Hy-Brid Lifts ZERO-TURN Series Maintenance & Troubleshooting Manual Download Page 1

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BY CUSTOM EQUIPMENT LLC

MAINTENANCE &

TROUBLESHOOTING

MANUAL

ZT-1230

ZT-1630

SERIAL NO.

MOBILE
ELEVATING
WORK
PLATFORMS

ANSI A92.20
CSA B354.6:17

ZERO-

TURN

SERIES

ZT5.0-M | REV A

ZERO-TURN

SERIES

INFORMATION

DE1317

To view machine specific information on your
mobile device, scan the code to the left.

Decals with this code can also be found on the
manual box and base of the machine.

Summary of Contents for ZERO-TURN Series

Page 1: ...BILE ELEVATING WORK PLATFORMS ANSI A92 20 CSA B354 6 17 ZERO TURN SERIES ZT5 0 M REV A ZERO TURN SERIES INFORMATION DE1317 To view machine specific information on your mobile device scan the code to the left Decals with this code can also be found on the manual box and base of the machine ...

Page 2: ...d before any attempt is made to service this machine The operation and safety manual is considered a part of the work platform and contains instructions and operating procedures essential to properly and safely operate the Custom Equipment Hy Brid Lift Users must read and understand all information in the Safety and Operations Manual before operation The user operator should not accept operating r...

Page 3: ...16 4 1 HYDRAULIC SCHEMATIC 16 4 2 WIRING SCHEMATIC 18 4 3 CONTROL BOARD DIAGNOSTIC 20 SECTION 5 WIRING DIAGRAMS 22 5 1 WIRING DIAGRAM 22 5 2 LOWER CONTROL WIRING DIAGRAM 24 5 3 UPPER CONTROL 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 CIRCUIT 34 SECTION 7 PARTS 36 SECTION 8 WARRANTY 38 8 1 LIMITED ...

Page 4: ...nal requirements set forth by ANSI OSHA CSA If you come across a situation that you think might be unsafe stop the platform and request further information from qualified sources before proceeding 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 i...

Page 5: ...TTERY The charger may include an interlock circuit If so equipped the unit will not operate while charging Operating while charging will shorten battery life To Charge Park the machine on a level surface Plug charger into AC outlet until charged For best battery life leave the charger plugged in until machine will be used again The charger will maintain the battery charge FIGURE 3 Charger Cord Loc...

Page 6: ...EQUIRING CHECKS Check safety functions as part of daily inspection Check that the brakes are holding 2 7 STORAGE After periods of storage exposure to extremes of ambient conditions heat cold moisture dust etc inspect the machine Batteries will need to be charged Refer to the Pre Delivery Frequent Inspection Checklist in the Maintenance Manual 2 8 MAJOR ALTERATIONS OR REPAIRS Any alterations must b...

Page 7: ...hat warning and instructional labels are legible and secure Ensure that load capacity is clearly marked Check the platform rails and safety gate for damage Platform and base controls 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 C...

Page 8: ...ELS Snap rings secure Bolts nuts tight All shields guards in place SCISSORS No broken welds No bent beam members All rollers turn freely Ret rings secure on pivots Maintenance locks Stored in designated location PLATFORM No bent rails No broken welds All rails in place secure 110V outlet safe working Entrance gate closes freely Y Yes Acceptable N No Unacceptable R Repaired N A Not Equipped Y N R N...

Page 9: ...ION 4 TECHNICAL REFERENCES 4 1 HYDRAULIC SCHEMATIC Part No HS 129 20 501 50 M 2 GPM AIR DESCRIPTION THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 6 F 1 262 2 HS ZT S5 T VUE 06 05 2020 DO NOT SCALE DRAWING 06 11 2020 T VUE APPROVED DAT DESCRIPTION OF CHANGE REVISION HISTORY ECO 04 16 REV A CONFIGURATIONS 50 GENERAL ASSEMBLY ...

Page 10: ...13 M 7 M 2 M 11 G 2 A 1 C 1 B 1 D 1 B 3 C 3 A 3 D 3 D 2 C 2 A 2 T 3 T 4 T 1 T 2 T 5 T 6 BUTT 6 2 1 2 1 BUTT 4 H 6 OPTIONAL FLASHING BEACON BUTT 1 1 2 20A NO NC PH LS L N 2 NC E STOPLWR I 5 I 2 I 1 I 4 G 6 B 2 M 3 N 5 E 2 E 1 F 2 F 1 Q 2 R 2 S 2 Q 1 R 1 S 1 Q 3 R 3 S 3 I 6 I 7 I 3 SIG AS1 SIG PS1 PS2 SIG AS2 SIG CHR INT LK IF EQUIPPED DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN ...

Page 11: ...k P9 wiring One or more signals showing outputs when all should be off 3 3 Check B stud connections on controller Voltage is too high 3 4 There is voltage on safe pre valve supply when there should not be Controller may need to be replaced 3 5 The drive brake current is too high Motor overload Check for a siezed motor or for power wiring to motors 4 x There is a problem with battery supply the hei...

