Hy-Brid Lifts HB-1030 Maintenance & Troubleshooting Manual Download Page 13 | Manualshive

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Hy-Br id Lif t s

Maintenance & Trouble Shooting Manual
HB-1030/ HB-1430

SUPO 611

REV K

SECTION 3 | MAINTENANCE CHECKLISTS

3.1 | PRE

START INSPECTION CHECKLIST

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.

CAUTION

Y

Yes/ Acceptable N

No/ Unacceptable R

Repaired

Description

Y

N

R

VISUAL INSPECTIONS

FUNCTIONAL TESTS

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Summary of Contents for HB-1030

Page 1: ......

Page 2: ......

Page 3: ...B 1430 SUPO 611 REV K FOR E W OR D DANGER THE OPERATION AND SAFETY MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE WARNING ANY MODIFICATION ON THISMACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER ISPROHIBITED Lanyard Attachm ent ...

Page 4: ... 2 MAINTENANCE 8 SECTION 3 MAINTENANCE CHECKLISTS 12 SECTION 4 TECHNICAL REFERENCES 16 SECTION 5 WIRING DIAGRAMS 22 SECTION 6 TROUBLE SHOOTING FLOWCHARTS 36 SECTION 7 PARTSDIAGRAMS 46 SECTION 8 WARRANTY 56 SECTION 9 INSPECTION AND REPAIR LOG 58 ...

Page 5: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K INDE XOFFIGUR E S ...

Page 6: ... MAY CAUSE DEATH OR PERSONAL INJURY CAUTION FAILURE TO FOLLOW THISWARNING MAY CAUSE INJURY OR DAMAGE TO EQUIPMENT 1 2 GENERAL RULESAND PRECAUTIONS WARNING NEVER REACH BETWEEN SCISSORSLINKSOR PROP UP PLATFORM UNLESSMAINTENANCE PINSARE IN PLACE WARNING MAINTENANCE INFORMATION ISFOR USE BY TRAINED PERSONNEL ONLY S E CTION1 S AF E TY ...

Page 7: ...rouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION1 S AFE TY 1 3 SAFETY GUIDELINES Maintenance Lock WARNING FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONSMAY RE SULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH ...

Page 8: ...INTE NANCE 2 1 BATTERY MAINTENANCE 2 2 CAUTION NEVER ADD ACID TO BATTERY CHARGING THE BATTERY WARNING LEAD ACID BATTERIESGENERATE EXPLOSIVE GASES KEEP SPARKSAND FLAME AWAY FROM BATTERIES DO NOT SMOKE WHILE CHARGING ...

Page 9: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION2 MAINTE NANCE WARNING DO NOT OPERATE UNIT WHILE CHARGING DO NOT DIS ABLE CHARGER INTERLOCK ...

Page 10: ...OMPONENTSREQUIRING ADJUSTMENT 2 5 EXAMINATION REPAIR REPLACEMENT OF LIMITED LIFE COMPONENTS 2 6 SAFETY DEVICESAND SYSTEMSREQUIRING CHECKS 2 7 STORAGE 2 8 MAJOR ALTERATIONSOR REPAIRS 2 9 OTHER PROCEDURES Setting the Tilt Sensor Voltage Test Points ...

Page 11: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION2 MAINTE NANCE ...

Page 12: ...NTE NANCECHE CKLIS TS CAUTION FAILURE TO PERFORM INSPECTIONSAND PREVENTATIVE MAINTENANCE AT RECOMMENDED INTERVALSMAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR ...

Page 13: ...E CKLIS TS 3 1 PRE START INSPECTION CHECKLIST THISCHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR AFTER EVERY SIX TO EIGHT HOURSOF USE FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR CAUTION Y Yes Acceptable N No Unacceptable R Repaired Description Y N R VISUAL INSPECTIONS FUNCTIONAL TESTS ...

Page 14: ...HALL BE INSPECTED SERVICED AND ADJUSTED TO MANUFACTURER SREQUIREMENTSBY A QUALI FIED MECHANIC PRIOR TO EACH SALE LEASE OR RENTAL AND EVERY 3 MONTHSOR 150 HOURS WHICHEVER COMESFIRST CAUTION Y Yes Acceptable N No Unacceptable R Repaired Description Y N R VISUAL INSPECTIONS FUNCTIONAL TESTS ...

