Hy-Brid Lifts | Scissor Lift Manufacturer | Scissor Equipment
Instruction Manual for HY-BRID LIFTS models including: HB-1230 Series III Self Propelled Aerial Work Platform, HB-1230 Series III, Self Propelled Aerial Work Platform, Propelled Aerial Work Platform, Aerial Work Platform, Work Platform, Platform
File Info : application/pdf, 21 Pages, 7.17MB
DocumentDocumentBY CUSTOM EQUIPMENT LLC
MAINTENANCE & TROUBLESHOOTING MANUAL
SELF-PROPELLED AERIAL WORK PLATFORM
SUPO-687 REV A
HB-1230
SERIES III
NOTES
FOREWORD
Original instructions written in English The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and maintaining Hy-Brid Lifts. All information in this manual must be read and understood 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.
DANGER
THE OPERATION AND SAFETY MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE.
· The user/operator should not accept operating responsibility until the manual has been read and understood as well as having operated the lift under supervision of an experienced and qualified operator.
· Because the manufacturer has no direct control over machine application and operation, proper safety practices are the responsibility of the user and all operating personnel.
WARNING
ANY MODIFICATION ON THIS MACHINE WITH OUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED.
MAINTENANCE & TROUBLESHOOTING HB-1230
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
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TABLE OF CONTENTS
NOTES.......................................................................................................................................................................................... 2 FOREWORD ................................................................................................................................................................................ 3 TABLE OF CONTENTS ............................................................................................................................................................... 4 INDEX OF FIGURES.................................................................................................................................................................... 5 SECTION 1 | SAFETY .................................................................................................................................................................. 6
1.1 | SAFETY SYMBOLS.......................................................................................................................................................................... 6 1.2 | GENERAL RULES AND PRECAUTIONS .................................................................................................................................. 6 1.3 | SAFETY GUIDELINES.................................................................................................................................................................... 7 SECTION 2 | MAINTENANCE ................................................................................................................................................... 8 2.1 | BATTERY MAINTENANCE ........................................................................................................................................................... 8 2.2 | CHARGING THE BATTERY......................................................................................................................................................... 8 2.3 | LUBRICATION.............................................................................................................................................................................. 10 2.4 | COMPONENTS REQUIRING ADJUSTMENT ...................................................................................................................... 10 2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS ............................................................. 10 2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING CHECKS ................................................................................................. 10 2.7 | STORAGE ..................................................................................................................................................................................... 10 2.8 | MAJOR ALTERATIONS OR REPAIRS ..................................................................................................................................... 10 SECTION 3 | MAINTENANCE CHECKLISTS ..........................................................................................................................11 3.1 | PRE-START INSPECTION CHECKLIST................................................................................................................................... 12 3.2 | PRE-DELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST .................................................................................. 13 SECTION 4 | TECHNICAL REFERENCES .............................................................................................................................. 14 4.1 | HYDRAULIC SCHEMATIC ......................................................................................................................................................... 14 4.2 | ELECTRICAL SCHEMATIC ....................................................................................................................................................... 16 4.3 | CONTROL BOARD DIAGNOSTIC.......................................................................................................................................... 18 SECTION 5 | WIRING DIAGRAMS..........................................................................................................................................20 5.1 | WIRING DIAGRAM .....................................................................................................................................................................20 5.2 | LOWER CONTROLS WIRING DIAGRAM ..............................................................................................................................22 5.3 | UPPER CONTROLS WIRING DIAGRAM................................................................................................................................24 SECTION 6 | TROUBLESHOOTING FLOWCHARTS ........................................................................................................... 26 6.1 | MAIN POWER/SAFETY CIRCUIT .............................................................................................................................................26 6.2 | DRIVE CIRCUIT ...........................................................................................................................................................................28 6.3 | ELEVATE CIRCUIT ......................................................................................................................................................................30 6.4 | LOWER CIRCUIT.........................................................................................................................................................................32 SECTION 7 | PARTS .................................................................................................................................................................34 SECTION 8 | WARRANTY........................................................................................................................................................ 36 NOTES........................................................................................................................................................................................ 38
INDEX OF FIGURES
FIGURE 1: Maintenance Lock Use ........................................................................................................................................................ 7 FIGURE 2: Maintenance Lock Storage ............................................................................................................................................... 7 FIGURE 3: Battery Charger LED Display.............................................................................................................................................11
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SECTION 1 | SAFETY
1.1 | SAFETY SYMBOLS
DANGER
FAILURE TO FOLLOW THIS WARNING WILL CAUSE DEATH OR PERSONAL INJURY.
