Hy-Brid Lifts PRO Series Maintenance & Troubleshooting Manual Download Page 1

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BY CUSTOM EQUIPMENT LLC

MAINTENANCE &

TROUBLESHOOTING

MANUAL

MOBILE
ELEVATING
WORK
PLATFORMS

ANSI A92.20
CSA B354.6:17

PRO

SERIES

PS-1030

PS-1430

PS-1930

PS5.0-M | REV B

SERIAL NO.

To view machine specific information on your
mobile device, scan the code to the left.

Decals with this code can also be found on the
manual box and base of the machine.

Summary of Contents for PRO Series

Page 1: ...ATING WORK PLATFORMS ANSI A92 20 CSA B354 6 17 PRO SERIES PS 1030 PS 1430 PS 1930 PS5 0 M REV B SERIAL NO To view machine specific information on your mobile device scan the code to the left Decals with this code can also be found on the manual box and base of the machine ...

Page 2: ...en 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 This manual refers to serial number s PS 1030 PS10 50001 PS 1430 PS14 50001 PS 1930 PS19 50001 For older Seri...

Page 3: ... CONTROL BOARD DIAGNOSTIC 20 SECTION 5 WIRING DIAGRAMS 22 5 1 WIRING DIAGRAM 22 5 2 MACHINE HARNESS WIRING DIAGRAM 24 5 3 LOWER CONTROL WIRING DIAGRAM 26 5 4 UPPER CONTROL WIRING DIAGRAM 28 SECTION 6 TROUBLESHOOTING FLOWCHARTS 30 6 1 MAIN POWER SAFETY CIRCUIT 30 6 2 DRIVE CIRCUIT 32 6 3 STEER CIRCUIT 34 6 4 ELEVATE CIRCUIT 36 6 5 LOWER CIRCUIT 38 SECTION 7 PARTS 40 SECTION 8 WARRANTY 42 8 1 LIMITE...

Page 4: ...ional requirements set forth by ANSI OSHA or CSA If you come across a situation that you think might be unsafe stop the platform and request further information from qualified sources before proceeding NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE 1 3 SAFETY GUIDELINES Maintenance Lock The maintenance lock must be placed into position whenever the mach...

Page 5: ...rosion 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 NOTE The surrounding temperature greatly affects 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 efficiency 2 2 CHARGING THE BAT...

Page 6: ...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 ...

Page 7: ...hat 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 If machine is equipped with LeakGuard check tray for hydraulic fluid ...

Page 8: ...t SCISSORS No broken welds No bent beam members All rollers turn freely Retaining rings secure on pivots Maintenance locks Stored and securely connected Scissor beam tube bolts tight PLATFORM No bent rails No broken welds All rails in place secure 110V outlet safe working Entrance gate closes freely Y Yes Acceptable N No Unacceptable R Repaired N A Not Equipped Y N R N A DECALS Legibile Correct ca...

Page 9: ...0 S5 HS 112 20 501 1 1 N A 1 OF 1 T VUE 04 29 2020 SIZE B DWG NO A REV DO NOT SCALE DRAWING 04 29 2020 T VUE APPROVED DATE REV BY DESCRIPTION OF CHANGE REVISION HISTORY ECO THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CUSTOM E...

Page 10: ... SENSOR 1 ANGLE SENSOR 2 PRESSURE SENSOR SIGNAL SENSOR POWER LOW SIDE ALARM OUTPUT DOWN SIGNAL UP SIGNAL LOW SIDE LED OUTPUT BRAKE COIL SIGNAL MAIN POWER CONTACTOR SIGNAL POTHOLE L S SIGNAL PUMP CONTACTOR SIGNAL EZCAL 232 COM PORT CANBUS HIGH CANBUS LOW EZCAL 232 COM PORT EZCAL 232 COM PORT EZCAL 232 COM PORT LEFT STEER SIGNAL RIGHT STEER SIGNAL DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJE...

Page 11: ...mpting to drive or lift the motor may be stalled and causing an overload of the TS100 or there is a power wiring error like connecting the B cable to a motor stud LED Code Possible Cause 3 2 Check P9 wiring One or more signals showing outputs when all should be off 3 3 Check B stud connections on controller Voltage is too high 3 4 There is voltage on safe pre valve supply when there should not be ...

Page 12: ...EER LIMIT SWITCH R STEER LIMIT SWITCH NC NC 10AWG TS100 M2 10AWG TS100 M1 BATTERY CHARGER CONNECTION L C HARNESS TO MACHINE HARNESS EZ CAL MAIN CABLE 112 21 531 CONNECTION L C HARNESS TO MAIN CABLE NOT USED 300 AMP FUSE DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WIRING DIAGRAM PS1930 S5 WD 112 20 501 1 1 N A 1 OF 1 T VUE 04 29 2020 S...

