LOAD menu GP102 will activate the cutout to prevent vehicle operation until the platform load is reduced LED flash code 8 VEHICLE TILTED Either the X or Y tilt measured by the GP102 integral tilt sensor exceeds the X TRIP or Y TRIP setting in the ADJUSTMENTS TILT menu LED flash code 8 Part SUPO 613E Page 17 of 42 REV J WAITING FOR B ON P2 12 The supply on P2 12 provides power for the outputs P3 1 2 3 4 The GP102 cannot function if the supply is not present Since the supply on P2 12 is switched to P3 4 vehicle operation will be prevented LED flash cod
15. Off NA 50 to 75 charged On Blinking Off NA 75 to 100 charged On On Blinking NA 100 charged On On On NA Charge for flooded type batteries NA NA NA Off Charge for Sealed type batteries NA NA NA On Abnormal Cycle Off Off Blinking NA CAUTION DO NOT OPERATE UNIT WHILE CHARGING DO NOT DISABLE CHARGER INTERLOCK NEVER ADD ACID TO BATTERY 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 Lubrication Item Specification Frequency of Lubrication Wheels Teflon Spray Quarterly Part SUPO 613E Page 9 of 42 REV J Components requiring adjustment Under normal use no components should require adjustment Contact the manufacturer if adjustments are required Examination repair replacement of limited life components With proper use battery maintenance and regular inspection there are no limited life components that require routine replacement Safety devices and systems requiring checks Check safety functions as part of daily inspection Check that the electromagnetic brakes are holding Storage After periods of storage exposure to extremes of ambient conditions heat cold moisture dust etc inspect the machine Refer to the Pre Delivery Frequent Inspection Checklist in the Mainte
16. is corrected LED flash code 4 ELEVATION SWITCH STUCK The GP102 uses the elevation switch in combination with the height sensor to ensure correct functionality of both any of the following faults may be detected e When platform is elevated the measured height should be above that stored during load calibration e When platform is not elevated the measured height should be below that stored during load calibration All vehicle operation will be prevented until the problem is corrected LED flash code 4 EMS INPUTS FAULTY The EMS platform P2 1 and EMS ground P2 2 inputs are either both active or both inactive the GP102 cannot determine whether to be in platform or ground mode All vehicle operation will be prevented until the problem is corrected LED flash code 2 FACTORY OVERRIDE To allow vehicle movement during manufacture the GP102 is delivered in a FACTORY OVERRIDE state which disables all functionality The first load calibration even if not completed will terminate this state LED flash code 15 FAULT BAD TILT SENSOR The GP102 has detected that its integral tilt sensor is faulty the module may need to be replaced IMPORTANT If the GP102 is installed incorrectly this fault may occur erroneously LED flash code 8 HEIGHT NOT CALIBRATED During the first phase of load calibration DYNAMIC the GP102 calibrates the minimum and maximum output of the height sensor so that platform height can be determined This cal
17. with seal kit probably need to replace cylinder If ylinder are scratched or pitted cylinder needs replacement SUPO 613E HB S830CE Troubleshooting Flowchart Elevate amp Lower Problems Revision A Initial Release 4501 2019 42 Part SUPO 613E REV J Replacement Parts CAUTION USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS USE OF NON OEM PARTS WILL VOID WARRANTY DANGER REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH STABILITY OR SAFETY FUNCTION OF THE UNIT BATTERY HYDRAULIC CYLINDER JOYSTICK AND CONTROL MODULES AND ALL STRUCTURAL COMPONENTS Listed below are replacement parts that may be available and listed for reference These represent current 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 Safety and Control Decals Refer to Operator s Manual for decal part numbers and locations Part SUPO 613E Page 36 of 42 REV J Covers Other Item Part Description 1 1000500201 Cover Side 2 HARD 633C Cabinet Latch Cam 3 HARD 633B Cabinet Latch Handle 4 1000103001 Step 5 1000500701 Cover Pump Top 6 1000500201 Cover Side 7 1000500601 Cover Pump End Part SUPO 613E REV J Page 37 of 42 Main Power Safety Circuit