"DANGER" indicates 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 TO EQUIPMENT.
"CAUTION" indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to equipment
1.2 | GENERAL RULES AND PRECAUTIONS
An operator of any type of work platform is subject to certain hazards that cannot be protected by mechanical means. It is therefore essential that operators be competent, careful, physically and mentally fit and thoroughly trained in safe operation of this machine.
Although Custom Equipment, LLC conforms to specified ANSI & OSHA, it is the responsibility of the owner to instruct operators with the safety requirements made not only by Custom Equipment, LLC, but by the various safety boards in your area, as well as additional requirements set forth by ANSI and OSHA. If you come across a situation that you think might be unsafe, stop the platform and request further information from qualified sources before proceeding.
MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY
NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE
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C
SECTION 1 | SAFETY
C
1.3 | SAFETY GUIDELINES
Maintenance Lock The maintenance lock must be placed into position whenever the machine is being serviced in the raised or partially raised position. Serious injury and/or death could result if maintenance lock is not used properly.
FIGURE 1: Maintenance Lock Use
FIGURE 2: Maintenance Lock Storage
FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH.
Other Guidelines · Never work under an elevated platform until maintenance locks have been engaged. · Remove all rings, watches, and jewelry when performing any maintenance. · Do not wear long hair unrestrained or loose fitting clothing and neckties which may become caught on or
entangled in equipment. · Observe and obey all warnings and cautions on machine and in manual. · Keep oil, grease, water, etc. wiped from standing surfaces and handholds. · Before making any adjustments, lubricating or performing any other maintenance, shut off all power controls. · Battery should always be disconnected during replacement of electrical components. · 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.
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SECTION 2 | MAINTENANCE
2.1 | BATTERY MAINTENANCE
This unit is equipped with 12-volt AGM maintenance-free batteries. NOTE: The surrounding temperature greatly affects the power reserve within a battery. EXAMPLE: A battery that is 100% charged at 80° F (27°C) drops to 65% at 32°F (0°C). At 0°F (-18°C), this battery will drop to 40% efficiency.
NEVER ADD ACID TO BATTERY!
2.2 | CHARGING THE BATTERY
BATTERIES GENERATE EXPLOSIVE GASES. KEEP SPARKS AND FLAME AWAY FROM BATTERIES. DO NOT SMOKE WHILE CHARGING. The charger is equipped with an interlock circuit. The unit will not operate while charging. Shortened battery life will result. 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.
SECTION 2 | MAINTENANCE
DO NOT OPERATE UNIT WHILE CHARGING. DO NOT DISABLE
CHARGER INTERLOCK.
FIGURE 3: Battery Charger LED Display
How to read the battery displays
Power
Battery 1 Status
Charging
Ready
Green LED (ON) Red LED (OFF) Green LED (OFF)
Power
Battery 1 Status
Charging
Ready
Green LED (ON) Red LED (ON) Green LED (OFF)
Battery 2 Status
Charging
Ready
Red LED (OFF) Green LED (OFF)
This display indicates that the power is on but there is no connection to a battery. The charger must see approximately five (5) volts on a battery to deliver D/C current.
Battery 2 Status
Charging
Ready
Red LED (ON) Green LED (OFF)
This display indicates that power is on and that both outputs are delivering D/C current to the batteries.
Power
Green LED (ON)
Battery 1 Status
Charging
Ready
Red LED (OFF) Green LED (ON)
Battery 2 Status
Charging
Ready
Red LED (OFF) Green LED (ON)
This display indicates that power is on and that both outputs are finished charging and are in a float maintenance mode.
Power
Green LED (ON)
Battery 1 Status
Charging
Ready
Red LED (FLASHING)
Green LED (ON)
Battery 2 Status
Charging
Ready
Red LED (FLASHING)
Green LED (ON)
A flashing red light indicates there is a problem with a battery, such as low voltage or a bad cell.
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SECTION 2 | MAINTENANCE
2.3 | LUBRICATION
Item Wheels
Specification Teflon Spray
Frequency of Lubrication Quarterly
2.4 | COMPONENTS REQUIRING ADJUSTMENT
Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are required.
2.5 | EXAMINATION, REPAIR, REPLACEMENT OF LIMITED LIFE COMPONENTS
With proper use, regular battery charging, and regular inspection, there are no limited life components that require routine replacement.
