Hy-Brid Lifts HB-1030 Maintenance & Troubleshooting Manual
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Hy-Brid Lifts HB-1030 Maintenance & Troubleshooting Manual

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  • Page 3 AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE. WARNING ANY MODIFICATION ON THIS MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED. Lanyard Attachm ent Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 4: Table Of Contents

    TABLE OF CONTE NTS SECTION 1 | SAFETY ..............................6 SECTION 2 | MAINTENANCE ........................... 8 SECTION 3 | MAINTENANCE CHECKLISTS ......................12 SECTION 4 | TECHNICAL REFERENCES ........................ 16 SECTION 5 | WIRING DIAGRAMS ..........................22 SECTION 6 | TROUBLE SHOOTING FLOWCHARTS..................... 36 SECTION 7 | PARTS DIAGRAMS ..........................
  • Page 5 INDE X OF FIGUR E S Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 6: Section 1 | Safety

    S E CTION 1 | S AF E TY 1.1 | SAFETY SYMBOLS DANGER FAILURE TO FOLLOW THIS WARNING WILL CAUSE DEATH OR PERSONAL INJURY. WARNING FAILURE TO FOLLOW THIS WARNING MAY CAUSE DEATH OR PERSONAL INJURY. CAUTION FAILURE TO FOLLOW THIS WARNING MAY CAUSE INJURY OR DAMAGE TO EQUIPMENT 1.2 | GENERAL RULES AND PRECAUTIONS WARNING...
  • Page 7 1.3 | SAFETY GUIDELINES Maint enance Lock WARNING FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY RE SULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH. Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 8: Section 2 | Maintenance

    S E CTION 2 | MAINTE NANCE 2.1 | BATTERY MAINTENANCE CAUTION NEVER ADD ACID TO BATTERY 2.2 | CHARGING THE BATTERY WARNING LEAD ACID BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING.
  • Page 9 S E CTION 2 | MAINTE NANCE WARNING DO NOT OPERATE UNIT WHILE CHARGING. DO NOT DIS ABLE CHARGER INTERLOCK. Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 10 S E CTION 2 | MAINTE NANCE 2.3 | LUBRICATION 2.4 | COMPONENTS REQUIRING ADJUSTMENT 2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS 2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS 2.7 | STORAGE 2.8 | MAJOR ALTERATIONS OR REPAIRS 2.9 | OTHER PROCEDURES Set ting the Tilt Sensor Voltage Test Points...
  • Page 11 S E CTION 2 | MAINTE NANCE Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 12: Section 3 | Maintenance Checklists

    S E CTION 3 | MAINTE NANCE CHE CKLIS TS CAUTION FAILURE TO PERFORM INSPECTIONS AND PREVENTATIVE MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR.
  • Page 13 SHIFT OR AFTER EVERY SIX TO EIGHT HOURS OF USE. FAILURE CAUTION TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR. Yes/ Acceptable No/ Unacceptable Repaired Description VISUAL INSPECTIONS FUNCTIONAL TESTS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 14 S E CTION 3 | MAINTE NANCE CHE CKLIS TS 3.2 | FREQUENT INSPECTION CHECKLIST AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED, AND ADJUSTED TO MANUFACTURER S REQUIREMENTS BY A QUALI CAUTION FIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST.
  • Page 15 FIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST. Yes/ Acceptable No/ Unacceptable Repaire Base: Y N R Platform: Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 16: Section 4 | Technical References

    S E CTION 4 | TE CHNICAL R E FE R E NCE S 4.1 | HYDRAULIC SCHEMATIC...
  • Page 17 S E CTION 4 | TE CHNICAL R E FE R E NCE S Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 18 S E CTION 4 | TE CHNICAL R E FE R E NCE S 4.2 | ELECTRICAL SCHEMATIC...
  • Page 19 S E CTION 4 | TE CHNICAL R E FE R E NCE S Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 20 S E CTION 4 | TE CHNICAL R E FE R E NCE S 4.3 | LED DRIVE BOARD DIAGNOSTICS BLUE CONTROLLER...
  • Page 21 S E CTION 4 | TE CHNICAL R E FE R E NCE S 4.4 | LED DRIVE BOARD DIAGNOSTICS BLACK CONTROLLER Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 22: Section 5 | Wiring Diagrams

    S E CTION 5 | W IR ING DIAGR AMS 5.1 | WIRING DIAGRAM Part No. WD- HB2...
  • Page 23 S E CTION 5 | W IR ING DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 24 S E CTION 5 | W IR ING DIAGR AMS 5.2 | LOWER CONTROLS WIRING DIAGRAM Part No. SUB A8- 002...
  • Page 25 S E CTION 5 | W IR ING DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 26 S E CTION 5 | W IR ING DIAGR AMS S E CTION 5 | W IR ING DIAGR AMS S E CTION 5 | W IR ING DIAGR AMS 5.3 | UPPER CONTROLS WIRING DIAGRAM Part No. SUB A9- 002...
  • Page 27 S E CTION 5 | W IR ING DIAGR AMS S E CTION 5 | W IR ING DIAGR AMS S E CTION 5 | W IR ING DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 28 S E CTION 5 | W IR ING DIAGR AMS 5.4 | MAIN POWER/ SAFETY CIRCUIT Part No. SUB A9- 002...
  • Page 29 S E CTION 5 | W IR ING DIAGR AMS Part No. SUB A8- 002 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 30 S E CTION 5 | W IR ING DIAGR AMS 5.5 | DRIVE CIRCUIT Part No. SUB A9- 002...
  • Page 31 S E CTION 5 | W IR ING DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 32 S E CTION 5 | W IR ING DIAGR AMS 5.6 | ELEVATE/ LOWER CIRCUIT Part No. SUB A9- 002...
  • Page 33 S E CTION 5 | W IR ING DIAGR AMS Part No. SUB A8- 002 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 34 S E CTION 5 | W IR ING DIAGR AMS 5.7 | STEER CIRCUIT Part No. SUB A8- 002...
  • Page 35 S E CTION 5 | W IR ING DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 36: Section 6 | Trouble Shooting Flowcharts