18. 1 MOVIE DIN MOOTH3INI LIL X90 TH31NI 111 GSAOWSY 55010120075 201 99 s H 1 193 09 MS HOLIMS WIRING DIAGRAM DRIVE CIRCUIT 01903138 YILIN LIONYNOH 0310 SYSHM 1432 3 V9 8 S38IM 30151533 WHO 02 Page 27 of 42 9 010 349 180530 NMOGidn NMOQ 4104 XOVI8 8 3doNWHO4LVld Mo1sna st sna sr 137905 YOLONGNOD 0 diind 010105 935 u3Mod Ar 3079 90159 10311409 YAddN OL YOLOANNOD 1 09 0 HLON3T 3018 ON HOLIMS IQON OL eseg pajeoo1 801231402 Hd ANANIIOG 01808 E 57 5 SUPO 613E LIFT ENABLE DOWN SOL LOCATED SCISSORS Part SUPO 613 FX V 1002101094 1002101598 E SUB A13 BATTERY 1002101095 BATTERY 10004010108 PANEL MOUNT PLUG MALE 1002101597 1002101099A 1002101599 PUMP RESERVOR me 1002101098 LOWER 1002101090 CONTROLS 1002101051 1002101650 WIRING DIAGRAM ELEVATE LOWER CIRCUIT JOYSTICK SHARK MULTI AXIS POWER IN jS BUS LOW BATTERY NEG 10 CONDUCTOR CONN
19. 7 2E 1 Coil 24V 16 HYDR 007 2E 2 Down Valve 17 LAS M115 P E Down Valve Actuator 18 HARD 650 Shaft Collar 7 16 19 HYDR 044 FL 3 Hirschmann Connector with Diode 20 ELEC 648 Pressure Transducer 21 HYDR 600 5 High Pressure Hydraulic Hose 22 ELEC 636 Tilt indicator LED 23 ELEC 636 Overload Indicator LED 24 ELEC 602 amp ELEC 871 Lift Enable Button amp Contact Blocks 26 ELEC 133B Up Down Rocker Switch 27 HB PH 13 Guide Block 28 1000102004 PH Retaining Sleeve 29 HARD 702 Spring 30 HB PH 7 P PH Lock 31 HARD 701 Spring 32 1000106302 LS Plate 33 1000105902 PH Pick Up Arm 34 LAS M220 P PH Arm 35 ELEC 123 2 Limit Switch Not Pictured HYDR 032 Hydraulic Fluid Not available as a replacement part Replace with Flomite 150 Dexron 1 Mobil DTE 2 or equivalent Not Pictured HYDR 625 Pressure Compensated Flow Control Valve Not Pictured HARD 022 Retaining Ring Not Pictured ELEC 816 Time Delay Relay Part SUPO 613E REV J Page 41 of 42 Warranty LIMITED WARRANTY Warranty Statement Outside North America Custom Equipment Inc the Company warrants that all new units of equipment manufactured and sold by it conform to the Company s latest published specifications Also that all purchased components and sub assembled parts and assemblies shall be free from defect in material and or workmanship for a period of 24 months from the date a new unit is placed into service with the exception of batteries which a
20. ECTOR TO LOWER CONTROL 3 ORANGE ESTOPIN 4 BUE 5 RED 24V PONEROUT WHITE PUMP SOLENOID PUMP UP UP SWITCH YELLOW JS BUS HIGH PURPLE JS BUSLOW BROWN PLATFORM MODE BLACK BATTERY NEG GREEN PUMP DOWN DOWN SW DOWN ALARM GRAY TO LOWER CONTROLS 10 CONDUCTOR SOCKET FEMALE 0 Move stark Js RED WIRE FROM ENABLE TO 5 CONTACT 07222010 b ae MOVE TILT LED RED WIRE FROM CONN PLUG TERM 12 TO TERM 4 07 19 2010 l MOVE SHARK RED WIRE FROM E STOP TO LIFT ENABLE 06 23 2010 INITIAL RELEASE 05032010 DESORPTION Custom Equipment Inc UPPER CONTROL WIRING 8FT ETD Tae INPUTS OUTPUTS SENSOR P2 P3 co PHINTERLOCK LIMIT SWITCH 21 emo CHARGER Custom Equipment Inc Powe 640 CONTROL WIRING CE Welding Tolerances X 060 030 XXX 010 1 852 50 012001 761001200 4 08 4 esa 32 1031409 83MOT ININ 148 0061 79 292 euoug 9 1949103 Ulojsn 96065 IM Wavv 10 111 LY 530010 aaaav 010 390 1401 AY730 03009 yeys dung NANO OGAvZ 04 52 90 401 831 43315 0400 045080 HOLIMS LO3NNOOSIG 40 3016 OL 618
21. Hy Brid Lifts by Custom Equipment MAINTENANCE AND TROUBLESHOOTING MANUAL Hy Brid Lifts Model HB 830CE Self Propelled Aerial Work Platform Table of Contents SCIT 5 Safety SV IMIS esce dt UD NET ens M 5 General Rules and entes tentes tenen nnne 5 Stability EET T 6 Safety 7 Maintenance LOCK pas RES 7 li EIDIH HICIE 7 Battery ER EE SER Ru eed aries 8 9 Components requiring 10 Examination repair replacement of limited life components 10 Safety devices and systems requiring ennt nnns 10 SELON AGC EE D TTL IE 10 Major Alterations or Repalrs uev ed eripe ees a v e Ov Ee SERV 10 Inspection and Regular Maintenance 5 5 11 Monthly Battery Care ep Ere 11 Prestart Inspection ChecklIst 2 oet eR RE e is x c
22. IFT ENABLE 06 23 2010 INITIAL RELEASE 05 03 2010 DESCRIPTION Custom Equipment Inc UPPER CONTROL WIRING 8FT E L 2908817 1002101597 10021010994 10021010998 BATTERY 1002101599 PUMP gt RESERVOR me LIMIT SWITCH 1002101098 1002101097 LOWER CONTROLS 1002101091 1002101051 qum BATTERY DISCONNECT SEE INITIAL RELEASE 612912010 BATTERY DESCRIPTION DATE Custom Equipment Inc Rows Part SUPO 613E 6042 Sm 8FT MNI PARER CONTROL WIRING CE Welding Tolerances X 060 030 010 11 852 9 com T MOVED BATT CHARGER NEG WIRE TO DISCONNECT 9 8 06 2010 MOVED FUSE 6 29 2010 S00 F 60 060 F 010 080 090 X BuIpiam 5131 379 LON OG 1901012001 961001200 0 0 Hed esa 32 1031409 83MOT 148 0061 79 292 1949103 46069 IM EJ 10 2711 530010 aaaav HOLIMS LOANNOOSIC 010 390 Av 130 03049 JO 398 OL eus 0 dung jndino 0462 90 4331 04084 0080 HOLIMS LO3NNOOSIG 40 3016 OL 618 8
