TABLE OF CONTENTS
NOTES .......................................................................................................................................................................................... 2
FOREWORD ................................................................................................................................................................................ 3
TABLE OF CONTENTS ............................................................................................................................................................... 4
INDEX OF FIGURES .................................................................................................................................................................... 5
SECTION 1 | SAFETY .................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS .......................................................................................................................................................................... 6
1.2 | GENERAL RULES AND PRECAUTIONS ................................................................................................................................... 6
1.3 | SAFETY GUIDELINES .................................................................................................................................................................... 7
1.4 | STABILITY TESTING ...................................................................................................................................................................... 8
SECTION 2 | MAINTENANCE ................................................................................................................................................. 10
2.1 | BATTERY MAINTENANCE ......................................................................................................................................................... 10
2.2 | CHARGING THE BATTERY ....................................................................................................................................................... 10
2.3 | LUBRICATION...............................................................................................................................................................................11
2.4 | COMPONENTS REQUIRING ADJUSTMENT .......................................................................................................................11
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ..............................................................11
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ..................................................................................................11
2.7 | STORAGE ..................................................................................................................................................................................... 12
2.8 | MAJOR ALTERATIONS OR REPAIRS ..................................................................................................................................... 12
SECTION 3 | MAINTENANCE CHECKLISTS ......................................................................................................................... 14
3.1 | PRE-START INSPECTION CHECKLIST ................................................................................................................................... 15
3.2 | PRE-DELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST .................................................................................. 16
SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 18
4.1 | HYDRAULIC SCHEMATIC ........................................................................................................................................................ 18
4.2 | ELECTRICAL SCHEMATIC .......................................................................................................................................................20
4.3 | CONTROL BOARD DIAGNOSTIC ..........................................................................................................................................22
SECTION 5 | WIRING DIAGRAMS ..........................................................................................................................................24
5.1 | WIRING DIAGRAM .....................................................................................................................................................................24
5.2 | LOWER CONTROLS WIRING DIAGRAM .............................................................................................................................26
5.3 | UPPER CONTROLS WIRING DIAGRAM ...............................................................................................................................28
SECTION 6 | TROUBLESHOOTING FLOWCHARTS ...........................................................................................................30
6.1 | MAIN POWER/SAFETY CIRCUIT .............................................................................................................................................30
6.2 | DRIVE CIRCUIT ...........................................................................................................................................................................32
6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................34
6.4 | LOWER CIRCUIT .........................................................................................................................................................................36
SECTION 7 | PARTS ................................................................................................................................................................. 38
SECTION 8 | WARRANTY ........................................................................................................................................................40
SECTION 9 | INSPECTION AND REPAIR LOG .....................................................................................................................42
MAINTENANCE & TROUBLESHOOTING
HB-1230CE
SUPO-717
REV A
4
INDEX OF FIGURES
REVISION DATES:
REV A ..........................................................................................................................................................................................April 2016
FIGURE 1: Maintenance Lock Use ....................................................................................................................................................... 7
FIGURE 2: Maintenance Lock Pin Storage .......................................................................................................................................... 7
FIGURE 3: Battery Charger LED Display .............................................................................................................................................. 9
MAINTENANCE & TROUBLESHOOTING
HB-1230CE
SUPO-717
REV A
5