Custom Equipment Hy-Brid Lifts HB-830CE Maintenance & Troubleshooting Manual Download

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Self-Propelled Aerial Work Platform
Maintenance & Troubleshooting Manual
HB-830CE/HB-1230CE

© 2015 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
[email protected]

“Hy-Brid Lifts” is a trademark of Custom Equipment, LLC.
These machines comply with specified EN: 280 requirements

Revision Date: March 2015

Printed In The USA

BY CUSTOM EQUIPMENT LLC

Summary of Contents for Hy-Brid Lifts HB-830CE

Page 1: ...MAINTENANCE TROUBLESHOOTING MANUAL SELF PROPELLED AERIAL WORK PLATFORM SUPO 653 REV C HB 830CE HB 1230CE SERIES II BY CUSTOM EQUIPMENT LLC ...

Page 2: ...HE 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 ANY MODIFICATI...

Page 3: ...PECTION CHECKLIST 14 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 LOWER CONTROLS WIRING DIAGRAM 24 5 3 UPPER CONTROLS WIRING DIAGRAM 26 SECTION 6 TROUBLESHOOTING FLOWCHARTS 28 6 1 MAIN POWER SAFETY CIRCUIT 28 6 2 DRIVE CIRCUIT 30 6 3 ELEVATE CIRCUIT 32 6 4 LOWER CIRCUI...

Page 4: ...at you think might be unsafe stop the platform and request further information from qualified sources before 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...

Page 5: ... 1 BATTERY MAINTENANCE This unit is equipped with 12 volt AGM maintenance free batteries 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 NEVER ADD ACID TO BATTERY 2 2 CHARGING THE BATTERY BATTERIES GENERATE EXPLOSIVE GASES KEEP SPARKS AN...

Page 6: ...aterial lifting devices or make any other alteration that is not part of the intended design of the machine SECTION 2 MAINTENANCE FIGURE 3 Battery Charger LED Display DO NOT OPERATE UNIT WHILE CHARGING DO NOT DISABLE CHARGER INTERLOCK Power Power Power Power Green LED ON Green LED ON Green LED ON Green LED ON Red LED OFF Red LED ON Red LED OFF Red LED FLASHING Green LED OFF Green LED OFF Green LED...

Page 7: ...ntrols 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 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 T...

Page 8: ...h Set properly Bolts Nuts Tight Wiring Scissors Switches secure Broken Welds Contactor s secure Bent Beam Members Tight on terminals No loose wiring All rollers Turn Freely Pothole guards deploy when platform elevated Ret Rings Secure On Pivots Pothole interlock functions correctly Emergency Down Operational Oil Level 1 from top Maintenance Locks Brakes Operational Pins in cabinet Check all hose f...

Page 9: ... 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 Schematic DRAWING HS 129 20 201 51 REV DESCRIPTION OF CHANGE DATE REV BY A ECO SHEET 1 OF 2 WEIGHT APPROX 0 00 LB A 4 1 HYDRAULIC SCHEMATIC SECTION 4 TECHNICAL REFERENCES BY CUSTOM EQUIPMENT LLC MAINTENANCE T...

Page 10: ...S R HORN 1K 1W PRESS SENS 1 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 HB 1230CE S2 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 S...

Page 11: ... 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 down if so platform l...

Page 12: ...6 5 4 3 2 1 B SIZE ORIGINALLY DRAWN BY Custom Equipment Inc Richfield WI 53076 Phone 262 644 1300 DATE WD HB 1230CE S2 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 129 20 201 51 REV DESCRIPTION OF ...

Page 13: ... at TS100 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 DJS Custom Equipment Inc Richfield WI 53076 Phone 262 644 1300 DATE 3 7 2014 WD LWR CTL HB 1230CE S2 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...

Page 14: ...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 WD UPR CTL HB 1230CE S2 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 Schematic DRAWING WD 129 21 006 51 REV DESCRI...

Page 15: ...TION 6 TROUBLESHOOTING FLOWCHARTS 6 1 MAIN POWER SAFETY CIRCUIT BY CUSTOM EQUIPMENT LLC MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C BY CUSTOM EQUIPMENT LLC 28 29 ...

Page 16: ...TS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 2 DRIVE CIRCUIT BY CUSTOM EQUIPMENT LLC MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C BY CUSTOM EQUIPMENT LLC 30 31 ...

Page 17: ...S SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 3 ELEVATE CIRCUIT BY CUSTOM EQUIPMENT LLC MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C BY CUSTOM EQUIPMENT LLC 32 33 ...

Page 18: ...TS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 4 LOWER CIRCUIT BY CUSTOM EQUIPMENT LLC MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C BY CUSTOM EQUIPMENT LLC 34 35 ...

Page 19: ...ake to a recycling center ELEC 047 5 Batteries Take to a recycling center 7 1 SAFETY AND CONTROL DECALS Refer to the Hy Brid Lifts Operation and Safety Manual for decal part numbers and locations 7 2 MAIN POWER SAFETY CIRCUIT Item Part Number Description 1 NA B CONNECTION POINT 2 NA B CONNECTION POINT 3 ELEC 641C CABLE 6GA RED 50 B R 38 EYES 4 ELEC 641A CABLE 6GA BLACK 63 B B 38 EYES 5 ELEC 080 CA...