23. OV ground has been detected Check wiring from pins P3 4 and P3 6 LED flash code 6 This indicates a fault with the load measurement check the pressure transducer and wiring from it to connector P4 LED flash code 7 This indicates a fault with the supply to the GP102 check battery supply at least 8V on pin P2 12 also check that there is not a short to OV ground on pin P4 1 If load cells or strain gauges are connected to P5A P5B P6A P6B disconnect them if the fault changes then one or more is shorting the supply on each pin 1 LED flash code 8 This is not a fault it indicates the GP102 has prevented a function functions can be prevented if the platform is overloaded if the machine is tilted too far or if the platform is too high LED flash code 9 This indicates a fault with the height measurement check the height transducer EZfit and wiring from it to connector P4 LED flash code 10 This indicates the GP102 is carrying out startup tests LED flash code 15 This indicates the GP102 is in FACTORY OVERRIDE see Appendix Nine and overload functions are disabled this aids manufacture by allowing vehicle movement before the machine is built sufficiently to be calibrated Part SUPO 613E Page 18 of 42 REV J 12058 4 4 04044 25 9 oles 90 8 gH SH ON 1400 390E8S HH 31925 LUN 1 1 1 ouag 15 GIU 020 X
24. am Replace mode limit switch Contact CEI for further troubleshooting Consider board failure or incorrect wiring tch Clean any debris from limit switch area Check for proper connection inside limit switch See wiring 1 with diagram Replace mode limit switch Contact CEI for further troubleshooting Consider board failure or loose wiring tact CEI for further troubleshooting oard failure pothole interlock limit switch failure Allow to dry for 24 hours and try again Board probably will need replacement Apply dielectric grease to connectors at main wire harness Part SUPO 613E REV J Contact CEI for further troubleshooting Consider board failure SUPO 613E HB S830CE Troubleshooting Flowchart Drive Problems Revision A Initial Release 06 01 2010 Page 33 of 42 Does machine raise lower Yes but not properly Check GP102 for flash codes and diagnose if possible No Does pump operate Yes Is emergency down valve open Is hydraulic fluid lo Check for power connection See Main Troubleshooting Close emergency down valve or cable connections Is power solenoid damaged Are diodes functioning properly With platform lowere pump reservoir to 1 top of reservoir Replace solenoid Replace pump assembly
25. ch if not avoided will result in death or serious injury WARNING 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 CAUTION FAILURE TO FOLLOW THIS WARNING MAY CAUSE INJURY OR DAMAGE EQUIPMENT CAUTION indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or damage to equipment General Rules and Precautions Custom Equipment Inc designed the Hy Brid Lift self propelled scissor lift to be safe and reliable It is intended for elevating personnel along with their necessary tools and materials to overhead work locations Vibration does not create significant hazards on this machine 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 Inc conforms to specified EN 280 requirements it is the responsibility of the owner to instruct operators with the safety requirements made not only by Custom Equipment Inc 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 plat
26. d maintaining Hy Brid Lifts All information in this manual must 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 DANGER 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 WARNING ANY MODIFICATION ON THIS MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED If there is a question on application and or operation contact Custom Equipment Inc 2647 Hwy 175 Richfield WI 53076 USA Phone 262 644 1300 Fax 262 644 1320 www hybridlifts com Part SUPO 613E Page 4 of 42 REV J Safety Safety Symbols DANGER FAILURE TO FOLLOW THIS WARNING WILL CAUSE DEATH OR PERSONAL INJURY DANGER indicates an imminently hazardous situation whi