Page 15: ... TS 3 3 PRE DELIVERY ANNUAL CHECKLIST AERIAL PLATFORMSSHALL BE INSPECTED SERVICED AND ADJUSTED TO MANUFACTURER SREQUIREMENTSBY A QUALI FIED MECHANIC PRIOR TO EACH SALE LEASE OR RENTAL AND EVERY 3 MONTHSOR 150 HOURS WHICHEVER COMESFIRST CAUTION Y Yes Acceptable N No Unacceptable R Repaire Base Y N R Platform Y N R ...

Page 16: ...S E CTION4 TE CHNICALR E FE R E NCE S 4 1 HYDRAULIC SCHEMATIC ...

Page 17: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION4 TE CHNICALR E FE R E NCE S ...

Page 18: ...S E CTION4 TE CHNICALR E FE R E NCE S 4 2 ELECTRICAL SCHEMATIC ...

Page 19: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION4 TE CHNICALR E FE R E NCE S ...

Page 20: ...S E CTION4 TE CHNICALR E FE R E NCE S 4 3 LED DRIVE BOARD DIAGNOSTICS BLUECONTROLLER ...

Page 21: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION4 TE CHNICALR E FE R E NCE S 4 4 LED DRIVE BOARD DIAGNOSTICS BLACK CONTROLLER ...

Page 22: ...S E CTION5 W IR INGDIAGR AMS 5 1 WIRING DIAGRAM Part No WD HB2 ...

Page 23: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS ...

Page 24: ...S E CTION5 W IR INGDIAGR AMS 5 2 LOWER CONTROLSWIRING DIAGRAM Part No SUB A8 002 ...

Page 25: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS ...

Page 26: ...S E CTION5 W IR INGDIAGR AMS S E CTION5 W IR INGDIAGR AMS S E CTION5 W IR INGDIAGR AMS 5 3 UPPER CONTROLSWIRING DIAGRAM Part No SUB A9 002 ...

Page 27: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS S E CTION5 W IR INGDIAGR AMS S E CTION5 W IR INGDIAGR AMS ...

Page 28: ...S E CTION5 W IR INGDIAGR AMS 5 4 MAIN POWER SAFETY CIRCUIT Part No SUB A9 002 ...

Page 29: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS Part No SUB A8 002 ...

Page 30: ...S E CTION5 W IR INGDIAGR AMS 5 5 DRIVECIRCUIT Part No SUB A9 002 ...

Page 31: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS ...

Page 32: ...S E CTION5 W IR INGDIAGR AMS 5 6 ELEVATE LOWER CIRCUIT Part No SUB A9 002 ...

Page 33: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS Part No SUB A8 002 ...

Page 34: ...S E CTION5 W IR INGDIAGR AMS 5 7 STEER CIRCUIT Part No SUB A8 002 ...

Page 35: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION5 W IR INGDIAGR AMS ...

Page 36: ...gram battery connection sequence Is key switch turned on Turn key switch on No Are both E Stop buttons off Reset E Stop buttons Pull out at both upper control and lower control locations No Is there a different problem Contact CEI for further troubleshooting See Drive Problems Flowchart See Elevating Lowering Problems Flowcharts See Steer Problems Flowchart Yes but some function s are not working ...

Page 37: ... voltage rises on the battery the charger is working If batteries do not take charge No Is short protection fuse at pump blown Replace with 20 Amp AGC Fuse If fuse continues to blow steering actuator may need replacement Yes Check for loose wiring connections Check for ground connection at pump See wiring diagrams Check for continuity in connections Use Voltmeter Multi meter at 400V setting Contac...

Page 38: ...be a Drives slow when lowered Drives fast when elevated Does not drive when elevated Is mode limit switch damaged or blocked with debris Do pothole guards and lock deploy properly Clean any debris from pothole arm mechanism Yes Contact C Consider board Is mode limit switch damaged or blocked with debris Yes Are brakes hot Drives intermittently Check wiring connection integrity Lower control termin...

Page 39: ... Ω approx 4 Ω Clean any debris from limit switch area Check for proper connection inside limit switch See wiring diagram Replace mode limit switch Yes Contact CEI for further troubleshooting Consider board failure or loose wiring CEI for further troubleshooting failure pothole interlock limit switch failure Clean any debris from limit switch area Check for proper connection inside limit switch See...

