background image



Frequent

Inspection

Checklist

WARNING

AERIAL PLATFORMS SHALL BE INSPECTED, 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

NUMBER

___________

SERIAL

NUMBER

______________

x

Check

each

item

listed

below.

x

Use

proper

operating,

service,

and

maintenance

manual

for

specific

information

and

settings

x

If

an

item

is

found

to

be

unacceptable

make

the

necessary

repairs

and

check

the

“repaired”

box.

x

When

all

items

are

“acceptable”,

the

unit

is

ready

for

service.


Description 

Y N R 

Visual

Inspections

Perform

all

checks

on

the

Pre

Ͳ

Start

Inspection

Checklist.

Inspect

the

condition

of

hydraulic

fluid

in

reservoir.

Oil

should

have

a

clear

amber

color.

Inspect

the

entire

machine

for

signs

of

damage,

broken

welds,

loose

bolts,

or

improper

repairs.

(Check

for

corrosion,

cracking,

abrasion,

etc.)

Check

that

all

snap

rings

are

secure

in

grooves

on

pivot

pins.

Check

if

tires

are

leaning

in

or

out.

Check

electrical

motor

brushes

(every

150

hours)

Verify

that

maintenance

and

inspection

records

are

up

to

date.

Functional

Tests

Perform

all

checks

on

the

Pre

Ͳ

Start

Inspection

Checklist.

Functions

operate

smoothly.

Functions

operate

over

full

range

of

motion.

Elevated

and

Lowered

drive

speeds

do

not

exceed

specifications

listed

in

Operators

manual.

Emergency

Lowering—Manual

override

functions

properly.

Ground

Controls

override

platform

controls.

Check

that

the

platform

does

not

drift

down

with

a

full

load.

Wheels

lubricated

if

needed.

Comments:



DATE

_______________

INSPECTED

BY

_______________________________

Part #SUPO-613 
REV E 

Page 12 of 38



Pre

Ǧ

Delivery/Annual

Inspection

Checklist

WARNING

AERIAL

PLATFORMS

SHALL

BE

INSPECTED,

SERVICED

AND

ADJUSTED

TO

MANUFACTURER'S

REQUIREMENTS

BY

A

QUALIFIED

MECHANIC

PRIOR

TO

EACH

SALE,

LEASE,

OR

RENTAL,

AND

EVERY

12

MONTHS

.

MODEL

NUMBER:

HB

Ǧ

830

SERIAL

NUMBER

______________

x

Check

each

item

listed

below.

x

Use

proper

operating,

service,

and

maintenance

manual

for

specific

information

and

settings

x

If

an

item

is

found

to

be

unacceptable

make

the

necessary

repairs

and

check

the

“repaired”

box.

x

When

all

items

are

“acceptable”,

the

unit

is

ready

for

service.

Check

Y

N

R

Check

Y

N

R

Base:

Inspect roller tracks for damage

Decals:

All frame bolts tight

Legibility

Pump Secure

Correct capacity noted

DC motors secure

Proper placement quantity

Battery Hold Downs Secure

Wiring:

Batteries Fully Charged

Switches secure

Wheels: Snap Rings Secure

Contactor(s) secure

Wheels: Bolts/Nuts Tight

Tight on terminals (No loose wiring)

Maintenance Locks: Pins in cabinet

Functions:

All Shields/Guards in place

Drive, Lift, Steer Functions Operational

Hydraulic Oil Level 1” from top

Emergency Stop Breaks Circuits

Check all hydraulic hoses for leaks

Slow Speed limit switch Set properly

Check all hydraulic fittings for leaks

Emergency Down Operational

Scissors:

Pothole guards deploy when platform

Broken Welds

Pothole interlock functions correctly

Bent Beam Members

Brakes: Operational

All rollers Turn Freely

Tilt sensor Functional

Ret. Rings Secure On Pivots

Motion Alarms Functional

Broken welds

Hour meter operational

Platform:

Battery indication operational

All rails in place/secure

Battery Charger Secure/Operational

No bent rails

No broken welds
110V outlet safe/working (if installed)

Entrance gate Closes Freely
Operator/Service Manual Included

Cables in place/secure
Extending platform extends freely

Extending platform Locks in Stowed Position
Extending

platform

Locks

in

Extended

Position

Comments:

̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴̴

Part #SUPO-613 
REV E 

Page 13 of 38

Summary of Contents for HB-830

Page 1: ...M TRO MAIN OUBL MA Hy M H Sel Aerial W NTENA AND LESHO ANUA Brid L Models HB 830 f Propel Work Pla ANCE OOTIN AL Lifts s 0 lled atform NG ...

Page 2: ...Service Flash Codes 14 Technical References 15 Hydraulic Schematic 15 Electrical Schematic 16 Wiring Diagrams 18 Wiring Diagram 18 Main Power Safety 20 Drive Circuit 22 Elevate Lower Circuit 24 Troubleshooting 26 Troubleshooting Flowchart 26 Part SUPO 613 REV E Page 2 of 38 Troubleshooting Flowchart Drive Steer Circuit 28 Troubleshooting Flowchart Elevate Lower Circuit 30 Replacement Parts 32 Safe...

Page 3: ...dicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING FAILURE TO FOLLOW THIS WARNING MAY CAUSE DEATH OR PERSONAL INJURY WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION FAILURE TO FOLLOW THIS WARNING MAY CAUSE INJURY OR DAMAGE EQUIPMENT CAUTION indicates a potentially haz...