27. dirt debris acid etc off battery whenever corrosion is detected Use a solution of 5 tsp baking soda per quart of warm water e Coat terminals with a commercially available coating Figure 4 Battery Maintenance CAUTION NEVER ADD ACID TO BATTERY Charging the Battery This unit is equipped with deep cycle 12 volt batteries 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 Note The surrounding temperature greatly affects the power reserve within a battery Example A battery that is 10096 charged at 80 27 C drops to 6596 at 32 F 0 C At 18 C this battery will drop to 4096 efficiency WARNING LEAD ACID BATTERIES GENERATE EXPLOSIVE GASES KEEP SPARKS AND FLAME AWAY FROM BATTERIES DO NOT SMOKE WHILE CHARGING e Park the machine on a level surface e Plug charger into AC outlet until charged e Unplug charger Part SUPO 613E Page 8 of 42 REV J The charger will not begin charging on severely discharged batteries This will be evident by the three indicators blinking simultaneously Figure 5 Battery Charger LED Display 50 75 100 rger LED Display 2 0 to 50 charged Blinking Off
28. e 7 WAITING FOR NEUTRAL When the GP102 is powered up all controls must be in neutral to allow safe testing of the failsafe output no functions are allowed until testing is complete LED flash code 2 Control Module Flash Codes The GP102 has a built in LED to provide simple diagnostics when no EZcal is available Please note that the use of an EZcal provides significantly better diagnostics through the HELP messages see Appendix Three An EZcal is also necessary to calibrate a GP102 LED on steady This indicates no fault with the GP102 LED off always This indicates no power to the GP102 or idle timeout activate a lift or drive function to cancel the idle timeout LED flash code 1 This indicates the GP102 has not been properly calibrated LED flash code 2 This indicates a fault with the switch inputs to the GP102 Check wiring to connector P2 LED flash code 3 This indicates a fault with the shutdown outputs of the GP102 a short to the supply has been detected Check wiring from pins P3 4 and P3 6 LED flash code 4 This indicates that armguard is active or that there is a fault with the elevation switch the GP102 verifies correct opening and closing of the elevation switch against the height sensor Checking the elevation switch on P2 10 If the height sensor has been adjusted or replaced repeat the CALIBRATE HEIGHT procedure LED flash code 5 This indicates a fault with the shutdown outputs of the GP102 a short to
29. e Remote Joystick 8 Power Module Fault Check the Communications Bus connectors and wiring Replace the Power Module 9 Communications Fault One cause of this error is when the unit is powered down without turning off the joystick i e using the emergency stop To clear with the machine on using the key switch turn the joystick off and back on joystick on off button Check that battery voltage is greater than 17V Check the Bus Cable Replace the Power Module Replace the Remote Joystick 10 Unknown Fault Check all connections and wiring Contact manufacturer 11 Incompatible Remote The Remote is incompatible with the Power Module Ensure that the correct part number is used See also Upper Control Battery Gauge Indicator codes listed in the Operator s Manual Part SUPO 613E REV J Page 15 of 42 Control Module GP102 Help Messages When the EZcal hand held device is connected to the GP102 control module the first menu available is HELP just press the ENTER button to see a message describing the current status of the GP102 this can be very helpful in diagnosing problems with the system When an EZcal is unavailable an LED on the GP102 flashes to provide limited diagnostics see Appendix Four The following messages might be displayed EVERYTHING OK The GP102 is in platform mode and detects no problems If problems are being experienced with the system use the DIAGNOSTICS menus to check for fault
30. eck electrical motor brushes every 150 hours Verify that maintenance and inspection records are up to date Functional Tests Perform all checks on the Pre Start Inspection Checklist Functions operate smoothly Functions operate over full range of motion Elevated and Lowered drive speeds do not exceed specifications listed in Operators manual Emergency Lowering Manual override functions properly Ground Controls override platform controls Check that the platform does not drift down with a full load Wheels lubricated if needed Comments DATE INSPECTED BY Part SUPO 613E REV J Page 13 of 42 Pre Delivery Annual Inspection Checklist WARNING 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 12 MONTHS MODEL NUMBER HB 830CE SERIAL NUMBER Check each item listed below e Use proper operating service and maintenance manual for specific information and settings e item is found to be unacceptable make the necessary repairs and check the repaired box e When all items are acceptable the unit is ready for service Check nspe oller tracks for damage ame Do Pump Se DC moto e e D Downs Se e Batterie Nhee nap Rings Se e Nhee Bo N Maintenance Locks Pins in cabine
