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SECTION 2 | MAINTENANCE

2.1 | BATTERY MAINTENANCE AGM BATTERIES

Battery cycle life will vary significantly depending on the depth of discharge. The deeper the depth of discharge the 
fewer cycles a battery will deliver. Conversely, the shallower the depth of discharge the more cycles a battery will 
deliver. To optimize the health of your battery, limit discharge to 80%.

The performance and life of a battery will vary with application, usage, temperature and depth of discharge. AGM 
batteries tend to deliver higher than their rated capacity (up to 10-15% higher) for -30 cycles until they are “broken in” 
and settle at their rated capacity. 

Operating batteries above 80°F (27°C) will yield runtimes above the rated capacity and operating batteries below 
80°F (2rC) will yield runtimes below the rated capacity. Cold temperatures can significantly reduce battery capacity. 
Although higher temperatures increase the battery capacity they also accelerate corrosion and reduce overall 
battery life.

2.2 | BATTERY MAINTENANCE WET CELL BATTERIES 

If this unit is equipped with a deep cycle 12-volt Group 27 battery, 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.

• 

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 latch in place.

FIGURE 4: Battery Maintenance Access

MAINTENANCE & TROUBLESHOOTING
HB-P4.5/HB-P5.0

SUPO-648

REV G

10

2.3 | CHARGING THE BATTERY

This unit is equipped with either a deep cycle 12-volt AGM maintenance-free battery or a deep cycle Group 27 
battery.

Batteries should be fully charged after each use. Opportunity charging can be done but the batteries should be fully 
charged at least every other day if they are used daily. Charge in a ventilated area as gases may be released through 
the pressure relief valve if the batteries are excessively over-charged.

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.

Do not operate unit while charging.  Shortened battery life will result.
• 

Park the machine on a level surface.

• 

Plug charger into AC outlet until charged.

• 

For best battery life, leave charger plugged in until machine will be used again.  The charger will maintain the 
battery charge

BATTERIES GENERATE EXPLOSIVE GASES.  KEEP SPARKS AND FLAME 

AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.

DO NOT OPERATE UNIT WHILE CHARGING

NEVER ADD ACID TO BATTERY!

SECTION 2 | MAINTENANCE

MAINTENANCE & TROUBLESHOOTING
HB-P4.5/HB-P5.0

SUPO-648

REV G

11

Содержание HY-BRID LIFTS I HB-P4.5

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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