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Hy-Brid Lifts HB-830 Maintenance And Troubleshooting Manual

Series ii. self-propelled aerial work platform
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BY CU STO M EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-658
REV A
HB-830
HB-1230
SERIES II

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  • Page 1 BY CU STO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING MANUAL SUPO-658 REV A SELF-PROPELLED AERIAL WORK PLATFORM HB-830 HB-1230 SERIES II...

  • Page 2: Notes

    NOTES If there is a question about application and/or operation, contact: Custom Equipment, LLC 2647 Hwy 175 Richfield, WI 53076 U.S.A. P: +1-262-644-1300 F: +1-262-644-1320 www.hybridlifts.com BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 3: Foreword

    FOREWORD BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 4: Table Of Contents

    7.2 | MAIN POWER/SAFETY CIRCUIT .............................35 7.3 | DRIVE CIRCUIT ....................................39 7.4 | COVERS ......................................50 7.5 | RAILINGS ....................................... 51 SECTION 8 | WARRANTY ................................ 52 NOTES ......................................54 BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 5: Index Of Figures

    INDEX OF FIGURES FIGURE 1: Maintenance Lock Use ................................ 7 FIGURE 2: Maintenance Lock Storage ............................... 7 FIGURE 3: Battery Charger LED Display .............................. 9 BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 6: Section 1 | Safety

    MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 7: Safety Guidelines

    Keep all support equipment and attachments stowed in their proper place. • Use only approved nonflammable cleaning solvents. • After maintenance, inspect the machine as described for Pre-delivery. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 8: Section 2 | Maintenance

    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. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 9: Figure 3: Battery Charger Led Display

    Green LED (ON) Red LED Green LED (ON) Red LED Green LED (ON) (FLASHING) (FLASHING) BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 10: Lubrication

    Never attach pipe racks, material lifting devices, or make any other alteration that is not part of the intended design of the machine. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 11: Section 3 | Maintenance Checklists

    The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20 hours per week, 5 load cycles per hour). BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 12: Pre-Start Inspection Checklist

    □ Pothole guards deploy and lock when platform is elevated. □ □ □ Lift does not elevate when pothole guards are blocked. □ □ □ DATE: INSPECTED BY: BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 13: Pre-Delivery/Annual/Frequent Inspection Checklist

    □ □ □ Legibility All Shields/Guards in place □ □ □ □ □ □ Correct capacity noted Operator/Service Manual □ □ □ Proper placement quantity Date: Inspected By: BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 14: Section 4 | Technical References

    SECTION 4 | TECHNICAL REFERENCES 4.1 | HYDRAULIC SCHEMATIC BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 15 SECTION 4 | TECHNICAL REFERENCES BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 16: Electrical Schematic

    MACHINING TOLERANCES: .X= .030 .XX= .015 .XXX= .005 FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010 LASER TOLERANCES: = .005 THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPECT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 17 SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 1 TATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 18: Control Board Diagnostic

    Functions Locked: Board is overheated. Check pump, drive motor wiring. Problem with controller internal voltage. Controller may need to be replaced. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 19 Motor B current too high. Motor B current too low. Check drive connections at both drives--short or multiple wiring faults. Check B+ stud connections on controller. Voltage is too low. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 20: Section 5 | Wiring Diagrams

    UPPER CONTROL 129-21-249-50 ANGLE SENSOR #1 ELEC-641C 129-01-090-51 BATTERY BLACK WHITE BATTERY CHARGER (129-01-090-51) THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EX BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 21 SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 7 XPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 22: Lower Controls Wiring Diagram

    1K-OHM 1W RESISTOR CHARGER ENABLE INTERLOCK PWR SOL PWR SOL BATTERY PWR SOL GAUGE (-) THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN E BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 23 SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 2 EXPECTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 24: Upper Controls Wiring Diagram

    MACHINING TOLERANCES: .X= .030 .XX= .015 .XXX= .005 FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010 WD-129-21-249-50 LASER TOLERANCES: = .005 THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO CUSTOM, EQUIPMENT AND IS LOANED IN EXPEC BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 25 SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 1 CTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED. BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 26: Section 6 | Troubleshooting Flowcharts