31. elevated Does not drive when elevated Part SUPO 613E REV J Drives intermittently damaged or blocked with debris Do pothole guards and lock deploy properly Yes Clean any debris from pothole arm mechanism Is machine tilted Is mode limit switch damaged or blocked debris Contact C Consider board Check wiring connection integrity s there moisture or corrosion in any connections Page 32 of 42 nit damaged Yes E drive unit No Multi meter 400 1 be approx 4 Q Are all connections to drive joystick and drive control board secure Yes No Y s there moisture or corrosion in any connections Yes Y Replace drive control board 9 9 and or joystick Still no drive Reconnect Allow to dry for 24 hours and try again Board probably will need replacement Apply dielectric grease to connectors at main wire harness Contact CEI for further troubleshooting Is a drive motor damaged Replace drive Consider brake damage broken joystick handle drive enable bad hour meter loose connections in lower and upper control Clean any debris from limit switch area Check for proper connection inside limit switch See wiring diagr
32. form and request further information from qualified sources before proceeding WARNING MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY WARNING NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE Part SUPO 613E Page 5 of 42 REV J Stability Testing The HB 830CE has been stability tested to standards EN280 or AS 14180 The most adverse stability test is the traveling forward configuration 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 830CE the test weight pull force is 50 3 kg 111 Ib Figure 1 Stability Testing Equivalent Part SUPO 613E Page 6 of 42 REV J 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 Maintenance Pin Location When in Use Pin Storage Location 10 di Figure 3 Maintenance Lock Pin Storage Maintenance WARNING FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH e Never work under an elevated platform until maintenance locks have been engaged Remove all rings watches and jewelry when pe
33. he current date to aid in vehicle maintenance A non zero date must be entered When load re calibration is begun the last CALDATE is erased and cannot be re entered until calibration is completed this ensures that a partly calibrated vehicle cannot be operated LED flash code 1 P3 4 SHORT TO 0V The GP102 startup tests detected that something is overloading the output on P3 4 All vehicle operation will be prevented until the problem is corrected LED flash code 5 P3 4 SHORT TO SUPPLY The GP102 startup tests or the continuous monitoring during any prevention of vehicle movement detected that something is providing a permanent supply on P3 4 defeating the internal cutout vehicle operation will be prevented until the problem is corrected LED flash code 3 P3 6 SHORT TO OV The GP102 startup tests detected that something is overloading the output on P3 6 All vehicle operation will be prevented until the problem is corrected LED flash code 5 P3 6 SHORT TO SUPPLY The GP102 startup tests detected that something is providing a permanent supply on P3 6 defeating the internal cutout All vehicle operation will be prevented until the problem is corrected LED flash code 3 P4 1 OR P5 1 SHORT TO OV The GP102 startup tests detected that something is overloading the 5V supply provided on P4 1 or P5 1 All vehicle operation will be prevented until the problem is corrected LED flash code 7 TESTING HWFS When the GP102 is powered up
34. ibration must be successfully completed LED flash code 1 IDLE TIMEOUT ACTIVE Part SUPO 613E Page 16 of 42 REV J If configured the GP102 will turn off all its outputs after a set time with no vehicle functions operated this saves battery power and silences any alarm still sounding when the vehicle was left Any vehicle function will end the idle timeout and restore normal operation of the GP102 outputs LED stays off INVALID HEIGHT CHECK SENSORS There is a problem which prevents the vehicle height being determined there may be a fault with the height sensor or the vehicle may have been modified or damaged since the last calibration occurred All vehicle operation will be prevented until the problem is corrected LED flash code 9 INVALID LOAD CHECK SENSORS There is a problem which prevents the estimated load being determined there may be a fault with the height sensor or the load sensor or the vehicle may have been modified or damaged since the last calibration occurred All vehicle operation will be prevented until the problem is corrected LED flash code 6 LOAD NOT CALIBRATED During the second and third phases of load calibration LOADED and EMPTY the GP102 calibrates the lift cylinder pressure at various heights corresponding to a fully loaded and unloaded platform This calibration must be successfully completed LED flash code 1 NO LAST CALDATE At the end of load calibration the GP102 prompts for entry of t