2.6 | SAFETY DEVICES AND SYSTEMS REQUIRING 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 be approved by the manufacturer. Major repairs, which affect the stability, strength, or performance of the machine must also be approved by the manufacturer, recorded, and include machine inspection and testing. Never attach pipe racks, material lifting devices, or make any other alteration that is not part of the intended design of the machine.
SECTION 3 | MAINTENANCE CHECKLISTS
Regular inspection and conscientious maintenance is important to efficient economical operation of this machine. It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at the stated intervals or more frequently if required by local operating conditions. The following inspection checklists are included in this manual:
· Pre-Start (required before operation at each work shift) · Pre-Delivery/Frequent/Annual (Required every 3 months, after periods of storage, and after any alterations or
repairs)
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).
MAINTENANCE & TROUBLESHOOTING
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SECTION 3 | MAINTENANCE CHECKLISTS
3.1 | PRE-START INSPECTION CHECKLIST
THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR AFTER EVER SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR.
MODEL NUMBER:
SERIAL NUMBER:
Keep inspection records up-to-date.
Record and report all discrepancies to your supervisor.
A dirty machine cannot be properly inspected.
Y -- Yes/Acceptable N -- No/Unacceptable R -- Repaired
Description
YNR
VISUAL INSPECTIONS
There are no loose or missing parts.
Check that 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.
Check the tires for damage. Check that wheel axle retaining rings and set screw in rear wheel are tight.
Check that all snap rings are secure in grooves on pivot pins.
Functional Tests
Gate closes automatically and latches.
Platform Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement)
Drive & Up/Down Mode Switch (Selects drive/steer or elevate mode)
Joystick (Return to neutral, drives forward & reverse, elevates & lowers)
Drive Enable Trigger (Must be activated to drive)
Base Controls: Check all switches and push buttons for proper operation.
Emergency Stop (Stops all movement)
Key Switch (Selects Platform Control, Ground Control, or Off)
Up/Down Rocker Switch (Elevates, Lowers)
Alarm (Not damaged, sounds for descent, overload)
Wheels: Front and rear wheels rotate freely. Front wheels pivot freely.
Drives in slow speed when elevated.
Brakes: Machine stops when joystick released.
Pothole guards deploy and lock when platform is elevated.
Lift does not elevate when pothole guards are blocked.
DATE:
INSPECTED BY:
MAINTENANCE & TROUBLESHOOTING
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SECTION 3 | MAINTENANCE CHECKLISTS
3.2 | PRE-DELIVERY/ANNUAL/FREQUENT INSPECTION CHECKLIST
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 3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST.
MODEL NUMBER:
SERIAL NUMBER:
Check each item listed below. Use proper operating, service, and maintenance manual for specific information and settings If an item is found to be unacceptable make the necessary repairs and check the "repaired" box. When all items are "acceptable", the unit is ready for service.
Base: Inspect slide tracks for damage All frame bolts tight Pump Secure DC motors secure Covers screwed on Batteries Fully Charged Wheels: Snap Rings Secure Bolts/Nuts Tight Scissors: Broken Welds Bent Beam Members All rollers Turn Freely Ret. Rings Secure On Pivots
Emergency Down Operational
Maintenance Locks: Pins in cabinet Platform: Bent rails Broken welds All rails in place/secure 110V outlet safe/working (if applicable) Entrance gate Closes Freely Decals: Legibility Correct capacity noted Proper placement quantity
Date:
Y N R Extending platform:
Y NR
Extends freely
Cables in place/secure
Locks in Stowed Position
Locks in Extended Position
Functions:
All Functions Operational
Emergency Stop Breaks Circuits
Slow Speed limit switch Set properly
Wiring:
Switches secure
Contactor(s) secure
Tight on terminals (No loose wiring)
Pothole guards deploy when platform elevated
Pothole interlock functions correctly