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.1 | MAIN POWER/SAFETY CIRCUIT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 27 SECTION 6 | TROUBLESHOOTING FLOWCHARTS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 28: Drive Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.2 | DRIVE CIRCUIT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 29 SECTION 6 | TROUBLESHOOTING FLOWCHARTS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 30: Elevate Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.3 | ELEVATE CIRCUIT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 31 SECTION 6 | TROUBLESHOOTING FLOWCHARTS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 32: Lower Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.4 | LOWER CIRCUIT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 33 SECTION 6 | TROUBLESHOOTING FLOWCHARTS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 34: Section 7 | Parts Diagrams

    WARRANTY. 7.1 | SAFETY AND CONTROL DECALS Refer to the Hy-Brid Lifts Operation and Safety Manual for decal part numbers and locations. REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY (ELEC-047-5), HYDRAULIC CYLINDER (HYDR-012 OR HYDR-013), CONTROL BOARD (129-21-227-50), AND ALL STRUCTURAL COMPONENTS.

  • Page 35: Main Power/Safety Circuit

    CTL,WIRE HARNESS MAIN HB-1230 ELEC-747-60 CHARGER,24V HYDR-666 SOLENOID,24V,ISOLATED,SPST 129-21-227-50 BOARD,DRIVE/LIFT CTL HB-MID ZTR 129-21-206-50 BASE,ASM CTL PANEL ELEC-047-5 BATTERY,12V,GR27 AGM ELEC-634D TERMINAL BOOT (BLACK) ELEC-634C TERMINAL COVER (RED) 129-01-305-01 BASE,COVER HINGE BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 36 129-21-206-94 CTL,WIRE HARNESS, LS-R 129-21-206-95 CTL,WIRE HARNESS, LS-L 129-21-206-96 CTL,WIRE HARNESS 12C 129-21-206-99 CTL,WIRES LWR CTL ELEC-071-KIT BUTTON,PUSH/PULL RED E-STOP ELEC-073D SWITCH,KEY,3-POS MAINTAINED ELEC-610-2 METER,HOUR ELEC-633-4 SWITCH,MASTER DISCONNECT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 37 SECTION 7 | PARTS DIAGRAMS  COMPONENTS OF POWER SWITCH ELEC-633-4 Item # Part Number Description ELEC-633-5 SWITCH KNOB,MASTER DISCONNECT COMPONENTS OF KEY SWITCH ELEC-073D Item # Part Number Description ELEC-073EKEY KEY,SPARE BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 38 Part Number Description 129-21-006-90 CTL,WIRE HARNESS,UPR CTL ELEC-002C-KIT SWITCH,ROTARY MAINTAINED ELEC-071-KIT BUTTON,PUSH/PULL RED E-STOP ELEC-610-4 METER,VOLT,24V COMPONENTS OF CHARGER ELEC-747-60 Item # Part Number Description ELEC-670-6 FUSE 30 AMP,PCS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 39: Drive Circuit