35. ion at pump L p See wiring diagrams Check for continuity in connections use Voltmeter Hu Multi meter at 400V setting Remove load Safety function activated itteries Still no functions disconnected from machine 2 Contact further troubleshooting Consider charger failure interlock contacts SUPO 613E HB 830CE Troubleshooting Flowchart 06 01 2010 06 29 2010 Revision A Initial Release Revision B Added Sleep Timer Part SUPO 613E REV J Page 31 of 42 Does the machine drive Elevate Lower and Steer OK Yes but not properly Check connections at both pump and board See wiring diagrams Is there a trouble code displayed S either of two brake Switches damaged or disconnected Is either or two brakes manually released Yes Yes Refer to trouble Flip brake handle s at rear of code table machine to engage brakes Replace brake switch Note that brake limit switch tabs are delicate Use caution not to Driving slowly Drives slow when break off Are batteries fully charged Are brakes hot Is drive unit Yes Y Replace dri If resistor is installed check using Ohmmeter Mult setting Resistance across resistor should be s mode limit switch lowered Drives fast when
36. m Is master disconnect Switch open Is key switch turned on Connect batteries See wiring diagram amp battery Close Switch connection sequence Turn key switch on Are the batteries fully Is short protection fuse at charged YES pump blown No Yes Y Y Check voltmeter at lower control or check voltage across battery terminals using Replace Fuse voltmeter multi meter p Charge batteries Replace batterie If batteries do Or not take charge Replace charge Load test batteries individually disc gt See Drive amp Steer Problems Flowchart See Elevating amp Lowering Problems Flowcharts Is there a different Part SUPO 613E REV J problem NN for further 5 Page 30 of 42 Yes Are both E Stop buttons off Reset E Stop buttons Pull Yes Is unit in Sleep Mode Is Upper Control plugged in Is charger plugged in Yes Turn the power off and back Unplug charger Unit will not n out at both upper control and on using the key switch at the Connect Upper Control box operate while charging lower control locations base controls No gt Yes Is unit overloaded No Check for loose wiring connections Check for ground connect
37. nance Manual Major Alterations or Repairs Any alterations must be approved by the manufacturer Major repairs which affect 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 Part SUPO 613E Page 10 of 42 REV J Inspection and Regular Maintenance Checklists CAUTION FAILURE TO PERFORM INSPECTIONS AND PREVENTITIVE 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 efficient 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 Monthly Battery Maintenance 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 20h per week 5 load cycles per h M
38. nds for descent overload LED Flashes when overloaded Wheels Front and rear wheels rotate pivot freely Drives in slow speed when elevated Brakes Machine stops when joystick released Pothole guards deploy and lock when platform is raised Lift does not elevate when pothole guards are blocked DATE INSPECTED BY Part SUPO 613E REV J Page 12 of 42 Frequent Inspection Checklist WARNING 3 MONTHS OR 150 HOURS WHICHEVER COMES FIRST 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 MODEL NUMBER __ Check each item listed below Use proper operating service maintenance manual for specific information and settings e item is found to be unacceptable make the necessary repairs and check the repaired box e When all items are acceptable the unit is ready for service Description Visual Inspections Perform all checks on the Pre Start Inspection Checklist Inspect the condition of hydraulic fluid in reservoir Oil should have a clear amber color Inspect the entire machine for signs of damage broken welds loose bolts or improper repairs Check for corrosion cracking abrasion etc Check that all snap rings are secure in grooves on pivot pins Check if tires are leaning in or out Ch