Oil: Level 1" from top (when platform is stowed)
Brakes: Operational
Check all hose for leaks
Check all fittings for leaks
Battery Charger:
Secure/Operational
Tilt sensor
Warning Horn (if applicable)
Hour meter operational
Battery indication operational
All Shields/Guards in place
Operator/Service Manual
Inspected By:
MAINTENANCE & TROUBLESHOOTING
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SECTION 4 | TECHNICAL REFERENCES
4.1 | HYDRAULIC SCHEMATIC
SECTION 4 | TECHNICAL REFERENCES
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SECTION 4 | TECHNICAL REFERENCES
4.2 | ELECTRICAL SCHEMATIC
WS-129-20-301-50
8
7
6
5
4
3
2
SECTION 4 | TECHNICAL REFERENCES
1
NO NO
NC NO
D
+
NC E-STOP
V JOYSTICK
ELEV. ENABLE DRIVE ENABLE
NC E-STOP
KEYSWITCH
UP/DOWN ROCKER LOWER CONTROL
OFF
OFF
-
C
+
B
-
BRAKE SWITCH BRAKE SWITCH
(CTL SIDE)
(PUMP SIDE)
4
3
ANG. SENS. 1
2
PH LS-L
NC
NO
NC
NO
PH LS-R
(OPTIONAL FLASHING BEACON)
1
BRAKE BRAKE (PUMP (CTL SIDE) SIDE)
56
P12-2 P12-12 P12-7 P12-10 P9-8 P12-3 P12-9 P15-3 P15-2 P12-11 P15-6 P15-5 P15-13 P15-14 P15-8 P15-1 P12-1P15-9 P12-5 P12-4P15-11 B+
C
TS-100
P9-7 P15-4 P15-7 P15-10
P9-3
P15-12P15-15 P12-8 P12-6 P9-9 P9-6 P9-2 P9-1 P9-4 P9-5 M1+ M1- M2+ M2- B-
M
1K
+
1W
-
M
B
M
REV
DESCRIPTION OF CHANGE
A Revised Drive Motors
ORIGINALLY DRAWN BY:
DATE:
ECO # DATE REV BY
2014-2339 12/09/2015 GLH
A
Custom Equipment, Inc.
Richfield, WI 53076 Phone: (262)644-1300
A
PART NUMBER
WS-129-20-301-50
DEBURR ALL EDGES/CORNERS FOR SAFE HANDLING PER UL 1439 WELDING TOLERANCES: .X= .060 .XX= .030 .XXX= .010 MACHINING TOLERANCES: .X= .030 .XX= .015 .XXX= .005
FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010 LASER TOLERANCES: = .005
ELEC SCH,HB-1230 S3
SPEC/MATL: Schematic
WEIGHT: APPROX. 0.00 LB.
DRAWING #: WS-129-20-301-50
A
SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 1
8 THIS DRAWING IS CONFIDEN7TIAL AND PROPRIETARY TO CU6STOM, EQUIPMENT AND IS LO5ANED IN EXPECTATION THAT IT4WILL BE KEPT CONFIDENTIAL3AND USED ONLY FOR THE PUR2POSE FOR WHICH IT IS LOANED1.
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SECTION 4 | TECHNICAL REFERENCES
4.3 | CONTROL BOARD DIAGNOSTIC
When using the LED for diagnosis, note that a DUAL FLASH code is indicated. The LED will flash on/off a certain number of times, pause off for a short delay, then flash on/off a second certain number of times, followed by a much longer pause off. The sequence will then repeat.
Example: The LED flash code 3-2 will look like: on/off/on/off/ on/off-short-delay/on/off/on/off-long-delay/repeat
LED Code Fast Flash Steady 1-1 2-1
2-2
3-x
3-2 3-3 3-4 3-5
4-x
Possible Cause
Control Module is not calibrated, Do not operate unit.
Unit has just been powered on. You may need to wait for initialization, then re-select function. Ready to operate, things should be working normally. A function is selected but the enable trigger is not squeezed.
The control module is not calibrated. Do not use this unit.
The key switch selector switch indicate the mode in which the TS100 must operate. If neither input is active, or if both are active together, the TS100 does not know how to function. Check key switch and wiring to P15-1 and P12-1.
A safety feature is locking functions or a switch has failed. Check that platform is not overloaded, operating on a level surface, and pothole guards deploy/ Check that joystick is neutral when powered on. Check that joystick trigger is not closed for too long without selecting a function. Check for failed joystick, selector switches, and up/down switches.
There is a problem with the drive contactor or valve wiring, or with the motor power wiring; disconnect connector P9 to see if the problem is caused by drive contactor or valve wiring (if the fault clears, check for an illegal B+ supply in to P9) Check motor power wiring; with the drive contactor open the B+ power terminals should be at 10V-15V (significantly lower than B+) If the LED is steady at power-on, and the fault (3-5) occurs after a delay when attempting to drive or lift, the motor may be stalled and causing an overload of the TS100 or there is a power wiring error like connecting the B+ cable to a motor stud
Check P9 wiring. One or more signals showing outputs when all should be off.
