Hy-Brid Lifts PS-1030 Maintenance & Troubleshooting Manual Download

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MAINTENANCE & TROUBLESHOOTING

MANUAL

SUPO-742 | REV A

PS-1030

PS-1430

MOBILE ELEVATING WORK PLATFORM

BY CUSTOM EQUIPMENT LLC

Summary of Contents for PS-1030

Page 1: ...MAINTENANCE TROUBLESHOOTING MANUAL SUPO 742 REV A PS 1030 PS 1430 MOBILE ELEVATING WORK PLATFORM BY CUSTOM EQUIPMENT LLC ...

Page 2: ... 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...

Page 3: ...TS 12 3 1 PRE START INSPECTION CHECKLIST 14 3 2 PRE DELIVERY ANNUAL FREQUENT INSPECTION CHECKLIST 15 SECTION 4 TECHNICAL REFERENCES 16 4 1 HYDRAULIC SCHEMATIC 16 4 2 ELECTRICAL SCHEMATIC 18 4 3 CONTROL BOARD DIAGNOSTIC 20 SECTION 5 WIRING DIAGRAMS 22 5 1 WIRING DIAGRAM 22 5 2 LWR CTL WIRING DIAGRAM 24 5 3 UPPER CONTROLS WIRING DIAGRAM 26 SECTION 6 TROUBLESHOOTING FLOWCHARTS 28 6 1 MAIN POWER SAFET...

Page 4: ...e 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 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...

Page 5: ...TTERY 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 le...

Page 6: ... cover 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 latch in place M 2 5 LUBRICATION Item Specificatio...

Page 7: ...peration 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 OPERAT...

Page 8: ...MAINTENANCE CHECKLISTS 3 1 PRE START INSPECTION CHECKLIST 3 2 PRE DELIVERY ANNUAL FREQUENT 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 sa...

Page 9: ...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 HS HB REV DESCRIPTION OF CHANGE DATE REV BY A ECO SHEET 1 OF 2 WEIGHT APPROX 0 00 LB A 4 1 HYDRAULIC SCHEMATIC Part No HS HB SECTION 4 TECHNICAL REFERENCES MAINTENANCE TROUBLESHOOTING PS 1030 PS 1430 SUPO 74...

Page 10: ... J 4 J 13 J 8 H 3 J 12 J 11 H 5 H 8 H 7 D 1 D 3 D 2 T 4 T 5 T 1 T 2 T 3 T 6 T 7 T 8 H 6 BUTT 1 1 2 20A NC OFF NO SIG AS1 OPTIONAL FLASHING BEACON 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 262 644 1300 DATE ELEC SCH HBLG S4 SCALE 1 1 DO NOT SCALE DRAWING THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM EQUIPMENT AND ...

Page 11: ...ng to motors 4 x There is a problem with battery supply the height and or pressure sensors the supply to them or the temperature sensor inside the TS100 Check battery supply to EMS inputs P15 1 or P12 1 relative to the B stud the battery supply should be between 15V and 32V Check the output from height sensor P12 12 If the TS100 heatsink is very hot then perhaps the controller has temporarily shut...

Page 12: ...4 3 2 1 8 6 2 3 7 1 5 4 LWR CTL WD 112 21 405 50 1 2 BATTERY BATTERY 112 21 407 50 112 21 314 50 BEACON LIGHT IF SO EQUIPPED 112 01 320 50 1002101650 ELEC 117 DC 1 ELEC 641C ELEC 641E ELEC 641A 112 21 304 50 112 21 420 50 112 21 425 50 CHR INTERLOCK IF SO EQUIPPED JUMPER IF NOT 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 LLC Richfield WI 53076...

Page 13: ... 3 BLU 4X 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 LLC Richfield WI 53076 Phone 262 644 1300 DATE WD LWR CTL HBLG S4 SCALE 1 4 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 Wiring Diagr...

Page 14: ...m Equipment Inc Richfield WI 53076 Phone 262 644 1300 DATE WD UPR CTL HBLG S4 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 Wiring Diagram DRAWING WD 112 21 404 51 REV DESCRIPTION OF CHANGE DATE REV BY B Swapped Wires 2 3 at...

Page 15: ...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 modification on this machine without the express consent of the manufacturer is prohibited WARNING Failure to c...

Page 16: ... 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 failure or loose wiring Contact CEI for further troubleshooting Consider board failure pothole interlock limi...

Page 17: ...a n e t n i a m r e w o p e r A o t s n o i t c e n n o c d n a t i u c r i c e t a v e l e g n i n o i t c n u f s e h c t i w s y l r e p o r p r o e c a l p e R d e i f i t n e d i r i a p e r e e S m e l b o r p t i u c r i C c i l u a r d y H k c e h C r e h g i h d n a s l o o t l a n o i t i d d A e e S d e r i u q e r l l i k s f o l e v e l e c a l p e R c i l u a r d y h e s o h e l o h ...

Page 18: ...ions 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 between scissors links or prop up platform unless maintenance pins are in place Yes but not properly No No Chec...

Page 19: ...ing 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 crimp on new connector s Consider mode limit switch wiring or switch failure red and or black wires Continuity test on switc...

Page 20: ...424 50 K BUTTON PUSH PULL RED E STOP ELEC 071 KIT USED ON LOWER CONTROLS BUTTON PUSH TWIST RED E STOP ELEC 065 USED ON UPPER CONTROLS CHARGER 24V ELEC 795 CORD NEMA 5 15P 5 15R 24 0 ELEC 639 9 CTL ASM LWR 112 21 405 50 CTL ASM UPR 112 21 404 51 CTL WIRE HARNESS MAIN PS SERIES 112 21 425 50 DECALS PS 1030 KIT 112 21 418 50 K DECALS PS 1430 KIT 112 21 418 55 K DRIVE MOTOR 24VELE HB AUB ELEC 790 HYDR...

Page 21: ...ection 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 1 of this Limited Warranty shall be for the Company at its option to repair or replace or have one of its designated authorized dealers repair or replace the Product or p...

Page 22: ...NSPECTION AND REPAIR LOG Date Comments Date Comments SECTION 9 INSPECTION AND REPAIR LOG MAINTENANCE TROUBLESHOOTING PS 1030 PS 1430 SUPO 742 REV A MAINTENANCE TROUBLESHOOTING PS 1030 PS 1430 SUPO 742 REV A 42 43 ...

Page 23: ... 1030 PS 1430 2019 Custom Equipment LLC 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 ANSI SIA A92 6 Revision Date May 2019 Printed in the U S A ...

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