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Hy-Brid Lifts HB-830, Maintenance And Troubleshooting Manual, Page: 8 / 20

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Hy-Brid Lifts HB-830 Maintenance And Troubleshooting Manual Download Page 8



Technical

References

Joystick

Service

Flash

Codes

The

amber

Service

Indicator

LED

displays

diagnostic

codes.

A

flash

code

is

a

sequence

of

flashes,

separated

by

a

pause,

followed

by

a

repetition

of

the

sequence.

The

number

of

flashes

indicates

a

condition.

Flash

Code

Description

Notes

1

User

Fault

Possible

stall

timeout

or

user

error.

Release

the

joystick

to

neutral

and

try

again.

2

Battery

Fault

Try

charging

batteries.

Batteries

may

require

replacing.

Check

batteries

and

cables.

3

Left

Motor

Fault

Check

left

motor,

connections,

and

cabling

4

Right

Motor

Fault

Check

right

motor,

connections,

and

cabling.

5

Left

Park

Brake

Fault

Check

left

park

brake,

connections,

and

cabling.

6

Right

Park

Brake

Fault

Check

the

right

park

brake,

connections

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

switch),

turn

the

joystick

off

and

back

on

(joystick

on/off

button).

Check

that

battery

voltage

is

greater

than

17V.

Check

the

Bus

Cable.

Replace

the

Power

Module.

Replace

the

Remote

(Joystick).

10

Unknown

Fault

Check

all

connections

and

wiring.

Contact

manufacturer.

11

Incompatible

Remote

The

Remote

is

incompatible

with

the

Power

Module.

Ensure

that

the

correct

part

number

is

used.

See

also

“Upper

Control

Battery

Gauge

Indicator”

codes

listed

in

the

Operator’s

Manual.

Part #SUPO-613 
REV E 

Page 14 of 38

Part #SUPO-613 
REV E 

Page 15 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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