Check B+ stud connections on controller. Voltage is too high.
There is voltage on safe pre-valve supply when there should not be. Controller may need to be replaced.
The drive brake current is too high. Motor overload. Check for a siezed motor or for power wiring to motors.
There is a problem with battery supply, the height and/or pressure sensors, the supply to them, or the temperature sensor inside the TS100 Check battery supply to EMS inputs P15-1 or P12-1 (relative to the B- stud); the battery supply should be between 15V and 32V Check the output from height sensor (P12-12) If the TS100 heatsink is very hot then perhaps the controller has temporarily shut down if so, platform lowering is still allowed; wait for the controller to cool down
MAINTENANCE & TROUBLESHOOTING
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SECTION 4 | TECHNICAL REFERENCES
4-2
Functions Locked: Board is overheated. Check pump, drive motor wiring. Problem with controller internal voltage. Controller may need to be replaced.
4-3
Problem with controller internal voltage. Controller may need to be replaced.
Battery supply is too low or too high.
4-4
Make sure batteries afe fully charged.
Do not operate while charging.
4-5
Joystick signal problem. Wiring problem-check for short circuits, misconnection, check P15-12 connection.
There is a problem with the height measurements, or the elevation switch disagrees with the
6-x
height sensor.
Check that the output from height sensor (P12-12) is in range (between 0.5V and 4.5V)
6-1
Problem with angle sensor or its connections
6-2
This feature does not apply on ANSI/CSA models.
6-3
Problem with elevation switch or its connections
6-6
This feature does not apply on ANSI/CSA models.
7-x
There is a problem with the power wiring the voltage on the B+ stud is too low Check for a short-circuit to the B+ stud
7-1
Motor A current too high.
7-2
Motor A current too low.
7-3
Motor B current too high.
7-4
Motor B current too low.
7-5
Check drive connections at both drives--short or multiple wiring faults.
7-7
Check B+ stud connections on controller. Voltage is too low.
MAINTENANCE & TROUBLESHOOTING
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SECTION 5 | WIRING DIAGRAMS
SECTION 5 | WIRING DIAGRAMS
5.1 | WIRING DIAGRAM
Part No. WD-129-20-301-50
8
D
UPPER CONTROL 129-21-249-50
C
BATTERY
7 ELEC-641A
ELEC-641C
6
5
4
3
2
HYD PUMP
-
+
DOWN
PUMP
GND STUD
UP
M
-
+
PUMP RESERVOIR
ELEC-641A
ELEC-641E
ANGLE SENSOR #1
129-01-090-50
TS-100 B+ M1+ M1- B- M2- M2+
1
DRIVE
M
BRAKE MICROSWITCH
C
MICROSWITCH BRAKE
NC
NO
NC
NO
129-01-090-51 B
L0WER CONTROL 129-21-266-50
BATTERY
BLUE RED
TAN
TB #2
P12-8 P9-9
1 23456
M
DRIVE
B
BLACK
WHITE
REV
DESCRIPTION OF CHANGE
ECO # DATE REV BY
A REVISED DRIVE MOTORS
2014-2339 10/06/2016 GLH
A
BATTERY CHARGER
ORIGINALLY DRAWN BY:
DATE:
POWER SWITCH
Custom Equipment, Inc.
Richfield, WI 53076 Phone: (262)644-1300
A
(129-01-090-51)
WD,HB-1230 S3
SPEC/MATL: Schematic
WEIGHT: APPROX. 0.00 LB.
TAN
DRAWING #: WD-129-20-301-50
A
SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 6
8 THIS DRAWING IS CONFIDEN7TIAL AND PROPRIETARY TO CU6STOM, EQUIPMENT AND IS LO5ANED IN EXPECTATION THAT IT4WILL BE KEPT CONFIDENTIAL3AND USED ONLY FOR THE PUR2POSE FOR WHICH IT IS LOANED1.
MAINTENANCE & TROUBLESHOOTING HB-1230
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SECTION 5 | WIRING DIAGRAMS
5.2 | LOWER CONTROLS WIRING DIAGRAM
Part No. WD-129-21-266-50
8
7
6
5
4
3
2
SECTION 5 | WIRING DIAGRAMS
1
D 129-21-004-96
SOCKET: ANGLE SENS #1
B- at TS100
TO TS-100
SOCKET:12-PIN
TO TS-100
SOCKET: 9-PIN
PUMP SOL./COIL CONNECTIONS
B- at TS100
129-21-206-96 129-21-206-97
SOCKET: ANGLE SENS #2
SOCKET: SOCKET: PRESSURE PRESSURE SENSOR-2 SENSOR-1
C PH LS-R 129-21-206-94 PH LS-L 129-21-206-95
B
C
ALARM
1K-OHM 1W RESISTOR
NC 12
E-STOP
HOURMETER
LWR CTL ROCKER SW.