39. nsibility for alterations or modifications to the unit or damages caused by any natural disasters such as fire flood wind and lightning THE PREVIOUS WARRANTY STATEMENT IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE no event shall the Company be liable for any indirect incidental consequential or special damage including without limitation to loss of profits loss of revenue cost of capital cost of substitute equipment downtime examination fees claims of third parties and injury to person or property based upon any claim of breach of warranty breach of contract negligence strict liability in tort or any other legal theory This limited warranty statement recognizes the risks and limitations of product failure between Custom Equipment Inc and the Buyer This written warranty is also understood to be the complete and exclusive agreement between the parties superseding all prior agreements oral or written and all other communications between the parties relating to the subject matter of this warranty No employee agent or distributor of the Company or any other person is authorized to state or imply any additional warranties on behalf of the Company nor assume for the Company any other liability in connection with any of its products unless made in writing dated and signed by an officer of the Company
40. on Terminals 8 1000106450 Drive Control Board specific to this model series only 9 ELEC 627 3R Brake Left 10 ELEC 627 4 Brake Micro switch 11 ELEC 627 3L Brake Right 12 ELEC 826 3R Electric Drive Motor Right Side 13 ELEC 604 amp ELEC 871 Horn Button amp Contact Block Base 14 ELEC 551 Joystick 15 ELEC 602 amp ELEC 072 Drive Enable Button amp Contact Blocks 16 ELEC 826 3L Electric Drive Motor Left Side 17 WHEE 707 Wheel 10 18 ELEC 610 2 Hour Meter 19 ELEC 631 Relay 20 WHEE 706 amp HARD 001 2 Wheel 8 amp Bearing Not Pictured ELEC 809 120 Ohm Resistor Part SUPO 613E REV J Page 39 of 42 Elevate Lower Circuit Parts Page 40 of 42 Part SUPO 613E REV J Item Part Description 1 HYDR 050 3 Hydraulic Pump 2 1000101701 Pothole Bar R 3 HB M215 P Maintenance Lock Pin 4 1000106450 Load Control Module GP102 Program Specific to this Model Series Only 5 1002100351 Hydraulic Cylinder Assembly 6 ELEC 647 Angle Transducer 7 HARD 644 Low Friction Cable E Down 8 ELEC 133B Up Down Rocker Switch 9 ELEC 635 3 Alarm Overload 10 ELEC 635 Alarm Descent 11 1000101601 Pothole Bar L 12 HYDR 666 1 24V Solenoid 13 1000104401 Pump Mount Plate 14 HYDR 664 18 V Coil 15 HYDR 665 Up Valve 16 HYDR 007 2E Down Valve with Coil 16 HYDR 00
41. onthly Battery Care WARNING THIS CHECKLIST MUST BE USED AT MONTHLY OR AFTER EVERY 100 HOURS OF USE FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR MODEL NUMBER SERIAL NUMBER 1 Keep inspection records up to date 2 Record and report all discrepancies to your supervisor 3 Adirty machine cannot be properly inspected Y Yes Acceptable N No Unacceptable R Repaired Description YIN Monthly Battery Care 1 Remove battery cabinet cover 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 solution of 5 tsp baking soda per quart of warm water 6 Coat terminals with a commercially available coating Part SUPO 613E Page 11 of 42 REV J Prestart Inspection Checklist WARNING 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 MODEL HB 830CE 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 Visual Inspections Check that there are no damaged dented or bent structural members There are no loose or missing part
42. re covered by the battery manufacturer for a period of ninety 90 days pro rated for one 1 year on batteries Further that all structural components manufactured purchased and installed by Custom Equipment Inc shall be free of any defect in material and or workmanship for a period of 60 months from the date a new unit is placed into service If the equipment owner end user experiences a failure or deficiency within the specified warranty period they must promptly notify an authorized Dealer service repair facility Custom Equipment s warranty policy requires that ALL warranty claims parts be held for inspection for up to six months or returned to us in a timely fashion if requested Parts will be reguested when we will be returning these parts to our vendor fore credit During the Warranty period Custom Equipment Inc reserves the right to replace repair exchange or to provide a new used or rebuilt component assembly sub assembly or weldment at their discretion dependent upon circumstance situation and or availability For battery warranty call the number listed on The battery for further instructions This Warranty Policy does NOT cover damage caused by shipment misuse of unit includes operation beyond Factory established limits loads and or specifications failure to properly service and maintain the unit in accordance with the Company s manuals or Factory Service Bulletins Custom Equipment Inc DOES NOT accept any respo