Page 20: ...TER HOUR 11 ELEC 633 4 SWITCH MASTER DISCONNECT 12 ELEC 636 LED RED COMPONENTS OF POWER SWITCH ELEC 633 4 Item Part Number Description 1 ELEC 633 5 SWITCH KNOB MASTER DISCONNECT COMPONENTS OF KEY SWITCH ELEC 073D Item Part Number Description 1 ELEC 073EKEY KEY SPARE MAIN POWER COMPONENTS OF UPPER CONTROL 129 21 006 51 Item Part Number Description 1 129 21 006 90 CTL WIRE HARNESS UPR CTL 2 ELEC 002...

Page 21: ...K ASM CASTER 13 WHEE 719 1 14 HEX SLOTTED AXLE SPINDLE NUT 14 WHEE 716 WASHER 1 06 ID X 1 75 OD X 155 THK 15 HARD 725 COTTER PIN 3 16 X 2 16 WHEE 714 100 HUB COVER 17 129 01 250 04 BEARING RACE 18 129 21 006 51 ASM CTL UPR 19 129 21 227 51 BOARD DRIVE LIFT CTL HB MID ZTR 20 129 01 101 05 HITCH PIN 5 8 X 5 DRIVE COMPONENTS OF UPPER CONTROL 129 21 006 51 Item Part Number Description 1 ELEC 604 KIT B...

Page 22: ... 4B DRIVE MOTOR HOUSING GASKET DUM 3 ELEC 627 5R DRIVE MOTOR BRAKE 4 ELEC 627 5L DRIVE MOTOR BRAKE COMPONENTS OF DRIVE MOTORS BRAKES ELEC 627 5L ELEC 627 5R Item Part Number Description 1 ELEC 627 6 SWITCH LIMIT STRAIGHT LVR MICRO SECTION 7 PARTS DIAGRAMS SECTION 7 PARTS DIAGRAMS 3 4 1 2 ITEM NO PART NUMBER DESCRIPTION QTY 1 ELEC 626 4A DRIVE MOTOR SHAFT SEAL DUM 1 2 ELEC 626 4B DRIVE MOTOR HOUSIN...

Page 23: ...MID 15 NUTS 2521 1 4 20 NYLOK NUT 16 HARD 641 6 CLEVIS PIN 1 2X1 75 PLATED 17 HARD 067 SNAP BUTTON 0 38 SINGLE END 18 HARD 682 1 2 HAIRPIN COTTER PIN LOCK 19 129 01 232 02 BASE SCISSORS LOCK 20 129 01 268 BASE E DOWN BRKT REAR WLDMNT 21 MISC 007 001 KIT 1 3 8 MOLDING BOND 22 HARD 022 RET RING 1 25 23 129 21 015 51 K ASM CYL HB 1230 CE 24 1021000102 SET COLLAR 1 25 ID 25 BM 6006 1 KIT ASM ROLLER 1 ...

Page 24: ...YDR 068 PUMP RESERVOIR O RING 3 HYDR 664 COIL 18V 4 HYDR 665 VALVE NO 2W 2P 8 UP 5 HYDR 666 1 SOLENOID 24V ISOLATED SPST 6 HYDR 667 WASH 0 38 ID 0 75 OD PRES SEAL COMPONENTS OF LOWER CONTROL 129 21 206 51 Item Part Number Description Notes 1 ELEC 133B SWITCH ROCKER COMPONENTS OF UPPER CONTROL 129 21 006 51 Item Part Number Description Notes 1 ELEC 002C KIT SWITCH ROTARY MAINTAINED 2 ELEC 606 JOYST...

Page 25: ...ND WLDMNT 3 129 03 208 01 RAIL SO FLOOR BOLT ON 4 129 03 209 01 RAIL WC R 5 129 03 211 01 RAIL SO TOE BOARD 6 129 03 212 01 RAIL SO R 7 129 03 214 01 RAIL SO L 8 129 04 201 01 PF WLDMNT 9 129 21 228 01 ASM RAIL GATE 10 1002100692 KIT ASM RAIL SLIDE LOCK 11 HARD 603 MANUAL BOX 12 HARD 067 SNAP BUTTON 0 38 SINGLE END 13 HARD 645 PLUG 11 16 DIA BLACK 14 HARD 723 CABLE CLIP W CABLE TIE 6 15 HARD 808 P...

Page 26: ...pany 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 part component or assembly thereof that contains a defect in materials or work...

Page 27: ...s that occurred Additional notes on back or attached if necessary SECTION 8 WARRANTY DEALER PARTS EXPENSE CE Part Number Part Description Qty List Price Actual Price Total Cost Invoice Please RETURN ALL Defective Damaged or Failed Parts for evaluation and or examination purposes We reserve the right to inspect any item submitted for Warranty consideration Enclose ONE COPY of this Warranty Claim Re...

Page 28: ...NOTES NOTES BY CUSTOM EQUIPMENT LLC MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C MAINTENANCE TROUBLESHOOTING HB 830CE HB 1230CE SUPO 653 REV C BY CUSTOM EQUIPMENT LLC 54 55 ...

Page 29: ...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 specified EN 280 requirements Revision Date March 2015 Printed In The USA BY CUSTOM EQUIPMENT LLC ...

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