KEY SWITCH
1NO2 1NO2
B
1234 5 6
A
BATTERY GAUGE (-)
BPWR SOL
CHARGER INTERLOCK
ENABLE PWR SOL
B+ PWR SOL
3 2 1 SOCKET: UPR CTL
CASTER LOCK LED
REV
DESCRIPTION OF CHANGE
ECO # DATE REV BY
A INITIAL RELEASE
2015-2339 05/29/2015 GLH
ORIGINALLY DRAWN BY: DJS
DATE:07/21/2015
Custom Equipment, Inc.
Richfield, WI 53076 Phone: (262)644-1300
A
WD,LWR CTL HB-1230 S3
SPEC/MATL: Wiring Diagram
WEIGHT: APPROX. 0.00 LB.
DRAWING #: WD-129-21-266-50
A
SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 2
8 THIS DRAWING IS CONFIDEN7TIAL AND PROPRIETARY TO CU6STOM, EQUIPMENT AND IS LO5ANED IN EXPECTATION THAT IT4WILL BE KEPT CONFIDENTIAL3AND USED ONLY FOR THE PUR2POSE FOR WHICH IT IS LOANED1.
MAINTENANCE & TROUBLESHOOTING HB-1230
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SECTION 5 | WIRING DIAGRAMS
5.3 | UPPER CONTROLS WIRING DIAGRAM
Part No. 129-21-249-50
8
7
6
5
1
BATT+ BATT-
BATTERY GAUGE
4
D
RED (4")
E-STOP
NO RED (4") 12
C
2
3
STEER (GRAY) LIFT/DRIVE (BLUE)
JS NEG (GREEN) JS +5V (ORANGE) JS TRIG IN (RED) JS TRIG. OUT (BLACK)
4
3
2
JOYSTICK
SECTION 5 | WIRING DIAGRAMS
1
C
GRAY (4) BLUE (6) GREEN (8) ORANGE (3) RED BLACK(1)
RED
ORANGE (12")
321
B
B
7 654
R ED (6")
LIFT ENABLE
NO WHITE (12") 12
11 10 9 8 14 13 12
RED (4")
1NC2 YELLOW (12")
REV
DESCRIPTION OF CHANGE
ECO # DATE REV BY
A NEW WD
2014-2321 02/24/2015 GLH
ORIGINALLY DRAWN BY: DJS
DATE:12/24/2014
A
DRIVE ENABLE
RED (12") TAN (12")
Custom Equipment, Inc.
Richfield, WI 53076 Phone: (262)644-1300
A
WD,UPR CTL HB-1230 S2.5/3
SPEC/MATL: Wiring Diagram
WEIGHT: APPROX. 0.00 LB.
PART NUMBER
WD-129-21-249-50
MACHINING TOLERANCES: .X= .030 .XX= .015 .XXX= .005 FORMING TOLERANCES: .X= .06 .XX= .020 .XXX= .010 LASER TOLERANCES: = .005
DRAWING #: WD-129-21-249-50
A
SCALE:1:1 B-SIZE DO NOT SCALE DRAWING SHEET 1 OF 1
8 THIS DRAWING IS CONFIDEN7TIAL AND PROPRIETARY TO CU6STOM, EQUIPMENT AND IS LO5ANED IN EXPECTATION THAT IT4WILL BE KEPT CONFIDENTIAL3AND USED ONLY FOR THE PUR2POSE FOR WHICH IT IS LOANED1.
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS
6.1 | MAIN POWER/SAFETY CIRCUIT
SECTION 6 | TROUBLESHOOTING FLOWCHARTS
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.2 | DRIVE CIRCUIT
SECTION 6 | TROUBLESHOOTING FLOWCHARTS
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.3 | ELEVATE CIRCUIT
SECTION 6 | TROUBLESHOOTING FLOWCHARTS
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SECTION 6 | TROUBLESHOOTING FLOWCHARTS 6.4 | LOWER CIRCUIT
SECTION 6 | TROUBLESHOOTING FLOWCHARTS
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SECTION 7 | PARTS
USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF NON-OEM PARTS WILL VOID WARRANTY.
REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY (ELEC-047-5), HYDRAULIC CYLINDER (129-21-002-90-K), CONTROL
BOARD (129-21-227-50), AND ALL STRUCTURAL COMPONENTS.
Refer to the Hy-Brid Lifts Operation and Safety Manual for decal part numbers and locations. In addition to the decals listed in the Operation and Safety Manual, a partial list of replacement parts . These represent current model revisions. A full parts manual, part# SUPO-684 is available from Hy-Brid Lifts. 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.
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Description ALARM, CONTINUOUS
BOARD,DRIVE/LIFT CTL HB-MID
BUTTON,PUSH/PULL RED E-STOP CHARGER,24V CORD,NEMA 515/IEC C13,36
CTL,ASM LWR
CTL,ASM UPR CTL,WIRE HARNESS MAIN HB-1230 DECALS,HB-1230 S3 ANSI
Part Number ELEC-635-4
129-21-267-50
ELEC-071-KIT ELEC-747 ELEC-639-3
129-21-266-50
129-21-249-50 129-21-007-50 129-21-312-50-K
DRIVE MOTOR,24VELE,HB DUM,HT ELEC-759-KIT
DRIVE MOTOR,24VELE,HB DUM,HT ELEC-758-KIT
DRIVE MOTOR,BRAKE DRIVE MOTOR,BRAKE
ELEC-627-5L ELEC-627-5R
HYDRAULIC OIL
HYDR-032
KEY,SPARE MANUAL BOX METER,HOUR METER,VOLT,24V ORING,0.25 X 5 SWITCH KNOB,MASTER DISCONNECT SWITCH,KEY,3-POS MAINTAINED SWITCH,LIMIT,LVR MICRO SWITCH,LIMIT,ROT LVR,NO/NC PO SWITCH,MASTER DISCONNECT SWITCH,ROCKER DPDT SWITCH,ROTARY MAINTAINED WHL,12X4 NM RUBBER W/HUB WHL,8X2,GREY NM RUBBER ASM,SCISSOR CYL HB12-ANSI MANUAL,PARTS HBMD S3
ELEC-073EKEY HARD-603 ELEC-610-2 ELEC-610-4 HARD-606-2
ELEC-633-5
ELEC-073D-KIT ELEC-627-6 ELEC-123-5 ELEC-633-4 ELEC-133B ELEC-002C-KIT WHEE-618-KIT WHEE-706-KIT 129-21-002-90-K SUPO-684
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SECTION 7 | PARTS DIAGRAMS
Notes BEGINNING WITH SERIAL #D0830100
BEGINNING WITH SERIAL #D0830100
WHITE-YEL STRIPE/YEL LEADS BEGINNING WITH SERIAL #D0830100 ORANGE/VIOLET LEADS BEGINNING WITH SERIAL #D0830100 Not available as a replacement part. Replace with Flomite #150, Dexron II, Mobil-DTE 2 or equivalent.
SUPO-687 REV A
SECTION 8 | WARRANTY
LIMITED WARRANTY
WARRANTY STATEMENT--NORTH AMERICA ONLY
1. LIMITED WARRANTIES Subject to the terms, conditions and limitations set forth herein, Custom Equipment, LLC (the "Company") warrants to the first end-user ("Buyer") that:
a. Limited Product Warranty For a period of 12 months from the date that a new product manufactured by the Company ("Product") is delivered to the Buyer, the Product will (i) conform to the specifications published by the Company for such Product as of the date of delivery; and (ii) be free of any defect in material and/or workmanship under normal use and maintenance; and
b. Extended Structural and Chassis Warranty For a period of 60 months from the date that the Product is delivered to the Buyer, the chassis and other structural components of such Product will be free from defects in material and/or workmanship under normal use and maintenance.