Page 12: ...SURE SENSOR 2 SPARE 129 21 311 50 UPPER CONTROL WD 129 21 504 129 21 004 94 129 21 016 LOWER CONTROL HARNESS BUTT BATTERY CHARGER 6 AWG 6 AWG 6 AWG 6 AWG 10 AWG 10 AWG 10 AWG 10 AWG 6 AWG HIRSCHMANN CONNECTION DOWN VALVE DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WD ZT S5 WD 129 20 501 1 1 N A 1 OF 1 T VUE 05 29 2020 SIZE B DWG NO A ...

Page 13: ... 12 2 3 6 5 4 1 2 3 1 2 1 TS100 M1 SOLENOID SOLENOID UP VALVE SIGNAL DOWN VALVE SIGNAL JUMPER TO HIRSCHMANN CONNECTOR PUMP SOLENOID UP VALVE COIL DOWN VALVE COIL JUMPER TO HIRSCHMANN CONNECTOR TS100 M1 TS100 M2 TS100 M2 R MOTOR DRIVE R MOTOR DRIVE L MOTOR DRIVE L MOTOR DRIVE NEGATIVE PUMP SOLENOID DESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 24...

Page 14: ...ESCRIPTION SCALE WEIGHT LBS SHEET THIRD ANGLE PROJECTION DRAWN NAME DATE P 1 262 644 1300 F 1 262 247 0073 WD ZT UPR CTRL S5 WD 129 21 504 1 1 N A 1 OF 1 T VUE 05 20 2020 SIZE B DWG NO A REV DO NOT SCALE DRAWING 06 05 2020 T VUE APPROVED DATE REV BY DESCRIPTION OF CHANGE REVISION HISTORY ECO THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CUSTOM EQUIPMENT AND IS LOANED IN EXPECTA...

Page 15: ...ZERO TURN SERIES ZT 1230 ZT 1630 28 29 MAINTENANCE TROUBLESHOOTING MANUAL ZT5 0 M REV A SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 1 MAIN POWER SAFETY CIRCUIT ...

Page 16: ...E CIRCUIT Are the brakes released Cycle power to reengage brakes Contact Hy Brid Lifts for further troubleshooting Consider brake damage broken joystick handle drive enable bad hour meter loose connectiions in lower and upper control and control board failure Contact Hy Brid Lifts for further troubleshooting Consider board failure pothole interlock limit switch failure ...

Page 17: ...ZERO TURN SERIES ZT 1230 ZT 1630 32 33 MAINTENANCE TROUBLESHOOTING MANUAL ZT5 0 M REV A SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 3 ELEVATE CIRCUIT ...

Page 18: ...ZERO TURN SERIES ZT 1230 ZT 1630 34 35 MAINTENANCE TROUBLESHOOTING MANUAL ZT5 0 M REV A SECTION 6 TROUBLESHOOTING FLOWCHARTS SECTION 6 TROUBLESHOOTING FLOWCHARTS 6 4 LOWER CIRCUIT ...

Page 19: ...ility and pricing Description Part Number Notes ALARM CONTINUOUS ELEC 635 4 BOARD DRIVE LIFT CTL ZERO TURN S4 129 21 533 50 K BUTTON PUSH PULL RED E STOP ELEC 071 KIT BUTTON PUSH TWIST RED E STOP ELEC 065 USED ON SOME UPPER CONTROLS CHARGER 24V ELEC 795 CORD NEMA 5 15P 5 15R 12 0 ELEC 639 CTL ASM LWR 129 21 407 51 CTL ASM UPR 129 21 404 55 CTL WIRE HARNESS MAIN ZT 1230 ZT 1630 129 21 311 50 129 21...

Page 20: ...iable for any claim under this Limited Warranty if Buyer fails to satisfy the conditions set forth in this Section 8 5 EXCLUSIVE WARRANTY REMEDIES Exclusive Repair or Replace Remedy The Company 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 8 1 of this Limited Warranty shall be for the Company at i...

Page 21: ...ZERO TURN SERIES ZT 1230 ZT 1630 40 41 MAINTENANCE TROUBLESHOOTING MANUAL ZT5 0 M REV A SECTION 9 INSPECTION REPAIR LOG SECTION 9 INSPECTION REPAIR LOG DATE COMMENTS DATE COMMENTS ...

Page 22: ...ZERO TURN SERIES ZT 1230 ZT 1630 42 43 MAINTENANCE TROUBLESHOOTING MANUAL ZT5 0 M REV A SECTION 9 INSPECTION REPAIR LOG SECTION 9 INSPECTION REPAIR LOG DATE COMMENTS DATE COMMENTS ...

Page 23: ...Custom Equipment LLC 2647 Highway 175 Richfield WI 53076 U S A 1 262 644 1300 1 262 644 1320 hybridlifts com Hy Brid Lifts is a trademark of Custom Equipment LLC These machines comply with ANSI SIA A92 20 and CSA B354 6 17 Revision Date September 2020 Printed in the U S A 2020 Custom Equipment LLC ...

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