Page 4: ... 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 a...

Page 5: ... REV E Page 8 of 38 Components requiring adjustment Under normal use no components should require adjustment Contact the manufacturer if adjustments are required Examination repair replacement of limited life components With proper use battery maintenance and regular inspection there are no limited life components that require routine replacement Safety devices and systems requiring checks Check s...

Page 6: ...DO SO COULD AFFECT THE SAFETY OF THE OPERATOR MODEL HBǦ830 SERIAL NUMBER ______________ 1 Keep inspection records up to date 2 Record and report all discrepancies to your supervisor 3 A dirty 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 There are no loose or ...

Page 7: ...cklist WARNING AERIAL PLATFORMS SHALL BE INSPECTED SERVICED AND ADJUSTED TO MANUFACTURER S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO EACH SALE LEASE OR RENTAL AND EVERY 12 MONTHS MODEL NUMBER HBǦ830 SERIAL NUMBER ______________ x Check each item listed below x Use proper operating service and maintenance manual for specific information and settings x If an item is found to be unacceptable make...

Page 8: ...onnections and cabling 7 Remote Fault Check the Communications Bus connectors and wiring Replace the Remote Joystick 8 Power Module Fault Check the Communications Bus connectors and wiring Replace the Power Module 9 Communications Fault One cause of this error is when the unit is powered down without turning off the joystick i e using the emergency stop To clear with the machine on using the key s...

Page 9: ...Part SUPO 613 REV E Page 16 of 38 Part SUPO 613 REV E Page 17 of 38 ...

Page 10: ...Part SUPO 613 REV E Page 18 of 38 Part SUPO 613 REV E Page 19 of 38 ...

Page 11: ...WIRING DIAGRAM MAIN POWER SAFETY CIRCUIT Part SUPO 613 REV E Page 20 of 38 WIRING DIAGRAM MAIN POWER SAFETY CIRCUIT Part SUPO 613 REV E Page 21 of 38 ...

Page 12: ...WIRING DIAGRAM DRIVE CIRCUIT Part SUPO 613 REV E Page 22 of 38 WIRING DIAGRAM DRIVE CIRCUIT Part SUPO 613 REV E Page 23 of 38 ...

Page 13: ...WIRING DIAGRAM ELEVATE LOWER CIRCUIT Part SUPO 613 REV E Page 24 of 38 WIRING DIAGRAM ELEVATE LOWER CIRCUIT Part SUPO 613 REV E Page 25 of 38 ...

Page 14: ...Control Display a Fault Code Check Component or Condition Referenced by Fault Code Part SUPO 613 REV E Page 26 of 38 atteries harger disconnected from machine Are both E Stop buttons off Reset E Stop buttons Pull out at both upper control and lower control locations No Check for loose wiring connections Check for ground connection at pump See wiring diagrams Check for continuity in connections use...

Page 15: ...ntrol board secure Reconnect No Is there moisture or corrosion in any connections No Yes Allow to dry for 24 hours and try again Board probably will need replacement Apply dielectric grease to connectors at main wire harness Yes Replace drive control board and or joystick No Contact CEI for further troubleshooting Consider brake damage broken joystick handle drive enable bad hour meter loose conne...

Page 16: ...nctionning Remove obstruction Replace limit switch or repair connections Part SUPO 613 REV E Page 30 of 38 Is down valve stuck open uid low owered fill to 1 below ervoir Flush valve by simultaneously pressing up switch at base and down switch on platform control for 30 sec Contact CEI for further troubleshooting Check integrity of electrical connections There may be a loose connection or momentary...

Page 17: ...ent revisions Refer to our website www hybridlifts com for more complete part listings and earlier revisions Several parts are model serial number or manufacture date specific Contact your dealer for replacement part availability and pricing Safety and Control Decals Refer to Operator s Manual for decal part numbers and locations Part SUPO 613 REV E Page 32 of 38 Covers Other Item Part Description...

Page 18: ...ctured ELECͲ670Ͳ2 20 A AGC Fuse Not Pictured ELECͲ819 Sleep Timer Not Pictured 1002101550 Battery Cable Kit Not Pictured 1002101099 Drive Power Cable Kit Part SUPO 613 REV E Page 34 of 38 Drive Circuit Parts Item Part Description 1 1000108202 Caster 2 1000106451 Drive Control Board specific to this model series only 3 NA Brake Connection Terminals 4 LASͲM248Ͳ1ͲPC Limit Switch Mounting Bracket 5 EL...

Page 19: ...n Valve 14 HYDRͲ600Ͳ5 High Pressure Hydraulic Hose 15 ELECͲ602 ELECͲ871 Lift Enable Button Contact Blocks 16 ELECͲ133B Up Down Rocker Switch 17 HBͲPHͲ13 Guide Block 18 1000102004 PH Retaining Sleeve 19 HARDͲ702 Spring 20 HBͲPHͲ7ͲP PH Lock 21 ELECͲ123Ͳ2 Limit Switch 22 LASͲM222ͲP LS Plate 23 1000105902 PH PickͲUp Arm 24 LASͲM220ͲP PH Arm 25 ELECͲ629 Tilt Sensor 26 HYDRͲ664 18 V Coil 27 HYDRͲ665 Up ...

Page 20: ...esponsibility for alterations or modifications to the unit or damages caused by any natural disasters such as fire flood wind and lightning THE PREVIOUS WARRANTY STATEMENT IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE If field repair or parts replacement is necessary on any warranted...

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