Page 40: ...inuity check on switch Consider relay failure relay block wiring Check steer actuator f failure Apply 24V to lea Consider joystick failure or wiring connection problem 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 Cons...

Page 41: ... SUPO 611 REV K S E CTION6 TR OUBLES HOOTINGFLOW CHAR TS R1 Failure Replace Relay R2 R3 or R4 failure Listen for clicks try switching relays around Replace relay s n Replace limit switch and or readjust for ads Replace actuator Contact CEI for further troubleshooting ...

Page 42: ...Is battery fully charged Is emergency down valve open Are any structural members bent Contact manufacturer to arrange replacement Is Rep Charge battery Close emergency down valve Yes but not properly Is power solenoid damaged Replace solenoid Are diodes functioning properly Measure resistance across diode Ohm meter multi meter at 40 kΩ se side and red on other side should get a resistance reading ...

Page 43: ...tion or momentary short Flush down valve by simultaneously pressing up switch at base and down switch on platform control for 30 sec There may be foreign matter lodged there a restriction in hydraulic hose Replace pump May be worn or defective place hydraulic hose Is up down switch damaged Replace rocker switch at upper or lower control etting With black lad on stripe witch leads no reading Is ena...

Page 44: ...essing up switch at base control and down switch on platform control for 30 sec Replace down valve Faulty down valve Electr proble Foreign matter lodged in up or down valve Disconnect coil Check if u voltage at coil should be Check for power connect See Hy Brid troubleshoot No Are batteries fully charged and filled with water Charge batteries Check for obstructions between any scissors beams Consi...

Page 45: ...aulic fluid Replace as needed ALWAYS remember to use maintenance lock pins when doing any hydraulic work rical em unit stops drifting Check 0 V when not energized Damaged cylinder or damaged seal in cylinder Coil mounting nut too tight tion ting Check power solenoid See Elevating Problems Run unit up and then check for oil flow out of return line Bad cylinder seal if oil is flowing from return lin...

Page 46: ...F NON OEM PARTSWILL VOID WARRANTY DANGER REPLACEMENT OF THE FOLLOWING COMPONENTSWILL AFFECT THE STRENGTH STABILITY OR SAFETY FUNCTION OF THE UNIT BATTERY ELEC 047 HYDRAULIC CYLINDER HYDR 007 1 OR HYDR 041 2 DRIVE CONTROL BOARD ELEC 903 AND ALL STRUCTURAL COMPONENTS 7 1 SAFETY CONTROL DECALS ...

Page 47: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION7 P AR TSDIAGR AMS 7 2 MAIN POWER SAFETY CIRCUIT 10 6 9 8 5 2 1 4 5 14 12 6 13 7 ...

Page 48: ...S E CTION7 P AR TSDIAGR AMS S E CTION7 P AR TSDIAGR AMS 7 3 DRIVE CIRCUIT 8 9 10 7 1 11 5 3 4 2 6 16 13 12 14 15 ...

Page 49: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION7 P AR TSDIAGR AMS S E CTION7 P AR TSDIAGR AMS 7 4 STEER CIRCUIT 8 1 2 3 5 6 7 4 ...

Page 50: ...S E CTION7 P AR TSDIAGR AMS 7 5 ELEVATE LOWER CIRCUIT 19 1 2 3 13 16 12 17 14 18 9 8 20 15 27 4 6 5 7 10 11 ...

Page 51: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION7 P AR TSDIAGR AMS ...

Page 52: ...S E CTION7 P AR TSDIAGR AMS 7 6 COVERS 6 7 4 5 1 8 9 2 3 ...

Page 53: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION7 P AR TSDIAGR AMS 7 7 RAILINGS 28 32 27 20 21 22 23 24 25 26 33 29 30 31 ...

Page 54: ...S E CTION8 W AR R ANTY ...

Page 55: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K S E CTION8 W AR R ANTY ...

Page 56: ...S E CTION9 INS PE CTIONANDR E P AIRLOG Date Comments ...

Page 57: ...Hy Brid Lifts Maintenance Trouble Shooting Manual HB 1030 HB 1430 SUPO 611 REV K Date Comments S E CTION9 INS PE CTIONANDR E P AIRLOG ...

Page 58: ...Hy Brid Lifts by C ustom Equipment ...

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