2. EXCLUSIONS / WHAT IS NOT COVERED The following items are NOT covered under this Limited Warranty:
· Defects in, and damage or loss relating to, any batteries incorporated by the Company into or made a part of the Product. Any such defects, damage or loss shall be exclusively covered by the battery manufacturer's warranty, if any. For more information regarding the battery warranty, the Buyer should contact the battery manufacturer using the contact information shown on the battery;
· Damage or loss resulting from or caused by carrier handling; · Damage or loss resulting from or caused by normal wear and tear, weathering, lack of use or use with incompatible
equipment or software; · Damage resulting from or caused by improper maintenance, improper handling or storage, improper use, abuse,
neglect, operation beyond rated capacity, or operation after discovery of defective or worn parts; · Any part, component or assembly altered or modified in any way not approved in writing by the Company; · Damage to any equipment or parts not manufactured by the Company; and · Acts of God, accidents or any other causes beyond the Company's reasonable control. 3. MAKING A WARRANTY CLAIM As a prerequisite to making any claim under this Limited Warranty, Buyer must give the Company written notice of any suspected defect promptly after discovery. Such notice shall specifically identify the suspected defect, the original delivery date and complete Buyer identification and location information. The Company will not accept any Product for warranty service without receiving Buyer's written notice and issuing a return goods authorization. If requested by the Company, Buyer shall return the defective Product, or parts, components or assemblies thereof, to the Company, F.O.B, Company's designated location. All returned Products or parts, components or assemblies thereof that are replaced under this Limited Warranty shall become the property of the Company. The Company reserves the right to review Buyer's maintenance and operation records and procedures to determine if the alleged defect(s) were due to any of the items listed in Sections 2 of this Limited Warranty. The Company shall not be liable for any claim under this Limited Warranty if Buyer fails to satisfy the conditions set forth in this Section.
4. EXCLUSIVE WARRANTY REMEDIES a. Exclusive Repair or Replace Remedy The Company's sole obligation and Buyer's exclusive remedy with respect to any defect in the Product
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SECTION 8 | WARRANTY
occurring during the warranty periods set forth in Section 1 of this Limited Warranty shall be for the Company, at its option, to repair or replace (or have one of its designated authorized dealers repair or replace) the Product or part, component or assembly thereof that contains a defect in materials or workmanship. The Company reserves the right, at its discretion, to use new, re-manufactured or refurbished replacement parts. Notwithstanding anything in this Limited Warranty to the contrary, the Company shall not be obligated to replace the entire Product if a covered defect can be remedied by the repair or replacement of a defective part, component or assembly. The Company shall be responsible for the cost of all parts and labor charges, up to the Maximum Labor Amount determined in accordance with Section 4(b) of this Limited Warranty, necessary to remedy such defect.
b. Labor Charges If field repairs or parts replacement are necessary on any Product covered by this Limited Warranty, the Company will reimburse its designated authorized dealer for those direct labor costs incurred to perform such field repairs or parts replacement up to the maximum amount specified in the Company's current Field Service Rate (hereinafter, the "FSR") or in any `Flat Rate Guides' or similar agreement established with the authorized dealer (such maximum amount shall be referred to in this Limited Warranty as the "Maximum Labor Amount"). Current versions of the Company's FSR and Flat Rate Guides are incorporated by reference into this Limited Warranty. For a current copy of the Company's FSR and Flat Rate Guides, Buyer should contact the Company at 1-866-334-0756. Buyer shall be responsible for any costs or fees due to the authorized dealer in excess of the Maximum Labor Amount.
5. DISCLAIMER OF OTHER EXPRESS AND IMPLIED WARRANTIES EXCEPT FOR THE LIMITED WARRANTIES SET FORTH IN SECTION 1 ABOVE, THE COMPANY MAKES NO OTHER REPRESENTATIONS OR WARRANTIES AND HEREBY DISCLAIMS ALL EXPRESS OR IMPLIED REPRESENTATIONS OR WARRANTIES REGARDING THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY, NON-INFRINGEMENT OF PROPRIETARY OR THIRDPARTY RIGHTS OR FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. No employee or representative of the Company or any of its authorized dealers is authorized to modify any term, condition or limitation in this Limited Warranty unless such modification is made in writing and signed by an officer of the Company.
6. LIMITATION OF LIABILITY NOTWITHSTANDING ANYTHING IN THIS WARRANTY TO THE CONTRARY, IN NO EVENT SHALL THE COMPANY OR ANY OF ITS AFFILIATES OR SUBSIDIARIES BE LIABLE TO BUYER FOR ANY INDIRECT, SPECIAL, EXEMPLARY, PUNITIVE OR CONSEQUENTIAL DAMAGES (INCLUDING LOST PROFITS, LOST REVENUE, DOWN TIME, LOSS OF BUSINESS OPPORTUNITY OR OTHER ECONOMIC LOSSES), 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
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NOTES
NOTES
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BY CUSTOM EQUIPMENT LLC
Self-Propelled Aerial Work Platform Maintenance & Troubleshooting Manual HB-1230 Series III
© 2015 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: July 2015 Printed In The USA