    S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS 6.1 | MAIN POWER/ SAFETY CIRCUIT Are the batteries Does the machine have any Are both E-Stop buttons connected? function: Is key switch turned on? off? Check per wiring (Drive, Steer Elevate/Lower) diagram.
  • Page 37 Multi-meter at 400V setting. Still no functions? Contact CEI for further troubleshooting Consider charger failure (interlock contacts) Hy-Brid Troubleshooting Flowchart Revision A: Initial Release 01/14/2010 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 38 S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS 6.2 | DRIVE CIRCUIT Does the machine Is either of two brake drive? Is there a trouble Is either or two brakes switches damaged or Is drive unit da...
  • Page 39 Contact CEI for further troubleshooting. Apply dielectric grease to connectors at Consider board failure main wire harness. Hy-Brid Troubleshooting Flowchart Drive Problems Revision A: Initial Release 01/14/2010 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 40 S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS 6.3 | STEER CIRCUIT Check for power connection. Does machine steer ? No; Drive, elevate and See Hy-Brid Troubleshooting. (drive, elevate, lower OK) lower not operating (Power connections at pump, fuse, etc.) No;...
  • Page 41 Replace limit switch and/or readjust. R1 Failure. Replace Relay. R2, R3, or R4 failure. Listen for clicks, try switching relays around. Replace relay(s). Replace actuator ads. Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 42 S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS 6.4 | ELEVATE CIRCUIT Does machine raise/ Is emergency down Does pump operate? Is hydraulic fluid l lower? valve open? With platform lower Check for power connection. See Hy-Brid Close emergency down pump reservoir to 1"...
  • Page 43 There may be foreign matter short. lodged. place hydraulic hose. Hy-Brid Troubleshooting Flowchart Elevating Problems Revision A: Initial Release 01/14/2010 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 44 S E CTION 6 | TR OUBLE S HOOTING FLOW CHAR TS 6.5 | LOWER CIRCUIT Check for Is enable Does machine raise/ obstructions Check for power connect button lower? between any See Hy-Brid troubleshoot working? scissors beams. Yes, but not Replace enable button/ properly contact block at upper...
  • Page 45 Might be able to repair with seal kit;, probably need to replace cylinder. If walls inside cylinder are scratched or pitted, cylinder needs replacement. Hy-Brid Troubleshooting Flowchart Lowering Problems Revision A: Initial Release 01/14/2010 Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 46: Section 7 | Parts Diagrams

    S E CTION 7 | P AR TS DIAGR AMS CAUTION USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF NON OEM PARTS WILL VOID WARRANTY. DANGER REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY ELEC 047 , HYDRAULIC CYLINDER HYDR 007 1 OR HYDR 041 2 , DRIVE CONTROL BOARD ELEC 903 , AND ALL STRUCTURAL COMPONENTS.
  • Page 47 S E CTION 7 | P AR TS DIAGR AMS 7.2 | MAIN POWER/ SAFETY CIRCUIT Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 48 S E CTION 7 | P AR TS DIAGR AMS S E CTION 7 | P AR TS DIAGR AMS 7.3 | DRIVE CIRCUIT...
  • Page 49 S E CTION 7 | P AR TS DIAGR AMS S E CTION 7 | P AR TS DIAGR AMS 7.4 | STEER CIRCUIT Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 50 S E CTION 7 | P AR TS DIAGR AMS 7.5 | ELEVATE/ LOWER CIRCUIT...
  • Page 51 S E CTION 7 | P AR TS DIAGR AMS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 52 S E CTION 7 | P AR TS DIAGR AMS 7.6 | COVERS...
  • Page 53 S E CTION 7 | P AR TS DIAGR AMS 7.7 | RAILINGS Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 54: Section 8 | Warranty

    S E CTION 8 | W AR R ANTY...
  • Page 55 S E CTION 8 | W AR R ANTY Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...

  • Page 56: Section 9 | Inspection And Repair Log

    S E CTION 9 | INS PE CTION AND R E P AIR LOG Date Comment s...
  • Page 57 S E CTION 9 | INS PE CTION AND R E P AIR LOG Date Comments Hy-Br id Lif t s SUPO 611 Maintenance & Trouble Shooting Manual REV K HB-1030/ HB-1430...
  • Page 58 Hy-Br id Lif t s by C ust om Equipment...

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Hb-1430

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