    BEARING WHEE-717 SEAL 129-21-215-50-K ASM,CASTER WHEE-719 1-14 HEX SLOTTED AXLE NUT WHEE-716 WASHER,1.06IDX1.75ODX.155THK HARD-725 COTTER PIN, 3/16 X 2 WHEE-714-100 HUB,COVER 129-21-249-50 ASM,CTL UPR 129-21-227-50 BOARD,DRIVE/LIFT CTL HB-MID BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 40 SECTION 7 | PARTS DIAGRAMS  DRIVE COMPONENTS OF UPPER CONTROL 129-21-249-50 Item # Part Number Description ELEC-002C-KIT SWITCH,ROTARY MAINTAINED ELEC-606 JOYSTICK,MULTI-AXIS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 41 COMPONENTS OF CASTER ASSEMBLY 129-21-215-50-K Item # Part Number Description 129-01-260-01 BASE,CASTER WLDMNT 129-06-023-02 BASE,CASTER PIN HARD-021 RET RING 1.0" WHEE-609-SS WASHER, 1.015ID,2 OD,.03 THK SS WHEE-706-KIT WHL,8X2,GREY NM RUBBER BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 42 SECTION 7 | PARTS DIAGRAMS COMPONENTS OF CASTER WHEEL WHEE-706-KIT Item # Part # Description WHEE-708 WHL, RACEWAY SPLIT 2 IN. HARD-001-2 DU BEARING,1"ID X 1" L BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 43 COMPONENTS OF DRIVE MOTORS ELEC-626-5L & ELEC-626-5R Item # Part Number Description ELEC-626-4A DRIVE MOTOR SHAFT SEAL,DUM ELEC-626-4B DRIVE MOTOR HOUSING GASKET,DUM ELEC-627-5R DRIVE MOTOR,BRAKE ELEC-627-5L DRIVE MOTOR,BRAKE BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 44 SECTION 7 | PARTS DIAGRAMS  COMPONENTS FOR ELEVATE & LOWER BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 45 1 3/8 MOLDING BOND HARD-022 RET RING 1.25 129-21-002-90-K ASM,SCISSOR CYL HB12-ANSI 1021000102 SET COLLAR,1.25 ID BM-6006-1-KIT ASM,ROLLER,1.00 W/DU ELEC-647 SENSOR,ANGLE 129-02-202-01 SCISSOR, ANG SENSOR MNT 129-02-203-11 SCISSOR,CONDUIT BRKT BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 46 BASE,LOCK,PIVOT REAR RND-HB-002-P PIN,HINGE,0.50,5.0 129-01-254-01 BASE,PH BAR L (HBMD) 129-01-255-01 BASE,PH BAR R (HBMD) 129-21-202-14-K ASM,BASE PH ARMS 129-21-202-09-K ASM,BASE PH ARMS 129-21-239-50-K ASM,BASE MID-COVER 129-21-243-50-K ASM, CLAMSHELL BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 47 Item # Part Number Description HYDR-007-2E-5 VALVE,DOWN HYDR-067-3 RESERVOIR,MID HYDR-068 PUMP RESERVOIR O-RING HYDR-664 COIL,18V HYDR-665 UP VALVE-HB HYDR-666-1 SOLENOID,24V,ISOLATED,SPST HYDR-667 WASHER,0.38 ID,0.75 OD,PRES SEAL HYDR-683 FLOW CONTROL,2.5 GPM BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 48 ELEVATE/LOWER COMPONENTS OF LOWER CONTROL 129-21-206-50 Item # Part Number Description ELEC-133B SWITCH,ROCKER ELEVATE/LOWER COMPONENTS OF UPPER CONTROL 129-21-249-50 Item # Part Number Description ELEC-002C-KIT SWITCH,ROTARY MAINTAINED ELEC-606 JOYSTICK,MULTI-AXIS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 49 THIS PAGE WAS INTENTIONALLY LEFT BLANK BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 50: Covers

    7.4 | COVERS Item # Part Number Description Notes 129-01-321-06 BASE,COVER REAR SIDE 129-01-321-11 BASE,COVER REAR SIDE 129-05-203-01 BASE,COVER,L 129-05-202-01 BASE,COVER,R HARD-658 PLUG,0.38 DIA,TRANSPARENT 129-01-269-06 BASE,COVER LS 129-01-296-11 BASE,COVER LS BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 51: Railings

    ASM,RAIL SLIDE CHNL W/WASHERS 129-03-211-01 RAIL, SO TOE BOARD 129-03-206-01 RAIL,SO END WLDMNT HARD-603 MANUAL BOX HARD-067 SNAP BUTTON,0.38 SINGLE END MISC-031-11-KIT ANTI-SLIP TAPE,4.00,54.00 LENGTH MISC-031-01-KIT ANTI-SLIP TAPE,4.00,31.00 LENGTH BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 52: Section 8 | Warranty

    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 1 of this Limited Warranty shall be for the BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 53 WHETHER IN AN ACTION IN CONTRACT OR TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHERWISE, EVEN IF THE COMPANY HAS BEEN SPECIFICALLY ADVISED OF THE POSSIBILITIES OF SUCH DAMAGES. Version of 2.1.13 BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...

  • Page 54: Notes

    NOTES BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 55 NOTES BY CUSTO M EQUIPMENT LLC MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A...
  • Page 56 © 2014 Custom Equipment, LLC 2647 Highway 175 Richfield, WI 53076 U.S.A. Tel.: +1-262-644-1300 Fax: +1-262-644-1320 www.hybridlifts.com Service@Customequipmentlifts.com “Hy-Brid Lifts” is a trademark of Custom Equipment, LLC. These machines comply with specified ANSI/SIA A92.6 requirements Revision Date: November 2013 Printed In The USA...

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Hb-1230

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