43. rforming any maintenance e Do not wear long hair unrestrained or loose fitting clothing and neckties which become caught on or entangled in equipment e Observe and obey all warnings and cautions on machine and in manual e 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 e Battery should always be disconnected during replacement of electrical components Keep all support equipment and attachments stowed in their proper place e Use only approved nonflammable cleaning solvents e After maintenance inspect the machine as described for Pre delivery Part SUPO 613E Page 7 of 42 REV J Battery Maintenance This unit is equipped with deep cycle 12 volt batteries 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 Remove battery cabinet cover Remove battery caps and check fluid level e Fill each cell if needed to split ring with distilled water e Reinstall caps e Wash all
44. s 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 Check that hoses and the cables have no worn areas or chafing Check the hydraulic fluid level with the platform fully lowered Check the tires for damage Check that wheel axle retaining rings and set screw in rear wheel are tight 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 if necessary Platform Controls Check all switches and push buttons for proper operation Emergency Stop Stops all movement Drive Enable Must be activated to drive Joystick Return to neutral drives forward reverse left right Lift Enable Must be activated to elevate Rocker Switch Elevates Lowers Horn Tilt amp Overload LED Indicators Base Controls Check all switches and push buttons for proper operation Emergency Stop Stops all movement Key Switch Selects Platform Control Ground Control or Off Up Down Rocker Switch Elevates Lowers Hour meter Displays Drive Hours Alarms Not damaged sou
45. tom Equipment Inc UPPER CONTROL WIRING 8FT Ta 1002101094 INPUTS OUTPUTS SENSOR P2 P3 co E L 2908817 1002101597 10021010994 10021010998 BATTERY DOWN SOL Pres 1002101599 PUMP RESERVOIR m LIMIT SWITCH PHINTERLOCK LIMIT SWITCH LOCATED ON SCISSORS 1002101098 1002101097 LOWER CONTROLS 902016 502101089 1002101051 BATTERY BATTERY DISCONNECT CHARGER BATTERY DESCRIPTION DATE Custom Equipment Inc Rows Part SUPO 613E D 22 NE WIRING EE Welding Tolerances X 060 030 010 1 Wainy Tome T MOVED BATT CHARGER NEG WIRE TO DISCONNECT 9 8 06 2010 MOVED FUSE 6 29 2010 INITIAL RELEASE 6 29 2010 1901012001 961001200 0 Hed S00 F 910 060 F X 580460 010 0 0 F 090 F X 880061 o 30 104109 ININ 148 214080400 0061 79 292 euoug 9 1949103 Ulojsn 46069 IM Wavv 10 111 LY 530010 aaaav HOLIMS LOANNOOSIC 010 390 1401 03009 JO 398 OL xyeug oj duing OGAvZ
46. y sensors and or switches LED on steady IN GROUND MODE The GP102 is in ground mode and detects no problems IMPORTANT Normally the overload cutout system is inhibited in ground mode The vehicle should not be used to raise heavy loads in ground mode in case the platform is overloaded LED on steady ARMGUARD ACTIVE The GP102 has stopped descent at the Armguard height and is delaying to give the operator the opportunity to see whether persons could be injured per EN 280 5 4 4 Vehicle movement will continue to be stopped after the delay until all functions are released LED flash code 4 B SUPPLY TOO LOW The GP102 is designed for use on 12V and 24V battery powered vehicles it cannot operate with a supply below about 9V The BATTERY voltage can be checked in the SENSORS menu available in the DIAGNOSTICS menu LED flash code 7 DRIVE LIFT SELECT INPUTS FAULTY Neither the drive select P2 7 nor the lift select P2 8 input is active or both are active the GP102 cannot determine the vehicle use All vehicle operation will be prevented until the problem is corrected LED flash code 2 ELEVATION SWITCH SHIFTED The GP102 uses the elevation switch in combination with the height sensor to ensure correct functionality of both any of the following faults may be detected e elevation switch should change state near the point at which it did during load calibration All vehicle operation will be prevented until the problem
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