Hy-Brid Lifts HB-830 Maintenance & Troubleshooting Manual
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Hy-Brid Lifts HB-830 Maintenance & Troubleshooting Manual

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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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Summary of Contents for Hy-Brid Lifts HB-830

  • 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

    FOREWORD 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 3: 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 4: Section 1 | Safety

    Use only approved nonflammable cleaning solvents. • After maintenance, inspect the machine as described for Pre-delivery. NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 5: Section 2 | Maintenance

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

  • Page 6: Lubrication

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

  • Page 7: Pre-Start Inspection Checklist

    Pothole guards deploy and lock when platform is elevated. Proper placement quantity Lift does not elevate when pothole guards are blocked. Date: Inspected By: DATE: INSPECTED BY: MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 8: Section 4 | Technical References

    SECTION 4 | TECHNICAL REFERENCES CHNICAL REFERENCES SECTION 4 | TECHNICAL REFERENCES SECTION 4 | TECHNICAL REFERENC 4.1 | HYDRAULIC SCHEMATIC ATIC ATIC MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 9: Electrical Schematic

    SECTION 4 | TECHNICAL REFERENCES SECTION 4 | TECHNICAL REFERENCES SECTION 4 | TECHNICAL REFERENCES 4.2 | ELECTRICAL SCHEMATIC 4.2 | ELECTRICAL SCHEMATIC ICAL SCHEMATIC WS-129-20-201-50 WS-129-20-201-50 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 10: Control Board Diagnostic

    Functions Locked: Board is overheated. Check pump, drive motor wiring. Problem with controller internal voltage. Controller may need to be replaced. MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 11: Section 5 | Wiring Diagrams

    SECTION 5 | WIRING DIAGRAMS SECTION 5 | WIRING DIAGRAMS 5.1 | WIRING DIAGRAM 5.1 | WIRING DIAGRAM Part No. WD-129-20-201-50 Part No. WD-1 1 29-20-201-50 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 12: Lower Controls Wiring Diagram

    SECTION 5 | WIRING DIAGRAMS 5.2 | LOWER CONTROLS WIRING DIAGRAM 5.2 | LOWER CONTROLS WIRING DIAGRAM R CONTROLS WIRING DIAGRAM Part No. WD-129-21-206-50 Part No. WD-12 2 9-21-206-50 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 13: Upper Controls Wiring Diagram

    SECTION 5 | WIRING DIAGRAMS SECTION 5 | WIRING DIAGRAMS 5.3 | UPPER CONTROLS WIRING DIAGRAM 5.3 | UPPER CONTROLS WIRING DIAGRAM Part No. 129-21-249-50 Part No. 129-21-249-50 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 14: Section 6 | Troubleshooting Flowcharts

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.1 | MAIN POWER/SAFETY CIRCUIT MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 15: Drive Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.2 | DRIVE CIRCUIT MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 16: Elevate Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.3 | ELEVATE CIRCUIT MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 17: Lower Circuit

    SECTION 6 | TROUBLESHOOTING FLOWCHARTS SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.4 | LOWER CIRCUIT MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 18: 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 19 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 Item # Part Number Description ELEC-073EKEY KEY,SPARE MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 20: Drive Circuit

    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 Item # Part Number Description 129-21-227-50 BOARD,DRIVE/LIFT CTL HB-MID ELEC-670-6 FUSE 30 AMP,PCS MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 21 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 Item # Part Number Description ELEC-002C-KIT SWITCH,ROTARY MAINTAINED ELEC-606 JOYSTICK,MULTI-AXIS MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 22 DU BEARING,1"ID X 1" L 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 23 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 24 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 25 Part Number Description ELEC-133B SWITCH,ROCKER THIS PAGE WAS INTENTIONALLY LEFT BLANK 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 26: Covers

    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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...

  • Page 27: 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 MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 28 NOTES NOTES MAINTENANCE & TROUBLESHOOTING SUPO-658 MAINTENANCE & TROUBLESHOOTING SUPO-658 HB-830/HB-1230 REV A HB-830/HB-1230 REV A...
  • Page 29 © 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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