Page 13: ... MOTOR DRIVE L MOTOR DRIVE KTI PUMP A2 KTI PUMP UP VALVE COIL KTI PUMP SOLENOID POSITION 4 KTI PUMP SOLENOID POSITION 3 REFERENCE ONLY PREFERED CONNECTION DIODE CEI PN ELEC 755 TVS 5 0 KP DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WD MACHINE HARNESS PS S5 WD 112 21 532 1 1 N A 1 OF 1 T VUE 02 24 2020 SIZE B DWG NO A REV DO NOT SCALE ...

Page 14: ...RNESS J LED ROCKER SWITCH KEY SWITCH MAIN CABLE D 20 AMP FUSE SOLENOID 1 TS100 B E STOP DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WD LWR CTL PRO SERIES S5 WD 112 21 505 1 1 N A 1 OF 1 T VUE 02 14 2020 SIZE B DWG NO P02 REV DO NOT SCALE DRAWING 02 14 2020 T VUE APPROVED DATE REV BY DESCRIPTION OF CHANGE REVISION HISTORY ECO THE INFOR...

Page 15: ...WN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WD UPR CTL PS1930 S5 WD 112 21 506 1 1 N A 1 OF 1 S MCG 03 10 2020 SIZE B DWG NO A REV DO NOT SCALE DRAWING 04 17 2020 T VUE APPROVED DATE REV BY DESCRIPTION OF CHANGE REVISION HISTORY ECO THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND IS LOANED IN EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL ANY REPRODUCTION I...

Page 16: ...tered After each step check if problem has been indentified and or resolved If so make the recommended fix or see a referenced document If not continue troubleshooting If a part has been identified as needing replacement see the Parts Manual to identify part number to order If any wiring or components have been altered from the original manufacture problems may not be identifiable WARNING Any modi...

Page 17: ...ing Consider brake damage broken joystick handle drive enable bad hour meter loose connections in lower and upper control and control board failure Still no drive Driving slowly Are batteries fully charged Drives slow when lowered Drives fast when elevated Does not drive when elevated Do pothole guards and lock deploy properly Yes Contact Hy Brid Lifts for further troubleshooting Consider board fa...

Page 18: ...lure relay block wiring Check steer actuator for failure Apply 24V to leads Replace actuator Consider joystick failure or wiring connection problem Contact Hy Brid Lifts for further troubleshooting Consider damaged main cable main cable connections at upper and lower control Check terminals 17 22 No Steering Not operating properly Check wire connections at actuator Pull test connections if failure...

Page 19: ...PRO SERIES PS 1030 PS 1430 PS 1930 36 37 MAINTENANCE TROUBLESHOOTING MANUAL PS5 0 M REV B SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 4 ELEVATE CIRCUIT ...

Page 20: ...without the express consent of the manufacturer is prohibited WARNING Failure to comply with safety precautions may result in damage injury or death Refer to Maintenance Manual for complete warnings See also Wiring Diagram or Schematic And Hydraulic Schematic WARNING Set up for maintenance safety Remove load from platform Check for overhead obstructions Platform movement may occur Never Reach betw...

Page 21: ...e date specific Contact your dealer for replacement part availability and pricing Description Part Number Notes ALARM CONTINUOUS ELEC 635 4 BOARD DRIVE LIFT PS 10ANSI S5 112 21 526 50 K BOARD DRIVE LIFT PS 14ANSI S5 112 21 526 53 K BOARD DRIVE LIFT PS 19ANSI S5 112 21 526 56 K BUTTON PUSH PULL RED E STOP ELEC 071 KIT CHARGER 24V ELEC 795 CORD NEMA 5 15 P 5 15R 24 IN ELEC 639 9 CTL ASM LWR PS S5 CA...

Page 22: ...liable for any claim under this Limited Warranty if Buyer fails to satisfy the conditions set forth in this Section 8 5 EXCLUSIVE WARRANTY REMEDIES Exclusive Repair or Replace Remedy The Company s sole obligation and Buyer s exclusive remedy with respect to any defect in the Product occurring during the warranty periods set forth in Section 8 1 of this Limited Warranty shall be for the Company at ...

Page 23: ...PRO SERIES PS 1030 PS 1430 PS 1930 44 45 MAINTENANCE TROUBLESHOOTING MANUAL PS5 0 M REV B SECTION 9 INSPECTION REPAIR LOG SECTION 9 INSPECTION REPAIR LOG DATE COMMENTS DATE COMMENTS ...

Page 24: ...PRO SERIES PS 1030 PS 1430 PS 1930 46 47 MAINTENANCE TROUBLESHOOTING MANUAL PS5 0 M REV B SECTION 9 INSPECTION REPAIR LOG SECTION 9 INSPECTION REPAIR LOG DATE COMMENTS DATE COMMENTS ...

Page 25: ...ual Custom Equipment LLC 2647 Highway 175 Richfield WI 53076 U S A 1 262 644 1300 1 262 644 1320 hybridlifts com Hy Brid Lifts is a trademark of Custom Equipment LLC These machines comply with ANSI SIA A92 20 and CSA B354 6 17 Revision Date November 2020 Printed in the U S A 2020 Custom Equipment LLC ...

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